Charge Air Cooler C5.05.06.30.17.

33
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M20

Charge Air Cooler

en / 23.10.2007 FD033965 1/14

 Content

1. DESCRIPTION

2. WORKING PRINCIPLE

3. INSTALLATION

4. MAINTENANCE

5. CLEANING THE COOLER

6. INSTRUCTIONS FOR REPARING AIR COOLER TUBES

7. OUT OF SERVICE PERIODS

8. DIFFICULTIES IN SERVICE

9. ORDERING SPARE PARTS

10. TECHNICAL DATA

 1. DESCRIPTION
Vestas aircoil charge air coolers consist of a number of tube stacks,
each built up on aluminium-brass or more commonly cupro-nickel
tubes. Both types are fitted with copper fins. Each fin is mechanically
bonded to all the tubes in a stack. Depending on cooler type, the fins
are either expanded or dip-soldered on to the tubes. The cooler type is
described in section 10. ”TECHNICAL DATA.” The tube stacks are
mounted between two tube plates, into which the tube ends are
expanded to give a secure and permanent seal. Furthermore, each
tube inlet is bell formed to minimise the risk of local turbulence which
can cause erosion/corrosion.

The tube plates of the cooler are either fitted with an end cover or a
reversing chamber. The end cover provides the connection to the inlet
and outlet pipes of the cooling water system. Further information is
given in engine manufacturer's instructions. The end cover is fitted with
plugs for venting and draining of the cooler. Depending on cooler type
the reversing chamber is also fitted with plugs for the same reason.

IMPORTANT: If the cooler has been Covers

drained for any reason, proper venting
of the water side is essential. Failure
to bleed off the air can lead to Block
cavitation of tubes and plates. On sea
water cooled systems, failure to vent
can lead to a build up of salt on the
upper rows of tubes.

The covers are either welded or cast

in an alloy to fit the application.
Depending on the alloy and cooling Side plate
water quality, the inside can be treated tube plates

with a protective coating.

The two side plates of the air cooler are bolted onto the tube plates.
Depending on the size of the cooler, the side covers are supported by
stays.

Please refer to article 10 “Technical Data” for information on materials

used in the cooler.

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 2. WORKING PRINCIPLE

General:

Charge air coolers are installed on supercharged diesel engines, to

remove heat from the charge air. The heat builds up in the inlet air as it
is pressurised by the turbo charger. When the charged air passes
through the tube and fin cooling block, heat is transferred to the cooling
water in the tubes. In this way the engine receives cold air at high
pressure to ensure efficient combustion, and cooling of highly heat-
loaded engine components. The cooler can either be one stage or have
multiple stages.

1-stage 2-stage

A one stage cooler can consist of a single cooler block, with one water
inlet and one water outlet pipe.

A two stage cooler consists of two separate cooler blocks assembled in

one unit. The coolers in such a unit are specified as High Temperature
(HT) stage and Low Temperature (LT) stage. Each of the stages have
separate water connections. Often the water for the HT stage comes
directly from the cylinder cooling jacket. The water temperature in the
HT stage outlet pipe becomes very hot. This makes it useful for
purposes such as waste heat recovery for fuel heating, feed water
preheating and freshwater production. When working after this
principle, it is essential to ensure that the temperature in the HT stage
does not reach boiling point. This can cause severe damage to the
cooler. To avoid boiling of the HT water the minimum pressure is very
important. Proper monitoring of pressure and temperature is essential,
especially during the start up and shut down procedure.

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 3. INSTALLATION

NOTE: All coolers must be mounted with air flow according to the
direction plate on the cooler. This is to ensure correct thermal
expansion.

Prior to installation all bolts for the supporting stays must be checked,
to ensure that all locking plates are in place and correctly locked. Re-
tighten all bolts to the specified momentum. This is to ensure that the
vibrations during transport have not loosened any of the parts and
connections.

Vestas aircoil A/S recommend, that air intake for the turbo charger is
made through filters from outside the engine room, in a way that
exhaust gas is avoided in the charge air.

Please refer to article 9 “Technical Data” for information on materials

used in the cooler.

IMPORTANT: To avoid corrosion/erosion of the air cooler material, the

chemical composition of the cooling water and charge air must be in
accordance with the properties of the specified materials.

4. MAINTENANCE
IMPORTANT: During start up of the cooling system, accumulated and
trapped air is bled off through the venting plunges. It is
recommended that the cooling system is feed slowly to avoid water
hammering which can cause high local pressure in the cooler. Sudden
increases might result in damage to gaskets, tubes and other
components in the cooler.

For registration of the cooler operation, it is recommended that a U-

tube pressure gauge is installed between the air inlet and outlet of the
cooler. Then, by comparing pressure drop values across the air side of
the cooler against the engine load, it is possible to monitor pressure
drop changes or fouling. The recommendation from Vestas aircoil A/S
is to clean the cooler before the pressure drop exceeds the clean-
cooler value, by max. 50 per cent. The maximum cleaning interval
must not exceed 6 months of operation. Frequent cleaning
increases the life time of the cooler, and reduces fuel consumption.

Fouling of coolers on the water side can be monitored in a similar way.

Here, a differential pressure gauge is connected between the cooling
water inlet and outlet pipes. This makes it possible to compare
pressure drops for a constant cooling system setting, during operation.
Fouling of tube and water side will drastically decrease the capacity of
the cooler.

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 MAKE SURE THAT MANOMETER MERCURY NEVER ENTERS THE
COOLING SYSTEM!

5. CLEANING THE COOLER

5.1. General
The amount of fouling at the air and water side of the charge air cooler
will determine the operating conditions of the engine. Deposits reduce
the capacity of the cooler and thus engine output, fuel consumption will
also increase. Therefore the cooler should be cleaned at regular
intervals.

5.2. Air side. - Cooler removed from engine.

5.2.1 Immersion
The removed cooler is immersed in to a bath containing a cleaning
fluid. The fluid is agitated to give the most effective cleaning of fins
and tubes. After cleaning, the cooler is thoroughly flushed with pure
water and is blown dry with compressed air before being refitted on the
engine. See section 5.4. for recommended cleaning agents.

5.2.2 High-pressure cleaning - not recommended

5.2.3 Ultrasonic cleaning

Ultrasonic cleaning is normally performed by companies specialised in
this area. The procedure is to immerse the cooler in cleaning fluid
through which a transducer transmits a high-frequency sound wave to
loosen deposits on fins and tubes by "impact". This cleaning method is
not recommended for coolers where the fins are expanded on to the
tubes, as it can cause the fin collars to loosen from the tubes, resulting
in serious performance drop of the cooler.

Please refer to article 9 “Technical Data” for information on your cooler

type.

5.3. Water side

Cleaning of the water side is only possible after removing both end
covers and return flow chambers for thorough cleaning. After final
cleaning, any damage to cover surface treatment should be repaired.

Deposits and fixed impurities inside the tubes are best removed with a
rotary steel brush. If deposits in tubes are thick and calciferous it might
be necessary to carefully drill them out using a carbide bit. The inside
diameter of tubes is given in the spare part section. Be aware that in
some case deposits may have caused pitting or corrosion to the tubes.
Consequently removing the deposits can lead to leaks occurring after
the cleaning process is completed.

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 5.4 Cleaning agents

The following cleaning agents are recommended by the suppliers:

Supplier Product
Nordtec Maritime Services ApS Nordtec Air Cooler Cleaner (air and water
side)
Drew Ameroid Marine ACC-9
Nalfleet Marine Chemicals Nalfleet ACCC
VECOM Air Cooler Cleaner

Please refer to the producer's instructions before using any of the

above products. Vestas aircoil A/S can accept no responsibility for any
consequences arising from use of the products.

6. INSTRUCTIONS FOR REPARING AIR COOLER TUBES

The following is the recommended procedure, for repairing tubes in a

Vestas aircoil charge air cooler.

1. Drill the defect tube with a special drill to remove old scaling from the
tube. But do it slowly.

2. Clean the rolled areas in both ends for all impurities and avoid
scratching the surface. See fig 1.

3. Blow the tube and ensure that the tube is clean.

4. Put some heat transferring compound (White) all over the outside of
the new tube.

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 5. Mount the new tube with cork in the defect tube under constant
rotation of the tube. (The corked end first to prevent the compound
contaminating the inside of the new tube). See fig. 2.

6. Remove the cork; roll both tube ends using a three-rolled expander.

7. Chamfer the edges of the tube inlets.

8. Necessary tools/parts:
- Tubes
- Heat compound
- Expander, optimal with 2 sizes
- Cork
- Special drill
- Cleaning brush

If the repair is carried out according to the above mentioned procedure, it

can be done to approximately 5-10% of the cooling tubes, with only a
minor effect on the cooler performance.

7. OUT OF SERVICE PERIODS

During longer periods out of service, the air cooler must be drained and left
with drain and venting plugs open. Recommendations for the entire system
are given on the following pages.

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 8. DIFFICULTIES IN SERVICE

Difficulty Item Possible Cause Investigate/Remedy

Charge air Abnormally high charge air Dirty or defective
temperature too temperature ahead of air turbocharger.
high cooler High engine room temperature
Increased coolant inlet Maladjusted cooling system.
temperature. Blocked filter in sea chest.
Inadequate coolant flow Air cooler tubes partly blocked.
Defective pump.
Maladjusted cooling system.
Air in the coolant.
Fouling of tubes. Clean air cooler tubes.
Fouling of air side. (High Clean air cooler air side.
pressure drop)
Charge air Inadequate supply of hot water Maladjusted cooling system.
temperature too to heating stage.
low.
Charge air cooled in low Low temperature cooler stage
temperature cooler stage. to be bypassed or throttled.
High pressure Air side fouled. Clean air cooler fins.
drop in air side
Pressure gauge connections Re-tighten connections and
leaking. check with soapy water.
High pressure Air cooler water side fouled or Clean air cooler water side.
drop on water partly blocked.
side. (High temperature rise in
coolant).
Coolant flow too high. (Low Maladjusted coolant system.
temperature rise in coolant) Coolant pump capacity too
high.
Pressure gauge connection Re-tighten connections.
leaking. NOTE: Only when CAC is
cold.
External water Gasket between cover in-and Re-tighten cover and pipe
leakage. outlet pipe/cover and tube connections, if necessary
plate leaking. replace gasket. NOTE: Only
when CAC is cold.
Internal water Leakage between cooler tubes Use tube expander to secure
leakage. and tube plate. tube in tube plate.
Cooler tubes leaking. An insert tube is rolled into the
defect tube, using a tube-
repair kit.
Tubes to be plugged at both
ends.

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 9. ORDERING SPARE PARTS
To ensure the best performance OEM spares are recommended.
Original, approved spares and replacements are now available form
Vestas aircoil A/S at competitive prices. Please contact:

Phone +45 97 34 18 00
Fax: +45 97 34 14 14
E-mail va@vestas.biz
Home page: www.vestas.biz

When ordering spare parts please state the following data:

- Type of air cooler and No. in accordance with data on name plate.

- Designate parts with plate No. and item No.

_ Five digit order number from name plate.

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 Cleaning of
compact coolers

Test report by Vestas aircoil A/S

Summer 2001
Testing of charge air cooler with compact design

Introduction

Designing a new cooler geometry gives the opportunity to re-evaluate some of the
criteria’s for the existing products. One of those that was given a high priority, was the
possibility to clean the air side. As the earlier models, the compact design should be
clean able on the air side, in a degree that made it perform similar to a new cooler. This
started a discussion, on how to achieve high turbulation with the actual fin, to gain
higher efficiency. Consequently, it was decided to use corrugated fins instead of slit
louvered fins. To examine the clean ability of the new compact design, a test cooler
was made and put into service.

Scope of report.

One of the first charge air coolers from Vestas aircoil A/S based on the new compact
design was made for full scale testing at DFDS Seaways. The cooler was fitted on
DFDS Queen of Scandinavia, in connection with one of the support engines. The
purpose of the test was to see how the cooler performed under real operation
conditions. After approximately 6000 running hours, the cooler was returned to Vestas
aircoil A/S for inspection and testing. The entire process for the tests was as follows:

1 Test of a new identical cooler for reference

2 Visual inspection of the cooler for leaks and damages

3 Test of dirty cooler in the test facility of Vestas aircoil A/S

4 High pressure cleaning of cooler with water

5 Test of pressure cleaned cooler in the test facility of Vestas aircoil A/S

6 Chemical cleaning of cooler

7 Test of cleaned cooler in the test facility of Vestas aircoil A/S

The issue of these various tests, was to uncover the change in capacity an pressure
drop of a cooler, after a period in service. Furthermore, it was to examine the effect of
different cleaning methods.

By: Vestas aircoil A/S, Smed Hansens Vej 13, DK-6940 Lem Page 2 of 4
Internet: www.vestas.biz, E-mail: va@vestas.biz
The test

By visual inspection the cooler seems to be in perfect shape, except for some dirt
deposits between some fins and tubes. After the visual inspection a part of the cooler
was cut out and prepared for test in the test facility of Vestas aircoil A/S. The effective
cooling area of the test cooler was 9.45 m².

The test was carried out after the normal Vestas aircoil test procedure – using 4
different amounts of air. As the heat input to the charge air was kept at constant rate,
the use of 4 different air amount also reflect 4 different inlet temperatures of charge air.
The approximate amounts of air and charge air inlet temperature are stated below:

Test parameters
Test Air quantity Air inlet temperature Air outlet temperature
no:
Test 1: 1,5 kg/s 117°C 50°C
Test 2: 1,0 kg/s 140°C 45°C
Test 3: 0,8 kg/s 155°C 43°C
Test 4: 0,65 kg/s 170°C 40°C

On basis of the test results the characteristic pressure loss and capacity coefficients
are calculated to represent the fin configuration.

Test results.
When testing the fouled cooler it was discovered, that the capacity, compared to the
reference cooler, had gone down by approx. 0.5% where as the pressure drop was
increased approx. 37%.

The first cleaning attempt was done with

high pressure water. This removed a
reasonable amount of dirt and deposits.
After cleaning the cooler a new test was
made. This cleaning shows to have no
effect at all. Consequently the test cooler
was cleaned, using a chemical cleaning
procedure.

The cleaning procedure was done by

immersing the entire cooler into a tank filled
with heated water and a cleaner agent
specially developed for charge air coolers.

By: Vestas aircoil A/S, Smed Hansens Vej 13, DK-6940 Lem Page 3 of 4
Internet: www.vestas.biz, E-mail: va@vestas.biz
When the cooler was in place, air bobbles are blown through the cooler from
underneath. See fig. 1. This cleaning removed approx. 200 g of dirt and deposits,
which is a fairly high amount, having the surface area of 9.45 m² in mind.

Test of the cleaned cooler shows, that this cleaning method is very effective. The
capacity, compared to the reference cooler, is exactly the same and the pressure drop
is only approx. 3% higher.

Calculations of the new, the fouled and the cleaned cooler are enclosed in the back.

Conclusion
When designing the new geometry, it was the philosophy of Vestas aircoil A/S, to make
a new high performance cooler which, after a service period, could be cleaned back to
the original standard. The results of the made tests, shows that this has been
achieved.

Testing a cooler that has been in service, is one of the best ways to see if a cooler can
cleaned back to the original performance. The test of Vestas aircoil A/S new geometry
shows, that when undergoing the right cleaning procedure, the cooler is almost able to
perform as a new cooler. Furthermore it can be concluded, that the best way to clean a
cooler, is to immerse it into preheated water with a special cleaning agent, and letting
air blow through the fins. For details on this cleaning procedure, please see enclosed
data sheets.

By: Vestas aircoil A/S, Smed Hansens Vej 13, DK-6940 Lem Page 4 of 4
Internet: www.vestas.biz, E-mail: va@vestas.biz