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    Manual 1

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    CCR GPP
    This document provides guidelines for the storage, maintenance, start-up, and shut-down of air-cooled heat exchanger units. Key points include purging and pressurizing carbon steel bundles for storage over 45 days, rotating motor shafts during storage to prevent bearing damage, checking lubrication and removing covers prior to startup, gradually introducing process fluid during startup to prevent thermal shock, and steaming out bundles while still hot during shutdown.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Manual 1

    Uploaded by

    CCR GPP
    72 views4 pages
    This document provides guidelines for the storage, maintenance, start-up, and shut-down of air-cooled heat exchanger units. Key points include purging and pressurizing carbon steel bundles for storage over 45 days, rotating motor shafts during storage to prevent bearing damage, checking lubrication and removing covers prior to startup, gradually introducing process fluid during startup to prevent thermal shock, and steaming out bundles while still hot during shutdown.

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    manual 1

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    This document provides guidelines for the storage, maintenance, start-up, and shut-down of air-cooled heat exchanger units. Key points include purging and pressurizing carbon steel bundles for storage over 45 days, rotating motor shafts during storage to prevent bearing damage, checking lubrication and removing covers prior to startup, gradually introducing process fluid during startup to prevent thermal shock, and steaming out bundles while still hot during shutdown.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    72 views4 pages

    Manual 1

    Uploaded by

    CCR GPP
    This document provides guidelines for the storage, maintenance, start-up, and shut-down of air-cooled heat exchanger units. Key points include purging and pressurizing carbon steel bundles for storage over 45 days, rotating motor shafts during storage to prevent bearing damage, checking lubrication and removing covers prior to startup, gradually introducing process fluid during startup to prevent thermal shock, and steaming out bundles while still hot during shutdown.

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    © All Rights Reserved
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    Operation & Maintenance Manual

    3) For storage periods longer than 45 days, carbon steel bundles should be thoroughly drained,
    nozzle openings sealed with gasket blinds and bundles purged and pressured with nitrogen to 5
    psig. The exposed ends of carbon steel tubes between aluminum fins and tube sheets should be
    coated with epoxy to prevent external corrosion.

    2.2 Mechanical
    1) During assembly in our shop remote grease lines will be filled, connected to bearings and bearings
    filled allowing surplus grease to accumulate in bearing cavities for moisture-proofing. Light weight
    plastic sheeting will be taped tightly to the shaft just above the bearing to prevent accumulation of
    condensation or rain-water. The plastic sheeting will be taped in such a manner as to permit shaft
    rotation and should be left in place until equipment is placed in operation.
    2) Motors will be wrapped with light plastic sheeting to prevent entry of rainwater into bearing and motor
    cavities. Sheeting will be tightly taped to prevent removal by wind during transit yet loose enough to
    permit shaft rotation. The plastic cover should be left in place during storage and until unit is put in
    operation. If units are to be stored for more than 45 days, motors should be removed immediately and
    stored in a weather-poof area.
    3) If units are to be stored more than 45 days, sheaves should be protected preferably with a lacquer or
    plastic coating applied to the grooves to prevent corrosion. Exposed machine surfaces should be
    lightly coated with a rust preventative. If units have gear drives, gears should be filled with
    recommended lubricant to minimize interior corrosion.

    2.3 Inspection And Maintenance During Storage


    1) Motor shafts and fan shafts should be rotated several revolutions every thirty(30) days. This is to
    prevent pitting of bearings or bearing races which may occur when lubricant drains away from
    contacting parts.

    2.4 Steps To Be Taken Prior To Startup


    1) After units are installed, prior to startup, especially after extended period of storage, grease lines
    should be disconnected at the bearing hosing and old grease purged from lines. Lines should then
    be refilled, reconnected to bearing housing and old grease purged from bearing housing. Exhaust
    plugs should be removed from motor housings and new grease applied until old contaminated
    grease is removed and new grease appears at exhaust port. Motors should be started and
    operated 5-10 minutes before exhaust plug is tightened.
    (Caution : Be sure exhaust plug is removed prior to grease charge).
    2) The same protection procedure of rotating motor shafts and fan shafts as practiced during storage
    must be followed even after installation until the unit is put into operation

    3. Start-Up Instructions

    3.1 Prior to Start-Up


    1) General
    a. Check bearings for lubrication.
    Operation & Maintenance Manual

    b. Check fan blade pitch angle(16.5± 0.5°) and fan tip clearance(Min.6mm ~ Max.13mm). B
    c. Rotate fan by hand to see that shaft, speed reducer, and driver turn freely.
    d. Energize the fan driver momentarily to check for proper direction of rotation and fan blade
    orientation.
    e. If starting torque trips vibration switch, adjust sensitivity.
    2) Belt drive units
    a. Check belt tension.

    3.2 Start-Up
    1) General
    a. Start fan driver and check driver as outlined in manufacturer's instructions.
    b. Check unit for excessive vibration.
    2) Belt drive units
    a. Fin Fan for several hours; Check driver and bearings carefully for abnormal heating. During
    this period, check driver-output power and adjust fan blade pitch to load driver if necessary.
    b. Tighten belts. (Belts may continue to stretch during the first 30 days of operating requiring re-
    tensioning.)

    3.3 Tube Bundles


    1) Prior to introducing hot fluid including steam purge.
    a. Must remove bolts to tie the floating header to side frames. The floating header is boltd to
    side frames for transportation.

    b. Must remove all covers and tie-downs (If applicable).


    2) Introduction of process fluid
    a. All tube bundles have been hydrostatically tested to 150％ of maximum allowable pressure
    new and cold at the manufacturer's shops. To verify that no damage has been done during
    shipment and/or erection, it is good practice to hydrostatically test the entire system,
    including piping, heat exchangers, pumps, ect., prior to start-up.
    b. In general, the start-up procedure should be conducted in a manner that minimizes thermal
    Operation & Maintenance Manual

    shock of the heat exchanger bundles, and prevents over cooling of critical services during
    periods of low ambient temperature and low heat load.
    c. Special precautions should be observed during starting up units for there moval of heat from
    process streams of the following types;
    a) High viscosity fluids(N/A)
    Fluids with pour points above the prevailing air temperature. In many cases, the AFC units
    such streams sill be specially equipped with one or more of the following devices to assist
    in the prevention of start-up and operating problems.
    b) Variable speed motor (N/A)
    For units with these special devices, the start-up problems are considerably lessened. Prior
    to admitting the process fluid, close the louvers, start steam through the steam coil and
    then slowly admit the process fluid until normal flow through the unit is obtained, Gradually
    open the louvers, stop the flow of heating steam and start the auto-variable pitch fans at
    zero-fluid pitch. (Minimum airflow is usually obtained at 15psi. instrument pressure). Watch
    carefully the process fluid outlet temperature during the period, and if the danger of
    excessive cooling seems likely, start the flow of heating steam. Generally, however, the
    outlet fluid temperature will still be well above design, and the process of gradual increase
    in heat removal can be continued. Gradually increase the flow of air until the desired
    process fluid outlet temperature is attained, For units without louvers, steam coils, etc.,
    admit the process steam to the exchanger rapidly to prevent excessive cooling of the first
    liquid to reach the cold tubes, Care must be exercised, however, to prevent undue shock
    from a “hammering” effect, When normal flow is attained, start fans at a reduced pitch and
    then gradually increase fan pitch until the desired fluid outlet temperature is reached,
    d. For the removal or heat from process streams of low pour point and low viscosity, the startup
    procedure for AFC units is somewhat simplified, First, admit the process fluid at a low rate,
    and gradually increase the flow to the design rate. Start fans one at a time as the process
    fluid begins to exceed the design operating temperature. Finally, adjust the fan blade angle
    as required to attain design heat removal rate
    e. Maximum "fan-off" temperature at fan should not exceed 350℉. If exceeded, reduce
    temperature to a maximum of 250℉∼270℉ prior to energizing fans.

    4. Shut-down

    4.1 Turn off fans.

    4.2 Close inlet valves.


    Operation & Maintenance Manual

    4.3 Close outlet valves.


    4.4 Open all bundle drain.
    4.5 While bundle is the still hot, stream out with 300˚F. Or higher steam( But must be below
    ignition point of the tube fluid). Extreme caution should be exercised when isolating bundles for
    winter operation during periods of low ambient.
    4.6 All header drain plugs should be removed and all moisture residue purged from bundle with
    compressed air.

    5. Shop unit run-in procedure

    5.1 Set fan pitch to recommended angle. (Please find attached Fan datasheet)
    - Tolerance : ± 0.5°

    5.2 Check fan tip clearance


    Fan diameter Minimum Maximum

    ==>> 3’ through 9’ 6mm 13mm B

    9’ through 11’ 6mm 15mm


    11’ through 16’ 6mm 19mm

    5.3 Align and level gear reducer or motor


    - Tolerance : ± 0.5°

    5.4 Install and align belts. (Please find attached the Reducer data & manual)

    5.5 Make sure that the fan bearing is filled with the proper amount and type of lubricant.

    5.6 Rotate fan by hand to see that shaft and motor turn freely.

    5.7 Then turn on, allow fan to reach half speed, turn off, allow to coast down while checking for
    unusual noises.(Blade sticking, motor noises blade sticking, motor noise, etc.)

    5.8 If all is in order, start fan.

    5.9 Check amperage, voltage and record same.

    5.10 Check the noise level. B

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