BAC VTL-E Quick start guide

VTL-E Open Cooling Towers
RIGGING AND INSTALLATION INSTRUCTIONS
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About rigging and installation
The BAC equipment should be rigged and installed as outlined in this bulletin.
These procedures should be thoroughly reviewed prior to the rigging and operation to acquaint all personnel with
the procedures to be followed and to assure that all necessary equipment will be available at the job site.
Be sure to have a copy of the unit certified drawing available for reference. If you do not have a copy of this drawing
or if you need additional information about this unit, contact the local BAC Balticare representative. His name and
phone number can be found on the www.BaltimoreAircoil.eu. The model type and serial number of your equipment
are indicated on the unit nameplate.
Recommended maintenance and
monitoring programme
Checks and adjustments Start-Up Weekly Monthly Quarterly Every 6
months
Annually Shutdown
Cold water basin & strainer X X
Operating level and make-up X X
Blow down X X
Sump heater package X X
Belt tension X X
Drive alignment X X
Locking collar X X
Rotation of fan(s) and pump(s) X
Motor voltage and current X X
Unusual noise and/or vibration X X
Inspections and monitoring Start-Up Weekly Monthly Quarterly Every 6
months
Annually Shutdown
General condition X X
Heat transfer section X X
Drift eliminators X X
Water distribution X X
Fan shaft X X
Fan motor X X
Electric water level control package (optional) X X
TAB test (dip slides) X X
Circulating water quality X X
System overview X X
Record keeping as per event
Lubrication Start-Up Weekly Monthly Quarterly Every 6
months
Annually Shutdown
Fan shaft bearings X X X
Motor bearings* X X
Adjustable motor base X X X
* only for motors with grease fittings with typical frame size > 200L (>30 KW)
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Cleaning procedures Start-Up Weekly Monthly Quarterly Every 6
months
Annually Shutdown
Mechanical cleaning X X X
Disinfection** (X) (X) (X)
Drain basin X
** depends on applied code of practice
Notes
1. Water treatment and auxiliary equipment integrated in the cooling system may require additions to the table
above. Contact suppliers for recommended actions and their required frequency.
2. Recommended service intervals are for typical installations. Different environmental conditions may dictate
more frequent servicing.
3. When operating in ambient temperatures below freezing, the unit should be inspected more frequently (see
Cold weather operations in the appropriate Operating and Maintenance Instructions).
4. For units with belt drive, tension on new belts must be readjusted after the first 24 hours of operation and
monthly thereafter.
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Table of contents
RIGGING AND INSTALLATION INSTRUCTIONS
1 General information 5
About engineering and application practices 5
Shipping 5
Inspection before rigging 5
Unit weights 7
Anchoring 7
Leveling 7
Electrical connections 8
Connecting pipework 8
Freeze protection 8
Bleed Line Installation 8
Safety Precautions 8
Non-walking surfaces 10
Modifications by others 10
Warranty 10
2 Rigging 11
General notes 11
Rigging method discharge accessories 13
3 Optional accessories assembly 14
General Information 14
Clean out port 16
4 Inspection prior to start-up 17
General 17
5 Further Assistance & Information 18
Assistance 18
More information 18
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GENERAL INFORMATION
About engineering and application practices
This bulletin only refers to the assembly of the unit. To ensure a proper operation, a correct integration of the unit in
the overall installation is mandatory. For good engineering and application practices on layout, levelling,
connecting pipework, etc., please refer to our website:
http://www.baltimoreaircoil.eu/knowledge-center/application-information.
Shipping
BAC cooling equipment is factory assembled to assure uniform quality and minimum field assembly.
The models are shipped in one single section.
CAUTION
Do not cover units with PVC eliminators or fill with a plastic tarpaulin.
Temperature increase due to sun radiation could deform the fill or eliminators.
Inspection before rigging
When the unit is delivered to the job site, it should be checked thoroughly to ensure all required items have been
received and are free of any shipping damage prior to signing the bill of lading.
The following parts should be inspected:
• Sheaves and belts
• Bearings
• Bearing supports
• Fan motors
• Fan wheels and shafts
• Wet deck surface
• Water distribution system
• Strainers
• Float valve assembly
• Eliminators
• Interior surfaces
• Exterior surfaces
• Miscellaneous items
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An envelope with check-list is stored in a wooden no nail crate or a plastic container which is placed in the lower
section. For safety reasons, access doors / panels may be sealed with bolts. The following table specifies which
wrench is required to open them.
Wrench to open access door
17 mm
Required wrench to open access door
The wooden no nail crate / plastic container also contains miscellaneous parts such as gasket, hardware and
accessory items.
At temperatures below -10°C the butyl sealer tape might loose it's flexibility. We recommend to store the sealer
tape in a heated room before using it during rigging at freezing temperatures.
CAUTION
Be sure to remove all miscellaneous items from the pan before the unit is assembled.
The hardware is packed in a plastic container and located inside the lower section of the unit.
If a plastic container is used; it will be fixed to the make-up valve using a cable tie.
Hardware location
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If heaters are shipped loose, they will be wrapped in plastic and fixed to the strainer.
Heater location if shipped loose.
1. Heater
Unit weights
Before rigging any BAC equipment, the weight of each section should be verified on the unit certified drawing.
These weights are approximate and should be confirmed by weighing before lifting when available
hoisting capacity provides little margin for safety.
CAUTION
Before an actual lift is undertaken, ensure no water, snow, ice or debris has collected in the sump
or elsewhere in or on the unit. Such accumulations will add substantially to the equipment’s lifting
weight.
In the event of extended lifts or where hazards exist, the lifting devices should be used in conjunction with safety
slings placed under the unit.
Anchoring
The unit must be properly anchored in place.
Refer to the suggested support details on the certified drawing for locations of the mounting holes. Anchor bolts
must be provided by others.
Holes suitable for 20 mm bolts are provided in the bottom flange of the lower section for bolting the unit to the
support beams.
Leveling
The unit must be level for proper operation and ease of piping.
Support beams must also be level as shims should not be used between pan and support beams to level the unit.
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Electrical connections
The units are delivered with a number of electrical components that need to be connected after rigging.For all
electrical components, please refer to the specific wiring diagrams in the submittal package.
Connecting pipework
All piping external to BAC cooling equipment must be supported separately.
In case the equipment is installed on vibration rails or springs, the piping must contain compensators to eliminate
vibrations carried through the external pipework.
The equipment outlet piping must be installed under the operating level of the equipment to prevent air suction and
pump cavitation.
Suction pipe sizing should be done according to good practice, which may for larger flows require larger pipe
diameters than the outlet connection. In such cases adapter pieces need to be installed.
Freeze protection
These products must be protected against damage and/or reduced effectiveness due to possible freeze-up by
mechanical and operational methods. Please contact your local BAC Balticare representative for recommended
protection alternatives.
Bleed Line Installation
On all open cooling towers, install a bleed line with valve between the system circulating pump discharge riser and
a convenient drain. Locate the bleed line in a portion of the riser piping that drains when the pump is off.
The bleed valve should always be open when the unit is in operation, unless the bleed rate is automatically
controlled by a water treatment system.
Safety Precautions
All electrical, mechanical and rotating machinery constitutes a potential hazard, particularly for those not familiar
with its design, construction and operation. Accordingly, adequate safeguards (including use of protective
enclosures where necessary) should be taken with this equipment both to safeguard the public (including minors)
from injury and to prevent damage to the equipment, its associated system and the premises.
If there is doubt about safe and proper rigging, installation, operation or maintenance procedures, contact the
equipment manufacturer or his representative for advice.
When working on operating equipment, be aware that some parts may have an elevated temperature. Any
operations on elevated level have to be executed with extra care to prevent accidents.
AUTHORIZED PERSONNEL
The operation, maintenance and repair of this equipment should be undertaken only by personnel authorized and
qualified to do so. All such personnel should be thoroughly familiar with the equipment, the associated systems
and controls and the procedures set forth in this and other relevant manuals. Proper care, personal protective
equipment, procedures and tools must be used in handling, lifting, installing, operating, maintaining and repairing
this equipment to prevent personal injury and/or property damage. Personnel must use personal protective
equipment where necessary (gloves, ear plugs, etc...)
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MECHANICAL SAFETY
Mechanical safety of the equipment is in accordance with the requirements of the EU machinery directive.
Depending upon site conditions it also may be necessary to install items such as bottom screens, ladders, safety
cages, stairways, access platforms, handrails and toe boards for the safety and convenience of the authorized
service and maintenance personnel.
At no time this equipment should be operated without all fan screens, access panels and access doors in place.
When the equipment is operated with a variable fan speed control device, steps must be taken to avoid operating
at or near to the fan's «critical speed».
For more information consult your local BAC Balticare representative.
ELECTRICAL SAFETY
All electrical components associated with this equipment should be installed with a lockable disconnect switch
located within sight of the equipment.
In the event of multiple components, these can be installed after a single disconnect switch but multiple switches
or a combination thereof are also allowed.
No service work should be performed on or near electrical components unless adequate safety measures are
taken. These include, but are not limited to the following:
• Isolate the component electrically
• Lock the isolation switch in order to prevent unintentional restart
• Measure that no electrical voltage is present anymore
• If parts of the installation remain energized, make sure to properly demarcate these in order to avoid confusion
Fan motor terminals and connections may have residual voltage after unit shut-down. Wait five minutes after
disconnecting the voltage at all poles before opening the fan motor terminal box.
LIFTING
CAUTION
Failure to use designated lifting points can result in a dropped load causing severe injury, death
and/or property damage. Lifts must be performed by qualified riggers following BAC published
Rigging Instructions and generally accepted lifting practices. The use of supplemental safety
slings may also be required if the lift circumstances warrant its use, as determined by the rigging
contractor.
LOCATION
All cooling equipment should be located as far away as possible from occupied areas, open windows or air intakes
to buildings.
CAUTION
Each unit must be located and positioned to prevent the introduction of discharge air into the
ventilation systems of the building on which the unit is located and of adjacent buildings.
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For detailed recommendations on BAC equipment layout, please see the BAC Application Handbook EU-
Edition, the BAC website www.BaltimoreAircoil.eu or contact your local BAC-Balticare Representative.
LOCAL REGULATIONS
Installation and operation of cooling equipment may be subject to local regulations, such as establishment of risk
analysis. Ensure regulatory requirements are consistently met.
Non-walking surfaces
Access to and maintenance of any component needs to be performed in accordance with all local applicable laws
and regulations. If the proper and required access means are not present, temporary structures need to be
foreseen. Under no circumstance can one use parts of the unit, that are not designed as an access mean, unless
measures can be taken to mitigate any risks that might occur from doing so.
Modifications by others
Whenever modifications or changes are made by others to the BAC equipment without written permission of BAC,
the party who has done the modification becomes responsible for all consequences of this change and BAC
declines all liability for the product.
Warranty
BAC will guarantee all products to be free from manufactured defects in materials and workmanship for a period of
24 months from the date of shipment. In the event of any such defect, BAC will repair or provide a replacement.
For more details, please refer to the Limitation of Warranties applicable to and in effect at the time of the
sale/purchase of these products. You can find these terms and conditions on the reverse side of your order
acknowledgement form and your invoice.
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