Searle Adiabatic (Spray) Cooling Systems INSTALLATION & MAINTENANCE

Transcription

1 Searle Adiabatic (Spray) Cooling Systems INSTALLATION & MAINTENANCE

2 ADIABATIC SPRAY COOLING SYSTEM Content : Important Information 1. Adiabatic system profile 2. Health and Safety 3. Legionella 4. Warranty Procedure 5. Installation Clearance 6. Sequence controller 7. Maintenance 8. Spare parts Searle Adiabatic (Spray) Cooling Systems

3 1. ADIABATIC SYSTEMS PROFILE The Searle Adiabatic cooling system is designed to enhance the thermal performance of air-cooled condensers and dry air coolers by reducing the effective incoming air temperature. Temperature reduction is achieved by spraying water into the incoming air via a series of sparge pipes and nozzles located adjacent to the heat exchange coils. The energy used to evaporate the spray water results in a reduction in air temperature and an increase in humidity. Searle is offering the Behring technology ensuring a microbiologic control of water, in combining a destruction of biofilm (aggregate of solid particles potentially containing bacteria) by hydrodynamic cavitation, followed by a specific UV treatment suited to intermittent flows. Adiabatic Features - The following benefits and features may be achieved when fitting adiabatic systems: Fluid temperatures lower than the ambient dry bulb can be achieved when conditions are suitable. Reduction in physical size of plant. Increasing the capacity on existing systems. Standby - used as emergency capacity on critical applications or upgrades. A sequence of operation has been developed: To ensure no free standing water is left in the system when inactive for long periods. Water in the supply pipe flushes the system before high pressure nozzle spraying starts System Description Searle adiabatic cooling systems are made up of two principal assemblies. The adiabatic control box, which can be factory fitted to air-cooled condensers and dry air coolers. The sparge and nozzle assembly is factory fitted to V bank units and supplied loose (for shipment) on flat bed units. These items are also available as a retro fit kit for site upgrades. Three versions of the adiabatic control box are available: Option 1: Low pressure spraying - Without a pressurisation pump where the supply water pressure, at design low rate, is not less than 5 bar. Option 2: Average pressure spraying - A low flow rate pressurisation pump where the supply water pre sure, at design flow rate, is not less than 2 bar. Option 3: High pressure misting - A high pressurisation pump (>100bars) where the supply water pressure, at design flow rate, is not less than 2 bar. All adiabatic control boxes are fitted with water strainer, mains inlet solenoid valve, vent solenoid valve, pressure regulator and pressure gauges, pressure switch, ultraviolet lamp, hydrodynamic cavitator, scale inhibitor and a 230-volt control panel. The electronic controls are mounted in a polycarbonate box and contain a mains isolator, adiabatic sequence controller and transformer. Water is sprayed into the air stream via a sparge system made of stainless steel pipes fitted with atomising nozzles and connected together with push fittings. A drain solenoid is fitted to the lowest part of the system. 3

4 Note: pointing away from the coil face. Make the connection with the adiabatic box. Ensure that the drain solenoid is at the lowest point of the system. The drain solenoid is normally fitted onto the lowest point on the inlet of the sparge assembly (if the unit is raised on steels and the adiabatic box is remote then it may be necessary to reposition the solenoid to avoid water trapping in the pipe work). ADIABATIC SEQUENCE When water is passed through the ultra -violet lamp the dose of UV radiation received is lethal to pathogens - including Legionella - eliminating any health risks. Prior to this, all solid aggregates contained into the water (biofilm) have been destroyed by hydrodynamic cavitation, which will ensure an absolute effectiveness of the UV rays. Searle adiabatic cooling systems conform to the design requirements of ACOP L8 control of Legionella bacteria in water systems and NSF55 Class A. The adiabatic system is normally started from an external volt free signal provided by a capacity control system, BMS or emergency override. The ultraviolet lamp is switched on and the vent and drain solenoids are closed. After a set time delay the main solenoid is opened to flush the system before the pump is started. The pressure in the system and operation of the ultraviolet lamp as well as cavitation are monitored. If the water flow falls below the required limit, or the lamp fails the system will be closed down. The ultraviolet lamp and vent/drain solenoids are cycled off at the end of the day s operation, ensuring the lamp operates at full power and that flushing is not repeated unnecessarily, no free standing water is left in the system when inactive for extended periods. At the end of the sequence, the system (downstream of the main solenoid valve) has been fully drained and blown by compressed air. Searle Adiabatic (Spray) Cooling Systems

5 Control box and pipe schematic Sparge and nozzle assembly Adiabatic Control box main Inlet Strainer Mains solenoid normally closed Vent solenoid normally open Non return valve spray nozzles pointing away from the cooling coils Pump Restrictor 0-10 Bar guage 0-10 Bar gauge Bar pressure regulator UV Lamp spray nozzles pointing away from the cooling coils 1-10 Bar Pressure Switch Mechanical descaler Fitted in lowest free draining point of the system Drain solenoid normally open 5

6 TECHNICAL DATA Referring to the below tables choose the Dry Cooler/Condenser module designation and fan speed and then select the relevant letter (A, B or C) for the equivalent air velocity. Refer to the tables below for the selected letter and this will give you the adiabatic effective erature for the specified ambient conditions. Example 1 - Assume R/LFA with 080N6D fans = Table A. Assume ambient 32.0 / 50% RH / 23.6 = 27.0 o C WB effective adiabatic erature Example 2 - Assume M/DVA-L with 080N8D fans = Table C. Assume ambient 35.0 / 40% RH / 23.9 = 25.0 o C WB effective adiabatic erature Unit designation Fan designation models and speeds (Air speed codes) Module Ranges 091H6D 091H6S 091N6D 091N6S 080N6D 080N6S 080N8D 080N8S R/LF-A module A A A B A B B C R/LF-B module A A A B A B B C R/LF-C module A B A B B B B C R/LF-D module A B A B C C C C M/DVA - M A B A B A B B C M/DVB - M A B A B B B B C M/DVC - M B B B B B C C C M/DVA - L A B A B B B C C M/DVB - L B B B B B C C C M/DVC - L B C B C C C C C Table A - High air velocity Ambient o C Dry Bulb 30% RH Effective 40% RH Effective 50% RH Effective 60% RH Effective Searle Adiabatic (Spray) Cooling Systems

7 Table B - Medium air velocity Ambient 30% RH Effective o C Dry Bulb 40% RH Effective 50% RH Effective 60% RH Effective Table C - Low air velocity Ambient 30% RH Effective o C Dry Bulb 40% RH Effective 50% RH Effective 60% RH Effective

8 2. HEALTH AND SAFETY INSTRUCTION AND SIGNS This concerns the following hazards, which may be encountered when installing and maintaining this equipment: CAUTION All work on the unit s must be carried out by qualif ied personnel. Installation and maintenance manual must be kept with unit at all times. Ensure that instruction manual is understood before installation Ensure working environment is suitable. Use suitable PPE (Personal Protection Equipment) as per site regulations and as appropriate for the task. It is the responsibility of the person performing the task and their employer to ensure that all suitable PPE is provided and worn at all times. Detailed below is some of the suggested PPE during installation and commissioning of the unit. Head protection Foot protection Hand protection High visibility clothing Eye protection Before installation ELECTRICAL VOLTAGE Ensure that 1. The power supply is isolated before any installation or maintenance work is carried out. 2. The voltage, working fluid and the maximum working pressure stated on the product nameplate is suitable for the working environment. PROTECTIVE CLOTHING Sharp edges on the casework of the units and coil fins are a possible cause of cuts to fingers and hands. Appropriate protective clothing /gloves should always be worn. Ensure that: The proposed method of mounting is adequate to support the total operational weight of the unit. Dry Weights are given on the nameplate and the product sheet. Nameplate Data: When further pressure tests are carried out, the pressure applied shall not exceed 1.3 times the maximum operating pressure ( PS) given on the nameplate. When ancillary pressure equipment, such as a receiver, is supplied on a frame with a unit, but not a pipe to it, the parts must be treated as separate components and data taken from individual nameplates. Rotating blades dangling items of clothing, jewellery or any items that could be pulled into the fan set are a hazard. Keep safe working distance from the fan plate Searle Adiabatic (Spray) Cooling Systems

9 The fan guard should not be removed nor should the fanset be removed from the unit. During installation and maintenance, ensure that: The unit is installed and maintained by qualified personnel only. When pressure testing is carried out, the pressure applied shall not exceed 1.3 times the maximum operating pressure given on the nameplate of the unit. The temperature of coils with vinyl-coated fins does not exceed 150 C (e.g. during brazing), as toxic fumes would be produced. Be aware of burn hazard: Burn hazards 1. Burn hazards from pipes and pipeline components when the heat exchanger temperature exceeds 60 C. 2. Burn caused by refrigerant coming into contact with the skin or eyes. 3. LEGIONELLA An ultraviolet disinfection lamp is fitted as standard to the unit and will kill any Legionella in the supply water. (It is mandatory that the UV lamp is changed once a year. Under no circumstance should this system be run without a fully functioning disinfection lamp.) The system is designed to drain daily, so as to not harbour bacteria. Note, if the supply water temperature is lower than 20 C then multiplication of Legionella is inhibited. For this reason it is recommended that the unit is supplied directly from a cold mains whenever possible. To reduce the possibility of supply water exceeding 20 C and Legionella being in the supply water it is necessary to loop the supply, rather than create a dead leg in which water can stagnate. 9

10 4. WARRANTY PROCEDURE This warranty applies to all units detailed in this price list and, unless otherwise stated in product literature or specific contracts, provides for a manufacturer s guarantee of twenty four months from date of dispatch against faults in workmanship or materials. When submitting a warranty claim the following information is required: Customer s original reference number job / order number. Searle s job number / advice note number. Type of unit and serial number. Date of installation. Details of defect. When providing details of the defect, please give as much information as possible, Was the unit satisfactory on delivery? Frequency of fault (continuous / intermittent) Is the unit leaking? (+ location of leak) Items manufactured by Searle : No work should be undertaken to resolve the problem either by the customer or a 3rd party until approved by Searle failure to do so could invalidate the warranty. The item may be replaced or rectified if the guarantee claim is valid. For items that have been installed, Searle have the right to decide if rectification on site is suitable and who should undertake the work or whether to return / replace the unit(s). For items where Searle decides to replace, the original faulty item must be returned. All items which are returned will be inspected. If the guarantee claim is not valid the customer will be advised and further instructions requested, either to return the item or to issue an official order to replace or rectify the item. If you require a replacement product the buyer will be asked to supply a purchase order, when the unit has been returned and evaluated, the buyer will be notified by Searle if the claim is valid. Items NOT manufactured by Searle: The item will be replaced and the customer will be invoiced The item will be returned to the supplier for evaluation. If the claim is valid the credit received from the supplier will be passed on to the customer. Searle Adiabatic (Spray) Cooling Systems

11 5. INSTALLATION CLEARANCES Searle adiabatic spray system has three models in the range, two pumped and one non-pumped. The pumped systems are available with two sizes of single phase pump. All units are fitted with an ultraviolet disinfection lamp. The adiabatic system is housed in a steel IP55 enclosure and is available as a factory fitted option to all of Searle s condenser and dry cooler models. It can also be supplied as a retrofit kit for existing installations and can be remote mounted. Factory fitted units are supplied with the adiabatic box fitted to the opposite end to the inlet/outlet headers. V-bank units are supplied with the sparge pipes fully assembled; flat bed units are supplied with the sparge assemblies loose for fitting on site. This is because they would interfere with lifting the unit. Installation clearances for particular condenser/dry cooler model should be adhered to. In addition to these clearances, provision for opening the adiabatic door should be made (min 1025mm from door face). A clearance below the coil face on flat bed units is also required (min 250mm). Flat Bed Units Locate the sparge support beams under the coil at the specified pitches (refer to unit drawing) and secure to the side plates using clamps provided (note locate the channels in descending hole positions to enable a sufficient drop for draining). Fit the pipe clamps into the channels and locate the sparge pipes into the clamps, join using fittings supplied. The spray nozzles should be V Bank Units Rivet the sparge support brackets to the support beams on the coil face using the holes provided. Fit pipe clamp arrangement to appropriate fixing positions on sparge support brackets. Follow diagram for relevant positions to provide a drop that allows good drainage. The spray nozzles should be pointing across the coil face with all 3 rows pointing up at an angle of approximately 30 to the vertical. Make the connection with the adiabatic box ensuring that the lime scale inhibitor is fitted in line (if supplied loose). Ensure that the drain solenoid is at the lowest point of the system and non-return assembly at the highest. The drain solenoid is normally fitted onto the lowest point on the inlet of the sparge assembly. (If the unit is raised on steels and the adiabatic box is remote then it may be necessary to reposition the solenoid to avoid water trapping in the pipe work). All components must be handled with care during assembly. D 2 x D Fig 1 Avoid obstructions within 2 x diameter of the fan outlet 11

12 0.5L 0.15L 0.25L 0.3L Solid wall 0.5L 0.5L 0.4L 0.7L Solid obstructions along Solid obstructions along any two walls 3 side of unit(s) 0.5L Note: L = Unit Length W= Width Fig 2: Recommended dimensions for location of units to avoid inlet or outlet restrictions objects such as walls. Extended legs offer a cost effective way to reduce warm air recirculation, reducing inlet flow velocities and increasing the average distance between warm and cool air. Fig 3: Avoid wind creating additional pressure for fans to work against, particularly at low speed - < 400 rpm. Not applicable to V bank units W < 0.75 H >2m >=1m w w H Fig 4: Avoid inlet air being drawn from above the height of the outlet. Fig 5: Avoid outlet air pulled down between adjacent units Searle Adiabatic (Spray) Cooling Systems 0.3L

13 Water Supply and Drainage Ensure that the method of supply complies with local water regulations. The supply water must be clean and free from particles. Although the unit is fitted with an inline filter and some nozzle types have separate filters it is the responsibility of the end user to ensure a clean supply; no liability will be accepted for blockage of nozzles. The minimum supply pressure required is 2 bar. Ensure that the supply pipe work does not transmit any load or vibration to the unit pipe work. Supply pressure at the control valve must be positive before and during operation. A significant proportion of the delivered water is lost by evaporation, but there will be some over-spray and provision should be made for drainage. Under no circumstances should over spray water be recycled back to the spray nozzles. Units Fitted With Pumps The maximum pump flows at 3 bar are 23l/m for 2HM4T and 46l/m for 2HM5T. For exact flow rates for individual units refer to Searle quoting the operating conditions required. PUMPS ARE NOT SELF PRIMING AND REQUIRE A MINIMUM OF 2 BAR AT THE INLET. Pump ratings 2HM4 (1 phase) Input Power 0.66Kw Input Current V 2.92A 2HM5 (1 phase) Input Power 0.85Kw Input Current V 3.72A Frost Protection The pump and spray system are self-draining so frost protection is not necessary. However, frost protection is required for the supply pipes up to the mains solenoid. 13

14 6. SEQUENCE CONTROLLER Both pumped and non-pumped units are fitted with a Dedicated Function Controller, the controller is factory set using a laptop and these settings cannot be altered by the customer without a laptop and relevant Software. Two programs are available to download to the controller and have the following strategies Standard Settings Pumped: When the Enable signal is closed, the UV lamp is energised, after a warm up delay the mains solenoid is energised allowing water to fill the system for 1 minute. The pump is then started and the system allowed to pressurise, if the pressure switch (set to 3 bar) closes within 1 minute The system displays Healthy and the System will run until the enable signal is removed. If the UV switch contacts fail to close within 3 minutes or open during operation the system will lock out and Display UV Fail. The pressure switch will shut down the adiabatic system in the event of water supply failure. To reset press the ESC button. Standard Settings Non-Pumped: On enable, the UV lamp is energised, after a 1 minute delay the mains solenoid is energised allowing water directly to the nozzles. A pressure switch is incorporated with a 1 minute delay after the mains solenoid is opened, this should be set at 3 bar. The pressure switch will shut down the adiabatic system in the event of water supply failure. To reset interrupt the enable signal. Both adiabatic systems will shut down under fault conditions due to the following: If the UV lamp fails If the pump delivery pressure falls below 3 bar The controller will display its start and run functions as below, If the unit suffers a low pressure fault, then the controller will store the event even when the power is turned off. When the fault has been rectified press the ESC button to reset the controller. To employ the Back Light function press and hold any other button. 5 Commissioning Instructions Adiabatic flow 5 Bar Model 1 Fan 2 Fan 3 Fan 4 Fan 5 Fan l/m l/m l/m l/m l/m V- bank n/a Flat bed Model 2x2 FAN 2x3 FAN 2x4 FAN 2x5 FAN 2x6 FAN l/m l/m l/m l/m l/m V- bank Flat bed The adiabatic control system can be linked a number of different control systems; refer to the unit controller instructions to check the settings and to initiate the system. Before running the unit for the first time, check that all pipe joints are secure. Supply pressure at the control valve must be positive before and during operation and is recommended to be no less than 2 bar. The unit will not run unless an adequate supply is present. With condenser fans running, initiate the adiabatic system. Set the system pressure / flow rate using the flow regulator and pump bypass (pump models only). The discharge pressure should be set between 3.7 and 5 bar depending on the unit water flow requirements. Check the spray coverage is even and if necessary adjust the spray direction by rotating the sparge pipes. A pressure switch is incorporated with up to 8 minute monitoring timer (dependant on unit type) and this is factory set to close at 3 bar, this will shut down the adiabatic system in the event of water supply failure. Searle Adiabatic (Spray) Cooling Systems

15 The adiabatic system will shut down under fault conditions due to the following: 1. If the UV lamp fails 2. If the water pressure falls below 3 bar. 3. There is a monitoring timer that overrides the pressure switch for up to 8 minutes from the time the unit is enabled (factory set at 1 minute). This allows the water flow to stabilize. If the UV lamp or water supply has failed, after the set delay the timer will lock out all functions. To reset interrupt the enable signal. UNDER NO CIRCUMSTANCES SHOULD ANY OF THE ABOVE SAFETY FEATURES BE OVERRIDDEN Searle Adiabatic System Operating Sequence from Enable Signal Closing Yes UV Warm up Time Dry Contacts Close < 3 minutes and closed during normal running No Yes System pressure switch closes within 1 minute and remains closed during operation No 15

16 7. MAINTENANCE The following routine maintenance is required: When the system is in standby over the winter months it is important to initiate the system and allow the pump to run for a period of 5 minutes every 2 months to the prevent bearings drying up. Every 3 Months of use: 1. Remove and wipe clean the quartz sleeve of the UV lamp. 2. Remove and clean the strainer. 3. Check the drain tubes are clear. 4. Check for blocked nozzles and replace filters if necessary Additionally, every 12 months, in the spring: 1. Dismantle and clean nozzles, replace nozzle filters where applicable. 2. Check the coil for limescale deposition. If this is significant it is necessary to further soften the water supply. 3. It mandatory to remove and replace the UV lamp element and clean the quartz sleeve every 12 months. A lamp change record sheet is fitted inside the adiabatic box, this must be updated and the next due date recorded every time the lamp is changed. 4. Check that the pump rotates freely. 5. Run the spray system, check it functions correctly and also check the pipelines for damage / leaks and that the spray nozzles are not blocked. 6. Ensure that the system drains completely when UV lamp deactivates. Additionally, every 3 years, in the spring: 1. Upon removing UV lamp sleeve/element, both the UV lamp element and the quartz sleeve should be replaced. Lamp and sleeve can only be removed from the reactor chamber as 1 piece ensuring the user is aware of any build up of minerals on quartz sleeve. The lamp can be easily removed and replaced for maintenance. Instructions for UV Lamp replacement Shut Down 1. Shut off mains solenoid and allow system to drain. 2. Unplug the power supply and let the lamp cool for 5 minutes. 3. Squeeze the sides of the safety cap in the area opposite the tabs (do not squeeze tabs), and remove the cap. 4. Pull the lamp plug off the lamp end. Do not pull on the cord when removing the plug. Lamp Removal 1. Unscrew the lamp/sleeve assembly and carefully remove it from the reactor. Handle assembly by ends only. If required, a wrench can be placed on the two flat sides of the sleeve bolt. Do not apply the wrench to the lamp end, which sits within the sleeve bolt and protrudes 1/4. 2. To remove the lamp from its sleeve, use a glove or cloth to support and hold on to the sleeve. Holding the sleeve bolt tight, unscrew the lamp end, the top of which protrudes 1/4 above the sleeve bolt. Be careful not to drop the sleeve. If required, place an adjustable wrench on the two flat sides of the lamp end. Cleaning 1. Remove first O-ring, sleeve bolt and second O-ring from lamp sleeve. 2. Clean lamp sleeve and sleeve bolt using a soft, lint-free cotton cloth and a chemical scale-remover such as Lime-a-WayTM or CLRTM (follow manufacturer s directions). Alternatively, use spirit vinegar or hydrofluoric acid followed by mild detergent. Remove all traces of cleaning solution by thoroughly rinsing. Searle Adiabatic (Spray) Cooling Systems

17 Lamp Installation 1. Each lamp and sleeve comes with two new O-rings. Place the new O-rings and the original sleeve bolt on the lamp sleeve. Caution: Do not lubricate any of the O-rings. 1. Put the lamp completely into the sleeve. Maintain it in that position and screw the sleeve bolt into the lamp end until solidly hand-tight. 2. Carefully place the lamp/sleeve assembly into the reactor, making sure it is centred. Apply pressure to the assembly and screw it into the reactor until solidly hand-tight. Caution: Over tightening will break the quartz lamp sleeve. 1. Push the plug onto the end of the lamp while ensuring that the male tab on the lamp end meets with the female tab on the plug. 2. Push the safety cap on while ensuring that the grounding wires are under the cap and not in the way of the tabs. Restarting 1. Press and hold the push-button on UV controller. 2. Connect the power supply to the outlet while continuing to press the push-button. The indicator light will flash green. 3. Continue to hold the push-button until the indicator light flashes red, then release immediately. 4. If timer does not reset, unplug power supply, wait 15 seconds and then repeat steps 1-3 of Restarting. 5. Enable adiabatic system (force adiabatic system on). After system has filled, check for leaks Searle accepts no liability according to Searle s terms and conditions of sale, or for loss or damage arising as a result of: 1. Failure to ins tall, set up or put to work any par t of equipment in the manner specif ied in the I&M instructions, 2. Failure to maintain the equipment in the manner specified in the I&M instructions, or 3. Replacement parts, additional parts or accessories manufactured by persons other than Searle having been incorporated into, or attached to the equipment, or (iv) The equipment having been adapted for use, operated or used in such a way as does not conform to Searle s recommendations. 8. SPARE PARTS Description Part number Description Part number 2HM4 Pump 1 Phase HM5 Pump 1 Phase Inline scale inhibitor (blue)- pre spring 2005 Inline magnetic scale inhibitorpost spring Strainer c/w Ball Valve bar Pressure Regulator Spray Tip 301AF Rapid Pipe Clamp (7/8 ) Spray Tip Filter 301AF Restrictor Solenoid Valve 1/4 N/O ½ Non Return Valve Solenoid Valve 1/2 N/C Pressure Switch Solenoid Coil Millenium Controller Trojan UV Max D C/W Volt Free Contacts Pushfit 22mm Cu Straight Conn Replacement UV Bulb Trojan UV Max D Pushfit 22mm Cu Equal Tee Replacement Quartz Sleeve Trojan UV Max D Pushfit 22mm Cu Elbow Pressure Gauge 0-10 bar Pushfit Release Tool

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