Customer Atlas Copco (Shanghai) Trading Co., Ltd.
End User
Order No.53138224
Code Word Vietnam Air
TLV No. 6970412028
Factory No.30927
PRO. Name : Air Cooler IC3 (EO4423)
IC3 (EO4423)
Draw. No.:
KLQ1167.06-000
Serial No :
A100202
Manufacturer: HUBEI DENGFENG HEAT EXCHANGER CO.,LTD.
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Installation, Operation and
Maintenance Manual
Serial Number: A100202
Type: KLQ1167.06-00
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CONTENTS
1. Use and Scope
2. Structure
1). Air cooler
2). Shell
3. Operating Principle
4. A Guide to Use
1). Install
2). Start
3). Stop
5. Repair, Cleanout and Maintenance
1). Repair
2). Cleanout
3). Maintenance
6. Easily Damaged Parts List
7. Analysis of Risks due to Pressure
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1. Use and scope
The cooler is to cool the high temperature compressed air after compressed
one time or several times.
The design pressure of the waterside is less than 0.8MPa, the inlet design
temperature is less than 80, the design pressure of the air side is less
than 1.7MPa, the design temperature is less than 150, the cooling
medium is water, and the cooled medium is compressed air. The actual
working parameters please see the drawing for order or purchase contract.
2. Structure
The shell of the warm booster aftercooler is cylinder. The air cooler is
pipeline drawer structured, and its schematic diagram and main parts are
given as below:
Fig.1: schematic diagram and main parts
Air cooler and the shell are the two main parts of the warm booster
aftercooler.
1). Air cooler
The air cooler is to exchange between the hot and cold medium, it is
drawer structured, it consists of inlet and outlet water covers, return water
covers, core and separator, the core is the main part, it includes fixed tube
plate (big tube plate), movable tube plate (small tube plate), fin assemble,
side plate, reinforce plate etc.
The separator is at the wind output side of the core on the side plate, it is
to separate the condensed water after cooling the air, the condensed water
flows from the water let off under the separator to the shell, then flow out
from the condensed water let off the shell. There is air outlet plug on the
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water inlet and outlet covers, and water outlet under the water inlet and
outlet covers.
2). Shell
The shell is to hold the air cooler and let the compressed air flow normally.
It consists of cylinder, header, shell flange, there is air inlet and outlet
connecting pipe welded on the cylinder, there are two supporting bases
under the cylinder to keep the stability of the air cooler, there are three
kinds of baffles to control the flow direction of the compressed air. There is
a big square hole in the other side of the shell flange, it is for the air cooler
easy to install, there are bolt holes around the square hole, and then you
can connect the big plate with bolts and use gasket sealed in the middle.
There is supporting base with roller in the shell to support the air cooler,
and one condensed water outlet is set at two ends of the cylinder to drain
the condensed water.
3. Operating Principle
The air cooler lies horizontally in the shell, one side plate is above the core,
the other is under the core. The high temperature compressed air flows
from the air inlet connecting pipe into the shell, and flows the fin bundle of
the core and cooled by the cooling water of the tube, then flows from the
air outlet connecting pipe. The cooling water enters the shell through the
water inlet and outlet covers and then absorbs the heat of the compressed
air and drain from the outlet connecting pipe of the inlet and outlet water
covers. The hot and cold medium doesnt touch each other in the heat
transfer process.
When the high temperature air has cooled by the air cooler core and flows
through the separator of the wind outlet side of the air cooler, the steam
becomes condensed water and flows out through the separator and the
condensed water outlet of the shell.
4. A Guide to Use
1).Install
Open the case and remove the protect cover of the water inlet and outlet
pipe of the air cooler and the air inlet and outlet connecting pipe of the shell,
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eliminate the oil of the air flange and water flange. Be careful when hooking.
The air side flange connects the pipeline. The water inlet and outlet pipes
connect the inlet and outlet flanges of the cover, and gaskets are needed in
the above process. And please pay attention to the air flow direction of the
warm booster aftercooler and the water inlet and outlet direction of the air
cooler, the water inlet side is the air outlet side of the air cooler, and the
water outlet side is the air inlet side of the air cooler, and the separator is at
the air outlet side of the air cooler.
The condensed water outlet under the shell connects by the flange and the
pipeline, a valve is needed in the pipeline to control the condensed water
caused by operating and let it drain smoothly.
Enough space is needed of the shell flange to bring out the air cooler from
the shell flange when maintenance is needed.
2).Start
The start method of the warm booster aftercooler is input water and then
input air. Open the air outlet bolt above the water inlet and outlet covers of
the air cooler after input water and close it till water flows out. And then
check whether the connecting surfaces are correctly sealed. It can provide
air to the shell of the warm booster aftercooler when the water in the
cooling tubes circulates. Check whether the parameters are suitable when
the working pressure is met to let the air cooler work normally.
A lot of condensed water will be caused when the air humidity of the
environment is high or the water inlet temperature of the cooling water is
low. The water outlet pipeline valve under the shell should be open to drain
the condensed water smoothly.
3).Stop
When leakage happens because of the fracture, you can plug up the tubes
with tube plug, and the quantity is no more than 3% of the tubes. It is time
to stop using when it is no use to take measures when leakage happens.
The condensed water of shell and the cooling water of the air cooler should
be eliminated when the warm booster aftercooler stops using for a long
time to prolong its working life.
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When the air cooler pauses for some reasons, the water outlet valve under
the shell should be opened to drain the remained condensed water.
5. Repair, Cleanout and Maintenance
1).Repair
Fig. 2: Take-apart and assembly schematic diagram
Immediate repair should be given when leakage happens, the normal way is
pull out the air cooler from the shell flange, so enough repair space is
needed to pull out the air cooler from the shell flange of the shell as well as
the hang and air cooler pull and push equipments (for example: forklift).We
suggest the method of Fig.2 be used to take apart and assemble the air
cooler.
.Air leakage
Air leakage always happens on the connecting surface between the shell
flange of the shell and the big plate of the air cooler, you can wrench the
connecting bolts moderately, the sealing gasket is no use if the method
doesnt make any effect, and you should loosen the bolt and then pull out
the air cooler and change the gasket.
Water leakage
Water leakage always happens in the core or the connecting surface of the
water covers and the tube plates. You should change the sealing gasket of
the water side when it is no use to wrench the bolt. It is easier to change the
gasket of the water inlet and outlet covers connecting surface than the air
side, remove the water cover first, and eliminate the dross. You should
smear sealing glue if it is asbestos rubber gasket, and you can put it directly
if it is butyronitrile rubber gasket. If water leakage happens on the
connecting surface of return cover, you can fasten or change into new
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gasket only when you pull out the air cooler from the shell. Water leakage in
the core always happens because of the following: tube end becomes
flexible and tube breakage, now you should pull the core from the shell and
remove the headers and make a pressure testing with water or air to find
the place of leakage. You can fasten the tube end with tube fastener if the
tube end becomes flexible but it doesnt always happen. The core leakage
always happens because of tube leakage, in this circumstance you can plug
up the tube ends with tube plug, but the quantity is no more than 3% of the
tube total. You can make the tube plug with nylon stick or soft purple copper
stick.
2).Cleanout
If the cooling efficiency descends and the water inlet and outlet pressure
drop increases obviously, it means cleaning is needed for the cooling tubes;
and cleaning of the air side is needed if the pressure drop of the air side
increases obviously.
Cleanout of the water side
a. Cleanout by machine
The water side should be washed periodically, close the water inlet pipe
valve when cleaning, wrench the water outlet bolt and drain the remained
water in the air cooler, pull out the core from the shell and remove the
water inlet and outlet covers and the return covers, then wash the inner
wall of the tube with tube brush (with water), the sundries will be washed
out the tubes.
b. Cleanout by chemicals
If the dirt of the inner wall cant be washed out by machine or there is only
some remained water incrustation, you can clean with chemicals. Now you
need a set of cleaning equipment (a pump, tube needed and necessary
valve), you dont have to take apart the air cooler, you can only remove
the outer cooling tube of the air cooler and then connect the cleaning
equipment with the water inlet and outlet valve of the air cooler directly,
and let the cleaning solution circle in the air cooler to wash the air side of
the air cooler (because the flow direction of the cleaning solution is
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contrary to the direction of the cooling water).
You can make the cleaning solution with 10% hydrochloric acid with 0.5%
antioxidant, we suggest HS-2 boiler and large equipment cleaning
solutionof Yangyuan cleaning solution plant of Shanghai Daluo Industrial
and trading company (Pudong New Area, Shanghai).
Strong jet stream is needed after cleaning to wash the air cooler till it is
thorough clean.
Cleanout of the air side
a. Cleanout by machine or water
If the fins of the core are greasy, you should remove the air cooler from
the shell when you want to wash the air side, and eliminate the big
dross with acutilingual forceps or brush, and then wash the core in the
cleaning solution, for example: hot buck, special wash powder or
cleaning solution, we suggestHu-10 strong oil stain cleaning solutionof
Yangyuan cleaning solution plant of Shanghai Daluo Industrial and
trading company (Pudong New Area, Shanghai).
The cleaned core should be washed thoroughly with clean water. We
suggest you use high pressure spray gun with 3mm jet nozzle, and
you can stand 2m far away and wash the cooling tube directly with
1.2Mpa pressure upright, namely the jet water direction is contrary to
the fins. Dry with compressed air after cleaning.
b. Cleanout by chemicals
It is not easy to find a container to dip the core in it because the core is
too big, so you can wash the core in the shell when the fin oil stain is
not too much or after eliminating the big sundries by hand.
Fill the shell with 2-3% sodium carbonate liquor or Hu-10 strong oil stain
cleaning solution liquor, the upper fins should be dipped, and open the
bolt hole of the connecting pipe of the shell to aerate, and input steam
(the pressure is no more than 0.3MPa) from the water outlet which is at
the bottom of the shell, seethe for a few hours and change for clean
water for a few times till the water flows is clean.
Needed to do after cleanout
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Please make a pressure testing according to the drawing after
assembling the parts. The testing pressure is 1.5 multiple of the working
pressure, and there is no leakage in 5 to 10 minutes.
3). Maintenance
When you want to stop using the cooler for a long time, please drain the
remained water and close all inlets and outlets to keep the aridity of the air
side and water side. Periodically cleanout is needed for the air side and
water side in normal use, the cleanout period depends on the customer.
If you meet some problems cant be solved in the process of using or
repair the cooler, please contact us, we will provide consultant or sent
professionals to repair it.
Remark: The following tools are needed when the warm booster
aftercooler is sold: 1 tube brush and 10 tube plugs, other special tools and
parts should be claimed in the purchase order.
6. Easily Damaged Parts List
Name
Sealing gasket
of the air side
Sealing gasket
of the water
side
Material
Suggest change
time
Asbestos rubber or butyronitrile 2 years
rubber
butyronitrile rubber
2 years
If any unsolvable problem is met, please contact us. We will supply
consultations or send repairman to go on site at your service.
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