EVAPCO ATC-E Manuel utilisateur

Rigging and

Assembly nstructions

ATC-E, ATC-ES, ATWB, eco-ATWB and

eco-ATWB-E Evaporative Condensers and

Closed Circuit Coolers

Bulletin ATWB19RIG

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EVAPCO, Inc. — World H adquart rs & R s arch/D v lopm nt C nt r

P.O. Box 1300 • Westminster, MD 21158 USA

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EVAPCO-BLCT Dry Cooling, Inc.

Bridgewater, NJ 08807 USA

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Littleton, CO 80127 USA

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Calle Iglesia No. 2, Torre E

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Ciudad de México, D. . México 01090

+52 (55) 8421-9260 p

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R frig ration V ss ls & Syst ms Corporation

A wholl owned subsidiar of EVAPCO, Inc.

Bryan, TX USA

979-778-0095 p

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EvapT ch, Inc.

A wholl owned subsidiar of EVAPCO, Inc.

Lenexa, KS USA

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Tow r Compon nts, Inc.

A wholl owned subsidiar of EVAPCO, Inc.

Ramseur, NC USA

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A wholl owned subsidiar of EVAPCO, Inc.

York, PA USA

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Milan, Italy

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Sondrio, Italy

EVAPCO Europ GmbH

Meerbusch, Germany

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EVAPCO Air Solutions

A wholl owned subsidiar of EVAPCO, Inc.

Aabybro, Denmark

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EVAPCO Air Solutions GmbH

Garbsen, Germany

(49) 5137 93875-0 p

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Evap Egypt Engin ring Industri s Co.

A licensed manufacturer of EVAPCO, Inc.

Nasr City, Cairo, Egypt

2 02 24022866/2 02 24044997 p

primacool@link.net / shady@primacool.net

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Dubai, United Arab Emirates

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A licensed manufacturer of EVAPCO, Inc.

Isando 1600, Republic of South Africa

(27) 11-392-6630 p

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Baoshan Industrial Zone Shanghai, P.R. China

(86) 21-6687-7786 p

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B ijing EVAPCO R frig ration Equipm nt Co., Ltd.

Huairou District Beijing, P.R. China

010-6166-7238 p

[email protected]

EVAPCO Air Cooling Syst ms (Jiaxing) Company, Ltd.

Building 10, 1133 Taoyuan Road,

Jiaxing, Zhejiang, China

(86) 573 83119379 p

info@evapcoacs.cn

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Riverstone NSW 2765, Australia

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North Am rica

South Am rica

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Fan T chnology R sourc s

Cruz das Almas – Indaiatuba

São Paulo, Brasil 13308-200

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ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

Table of Contents

ntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Method of Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Structural Steel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rigging Basin Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Joining Multi-Cell Units Basin Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Equalizer Blank-Off Plate: Multi Cell Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Application of Sealer Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging Coil/Fan Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Extended Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Assembly of the Coil/Fan Section to the Basin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Containerized Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Assembly of the Fan Section to the Coil Section (Containerized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Assembly of the Coil Section to the Basin (Containerized) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

nstalling Watertight Partitions & Firewalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

External Motor nstallation – Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Optional Motor & Gear Box Davit nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Mounting Fan Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Sloped Ladder nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

External Platform and Vertical Ladder nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

Introduct on

This manual provides instructions and recommendations to safely and correctly install all ATC-E, ATC-ES, ATWB, eco-ATWB and eco-

ATWB-E Evaporative Condensers and Closed Circuit Coolers. It is recommended that all the instructions provided in this manual be

reviewed in detail prior to rigging and assembly. If at any point, specific circumstances not covered by this manual arise, please contact

your local EVAPCO representative for assistance.

Proper care must be taken by all parties involved in handling and assembling the equipment to ensure that safe and thorough

installation practices are implemented to prevent damage or injury to the equipment, persons and environment involved.

Method of Sh pment

Induced draft coil products are shipped with the top section(s) separate from the bottom section(s). These sections have mating flanges

and will join together in a waterproof joint when sealed and bolted together as described in the following instructions. Miscellaneous

items, such as sealer, self-tapping screws and any other required materials, are packaged and placed inside the pan for shipment. or

units consisting of multiple cells, drip channels and splash guards will ship loose in the basin for field installation.

or 7' and 8.5' (2.2 m and 2.6m) and 14' and 17' (4.3m and 5.2m) wide units, the motors and drives are factory aligned and then

shipped loose inside the basin section for mounting during installation. Refer to the “External Motor Installation” section in this bulletin.

NOTE: All casing sections are factory inspected prior to shipment to verify proper fit for rigging. Please take extra care to handle and rig

unit section per the instructions of this manual to avoid possible distortion and poor casing alignment. It is advisable to check each

section upon receipt and during each lift to ensure that the factory alignment has not been altered. Should the field inspection indicate the

section alignment (“square”) has been altered, please contact the factory or your local EVAPCO representative for additional instructions

to obtain proper section fit.

Structural Steel Support

Two structural “I” beams running the length of the unit are required for support of each cell of the units. These beams should be

located underneath the outer flanges of the unit (See Table 1). Mounting holes 3/4” (1.9mm) in diameter are located in the bottom

flanges of the unit for bolting to the structural steel (See steel support print in unit submittal for exact bolt hole location). Bolt the

bottom section to the steel support before rigging the top section.

Beams should be sized in accordance with accepted structural practices. Maximum deflection of the beam under the unit to be

1/360th of the unit length, not to exceed 1/2” (13mm). Deflection may be calculated by using 55% of the operating weight of the

unit as a uniform load on each beam (See certified print in unit submittal for operating weight).

The supporting “I” beams should be level before setting the unit. Do not level the unit by shimming between the bottom flanges

and the beams as this will not provide proper and continuous longitudinal support. Support beams and anchor bolts are to be

furnished by others. Always refer to the certified print in the unit submittal for unit weights, dimensions and technical data.

Please refer to the unit submittal for detailed, project specific steel support arrangement.

3' (0.914m), 4’ (1.2m), 7’ (2.2m), 8.5’

(2.6m), 10’ (3m), and 12' (3.6m) wide

single & multi-cell units

14’ (4.3m), 16' (4.8m), 17’ (5.2m), 20’

(6m) and 24’ (7.3) wide multi-cell units

Table 1 - Standard Longitudinal Steel Support Arrangement

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

R gg ng Bas n Sect on

Lifting devices are located in the upper corners of the basin

section for lifting and final positioning purposes as shown in

igures 1a and 1b. The hook of the crane must be a minimum

dimension of “H” above the top of the section being lifted to

prevent undue strain on the lifting devices. See Table 2 for the

minimum “H” dimension. These lifting devices should not be

used for extended lifts or where any hazard exists unless

safety slings are employed under the section. (See “Extended

Lifts” section for proper arrangement.) Bolt the basin section to

the steel support before rigging the coil/fan section.

Figure 1b - Basin Section 24' (7.3m) to 40' (12.2m) long

LIFTING

EARS

LIFTING

EARS

Basin Section Length Min. “H” Dim.

eet Meters eet Meters

3 - 6 0.9-1.8 8 2.4

8.5 2.6 10 3

9 2.7 10 3

10.5 3.2 11 3.4

12 3.6 15 4.6

14 4.3 17 5.2

18 5.5 19 5.8

20 6 21 6.4

21 6.4 22 6.7

24 7.3 15 4.6

28 8.5 16 4.9

36 11 19 5.8

40 12.2 21 6.4

Table 2 - Minimum “H” Dimension for Basin Sections

Figure 1a - Basin Section up to 21' (6.4m) long

Jo n ng Mult -Cell Un ts

On all 2-cell models, the two bottom sections are shipped

separately and are typically furnished with a connecting equalizer

flume box between them.

In addition to the equalizer flumes, these units are provided with

horizontal drip channels and vertical splash guards to keep water

from splashing out from between the cells. All units have one or

more horizontal drip channel and two vertical splash guards per

flume box. lume boxes are a standard offering on multi-cell units.

The equalizer flume box is factory installed on one section for field

connection to the other. It is important to connect the equalizer

flume to balance the water level in the pans for proper pump

suction operation. The procedures that follow should be

performed in sequence.

HORIZONTAL

DRIP

CHANNEL

VERTICAL

SPLASH

GUARD

FLUME BOX

SEALER

TAPE

RETAINING

CLIP

Figure 2 - Equalizer lume Connection, 12' (3.6m) Wide Models

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

For units on which the flume box ships loose:

1. Rig one of the bottom sections of the multi-cell unit. Bolt to steel support.

2. One face of the flume box is provided with 3/8” (10mm) welded bolts. Clean the mating flume opening on the rigged bottom

section and apply a layer of sealer tape on this surface, centered between the hole centers and the outside edge. Remove

paper backing strip from sealer tape.

3. Align the bolt holes in the rigged bottom section with the welded 3/8” (10mm) bolts on the flume box.

4. Install 3/8” (10mm) nuts and washers on every bolt around the flume opening and tighten.

5. ollow steps 4 through 10 as shown below.

For units on which the flume box ships mounted to one cell:

1. Install the bottom section with the factory installed flume box on it as described above.

2. Clean the flanges on the flume box on the end to be field connected. Apply a layer of sealer tape on the flange, centered

between the hole centers and the outside edge. Remove paper backing strip from the sealer tape.

3. Clean the mating surface of the flume opening of any dirt, grease or moisture.

4. Rig the second bottom section adjacent to the equalizer flume on the steel support as shown in the sequential figures that

follow.

5. Align the bolt holes in the flume box and flume opening with drift pins (by others) while drawing the second bottom section

against the flanged connection.

6. Install 3/8” (10mm) bolts, nuts, and washers in every hole around the flume opening and tighten.

7. Bolt the second bottom section to the steel support.

8. Remove the 1/4” (6mm) bolts which hold the drip channel retaining clips to the end panel. Place the drip channel over the

adjoining pan section flanges. Turn around the retaining clips and install them using the same hardware.

9. If there are multiple drip channels, fasten them together end-to-end by driving a self-tapping 5/16” (8mm) screw through the

section end with the larger hole into the mating end with the smaller hole. Stainless steel units will use 5/16” (8mm) stainless

steel nuts and bolts.

10. Place the vertical splash guard in the bend of the vertical supports. On galvanized units, attach the vertical splash guard using

5/16” (8mm) self-tapping screws. On stainless steel units, attach the vertical splash guards using 5/16” (8mm) stainless steel

nuts and bolts. (See figure 3a)

11. Once the bottom of the vertical splash guard has been attached to the drip channel, place the filler cap channel in the upper

flanges of the bottom section as shown in igure 3a. Attach to vertical splash guards using 5/16" (8mm) tappers (for galvanized

units) or stainless steel nuts and bolts (for stainless steel units).

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

FACTORY INSTALLED

EQUALIZER FLUME BOX

VERTICAL

SPLASH

GUARD

FLUME

BOX

DRIP CHANNEL

FILLER CAP

CHANNEL

SIDE PANEL

VERTICAL

SPLASH GUARD

VERTICAL

SPLASH

GUARD

EQUALIZER FLUME BOX

SEALER TAPE

DRIP CHANNEL

RETAINING CLIP

Figure 3a - Drip Channel and Vertical Splash Guard Installation

D IP CHANNEL

SECTION

SEALE TAPE

5/16” (8mm)

TAPPE

DRILLING IS

REQUIRED

IN THE FIELD

FOR THESE

HOLES

DRIP

CHANNEL

RETAINING

CLIP

END PANEL

TAPPERS (GALVANIZED)

OR STAINLESS STEEL

BOLTS (STAINLESS)

Figure 3 - Joining Bottom Sections – Multi Cell Units

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

Equal zer Blank-Off Plate:

Mult Cell Un ts

Equalizer blank-off plate(s) are available to isolate the

bottom sections for individual cell operation, periodic

cleaning, or maintenance.The optional equalizer blank-off

plate is factory installed on the equalizer flume and

secured by wing nuts. This plate is also known as a

“flume plate” or “positive closure plate.”

or units not requiring the blank-off plate under normal

operating conditions, remove the wing nuts, washers,

plate and gasket. Reinstall washers and wing nuts for

proper leak free operation of the equalizer flume box.

Appl cat on of Sealer Tape

Once the bottom section has been set on the supporting steel and bolted in place, the top flanges should be wiped down to remove

any dirt or moisture. Sealer tape should be placed over the mounting hole centerline on the side flanges along the entire length of

all sides. Apply two strips of sealer tape, one partially overlapping the other, on the entire length of the end flanges (flanges with no

bolt holes).

The sealer tape should overlap on the corners as shown in igure 5a. Do not splice the sealer tape along the end flanges and

preferably not on the side flanges if it can be avoided.

Always remove the paper backing from the sealer tape.

All models with two or more top sections must have sealer tape applied along the entire length of all internal flanges, as shown in

igure 5b.

DRIP

CHANNEL

SEALER TAPE

GASKET

RETAINER

CLIP

FLUME

BOX

BLANK

OFF PLATE

VERTICAL

SPLASH

GUARD

Figure 4 - Equalizer Blank-Off Plate Installation

2 OVERLAPPING LAYERS

OF SEALER TAPE

ON THE ENDS

1 LAYER OF SEALER TAPE

CENTERED OVER THE

MOUNTING HOLES

END SIDE

2 OVERLAPPING

LAYERS

OF SEALER

TAPE ON

THE ENDS

1 LAYER OF

SEALER TAPE

CENTERED

OVER THE

MOUNTING

HOLES

Figure 5b - Sealer Tape Detail for Center Joint of Units with

our Top Sections

Figure 5a - Sealer Tape on lange of Bottom Section

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

R gg ng Co l/Fan Sect on

our lifting ears are provided in the lower corners of most coil/fan sections for lifting into final position. Some 18' (5.5m) long

sections and longer will have two additional lifting ears in the middle of the section. (See igures 6a and 6b.)

Use all lifting ears. A spreader beam must be used for lifting the top section(s) as shown in igures 6a and 6b.

The hook of the crane must be a minimum dimension “H” above the lifting ear to prevent undue strain on the lifting ears. See Table

3 for the minimum “H” dimension. These lifting devices should not be used for extended lifts or where any hazard exists unless

safety slings are employed under the section. (See “Extended Lifts” for proper arrangement.)

Note: or 7' (2.24m) and 8.5' (2.6m) wide models, mount the external motor prior to rigging as detailed in the “External Motor

Installation” section.

Section Section Minimum "H"

Width Length Dimension

eet Meters eet Meters eet Meters

4 1.2 5 1.5

4 1.2 6 1.8 6 1.8

9 2.7 8 2.4

12 3.6 11 3.4

6 1.8 8.5 2.6 9 2.7

9 2.7 9 2.7

7 2.2 12 3.6 10 3

18 5.5 14 4.3

6 1.8 7 2.1

7.5 2.4 8 2.4

9 2.7 9 2.7

8/8.5 2.4/2.6 10.5 3.2 10 3

12 3.6 10 3

14 4.3 12 3.6

18 5.5 14 4.3

21 6.4 17 5.2

10 3 12 3.6 12 3.6

18 5.5 14 4.3

12 3.6 12 3.6

12 3.6 14 4.3 13 4

18 5.5 14 4.3

20 6 15 4.6

14 4.4 24 7.3 17 5.2

26 7.8 22 6.7

Table 3 - Minimum "H" Dimension for Coil/ an Sections

Figure 6a - our Point Lift

SPREADER BEAM

LIFTING EARS

SPREADER BEAM

LIFTING EARS

Figure 6b - Six Point Lift

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

LIFTING

EAR

LIFTING

EAR

SPREADER

BARS

SAFETY SLINGS

Figure 7 - Extended Lifts

Extended L fts

mportant: The lifting devices and “U” bolts should be used for final positioning only and for lifting where no danger

exists. f they are used for extended lifts, safety slings should be provided under the sections.

Safety slings and skids must be removed before final positioning of the unit.

The preferred method for extended lifts is to use slings under the unit, as shown in igure 7 below. Spreader bars should always be

used between the cables at the top of the section to prevent damage to the upper flanges or fan cylinders.

Assembly of the Co l/Fan Sect on to the Bas n

Before securing the upper section to the bottom section, remove any loose

parts shipped in the basin.

Wipe the flanges on the bottom of the upper section. Check to see that the

water distribution connection on the top section is in the correct position

relative to the bottom section (see unit certified drawing). Units are also

provided with match markings on each section (i.e. A1 of bottom section

should match up with A1 of top section).

Lower the upper section to within several inches of the bottom section making

sure the two sections do not touch and the sealer tape is not disturbed.

asten all four corners. Make use of drift pins to simplify the fastening

process, for further instructions on the use of drift pins, see page 10.

Install the remaining fasteners, working from the corners towards the center.

asteners must be installed in every hole in the side flanges. No fasteners

are required on the end flanges.

Figure 8 - Mating Upper Section to Basin Section

ATC-E, ATC-ES, ATWB, eco-ATWB and eco-ATWB-E Evaporative Condensers and Closed Circuit Coolers

Assembly of the Co l/Fan Sect on to the Bas n (Cont.)

Use of Drift Pins for Final Positioning

Drift pins are tools used to align holes in the flanges of the

upper and lower sections of the unit prior to final fastening. By

the time drift pins are needed, the lower section of the unit has

already been anchored to its support structure. The sealer tape

has been laid down on the lower section’s flanges, and the

upper section is now hovering over the lower section.

A drift pin should be driven in to each of the corner bolt holes

such that the upper and lower flanges are aligned as best as

possible with sideways motion restricted.

On units which are longer than 12’ (“L” > 12' [3.7m]), a drift pin

should be used at an intermediate pair of bolt holes in the

rigging seam to allow for proper alignment.

VERTICAL

SPLASH

GUARD

PAN SECTION

SIDE PANEL

FILLER CAP

CHANNEL

Figure 9 - Mating Upper Section to Basin Section

Figure 10 - iller Cap Channel Assembly

Notes:

For multi-cell units, the side flanges located in between cells

can be accessed from inside the unit.

Bolts can be driven upward through the mating flanges if

access is restricted.

All rigging hardware is provided by EVAPCO. Drift pins are

by others.

Autres manuels pour ATC-E

Ce manuel convient aux modèles suivants

Table des matières

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