BAC VTL User manual

RIGGING AND
INSTALLATION
1
RI_VL_SA 01/11-01
VTL Cooling Towers
VFL Closed Circuit Cooling Towers
VCL Evaporative Condensers
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 jobsite.
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 representative. The model
number and serial number of the unit are located on a
label on the sinde of the unit.
Table of Contents Page
General Information 2
Rigging 4
Optional Accessories Assembly 5
Inspection Prior to Start-up 7
Recommended Maintenance and
Monitoring Programme 8

2
GENERAL INFORMATION
BAC cooling equipment is factory assembled to assure uniform
quality and minimum field assembly.
The VL models are shipped in one single section.
For the dimensions and weights of a specific unit or section, refer to
the certified drawing.
When the unit is delivered to the jobsite, 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
-Fanmotors
- Fan wheels and shafts
- Wet deck surface (VTL)
-Coils(VFL,VCL)
- Water distribution system
-Strainers
- Float valve assembly
- Spray Pump (VFL, VCL)
-Eliminators
- Interior surfaces
- Exterior surfaces
- Miscellaneous items
An envelope with checklist is stored in a wooden crate or a plastic
container which is placed in the lower section. For safety reasons,
access doors / panels may be sealed with bolts.
The wooden crate / plastic container also contains miscellaneous
parts such as gasket, hardware and accessory items.
!
Be sure to remove all miscellaneous items from the pan before
the unit is assembled.
Before rigging any BAC cooling equipment, the weight of each
section should be verified on the unit certified drawing.
Note: These weights are approximate only and should be confirmed by
weighing before lifting when available hoisting capacity provides little margin
for safety.
!
Before an actual lift is undertaken, ensure no water or debris has
collected in the sump or elsewhere in the unit. Such
accumulations will add substantially to the equipment's lifting
weight.
The unit must be properly anchored in place before operation
begins.
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.
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 to unit.
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 installer of BAC condensers must ensure proper system purging
of air prior to operation. Entrained air can obstruct free drainage of
refrigerant and reduce condensing capacity, resulting in higher
operating pressures than design. To verify absence of non
condensables in the system, follow the instructions of the BAC
Evaporative Condenser Manual E115.
Refrigerant connections on site :
All connections in the external refrigerant pipework (installed by
others) must be leak free and tested accordingly.
All electrical, mechanical and rotating machinery constitute 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 advise.
Shipping
Inspection before Rigging
Unit Weights
Anchoring
Leveling
Connecting Pipework
Purge Requirements
Safety Precautions

GENERAL INFORMATION
3
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, procedures and tools
must be used in handling, lifting, installing, operating and repairing
this equipment to prevent personal injury and/or property damage.
MECHANICAL SAFETY
Depending upon site conditions it also may be necessary to install
items such as bottom air inlet 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
Each fan and pump motor associated with this equipment should be
installed with a lockable disconnect switch located within the sight
of the equipment. No service work should be performed on or near
the fans, motors, drives or inside the equipment unless fan and
pump motors, heaters etc. are electrically isolated.
LOCATION
All cooling equipment should be located as far away as possible
from occupied areas, open windows or air intakes to buildings.
LOCAL REGULATIONS
Installation and operation of cooling equipment may be subject of
local regulations, such as establishment of risk analysis. Ensure
regulatory requirements are consistently met.
Please refer to the Limitation of Warranties applicable to and in
effect at the time of the sale/purchase of these products.
Warranties

4
RIGGING
1. Never assemble the unit before lifting, as the lifting devices
provided are not designed to support the weight of the entire
assembled unit.
2. Spreader bars of the full width of the section must be used
between the lifting cables to prevent damage to the section.
For extended lifts or where hazards exist, it is recommended to
use the lifting devices in conjunction with safety slings placed
under the unit.
3. Lifting devices have been provided on all sections. The tables
below give the preferred method for rigging each section of a
unit.
1. Spreader Bar; 2. Lifting Device; 3. Safety Slings; 4. Spreader Bar Length.
1Discharge accessories can be: positive closure damper, tapered
discharge hood, sound attenuation.
1Discharge accessories can be: positive closure damper, tapered
discharge hood, sound attenuation.
2For asymmetrical load distribution (with external piping) shorten the
slings at one end so the casing is approximately horizontal.
1Discharge accessories can be: positive closure damper, tapered
discharge hood, sound attenuation.
2For asymmetrical load distribution (with external piping) shorten the
slings at one end so the casing is approximately horizontal.
General Notes
COOLING TOWERS VTL
Model N°
Minimum
"H
(mm)
Spreader
Bar
Length
(mm)
Discharge
Accessory1
Minimum “H”
VTL-039 to VTL-079 3100 1250 3100
VTL-076 to VTL-095 4300 1250 4300
VTL-089 to VTL-137 5000 1250 5000
VTL-139 to VTL-227 4300 2450 4300
VTL-225 to VTL-272 5000 2450 5000
Table 1: Rigging method VTL and discharge accessory
CLOSED CIRCUIT COOLING TOWERS VFL
Model N°
Minimum
"H
(mm)
Spreader
Bar
Length
(mm)
Discharge
Accessory1
Minimum “H”2
VFL-241 to VFL-243 3100 1250 3100
VFL-361 to VFL-383 3100 1250 3100
Table 2: Rigging method VFL and discharge accessory
Figure 1: Rigging method VL units
VFL-481 to VFL-484 3700 1250 3700
VFL-721 to VFL-724 3100 2450 3100
VFL-961 to VFL-964 3700 2450 3700
EVAPORATIVE CONDENSERS VCL
Model N°
Minimum
"H
(mm)
Spreader
Bar
Length
(mm)
Discharge
Accessory1
Minimum
“H”2
VCL-042 to VCL-079 3100 1250 3100
VCL-084 to VCL-133 3100 1250 3100
VCL-131 to VCL-159 3700 1250 3700
VCL-167 to VCL-258 3100 2450 3100
VCL-239 to VCL-321 3700 2450 3700
Table 3: Rigging method VCL and discharge accessory
Rigging Method Discharge Accessories
CLOSED CIRCUIT COOLING TOWERS VFL
Model N°
Minimum
"H
(mm)
Spreader
Bar
Length
(mm)
Discharge
Accessory1
Minimum “H”2
Table 2: Rigging method VFL and discharge accessory

OPTIONAL ACCESSORIES ASSEMBLY
5
1. Optional discharge accessories such as tapered hoods, positive
closure dampers, discharge sound attenuators and/or access
plenums can be fitted.
2. Rigging method of optional accessories is indicated in the
rigging tables (see section “Rigging).
3. Never assemble the unit before lifting, as the lifting devices
provided are not designed to support the weight of the entire
assembled unit.
4. Refer to the unit certified drawing for installation sequence of
optional accessories.
5. Position the lower section on the supporting steel and bolt in
place.
6. Remove any protective wood from the top horizontal flanges of
the lower section. Wipe down the flanges to remove dust, dirt or
moisture that may have accumulated during shipment and
storage.
7. Apply the 25 mm flat tape sealer around the periphery of the top
flange of the lower section.
This tape sealer must be centred directly over the centreline of
the tapper holes and on the centreline of the end flanges where
there are no tapper holes. The sealer is to be spliced only along
the flanges with tapper holes. When it is necessary to splice
sealer, mitre and press the two ends together so as to form a
smooth, continuous bead. Tape sealer is trapezoidal in shape
and must be installed wide side down (see Figure “Installation of
tape sealer”). Do not stretch sealer tape.
8. Sealer applied to the end flanges of the unit must be continuous.
1. Upper section; 2. Lower section; 3. Lower section frame; 4. 25 mm flat
tape sealer laid over punch line wide side down.
9. Remove the skid from the upper section. Lift the upper section
and position it over the lower section so that the flanges of the
upper section are about 50 mm above the lower section. Dot not
let the upper section swing and damage the sealer.
Using at least four drift pins (see figure) in the fastening holes
located on the long sides of the sections to align the top section
to the bottom section. To avoid incorrect alignment, refer to the
below drawing for the position of the fastening holes to be used.
Use additional drift pins in the middle of the unit if required, to
align long panels. Make sure all holes from upper section and
lower section are properly aligned before lowering the top
section completely to the bottom section.
1. Fastening hole; 2. Drift pin position; 3. The distance between the fastening
hole in which the drift pin is inserted and the corner should be at least 30 cm;
4. Usage of additional drift pin for long sides.
10.Using the self-tapping screws, drive screws down through the
upper section and into the lower section. Start next to lifting ear
towards centre of unit. Continue to install the screws using the
drift pin to align the screw holes until all holes are filled with
screws
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. Closed circuit cooling towers or condensers that are
furnished with a factory installed circulating pump include a bleed
line with valve.
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. Recommended bleed rates may be found in the
Operating and Maintenance Manual.
General
Figure 2: Installation of tape sealer
Bleed line installation
Figure 3: Position of the fastening holes to be used.
Figure 4: Usage of drift pin to align the screw holes

6
OPTIONAL ACCESSORIES ASSEMBLY
Due to transport width limits, the cover flanges of the clean out port
are mounted with flanges towards the inside (1). On site, the cover
can be placed with flanges to the outside for easy access to
hardware (2).
Clean out port
Figure 5: Clean out port cover mounted for transport
Figure 6: Final installation of clean out port cover

INSPECTION PRIOR TO START-UP
7
Prior to start-up, the following services, which are described in detail
in the Operating and Maintenance Manual (see Table
Recommended Maintenance and Monitoring Schedule- Start-up)
must be performed.
Proper start-up procedures and scheduled periodic maintenance
will prolong the life of the equipment and ensure trouble-free
performance for which the unit is designed.
Start-up Inspection

RECOMMENDED MAINTENANCE AND MONITORING PROGRAMME
www.BaltimoreAircoil.com
[e-mail]
Baltimore Aircoil Company SA
(Pty) Ltd.
Portland Road, Phillipi
Cape Town, South Africa
©Baltimore Aircoil Company SA (Pty) Ltd
Model: ........................................................................................... Serial number: .................................................................................
* only for motors with grease fittings
** 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. For units with Belt Drive, tension on new belts must be readjusted after the first 24 hours of operation and monthly thereafter.
Schedule
Type of Action Action Start-Up Weekly Monthly Quarterly Every Six Months Annually Shutdown
Checks and
Adjustments
Cold Water Basin and Strainers 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
General condition X X
Heat transfer section X X
Finned discharge coil (optional) X X
Drift eliminators X X
Water distribution X X
Fan Shaft X X
Fan Motor X X
Electric Water Level Control Package
(optional)
XX
TAB test (dip slides) X X
Circulating water quality X X
System overview X X
Record keeping as per event
Lubrication Fan shaft bearings X X
Motor bearings * X X
Adjustable motor base X X
Cleaning
procedures
Mechanical cleaning X X
Disinfection ** (X) (X) (X)
Table 4: Recommended Maintenance & Monitoring Schedule