1.0.M. Instructions ~ @cameron Heer INSTALLATION Drying of Coolers (On compressors used in nitrogen and dry air service the following is recommended prior to ‘commissioning of machine. 4, Remove drain plug(s) from bottom of cooler shell and shell cover assembly, if applicable. See cooler assembly drawing, in this section, for drain locations. 2. With drain plugs removed, purge machine with dry air for a minimum of 24 hours. 3. Remove purge from compressor and replace drain plugs. Bundle Removal Clearance must be provided at the water nozzle end of the cooler to remove the tube bundle. Refer to the Compressor Installation Arrangement drawing for clearance dimensions. Water Piping Ifthe cooler water manifold is not provided by Cameron, refer to the Water Schematic drawing for recommendations and definition of Cameron’s scope of supply. Control valves should be provided on the discharge line of each cooler. The manifold should include ‘couplings for temperature and pressure gauges on both inlet and discharge lines close to the heat exchanger. Drain piping should be isolated for each cooler and not piped to a closed manifold system. Before connecting piping, inspect all openings of the coolers and piping for contaminants. CAUTION Piping should be suitably supported so that forces are not directly applied to the heat exchanger. Condensate Removal Condensate will accumulate during normal operation of some heat exchangers. Refer to the Condensate Flow Schematic drawing for recommendations and definition of Cameron's scope of supply. CAUTION Condensate piping should drain to an open sump and never piped to a closed manifold system.€ CAMERON Heat Exchanger 1.0.M. Instructions a OPERATION Start-Up 1. Check water piping system for cizanliness to prevent blockage of tubes. 2, Loosen water side vent plugs be‘ore admitting water to the cooler. 3. Check all flange bolting for tightness. 4. Start flow of water, gradually at frst. When the system is completely filled and all air vented, tighten vent plugs. WARNING, Never operate the heat exchanger at pressures, temperatures or flows in excess of those specified on the nameplate. ‘Shut-Down Caution must be taken to avoid subjectiig the heat exchanger or the compressor to thermal shock. Excessive temperature could impose stresses resulting in catastrophic damage to the heat exchanger and/or the compressor. WARNING. Never stop water flov to the heat exchanger before NS shutting down the compressor. Winter Protection During Shut-Down Ifit becomes necessary to shut-down ths compressor in a location subject to freezing conditions the following procedure must be implemented to prevent coil damage. Thoroughly drain water by removing vent and drain plug from supply channel, 2. Replace drain plug, 3. Add two gallons (minimum) of antifreeze solution through vent in supply channel 4. Replace vent plugs. Performance When performance does not meet spec:fied requirements check the following: 1. Fouled tubes caused by sludge cr scale. 2. Incorrect piping connections. Refer to the Installation Arrangement and Water Flow Schematic drawings.1.0.M. Instructions . @ cameron Heat Exchanger 3. Airlocks caused by improper venting, 4, Operating at conditions other than design; refer to the Heater Exchanger Specifications. 5. By-passing of either air or water. Check partition gaskets and seal strips. MAINTENANCE WARNING Do not attempt to loosen any bolting unti all pressures have been relieved and fluids drained Cleaning A regular inspection program is important to determine frequency of cleaning. A reduction in performance and/or a marked increase of pressure drop usually indicates that cleaning is required NOTE Cameron's heat exchangers are designed to be mechanically cleaned without removing the bundle from the shell. ‘Water Side. Interior surfaces of the tubes can be cleaned by back-flushing to remove sludge and other soft deposits. A rotary brush with brass or nylon bristles will be more effective. if more severe fouling exists, contact a Cameron Compression Systems Representative. Gas Side. The extended surfaces (aluminum fins) should only be cleaned with detergent and high pressure steam, CAUTION If all tubes are not clean, flow may be partially blocked in some tubes causing overheating or cooling. This condition could develop severe stresses that can loosen tubs joints and fracture tubes. Special Draining Instructions for High Pressure Heat Exchanger (Design Pressure 2 160 PSIG) When fluid is added to the gas side of a fully assembled high pressure heat exchanger ‘some of the fluid will be trapped between the shell cover and retum channel. Itis necessary to remove the vent and drain plugs located on the shell cover to insure thorough draining. (See Heat Exchanger Assembly drawings for vent and drain locations.)€ CAMERON Heat Exchanger 1.0.M. Instructions ~~ Bundle Removal 1. Remove lantemn-ring (or shell cover) and O-ring from retumn water header O.D. 2. Remove return water header. 3. Remove supply water header. 4, Inspect for inoperative roller guices ~ replace if required. 5. __ Insert eyebolt in tapped hole provided on top of front tube sheet. 6. Supporting bundle from eyebott, begin sliding bundle out of shell WARNING. at Do not completely remove bundle from shell. Do ee not rest bundle on lower bypass seal. 7. After sufficient bundle is exposed, support and lift bundle with a nylon mesh sling as its center of gravity. WARNING Protect bottom bypass seal (silicone) with 4x4 timbers on both sides. NS 8. Complete removal from shell Handling of Tube Bundles Do not grasp bundles with hooks or other sharp tools which may damage the tubes or fins. Nylon mesh slings or straps are suitable for lifting the bundles in a horizontal position. Always take care to protect the lower bypass seal with 4x4’s in the area of the sling. ‘The bundles should not be dragged anc should only be moved about on cradles or skids. Reassembly w 1. Inspect upper and lower bypass seals for possible damage. If replacement is required, refer to Cameron Engineering Specification IL-2401 2. Spray top sheet of bundle and shell channel with silicone spray. CAUTION Failure to comply could destroy the bypass seals. 3. Position front tube sheet gasket on mating flange. Hold with tape or glue. 4, Remove top row of studs in rear tube sheet to prevent possible damage to upper bypass seal. + we1.0.M. Instructions. SN @ CAMERON Heat Exchanger 10. "1 12. 13, ‘Support bundle with sling near its center of gravity. (Protect bypass seal with 4x4’s.) Position bundle in shell. Align rollers on shell channel with guide legs on either side. Partially inert bundle to point of lft. Transfer s support to eyebolt on front tube sheet. WARNING. Do not reset bundle on lower bypass seal Complete Reinstall top row of studs in rear tube sheet. Position return water header gasket and install return water header. installation of bundie in shell NOTE Refer to Cameron’s Engineering Specification IL- 2401 for torque values and sequence. Position supply header gasket and install supply water header. (Torque per IL- 2401) Position o-ring on 0.D. of retum header and install lantem ring. (Torque per IL- 2401)Heat Exchanger € CAMERON .0.M. Instructions@ COOPER ENGINEERING SPECIFICATION TURBOCOMPRESSOR ‘101 BROADWAY A 80% 208 12401 SULTS Ww eis 20 OSA Assembly of Coolers ISSUED: RAV-107 04/16/85.——_~D. Glauber Rev. 1) RBL-236 01/16/92 K. Conroy Rev. 2: RBL-981 03/24/92. -—-K. Conroy Rev. 3 RBO-076 09/17/92‘. Conroy Rev. 4: RBS-611 07/28/93 K. Conroy Rev. 5: RDA-534 10/02/98 K. Conroy ‘Turbo Air® and MSG® Centrifugal Compressors Genuine JOY® Pars GBSRevisions | ()RBL-236 | (@)RBL-981 | ()RBO.076 | (4)RBS-611 | (S)RDA-534 oii692 —_fosrae2 —[ocn7s2 | o7asies | 10/02/98 11-2401 Page | of 8 SCOPE: ‘This specification describes the procedure for properly assembling the following cooler variations: Standard Cooler High Pressure Head Version Double Tubesheet Design Single Tubesheet Version of the Double Tubesheet Design 2BaH NOTE Interior (shell side) of cooler must be free of dirt, glycol residue. and hydrocarbon contamination. DESCRIPTION: I. Standard Cooler 1. Position by-pass seals on upper baffle and bottom sheets of bundle. Hold in place with Dow Coming silizone adhesive or equivalent. Allow to set and cure. NOTE Seal should run frora outside front shell flange to outside of rear skell flange at the top. At the bottom, the seal should run from the inside of the front tubesheet 10 1/16" beyond the outside of the rear tubeshee: 2. Lubricate top of bundle casing and bundle support channel in shell with solution ‘of dish soap and water. CAUTION Failure to comply could damage the by-pass seals. 3. Position front tubesheet gasket on front shell flange. Hold in place with tape.Revisions | (RBL-236 | @rBLos1 | @RBO.076 | (RBS611 | ()RDA-534 over —_foseas2 —_fosn7er omens | 10298 1L2401 Page 2 of 8 NOTE Some designs use an o-ring rather than a front ‘ubesheet gasket. For these designs position o-ring in o-ring groove on inside surface of front tubesheet. Hold in place by applying a thin coating of Dow Coming silicone adhesive or equivalent directly to the o-ring. Allow to set and cure. 4. Position foam gaskets over ends of bundle support channel. Hold with Dow Coming silicone adhesive or equivalent, if necessary. Allow to set and cure. 5. Remove top row of studs in rear tubesheet to prevent possible damage to upper by-pass seal 6. Place studs in front and rear shell flanges. End of studs stamped B-7 to face out 7. Protect bottom seal with 4 x 4 timbers on both sides of seal. Support bundle with sling near the bundle’s center of gravity. 8. Position bundle in shell. Align rollers on bundle support channel, with guide legs on either side of the channel. WARNING Do not rest bundle on lower by-pass seal. 9. Partially insert bundle to point of Lif. 10. Insert eye bolt in tapped hole provided on top of front tubesheet. 11, Transfer support to eye bolt of front tubesheet. 12. _ Insert bundle completely. WARNING Front tubesheet should be positioned with lifting hole at 12 o'clock location (ie. straddling the top two water channel studs). Failure to comply with requirement will result in interference between the water channel bypass partition and the tubes.Revisions | C)RBL236 | @RBL981 ) @RBO.076 | (RBS-6II | (RDA SH bine |osanr —_fosr7io2 | ovaeiss__| 1002/98 12401 Page 5 of 8 NOTE | In some designs a rear shell flange gasket is ‘used rather than an o-ring. For these designs, position gasket on rear shell flange. Hold with ‘Dow Corning silicone adhesive or equivalent. Allow to set and cure. | Install packing plate over rear tubesheet with packing plate o-ring towards shell flange. ‘WARNING Do not rip rear tubzsheet o-ring while installing acking plate. 5, Torque packing plate nuts to level liste in Table 1, Column 1 Page 6). 6. Position supply channel gasket and install supply channel. 7. Torque supply channel nuts to level listed in Table 1, Column 1 (Page 6). 8. Position return channel gasket and install return channel. a ‘Torque nuts on inner, rectangular stud pattern on return channel to level listed in Table 1, Column 1 (Page 5) in sequence illustrated in Figure 1. 10. Position flat washers, spring washers and nuts on cuter bolt circle of rerum channel, where applicable. 11, Hand tighten nuts, plus 1/8 turn, in sequence illustrated in Figure 2. 12. Follow steps 21-28 of standard cooler procedure.Revisions | ()RBL-236 ov1692 Q)RBL-981 oseai | 09/17/92 @)RBO-076 | (MRBS-611 07/2893 (RDA-S34 10/02/98 IV. Single Tubesheet Version of Double Tubesheet Design: 1L2401 Page 6 of 8 Follow procedure for double tubesheet cooler design, however, prior to placing the water channels on the cooler, perform a shell side pressure test. ‘This is in order to verify leak-tight tube to tubesheet joints. The shell should be pressurized to the shell side design pressure of the cooler or 150 PSIG, whichever is less. RECOMMENDED TORQUE VALUES FOR SA-193 GRADE B7 STUD MATERIAL COLUMN 1 COLUMN 2 Cc Gasketed Joint Non-Gasketed Joint Tensile Torque (Ft-#) Torque (Ft-#) Nominal ‘Stress Area Bolt Size (Sq. In.) | Minimum | Maximum | Minimum | Maximum 1/4-20 UNC 0.0318 & 10 3 4 $1618 UNC_| 0.0524 a 19 6 1 3/8-16 UNC 0.073 30 33 u 12 7/16-14 UNC 0.1063 47 53 17 19 1/2-13 UNC 0.1419 7 80 26 28 9/16-12 UNC 0.1820 105 us 37 41 pee UNC 0.2260 145, 160 SL 57 3/4-10 UNC 0.3340 255 280 90 100 I 718-9 UNC 0.4620 380 420 140 155 1-8 UNC 0.6060 570 630 210 230 L-V8, 8UNC | 0.7630 765 845 270 300 1-1/4, 8 UNC 0.9690 1075 1195 385 420 1.3/8, 8 UNC 1.1550 1410 1565 500 isostaceilRevisions | (1)RBL-236 | @)RBL-981 | (3)B0-076 | “RBS-611 | (S)RDA-534 ovies2 —_fosras2 former | ores | 1002/98 Page 7 of 8 eB 8 4 2 22 18 ot TTT 24-O— -o—10 ab ~bo6 a. _$- 2 io 9-29 ae — o~$- el 23 3-4 ae eee eae a +o—e—€—6—0—0—0+ 7 4 2d | | 4 i FIGURE_1: EXAMPLE OF RECTANGULAR TORQUING SEQUENCERevisions | (RBL-236 | @RBL-981 | (3)RBO-076 | (RBS-611 | (S)RDA-534 oe oiies2 fosaase | oors2 [areas | owe IL-2401 Page 8 of 8 4 10 \ ! |S. 6 FIGURE 2: EXAMPLE OF CIRCULAR TORQUING SEQUENCE