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Site image from a KLE AFC project

Air-Fin Cooler Upgrade & Replacement Service

Technical Service Process

Upgrade & Replacement AFC Fan Blades

Implementation Partner Cofimco Tandem Blade

Khanh Linh (KLE) provides a complete Air-Fin Cooler (AFC) system upgrade service, supporting increased cooling capacity without modifications to the existing structure. The five-step process below has been applied across actual projects at NSRP (more than 230 fan units, 23 rotating equipment assemblies, completed 10 days ahead of schedule) and LSP (18% reduction in power consumption and 5.35% increase in airflow).

NSRP 230+ fan units · 23 rotating equipment assemblies · completed 10 days ahead of schedule
LSP 18% reduction in power consumption · 5.35% increase in airflow
5-Step Process

From Site Assessment to Inspection and Commissioning

The process covers current-condition assessment, solution design, safety preparation, installation, and post-upgrade performance verification.

01

Site Survey and Condition Assessment

  • Measure actual airflow, vibration, and motor current against design values.
  • Identify the root causes of reduced cooling performance: legacy single-profile fan blades, shaft corrosion, and bearing wear caused by temporary cooling-water spraying.
  • Prepare an operational risk report and recommend an upgrade option compatible with the existing Cofimco/Moore hub.
02

Solution Design – Cofimco Tandem Blade

  • Select dual-profile/tandem fan blades to increase airflow within the same physical dimensions without increasing motor load.
  • Use a direct drop-in replacement design, with no changes required to the existing hub, shaft, or motor.
  • Recalculate the blade pitch angles to maintain aerodynamic balance.
03

Safety and Work Preparation

  • Complete the JSA/PTW documentation and obtain the owner’s safety approval.
  • Apply LOTO (energy isolation) to all connection points before work begins and confirm complete electrical isolation.
04

Installation

  • Remove the existing fan blades; inspect and clean the shaft and hub, including checks for corrosion and mating-surface condition.
  • Install the Tandem blades in accordance with the manufacturer’s tightening procedure, under OEM specialist supervision.
  • Adjust the blade pitch angles to within a tolerance of ≤ 0.2° across all fans to maintain consistent airflow.
05

Inspection and Commissioning

  • Check each fan against three parameters: motor current (A), vibration (mm/s), and airflow (m³/s).
  • Compare pre- and post-upgrade results and prepare an independent Performance Report.
  • Hand over the system in stable operating condition, with no further need for supplementary cooling-water spraying.
Project Photos

On-Site Implementation Photos

The images are compiled from different AFC projects to illustrate KLE’s on-site installation work and technical support.

Site photo from a KLE AFC project
Site photo from another KLE AFC project
Site image from KLE’s AFC implementation work
Image Note

The images are compiled from different projects; they do not represent a single job and should not be used to illustrate individual steps in the technical process above.

Project Results

Results from the NSRP and LSP Projects

The figures below are presented based on the project results provided by KLE.

NSRP 230+ fan units / 23 rotating equipment assemblies
Reached 125% of design capacity
Increased airflow by up to 30%
Eliminated water spraying (0 L) and completed the work 10 days ahead of schedule.
LSP Olefins Plant
18% reduction in power consumption
5.35% increase in airflow
The recorded reduction in power consumption was twice the customer’s target, with vibration reduced by more than 50%.