ACC Installation Manual (Knock-Down Delivery)

Name of document Installation Manual of ACC Equipment
Name of client
Project No.
Project Name
BTTC Doc. No. BTTC-D-XX-XXX-XXX Rev 0
Installation Manual of
ACC Equipment
Condensing Air Cooler
GEA Batignolles Thermal Technologies (Changshu) Co., Ltd.

Project No.
Installation Manual Project Name
XYZ Unit BTTC Doc. No.
BTTC-X-XX-XXX-XXX
Rev 0
No. of Page 2 of 49
Table of Contents
I. Overview
II. Steel Structure
III. Tube Bundle
IV. Shutter
V. Collecting Pipe
VI. Fan
VII. Auxiliary System Equipment
VIII. Pipeline
IX. Instrument Installation
X. Installation of Pressure and Temperature Reducing Devices
XI. Test of System Tightness
XII. System Flushing
XIII. Commissioning of Drainage Pump
XIV. Commissioning of Condensate Pump
XV. Commissioning of Fan
XVI. Starting of Vacuum Device
XVII. Starting of Shutter
XVIII. Inspection of Construction Materials
XIX. Attachment
Installation Manual of ACC Equipment Page 2 of 49

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No. of Page 3 of 49
I. Overview
1. This document describes the installation methods, technologies, processes,
quality requirements and commissioning scheme of single machine at cold
state of air cooler equipment manufactured and supplied by Batignolles
Thermal Technologies (Changshu) Co., Ltd..
2. This document belongs to technical guidance document which is compiled
for installation and commissioning of air cooler equipment by Batignolles
Thermal Technologies (Changshu) Co., Ltd., and it shall not be used as rule,
norm or standard.
3. The configuration, structure and features of air cooler equipment described
in this document are all those of general equipments; therefore before
installation and construction, the design drawings and related technical
documents on the project must be re-checked and necessary supplementary
instruction shall be probably compiled.
II. Steel Structure

1. The steel structure of air cooler is the support frame for installation of air
cooler equipment. Generally, structural members are supplied in bulk and
assembled on site. The overall frame is composed of concrete and rigid frame
with two kinds of composition forms: one form is that the crossbeam of
working plane of steel structure shall be installed on the top of concrete
frame, and the second form is that post of steel structure shall be installed on
the concrete foundation.

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2. All installation, connection and fixation of steel structure must adopt bolt-on
mode.
3. The connection and fixation of steel structure and concrete frame (foundation)
adopt two modes: one is welding of direct embedded parts and the other is
back-grouting.
Post base-plate of steel structure
Gap adjustment 0—20mm
Back-grouting
钢结构立柱与混凝土基础连接
Back-grouting Mode

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Base-plate of
beam
Gap adjustment of parallels:

Embedded Welding 0-20mm
iron
Welding Mode of Direct Embedded Parts
4. Installation sequence of steel structure:

4-1. The axis location of steel structure shall be confirmed based on general
layout.
4-2. The ground elevation of concrete foundation and vertical and horizontal
centre line of axial line shall be adjusted.
4-3. Select steel structure and assemble trusses on the ground, namely, pre-
assemble partial components (including crossbeam, connecting beam,
walkway beam, frame beam of seal-plate and others).
Lifeline
Assembly of trusses

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4-4. Hoisting of trusses
Hoisting of No. 1 truss
Operating condition of 30.5m tower arm

60.95m main arm
4 hoisting belts with 10t* 15m
Lifeline made of steel wire rope with diameter of 12mm
American-standard bow shackle 17t-4
4-5. Assemble A-type frame on the ground, namely, pre-assemble partial

components (including crossbeam of A-type frame, connecting beam and
others) on the ground.
4-6. Hoisting of A-type frame

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Hoisting of A-type frame

25m tower arm
27m main arm
3t*10m hoisting belt is equipped with one 3t*6m chain block,
and using 10t*15m two hoisting belts to bind both ends of steel beam below and connecting
them with two 9t shackles.
Use two 2t*5m hoisting belts to connect the structure at this point and chain block.
4-7. Assembly of wind break wall in four directions of steel structure to finish
installation of the whole structure.

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III. Tube Bundle

1. The tube bundle belongs to heat exchange equipment of air cooler, which is a
kind of platy equipment and composed of components like flash heating pipe,
channel, top slab, side beam, framework and others; there is no specific
sequence number for tube bundle equipment as long as staggering location of
hoisting lug when being installed (there are two kinds of spacing dimension of
hoisting lug).
2. Hoisting of tube bundle

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The angle of tube bundle can be adjusted by using 2 chain blocks with 5t.
Installation of sling of tube bundle.
5t*10m hoisting belt
3t*8m hoisting belt
3t*6m chain block
4 shackles with 6.5t

Hoisting of tube bundle
Operating condition of 30.5m tower arm
60.95m main arm
3. After the tube bundles being hoisted in position, connect and fix them with A-
type frame by using bolt-on mode.

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4. The tube bundles are equipped with expansive fixed points; tube bundles
without expansive fixed points shall be connected to A-type frame with bolts,
and after completing the welding and installation of collecting pipes,
dismantle the upper and middle connecting bolts.
5. Hoisting of ALEX tube bundle
5-1. ALEX tube bundle is divided into condensation bundle and counter-current
bundle, and the counter-current bundle is arranged at the middle position
of tube bundle.
5-2. Tube bundles are assembled on A-type frames on the ground and the
assembly dimension shall reach standard requirement of design drawing;
after completing the welding of top slab, an integral component including
tube bundle and an A-type unit has been formed.
5-3. Tube bundles have been hoisted in position piece by piece according to A-
type unit component.

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5-4. After tube bundle is hoisted in position, its location on sliding blocks is
supported by lower channel, and its fixation with welding connected with
steel structure beam and top plate is also supported by lower channel.
IV. Shutter
1. The shutter belongs to anti-freezing insulation equipment for tube bundles,
which is a kind of platy equipment and composed of rigid frame, blade and
rotary adapting piece and others.
2. The hoisting mode of shutters is similar to that of tube bundles; before being
hoisted, in order to prevent equipment from deforming, two strengthening
beams shall be installed provisionally, which are called hoisting beams during
supplying.
Shutter equipments

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Hoisting of shutters
3. After being hoisted in position, shutters shall be connected with tube bundles
by using bolt-on mode, and strip shaped seal-plates shall be installed on the
top of connected bundle equipments.
4. The starting actuator of shutter is divided into manual actuator and
pneumatic actuator.
4-1. The manual actuator is composed of seat frame, hand shank, junction plate
and others, all of which are installed at the starting connecting rod under
the shutter by using bolt-on mode.
4-2. The pneumatic actuator has one set of pneumatic equipment, which are also
installed at the starting connecting rod under the shutter by using bolt-on
mode.

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Connecting
with the
starting rod Connecting rod
of shutters
Actuator
Hand shank
V. Collecting Pipe
1. The collecting pipe belongs to the allocate equipment of steam at inlet of tube
bundles, which is supplied with several divided pieces; after being hoisted in
position on site, it is formed through butt welding.
2. The following construction items shall be finished before hoisting of collecting
pipes:
2-1. Top slabs of tube bundles shall be levelled and aligned to secure that the
spacing dimension of top slabs comply with design requirements and overall
butt welding shall be completed.
2-2. The welding and installation of exhaust U-tube shall be completed. Before
welding of U-tube, the sealing plastic cap of tube bundle shall be removed
and plank laying shall be used instead to seal tube bundles.
2-3. The welding and installation of arc slabs between top slabs of tube bundles
shall be completed (arc slabs are required to weld both in the right side and
the opposite side).
2-4. The spacing dimension of opening of collecting pipes shall be measured and
re-checked; there are bolt device for spacing adjustment inside of collecting
pipes, which can adjust weld gap when installing and welding of collecting
pipes.

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U-tube
Devices for
spacing
adjustment
Sealing arc slab on the bottom
3. Collecting pipes are hoisted piece by piece and butt-welded after being in
position.
4. After completing the installation of collecting pipes, two ends of them shall be
seal-welded.
Rectangular slab
Inlet end of
collecting
pipe Tube
bundle Tube
bundle
Arc slab
5. After completing welding and installation of collecting pipes, all bolt adjusting
devices inside of them shall be removed, and 100% dye penetration (PT) test

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shall be conducted on all welded joints and 20% RT test shall be conducted
on girth joints of collecting pipes.
VI. Fan
1. Gearbox-drive fan is composed of rigid support, gearbox, motor (variable
frequency motor), hub, blade, air duct, ventilating duct, mesh enclosure and
other equipments respectively.
2. Pulley-drive fan is composed of rigid support, driving and driven pulley,
synchronous belt, actuator, motor (variable frequency motor), hub, blade, air
duct, ventilating duct, mesh enclosure and other equipments respectively.
3. Installation of gearbox-drive fan:
3-1. The rigid support of fan shall be installed at the bottom of beam of fan aisle
of steel structure and fixed by using bolted connection mode. When
installing, ensure the levelness of precision machine surface on the top of
support and adjust it with gaskets supplied randomly.
3-2. The gearbox shall be horizontally installed at the plane of rigid support and
fixed by using bolted connection mode. For installation of gearbox, the
perpendicular degree of shaft extension of gearbox shall be detected as final
standard.
3-3. The motor shall be vertically installed at the plane on the top of gearbox and
fixed by using bolted connection mode. The installation position of double
pulleys of motor shall be confirmed before being installed to ensure that
certain gap can be maintained between double pulleys of motor and that of
gearbox after being connected.

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3-4. The gap between double pulleys of motor and that of gearbox after being
connected shall conform to requirements of following tables.
Component
Figure 5: ADR Compact Poly-Norm ®

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Component
Figure 6: AR/AZR Poly-Norm ®
Table 8: Dimension-AZR Compact and AR/AZR
Cast iron (EN-GJL-250) AZR
Compact and AR/AZR Poly-Norm ® , steel (S355 J2G3) 4N components
Size
Dimension (mm)
Normal dimension
Fixed screw and thread 1)

3-5. Hub is a plain disk, which is installed on the flange of shaft extension of
gearbox by central butt-joint and fixed by using bolted connection mode;
the blade is installed on the hub, which is fixed by special U-bolt. The
installation angle of blade, gap between blade and air duct and height
difference between blades shall be adjusted well based on requirements of
data sheet when installing of blade.
Hub
Blade Mesh enclosure
3-6. The air duct is made of arc zinc-coated steel plate and is installed under the
seal-plate of fan. Ventilating duct and mesh enclosure are installed on the
air duct, which are fixed by using bolted connection. The groove part of air
duct will adopt countersunk screw and special gasket.

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Air duct
For ventilation
4. Installation of pulley-drive fan:

4-1. The fan support belongs to H-shaped rigid frame, which is installed under
the air duct and connected and fixed to it by using bolt-on mode.
Actuator
Fan support
4-2. The actuator of fan is installed on the C-shaped crossbeam of fan support
and connected and fixed with bottom bolts. The levelness between the plane
on the C-shaped crossbeam of fan support and junction surface of actuator
shall be maintained when installing. The actuator must be captured and
levelled when installing. The shaft extension of actuator and centre of air
duct shall maintain coaxial, and the deviation of it shall not be more than
3mm.
4-3. The motor is installed on the support frame of motor with vertical and
upside-down form, and the support frame of motor is divided into plane
tabular form and vertical triangular form, both of which will not change

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the installation form of motor; the perpendicular degree of shaft extension

of motor shall be captured after being installed of motor.
4-4. Installation of belt pulley
4-4-1. The shaft sleeve of driven pulley shall be firstly installed at the axis of
rotation of actuator and height position shall be confirmed (make the belt
higher than frame of motor).
4-4-2. Driven pulley and driving pulley shall be installed and the deviation of the
symmetrical plane of two belt pulleys shall not be more than (1/400)×A
(centre distance of two belt pulleys).
4-4-3. For height adjustment of two pulleys, driven pulley is considered as
positioning pulley, and drive pulley is considered as adjusting pulley.
4-4-4. Inspection method of deviation of symmetrical plane of belt pulley:
Driven pulley Driving pulley
Detecting line
A B C D
Adjust A, B, C and D total four points of two pulleys

to the same straight line.
4-5. Installation of belt:

4-5-1. Before installing of synchronous belt, narrow the gap between belt pulleys
(loose displacement of motor and adjust bolt). After installing belt and
recover the gap between belts.
4-5-2. The installation pre-tightening of synchronous belt can be adjusted with
bolts through the adjustment of displacement of motor.
Caution: when installing of synchronous belt, do not overexert or install
powerfully with pinch bar to prevent tensile layer of synchronous belt
from breaking.
Reminder: installation of synchronous belt shall have certain tension. If
the tension is too small, the belt teeth will jump from tooth space of belt
pulley (jumping gear) when frequent starting or under shock load. If the
tension is too large, the service life of synchronous belt will be reduced.

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4-5-3. Pre-tightening adjustment of synchronous belt
F
W
F=0.16T mm
（ D2－D1）2
T= A2－ mm
4
D2 -----Diameter of bull pulley

D1 ------Diameter of pony pulley
Mode Width of belt (mm) Applied force W (N)

100 142.1
HTD-14M 115 166.6
130 196
150 225.4
4-6. Installation of fan blade:

4-6-1. A fan is composed of several blades respectively, which are installed on
the top of hub and fixed on it with two lines of U-bolts. The U-bolts shall
be equipped with retaining washer of nut.
4-6-2. Before installing and fixing blades, adjust well the gap between top of
blades and fan hoop and angle of blades.
The angle of blades shall be adjusted with level gauge based on
requirements of drawing. The installation angle of blades shall conform to

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the value stipulated in the data sheet of fan and the deviation of it shall not
be more than ±0.5 degrees. After being installed of several blades, the top
height of blades must keep the same horizontal plane. The deviation of
height of them shall not be more than 10mm (because blades with different
materials and different manufacturers have different requirements, refer
to special documents in combination).
Reminder 1: fan hubs and blades have been completed balanced

configuration in factory; therefore, they shall be installed based on the
sequence number.
Reminder 2: it is strictly forbidden to climb or lay stressed components on
blades because they will lead to sag and deformation of blades and thus
cause rotation and vibration of fan.
4-7. Installation of mesh enclosure
4-7-1. The mesh enclosure of fan is composed of mesh and mesh support.
4-7-2. The mesh support (which is made of square steel) shall be installed
between rack and support of ventilating duct, and fixed by using bolted
connection.
Mesh Support
4-7-3. Meshes shall be laid on the mesh support and fixed with bolt clip.
4-8. Installation of vibration switch of fan:
4-8-1. Based on requirements of design drawing, the support of vibration switch
shall be installed on the fan rack by using bolt-on mode.

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4-8-2. The vibration switch shall be calibrated orientation based on equipments

and installed on the support of vibration switch by using bolt-on mode.
4-8-3. The vibration value of vibration switch will be adjusted and set along with
starting of fan, and methods of adjustment and set will be given in
installation manual of products.
VII. Auxiliary System Equipment

The auxiliary system equipment includes cooling cylinder (hot well), cooling
water pump, draining pump, vacuum device (air ejector), catch box and others.
This kind of equipment belongs to aggregate unit, which is directly hoisted on
the concrete foundation and fixed through back-grouting of foundation bolt.
Installation of catch box

The condensate tank is installed according to the direction of thermal expansion
determined in design.
The water pump shall be installed based on the installation manual of products
or requirements of drawing.

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The vacuum device (air ejector) shall be installed based on the installation
manual of products or requirements of drawing.
VIII. Pipeline
System pipelines mainly include pump-line, pipe bundle condensate pipelines,
main exhaust pipes and connecting pipelines of auxiliary system.
1. Main exhaust pipe is connecting pipeline between outlet of steam turbine and
inlet of connecting pipe, and pipes will be supplied in section according to design
length. Welded junction will be connected on site, and the whole pipe is installed
on the support of concrete foundation.
Outlet section of steam turbine is installed on concrete foundation, and bottom

support and foundation are connected with embedded bolts.

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Vertical pipe
Horizontal pipe
1-1. In general, support of main exhaust pipe consists of fixed support, sliding
support and spring support.
1-1-1. Fixed support is laid under outlet elbow of steam turbine generally, and
before installation of pipeline, relevant person should check elevation of
concrete foundation and overall levelness of embedded steel plates. This
support is foundation bolt fixation form generally, after installation and
adjustment of upper rectangle-circle connector, rectangular expansion
joint, square flange and other equipments, relevant personnel can prepare
parallels solid support according to actual gap between support bottom
and concrete foundation, fasten foundation bolt, and finally perform back-
grouting (or foaming surface) for concrete foundation.
1-1-2. Before installation of sliding support, relevant person must check
elevation of concrete foundation and overall levelness of embedded iron,
and error must be adjusted. Relevant person should also install limit parts
(in general, limit parts use welding way for fixation) according to design
requirements and ensure than support moves in the same plane.
1-1-3. Spring supports are installed according to model selected in design and
referring to installation manual of the supplier. The connection between
spring support base and embedded iron of concrete foundation will use
foundation bolt fixation way, and welding method for fixation is not
recommended.
1-1-4. Upper plane of spring support and lower plane of pipe saddle are sliding
contact surfaces, and lower plane of pipe saddle of sliding support and
upper plane of embedded iron of concrete foundation are also are sliding
contact surfaces. Non-metallic gaskets will be arranged between sliding
contact surfaces.

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1-1-5. Stop pin (nail) must be released after installation of spring support
finishes and it reaches working load.
1-2. Expansion joints of all kinds of pipelines should be installed according to
model and form selected in design and referring to installation manual of
the supplier.
1-2-1. Before installation of expansion joints (including during installation), all
reinforcing members cannot be dismantled.
1-2-2. No stress connection between expansion joints and pipelines shall be
ensured.
1-2-3. Welding end of guide plate inside expansion joint is installed in the
upstream of medium flow direction.
1-2-4. After installation of expansion joint (including, installation of related
supports and equipments finish), transportation reinforcing members (bolt)
must be dismantled, and in general, dismantled parts (bolt) have yellow paint
marks.
2. Condensate water pipe of pipe bundle is connecting pipeline between outlet of

pipe bundle and cooling cylinder, and pipes are installed on the lower support of
steel structure walkway beam. Pipeline supports are configured by construction
units on site, and top of pipeline U shape water seal elbow keeps the same level
elevation line with external bottom of lower channel of pipe bundle. According
to design requirements, horizontal sections of pipeline tilt 0.3-0.5% along flow
direction of medium, and gaps should be left between pipe and steel structure as
well as pipe and equipments for construction of thermal insulation.
Piping of pipe bundle outlet (see Figure 0010)

3. Suction pipes are connecting pipelines between connecting pipe and vacuum
device, and pipes are installed on support of side beam of steel structure.
Pipeline supports are configured by construction units on site.

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Installation of suction pipe at the outlet of connecting pipe Connecting transportation piping
4. Pipelines inside auxiliaries building include inlet pipeline of condensate tank,

connecting pipeline of condensate pump of condensate tank, connecting
pipeline of air ejector of condensate pump, outlet pipeline of air ejector, etc.
4-1. Pipelines inside auxiliaries building are all pipelines configured on site
which are configured and installed by construction unit according to the
requirements of design drawings.
4-2. Stress connection of inlet/outlet pipelines of condensate pump and drainage
pump must be conducted after adjustment completion of water pump (double
pulley capturing).
4-3. Variable neck pipelines have two kinds of installation locations: upper flat
and lower flat, and they should be correctly installed according to the
requirements of design drawing. If there is not design requirement, installation
can use lower flat position to avoid water accumulation inside pipeline.
5. For pipeline installation, in addition to complying with design requirements,

GB50235-2010 and GB50236-2011 two regulations are met generally.
IX. Instrument Installation

1. Auxiliary instruments of air cooler can include the following scope:
1-1. Pressure transmitter, temperature transmitter, liquid level transmitter.
1-2. Local pressure gauge, thermometer, level gauge.
1-3. Meter terminal box, distribution box, branch cable, bridge (pipe).
1-4. Electric valve, pneumatic valve, shutter actuator.
1-5. Temperature switch, pressure switch, vibration switch
2. Equipments should maintain original installation form and state.
3. Typical installation samples of instruments

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Bimetallic thermograph Thermal resistance
Flange type thermal sleeve Flange type thermal sleeve
Flange type thermal sleeve Flange type thermal sleeve
Water tank body connecting flange Water tank body connecting flange
Water tank Water tank

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Thermal resistance
Straight fitting
Threaded thermal sleeve

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Water tank body flange Flange type globe valve
Flange on level instruments
Magnetic level gauge/Installation valve of liquid level transmitter

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Main exhaust pipe of steam turbine
Bypass steam pipe/inlet of vacuum-pumping device

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Pipe of condensate pump
Condensate water tank

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6 Damper (two ends are M20 female threads), one end fitting serial number 4, and the other end
fitting (one end is M20* 1.5 female thread, and the other end is ferrule fittingφ14*2)
5 Pressure gauge, M20* 1.5 male thread
4 Fitting of pressure gauge (one end is fitting of pressure gauge M20* 1.5 (female thread); and the
other end is M20* 1.5 (male thread), connected to damper)
3 Condensation coil:14 ×2
2 Stainless steel instrument valve with 14 ×2 pipe (one end is 1/2”NPT male thread, and the other
end is double ferrule fitting equipped with 14 ×2 gauge pipe)
1 Pressure tap (φ30mm; length: 120mm; one end is welding groove and the other end is 1/2”NPT
female thread)
NO. Name
Material list
X. Installation of Pressure and Temperature Reducing Devices

1. Pressure and temperature reducing devices consist of barrel, pressure
reducing control valve, temperature reducing spray water control valve, spray
water booster pump, instrument, pipeline, etc. Devices are installed on platform
layer of steam turbine generally, and equipments are supplied in bulk and
assembled on site.
Start-up bypass device

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Pressure reducing
valve
High pressure
steam pipe
Spray water
control valve
Booster pump
Water
spray pipe
Direction of steam admission opening is consistent with that of steam flow.
Flushing reserved hole
2. Start-up bypass flushing:
According to design requirements, start-up bypass of air cooler (pressure and

temperature reducing devices) must ensure cleaning of inner pipeline. If
cleaning requirements of inner pipeline can’t be met in construction, pipeline
flushing needs to be conducted before commissioning of devices.
2-1. Arrangement of flushing pipeline:

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Bypass steam
inlet pipe
Flushing
reserved hole
Orifice Flushing temporary

plate pipeline
Temporary Welding
blocking
board
Steam delivery
manifold
2-2. Enter inside the steam transfer pipe from manhole of steam transfer pipe
and block off temporary welding of bypass steam admission orifice plate.
Thickness of blocking board is 10 mm.
2-3. Flush connecting flange opening from steam inlet of device and take out
flushing temporary pipeline (flange connection).
2-4. Open pressure reducing valve through the whole process.
2-5. Open high pressure steam isolating valve to flush pipeline (use pressure-
stabilized interval flushing, directly visually observe if outlet steam is clean).
2-6. Flushing finishes and cut off temporary blocking of orifice plate (sand
welding ).
2-7. Dismantle temporary flushing pipeline, manually clear orifice plate parts,
and then block off flange door hole.
2-8. For spray pipe flushing, all that is needed is to take apart connecting flange
of nozzle inlet and start booster pump to do pipeline flushing.
XI. Test of System Tightness
1. Required conditions for system tightness test:

1-1. Pipe bundle, connecting pipe, condensation water tank, condensate
pump, catch box, drainage pump, vacuum device and other system
equipments finish installation, and are accepted as qualified.
1-2. Steam delivery manifold, condensate pipeline, vacuum-pumping
pipeline, drainage pipeline, vent pipe and other system pipelines as well
as related isolation valve, drain valve, vent valve, gauge valve, filter
valve installation and other items finish installation, and are accepted

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as qualified.
1-3. System equipments, pipe supports and hangers finish installation, and
are accepted as qualified.
1-4. Welds of connecting pipe and vacuum-pumping U shape pipe
completes flaw detection.
1-5. Cleaning inside steam delivery manifold, connecting pipe and catch box
(use a cleaner to clear away dust in the pipe) is over and door hole is
blocked off.
1-6. Reliable test air source supply.
2. Scope of system tightness test
Blocking of exit
section of steam
Outlet of Catch box Steam turbine
steam turbine delivery
manifold
Connecting Pipe bundle Condensate Condensate

pipe connecting water tank
pipe
Blocking of inlet of condensate water

tank
U shape Vacuum-pumping
vacuum manifold
pipe
Blocking of inlet of
vacuum device
Vacuum
device
3. Temporary system for tightness test:

3-1. Steam delivery manifold uses steel plate welding to block in parts of outlet
elbow of steam turbine.
3-2. Inlet of drainage pump uses blind flange to block.
3-3. Inlet of condensate tank uses blind flange to block.
3-4. Inlet of vacuum device uses blind flange to block.
3-5. Inlet of gland steam exhauster uses blind flange to block.
3-6. Inlet of safety valve uses blind flange to block.

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3-7. Choose a connecting hole site in test system (can consider hole sites on the
catch box), and connect test air supply duct of compressed air.
3-8. Install test pressure gauge, and specification of pressure gauge choose Y -
150 (0-2.5 kg).
4. Technical parameters of tightness test:

4-1. Test pressure is in accordance with the requirements for system pressure
parameters of this engineering project (general select 0.4 kg/cm2).
4-2. After system pressure booster reaches test pressure, perform constant
pressure test 4 hours.
5. Test operation:
5-1. Open all system connection valves
5-2. Shut down primary isolating valves of all instruments in the system
(instrument does not take part in test).
5-3. Shut down all outward discharge isolating valves in the system, and no
isolating valves are blocked temporarily.
5-4. Open air source isolating valve and convey gas to the system for pressure
boost.
5-5. System pressure rises to test pressure, shut down air source isolating
valve, use soapy water spraying method to conduct leakage inspection for the
system, and perform constant pressure test for the system for 4 hours.
5-6. Record pressure drop value which should not exceed 200 Pa/min
6. Test ends, dismantle temporary facilities and restore system.
XII. System Flushing:

1. Perform manual clear for pipe wall of steam delivery pipeline, connecting
pipe, condensate water tank, catch box and other items, and cleaned matters
cleared out by a cleaner.
2. Other equipments and piping systems use operation medium for flushing.
2-1. Medium flushing is conducted in the whole set start-up operation of the
system.
2-2. Condensed water outlet section connects temporary discharge pipe,
directly discharge system medium to achieve flushing purpose.
2-3. After medium discharge meets clear requirements, restore system.
XIII. Commissioning of Drainage Pump

1. Commissioning conditions:
1-1. Installation work of drainage pump, catch box and related connecting
pipelines, instrument is complete, and acceptance is qualified.
1-2. Supply of power has been put in service normally.

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
1-3. Electrical motor insulation and grounding devices pass the acceptance.
1-4. Layout of temporary water source and drainage channel is ready.
1-5. Lubricating oil depot, bearing and other rotating parts are injected with
lubricating oil.
1-6. Manual hand-pulley rotates flexibly.
1-7. Connect water supplement pipe of catch box, and possess water supply
condition.
2. Commissioning system:
2-1. Catch box Water inlet manifold Water pump Water outlet manifold Catch box
2-2. Temporarily connect main drainage pipe of water pump and isolating
valve of water level transmitter to form a circulating system.
3. Operation sequence:
3-1. Shut down drainage isolating valve of catch box and isolating valve of
instrument.
3-2. Open isolating valve of liquid level meter of catch box.
3-3. Open inlet and outlet isolating valves of drainage pump.
3-4. Shut down drainage isolating valves of drainage pump.
3-5. Open water supplement isolating valve, feed water into catch box. After
water level of catch box reaches high water level, shut down water
supplement isolating valve.
3-6. Open drainage isolating valve of drainage pump, and shut down this
valve after determining that water enters into water pump.
3-7. Shut down outlet isolating valve of B pump, and ready to start A pump.
3-8. Start A pump with point contact, and confirm direction of rotation.
3-9. Start A pump, and confirm that there is not abnormal condition at the
time of stopping pumping after pump reaches full speed (starting
current, mechanical contact, vibration, etc).
3-10. Restart A pump, enter into commissioning, and commissioning time is
two hours (record running current of motor, temperature of motor
and pump bearing), stop pumping.
3-11. Shut down outlet isolating valve of A pump, open outlet isolating
valve of B pump, and ready to start B pump.
3-12. Start B pump with point contact, and confirm direction of rotation.
3-13. Start B pump, and confirm that there is not abnormal condition at the
3-14. Restart B pump, enter into commissioning, and commissioning time is
two hours (record running current of motor, temperature of motor
and pump bearing), stop pumping.
4. System recovery:
4-1. Shut off power.

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
4-2. Open drainage isolating valves of drainage pump, and drain all
remaining water in commissioning system.
4-3. Cut off temporary pipelines, and restore system.
XIV. Commissioning of Condensate Pump

1-1. Installation work of condensate pump, condensate water tank, vacuum
device, control valve and related connecting pipelines, instrument and other
items is complete, and acceptance is qualified.
1-2. Supply of power has been put in service normally.
1-4. Connect water supplement pipe of condensate water, possess water
supply condition and layout of drainage channel is ready.
1-5 Lubricating oil depot, bearing and other rotating parts are injected with
lubricating oil.
1-6 Manual hand-pulley rotates flexibly.
2 Commissioning system:
2-1Condensate water tank Main water inlet Water pump Main water outlet condenser of vacuum device
Bypass recirculation pipe of control valve Condensate water tank
2-2 Shut down inlet and outlet isolating valves of control valve and open bypass
isolating valve to form a circulating system.
2-3 Dismantle inlet flow orifice plate of condensate water tank.
3 Operation sequence:
3-1 Shut down intake isolating valve of condensate water tank and isolating
valve of instrument.
3-2 Open isolating valve of liquid level meter of condensate water tank.
3-3 Open inlet and outlet isolating valves of condensate pump.
3-4 Shut down drainage isolating valves of condensate pump.
3-5 Open water supplement isolating valve, feed water into catch box. After
water level of catch box reaches high water level, shut down water
supplement isolating valve.
3-6 Open drainage isolating valve of condensate pump, and shut down this
valve after determining that water enters into water pump.
3-7 Shut down outlet isolating valve of B pump, and ready to start A pump.
3-8 Start A pump with point contact, and confirm direction of rotation.
3-9 Start A pump, and confirm that there is not abnormal condition at the
3-10 Restart A pump, enter into commissioning, and commissioning time is
two hours (record running current of motor, temperature of motor and
pump bearing), stop pumping.

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
3-11 After formation of water circular flow, supplement water to condensate

water tank until water reaches high water level.
3-12 Shut down outlet isolating valve of A pump, open outlet isolating valve of
B pump, and ready to start B pump.
3-13 Start B pump with point contact, and confirm direction of rotation.
3-14 Start B pump, and confirm that there is not abnormal condition at the
3-15 Restart B pump, enter into commissioning, and commissioning time is
two hours (record running current of motor, temperature of motor and
pump bearing), stop pumping.
4 System recovery
4-1 Shut off power.
4-2 Open drainage isolating valves of condensate pump, and drain all
remaining water in commissioning system.
4-3 Reassemble flow orifice plate, and restore system.
XV. Commissioning of Fan

1-1. Installation work of motor, gearbox, blade, drum, guard, instrument
equipment and other items of fan is complete, and acceptance is qualified.
1-2. Supply of power (MCC) has been put in service normally.
1-4. Motor breaks away temporarily and be fixed.
1-5. Gearbox, bearing and other rotating parts are injected with lubricating
oil.
1-6. Manual hand-pulley rotates flexibly.

1-7. Vibration switch has been put in service.
1-8. Aerological measurement scaffold has been set up.
2. Commissioning sequence of double speed motor:

2-1. Connect power supply of motor with point contact, confirm rotation
direction of motor.
2-2. Start low speed power supply, and confirm that there is not abnormal
condition at the time of shutdown after reaching full speed (starting
current, bearing friction, motor vibration).
2-3. Restart low speed power supply, perform commissioning of motor for one
hour, shut down (after 30 seconds).

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
2-4. Start high speed power supply, and confirm that there is not abnormal
2-5. Restart high speed power supply, perform commissioning of motor for
one hour, shut down.
2-6. Motor connects, find fastening place, manually coil up blades of fan for
several circuits.
2-7. Start low speed power supply, and confirm that there is not abnormal
2-8. Restart low speed power supply, perform commissioning of motor at low
speed for two hours, shut down.
2-9. After an interval of 30 seconds, start high speed power supply, and
confirm that there is not abnormal condition at the time of shutdown
after reaching full speed (starting current, gearbox and bearing friction,
motor vibration).
2-10. Restart low speed power supply, perform commissioning of motor at
high speed for two hours, shut down.
2-10-1. Measure and record wind speed at fan inlet.
2-10-2. Check and record operation voltage and three-phase current value of
motor.
2-10-3. Check and record operation power and power factor of motor.
2-10-4. Check and record temperature of motor and gearbox bearing.
2-10-5. Check and record vibration value of fan rack.
2-10-6. Check and record temperature of site environment.
2-11. Adjust vibration switch during commissioning of fan.
2-12. Commissioning finishes, and cut off power supply.
3. Commissioning sequence of variable frequency motor:

3-1. Connect power supply of motor with point contact, confirm rotation
direction of motor.
3-2. Start power supply of motor, start motor according to the set minimum
rotation speed and confirm that there is not abnormal condition at the time of
shutdown after reaching full speed (starting current, bearing friction, motor
vibration).
3-3. Restart power supply of motor, speed up from low to high according to
the set speed change curve for motor, perform commissioning of motor for
two hours after reaching maximum rotation speed, speed down step by step,
shut down.
3-4. Motor connects to gearbox, find fastening place, manually coil up blades of
fan for several circuits.

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
3-5. Start power supply of motor, rotates at low speed, shut down after motor
stabilizes and confirm that there is not abnormal condition (starting current,
gearbox and bearing friction, motor vibration).
3-6. Restart power supply of motor, speed up from low to high according to the
set speed change curve for motor, shut down after reaching full speed and that
there is not abnormal condition (starting current, gearbox and bearing friction,
motor vibration).
3-7. Restart fan according to process, perform commissioning of motor for two
hours, speed down step by step, shut down.
3-8. Record related data during commissioning of fan.
3-8-1. Measure and record wind speed at fan inlet.
3-8-2. Check and record operation voltage and three-phase current value of
motor.
3-8-3. Check and record operation power and power factor of motor.
3-8-4. Check and record temperature of motor and gearbox bearing.
3-8-5. Check and record vibration value of fan rack.
3-8-6. Check and record temperature of site environment.
3-9. Adjust vibration switch during commissioning of fan.
3-10. Commissioning finishes, and cut off power supply.
XVI .Starting of Vacuum Device

1. Starting conditions
1-1. Air-cooling system has a whole set of start-up conditions.
1-2. Power steam is put in service normally.
1-3. Circulating system of condensate water is put in service normally.
1-4. Local instruments are put in service normally.
2. Starting procedure
2-1. Check that all valves are shut down.
2-2. Circulating system of condensate water is put in service.
2-3. Open discharge valve of primary nozzle.
2-4. Open drainage bypass valve.
2-5. Open main valve of power steam.
2-6. Open power valve of bending nozzle slowly.
2-7. Open suction valve of bending nozzle.
2-8. Wait, vacuum reaches lowest point.
2-9. Open power valve of secondary nozzle of the first group or the second
group slowly.
2-10. Open suction valve of secondary nozzle of the first group or the second
group.
2-11. Open power valve of primary nozzle of the first group or the second
group slowly.

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
2-12. Open suction valve of primary nozzle of the first group or the second
group.
2-13. Shut down suction valve of bending nozzle, and then shut down steam
valve of bending nozzle.
2-14. Open discharge valve of silencer.
2-15. Shut bypass valve. Immediately open condenser valve.
2-16. Shut down and close valves according to reverse procedure.
XVII. Starting of Shutter

1. Conditions of starting test:
1-1. Installation of shutter finishes and passes acceptance inspection.
1-2. Installation of shutter actuator finishes and passes acceptance inspection.
1-3. Installation of control air piping finishes, and this piping has air supply
conditions
1-4. Installation of DCS control system finishes, and signal testing is qualified.
2. Test procedure:
2-1. Open control air source, and check if control air source has leakage
phenomenon or not.
2-2. Close control air source, manually operate shutter actuator action, open
the shutter 90 degrees in whole process, and close it again to check
tightness.
2-3. Open control air source, DCS operates shutter actuator action from far,
open the shutter 90 degrees in whole process, and close it again to check
tightness.
XVIII．Inspection of Construction Materials

In the progress of installation construction of the project, construction unit must
deliver the following technical and qualitative materials to installation guidance
engineer in time for GEA inspection.
1. Construction organization design or construction technical scheme. (Delivered

before construction)
2. Welding procedure qualification. (Delivered before welding of project)
3. Handover report for completion of concrete frame. (Delivered before hoisting
of steel structure)
4. Inspection report for completion of main framework of steel structure.
(Delivered before hoisting of tube bundle)
5. Installation technology record of tube bundle. (Delivered before hoisting of
collecting pipe)
6. Test report on welding dye of U shape vacuum pipe. (Delivered before
hoisting of collecting pipe)
7. Installation technology record of fan. (Delivered before commissioning of fan)

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
8. Installation technology record of water pump. (Delivered before

commissioning of water pump)
9. Acceptance visa of pipe Completion . (Delivered before tightness test of
system)
10. Test report of system tightness. (Delivered within one week after test)
11. Temperature record for commissioning of motor bearing. (Delivered within
one week after commissioning of motor)
12. Record of commissioning current value of motor. (Delivered within one week
after commissioning of motor)
13. Report of instrument calibration (test). (Delivered before installation of
instrument)
14. Report of safety valve calibration. (Delivered before installation of safety
valve)
If inspection materials are not delivered to GEA engineer for field installation
guidance, GEA will consider that construction unit doesn’t need technical
guidance.

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
Attachment Ⅰ Test Report of Fan Air Volume
R1
10
R2 R4
R3
Tag Number of Fan

Determination of wind speed
Measuring R1 R2 R3 R4 Average
position value
1（0.013D）
2（0.039D）
3（0.067D）
4（0.097D）
5（0.129D）
6（0.165D）
7（0.204D）
8（0.25D）
9（0.306D）
10（0.388D）
Average wind velocity (M/S)
Fan area: 00.00M2
Total air volume of fan: fan area × average wind velocity (M3/S)
BTTC inspection： Client inspection：

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
Attachment Ⅱ
Test Report of Fan Operation
Mot 2 Vibration
or 3 Vibration
of motor
1 Vibration of of rack
gearbox
Gearbox
Tag
number of
unit
No. ( ) fan No. ( ) fan
Model of motor
Dynamic votage (V)
Motor insulation (MΩ)
Operation currrent value Phase Phase Phase Phase Phase Phase
(A) A B C A B C
Blade angle (Degree)

Gap between blade and
wind chamber (mm)
Oil temperature of
gearbox (degree)
Temperature of motor Upper Lower Upper Lower
bearing (degree) bearing bearing bearing bearing
Temperature of actuator Upper Lower Upper Lower

bearing (degree) bearing bearing bearing bearing
Vibration value (μm) 1 2 3 1 2 3

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
Maximum amplitude of steel structure (peak to peak) is 0.006 inches (150 mm)
or vibration velocity is no more than 6.3 mm/s.
BTTC inspection Client inspection

Attachment Ⅲ
Test report of noise
Client: Date:
Document: Time:
Item:
Place: Elevation (m) :

Temperature: (degree) Atmospheric pressure (Pa)
Wind velocity: (m/s) Wind direction:
Revolving speed of Pinch angle (°)

fan (rpm)
Fan M1 M2 M3 M4 M5 Remark
Measurement Lp （dB(A)）
Background noise （dB(A)）

Correction of background
noise
Calibration
Correction Lp (M point)
Guarantee Lp （dB(A)）
Drawing of site of measuring point
1 meter
1 meter Front
·
channe
1米
l
Side view Top view
Client inspection
personnel

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
GEA-BTT inspection
personnel
Attachment Ⅳ
Test report of vacuum device start-up
Start-up nozzle
Primary nozzle A
Primary nozzle B
Secondary
class nozzle A Conde
nser
Secondary
class nozzle
B
Dynamic steam
Air-cooling number
Model of vacuum device
Recording items Start-up nozzle Primary Secondary
nozzle class nozzle
Dynamic steam pressure
(kg/cm2)
Dynamic steam temperature
(℃)

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
Start-up time (minute)

Vacuum pressure （kg/cm2）
Vacuum attenuation degree
（kg/cm2/minute）
BTTC inspection Client inspection
Attachment Ⅴ
Test Report of Vacuum of Shutter Start-up
Air cooler number

Shutter Manual test Pneumatic test
number Opening Closing Control Opening Closing
angle tightness air pressure angle tightness
2 2
（kg/cm ）（kg/cm ） (degree)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Project No.
BTTC-X-XX-XXX-XXX
Rev 0
16
17
18
19
20
BTTC inspection: Client inspection:

ACC Installation Manual (Knock-Down Delivery)

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Name of document Installation Manual of ACC Equipment

GEA Batignolles Thermal Technologies (Changshu) Co., Ltd.

Installation Manual of ACC Equipment Page 2 of 49

II. Steel Structure

Installation Manual of ACC Equipment Page 3 of 49

Post base-plate of steel structure

Gap adjustment 0—20mm

Installation Manual of ACC Equipment Page 4 of 49

Gap adjustment of parallels:

Welding Mode of Direct Embedded Parts

4. Installation sequence of steel structure:

Installation Manual of ACC Equipment Page 5 of 49

4-4. Hoisting of trusses

Hoisting of No. 1 truss

Operating condition of 30.5m tower arm

American-standard bow shackle 17t-4

4-5. Assemble A-type frame on the ground, namely, pre-assemble partial

Installation Manual of ACC Equipment Page 6 of 49

Hoisting of A-type frame

3t*10m hoisting belt is equipped with one 3t*6m chain block,

Installation Manual of ACC Equipment Page 7 of 49

III. Tube Bundle

Installation Manual of ACC Equipment Page 8 of 49

Installation of sling of tube bundle.

5t*10m hoisting belt

3t*8m hoisting belt

3t*6m chain block

4 shackles with 6.5t

60.95m main arm

Installation Manual of ACC Equipment Page 9 of 49

Installation Manual of ACC Equipment Page 10 of 49

Installation Manual of ACC Equipment Page 11 of 49

Installation Manual of ACC Equipment Page 12 of 49

Installation Manual of ACC Equipment Page 13 of 49

Sealing arc slab on the bottom

Installation Manual of ACC Equipment Page 14 of 49

Installation Manual of ACC Equipment Page 15 of 49

Installation Manual of ACC Equipment Page 16 of 49

Fixed screw and thread 1)

Installation Manual of ACC Equipment Page 17 of 49

4. Installation of pulley-drive fan:

Installation Manual of ACC Equipment Page 18 of 49

the installation form of motor; the perpendicular degree of shaft extension

Driven pulley Driving pulley

Adjust A, B, C and D total four points of two pulleys

4-5. Installation of belt:

Installation Manual of ACC Equipment Page 19 of 49

4-5-3. Pre-tightening adjustment of synchronous belt

D2 -----Diameter of bull pulley

Mode Width of belt (mm) Applied force W (N)

4-6. Installation of fan blade:

Installation Manual of ACC Equipment Page 20 of 49

Reminder 1: fan hubs and blades have been completed balanced

Installation Manual of ACC Equipment Page 21 of 49

4-8-2. The vibration switch shall be calibrated orientation based on equipments

VII. Auxiliary System Equipment

Installation of catch box

Installation Manual of ACC Equipment Page 22 of 49

Outlet section of steam turbine is installed on concrete foundation, and bottom

Installation Manual of ACC Equipment Page 23 of 49

Installation Manual of ACC Equipment Page 24 of 49

2. Condensate water pipe of pipe bundle is connecting pipeline between outlet of

Piping of pipe bundle outlet (see Figure 0010)

3t10m hoisting belt is equipped with one 3t6m chain block,