Charge Air Cooler C5.05.06.30.17.

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Charge Air Cooler

en / 04.02.2008 FD022685 1/15

 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

GEA CHARGE AIR COOLERS

GENERAL; OPERATION AND MAINTENANCE MANUAL

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

Contents
Item Title Page
1. General 3
2. Cooler design 3
2.1 Removable stack cooler with casing 3
2.2 Removable stack cooler without casing 3
2.3 Block cooler 3

3. Storage, Installation and Removing of Cooler Bundles 4

3.1 Storage 4
3.2 Installation of Cooler Bundles 4
3.3 Removing of Cooler Bundles 4

4. Commissioning 4
4.1 Pressure Test 4
4.2 Venting 4
4.3 Open Cooling Circuit 5
4.3.1 Cooling Water Flow 5
4.3.2 Protective Film 5
4.4 Closed Water Circuit 6
4.4.1 Cooling Water Flow 6
4.4.2 Protective Film 6

5. Standstill 7
5.1 Standstill in Case of Open Cooling Water Circuit 7
5.2 Standstill in Case of Closed Cooling Water Circuit 7
5.3 Standstill at Freezing Conditions 7

6. Service control 8
6.1 General 8
6.2 Performance Test 8

7. Cleaning 8
7.1 Cleaning at the air-side 8
7.2 Cleaning agents 8
7.3 Continues cleaning 9
7.4 Chemical cleaning 9
7.5 Mechanical cleaning 9

8. Possible Solutions for Operations errors 10/11

9. Tube Leaks 12
9.1 Repair of Water Leakage 12

10. Tightening Torque [Nm] 12

11. Stack cooler with housing (Drawing) 13
12. Block cooler (Drawing) 14

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

1. General
The GEA Charge air cooler is a finned tube heat exchanger. The hot air flows over the fins on
the outside of the tubes and the cooling fluid flows through the tubes. The heat exchange
surface of the cooler consists of round expanded tubes and continuous flat plate fins.
The bond between fin and tube is achieved by mechanical expansion of the tubes.

The tubes are rolled into the tube sheets at each end of the tubes by the use of
tube expanders. The sidewalls form an integral part of the cooler and are bolted to tube sheets.
Water headers are provided for water handling and pipe joints. The number of division rips are
conform to the number of water passes. The headers are bolted to the tube sheets, gaskets are
interposed for sealing. Plugs in the headers are provided for cooler venting and draining.

The materials for headers and tube are chosen in accordance to the cooling water specification
and also depend on the velocity in the tubes. Charge air coolers are designed as one stage,
two stage or three stage coolers according of the demand of the engine design and
performance.

2. Cooler design
The charge air cooler is an integral part of the diesel engine. Mounting situation inlet and outlet
water pipe connection as well as air duct connection are designed by the engine manufacture.
Further information’s are given in the manual of the engine manufactures. Principle cooler
sketches see page 13 - 14.

2.1 Removable stack cooler with casing

A removable stack cooler refers to a design of a casing with a removable tube stack.
The cooler casing is bolted between the air ducts. The tube stack is pushed into the casing
and is bolted with the protruding tube sheet (fixed end). The lose end is bolted with a frame
which allows movements in horizontal direction to compensate extension coursed by
temperature.

2.2. Removable stack cooler without casing

Removable stack coolers are used where a casing is an integral design of the Diesel engine.
The tube stack is slided into the casing. The protruding tube sheet (fixed end) of the tube stack
is bolted to the casing.

2.3. Block cooler

A “Block cooler” refers to the design mounted, directly between the air ducts of engine.
The block cooler is bolted with the air ducts at the side walls and the tube sheets.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

3. Storage, Installation and Removing of Cooler Bundles

3.1. Storage

The coolers have to be stored in a dry and vented hall. They have to be protected against
dirt and mechanical damages.

The cooler bundles are drained before dispatch. The water flanges are closed with plastic caps
and the fin bay is covered with a protection plate.

3.2. Installation of Cooler Bundles

Before first installation the protection plates have to be removed from the tube bundle.

The air connections have to be sealed with new gaskets provided at site.

The water connections have to be fitted to the water piping with new gaskets provided at site.
All connections must be free of tensions.

3.3. Removing of Cooler Bundles

Before removing the cooler has to be drained. Removing the cooler is carried out vice versa as
the mounting. The cooler has to be deposit at a suitable place. The fin bay has to be protected
against damages and dirt. For long term storage the water connections have also be closed.

4. Commissioning
4.1 Pressure Test

After the water pipes are connected, GEA/GMT recommends to check the tightness before
commissioning. Clean water (drinking water quality) has to be used for the pressure test.
If the cooler is not taken into operation immediately after the pressure test the cooler has
to be drained (see item 5 Standstill).

After a longer period of storage or extended stand still the header screws have to be checked
with the recommended torque and shall be tightened with the recommended torque if
necessary. After that the cooler has to be pressure tested. In case of leakage's the gaskets
have to be changed.

4.2 Venting

For cooler venting use the venting plugs which you will find on the nozzle header.
For continuously venting a venting pipe should be installed.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

4.3 Open Cooling Circuit

4.3.1 Cooling Water Flow

The flow rate of the cooling water has to be in accordance to the layout values of the cooler.

Frequent fluctuations of the cooling water velocity prevent the formation of a natural protective
film against corrosion. In case of open cooling circuits a too low water velocity encourages
dangerous dirt deposits and too high velocity causes erosion. In case of open cooling water
circuits never operate at min. or max velocity for a prolonged period. The recommended
velocity for a prolonged period is 2 m/s.

The following water velocities have to be observed

Material DIN Material Comparable admissible Cooling Water Velocity m/s

ASTM-Nr./No. min max
Nr./No.
CuNi10Fe1Mn 2.0872 B-111 C70600 1,5 2,5
CuNi30Mn1Fe 2.0882 B-111 C71500 1,5 3,0

4.3.2 Protective Film

The good chemical resistance of copper/nickel alloys is due to their ability to form a
natural protection film which has the capability to prevent corrosion attacks.

New cooling tubes of which the protection coat has not yet fully developed shall not
come into contact with contaminated water. The immediately forming dirt deposit will
destroy the formation of a protective coat.

Water pressure test has to be done therefore only with clean water.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

4.4 Closed Water Circuit

4.4.1 Cooling Water Flow

The flow rate of cooling water has to be in accordance with the layout values of the cooler.

It must be guaranteed that the circuit water is clean and no deposits in the tubes can occur.
(Drinking water quality).

The following water velocities have to be observed:

Material DIN Material Comparable admissible Cooling Water Velocity m/s

ASTM-Nr./No. max
Nr./No.
CuNi10Fe1Mn 2.0872 B-111 C70600 3,5

4.4.2 Protective Film

The good chemical resistance of copper/nickel alloys against corrosion is due to the
ability to form a natural protection film which is difficult to dissolve.

New cooling tubes of which the protection coat has not yet fully developed shall not
come into contact with contaminated water. The immediately forming dirt deposit will
destroy the formation of a protective coat.

Water pressure test has to be done therefore only with clean water.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

5. Standstill
5.1 Standstill in Case of Open Cooling Water Circuit

In case of a standstills for more than 3 days the water side has to be drained.

A standstill is especially dangerous for copper alloy tubes in case of a not fully build up
protective coat or the risk of getting disturbed by corrosion under deposits.

If possible the cooler operation should not be interrupted during the first 2 months after
commissioning. However, if there is a failure in cooling water supply and operation is resumed
within three days time, the cooler can be left undrained. It must be guaranteed that the tubes
are free of deposits.

In case of deposits the cooler must be drained, the tubes have to be cleaned, flushed with clean
water and dried. A blow through with warm predried air through the pipes is recommended. The
cooler has to be sufficient vented. If sea water, brackish or saline water (reference value
chloride content ≥500 mg/l) is used as cooling water for flushing clean water
(drinking water quality) has to be used.

In case of standstills for more than 3 days during the start-up period of 2 months and later on
during standstills for more than 2 weeks the same cleaning procedure has to be used.

In case of short standstills operating with low water velocity is to be preferred to water standstill.

5.2 Standstill in Case of Closed Cooling Circuit

Drinking water quality is prescribed for closed cooling water circuits (see item 4.3).
Under this conditions no draining in case of standstill is necessary.

5.3 Standstill at Freezing Conditions

The cooler has to be drained in case of wintertime standstills, when a frost injury to the cooler
must be feared, also during short standstill periods.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

6. Service control
6.1 General

For Service control, the manometers have to be installed in the air ducts and in the cooling
water piping. We recommend to keep record of the air and water temperatures in the machine
log book periodically. Further control instruments can be provided in accordance with the
individual requirement.

A possibility to drain the condensate must be assured for installation.

6.2 Performance Test

The performance guarantee given by GEA is mainly expressed by the temperature difference
between cold water and cold air during normal operation and should be checked from time to
time.

A differential pressure gauge can also be used to check whether or not cleaning of the air or
water side of the cooler is necessary. We recommend to install differential pressure gauges in
the air duct and water piping before and after the cooler.

7. Cleaning
7.1 Cleaning of the air-side

Cleaning of the air-side should be done early to avoid accumulations of sludge and oil. The
cleaning has to be done in regular intervals. The time interval of cleaning depends on the
ambience condition of the engine. Soiling of the air-side has a low influence on the thermal
capacity of the cooler but on the pressure drop. High pressure drop has an influence on the
thermal load of the engine. Limits of the allowable increase of the pressure drop are given by
the engine builder (see engine maintenance manual)

7.2 Cleaning agents

Use only agents which have no corrosive effect to copper and copper nickel alloys.
Wrong chemical cleaning agents may occur defects on the cooler. GEA GMT can not accept
responsibility for defects coursed by using wrong cleaning agents.

The requisite cleaning agent depends on the kind of soiling of the fins. Cleaning agents for
different soiling are offered by following expert companies:

Drew Ameroid Marine

Nalfleet
Unitor
Vecom
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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

7.3 Continues cleaning

Some cleaning companies offer continues cleaning systems. This systems may influence the
engine operation. Use continues cleaning only on release of the engine builder.

7.4 Chemical cleaning

GEA GMT recommend to contact a cleaning expert company.

For cleaning the cooler, the cooler stack has to be removed from the engine. The cooler is
immersed in a cleaning bath which has to be filled with the cleaning agent. The cleaning agent
has to be according to the recommendations of the engine builder or there suppliers.

Immersing the cooler in a cleaning bath may not have a satisfying cleaning result.
Using a circulation pump will improve the cleaning result.

The best cleaning result can be obtained by using ultra sonic transducer.
This cleaning system is normally performed by expert companies.

The time of cleaning depends on the degree of fouling as well as the kind of fouling.
It may be advisable to scour the cooler over night in the cleaning agent.

After cleaning the cooler, the fin stack has to be rinsed with tap water using a water jet.
The water jet has to be applied in minimum ½ m distance from the fins and only parallel to fins.
Maximum water pressure is 120 bar. After rinsing the fin stack it has be dried with compressed
air before refitted on the engine.

7.5 Mechanical cleaning

Mechanical cleaning is done by the use of nylon brushes fitted to a rod. Tube brushes are
available at GEA/GMT service department. Regular cleaning is necessary, the cleaning
intervals depend on the used cooling water. The cleaning of the water side is not only required
to maintain the thermal performance of the cooler. Scaling increases the risk of pitting corrosion
and obstacles particles blocking the tubes and favours erosion. Mechanical cleaning can be
done on side or when the cooler is removed. At least one header has to be removed, the wet
tubes should be brushed clean one after the other by pushing the nylon brush through the
whole tube until all the dirt is flushed out and no residues are left. After finishing cleaning
activities the headers have to be re mounted with new gaskets. Venting must be repeated after
cooling water is refilled.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

8. Possible Solutions for Operation errors

All remedies have to be done in conformity with the technical specifications of the engine
manual and Charge air cooler manual. Compare measured value with test bed values.
Difficulty Possible Cause Fault Location Remedy, see
Engine Manual

Charge air 1.1 Charge air High engine room Reduce engine load
temperature after temperature before temperature. according engine
cooler too high. cooler too high. manual.
Dirty, turbocharger. Clean turbocharger
according engine
manual.
1.2 Increased coolant Maladjusted cooling Readjust cooling
inlet temperature. system. system.
1.3 Increased coolant Maladjusted cooling Readjust cooling
outlet temperature, system. system.
Inadequate low Blocked sea-water Clean filter.
coolant flow. filter.
Cooler tubes are Clean air cooler.
partly blocked.
1.4 Low coolant outlet Fouling of the cooler Clean cooler tubes.
temperature, low tubes.
inlet
to out let Heavy fouling of air Clean cooler air
temperature side, high air side.
difference. pressure drop.
Charge air 2.1 Water inlet Maladjusted cooling Readjust cooling
temperature too low. temperature too low. system. system.
Low sea-water Recycle sea-water
temperature. into sea chest too
increase water inlet
temperature.
Reduce water flow
to allowable
amount, see water
velocities.
High pressure drop 3.1 Air side fouled. Check pressure Clean cooler air
on air side. gage. side.
Pressure gage Air temperature Repair or refit new
defect after cooler Ok, as pressure gage.
well as exhaust gas
temperature after
engine.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

Difficulty Possible Cause Fault Location Remedy, see

Engine Manual

High pressure prop 4.1 Increased coolant Maladjusted cooling Readjust cooling
on water side amount, high water system. Low water system.
flow. temperature
difference.
4.2 Air cooler water side High water Clean cooler.
partly blocked temperature
difference
4.3 Heavy fouled water Low water Clean cooler tubes.
side of tubes. temperature
difference.
4.4 Pressure gage Water temperature Repair or refit new
defect difference OK. pressure gage.

External water 5.1 Leaking gasket Retighten cover and

leakage pipe connections,
see torque value on
data sheet. If
necessary replace
gasket
Internal water 6. High air humidity may cause water
leakage, condensation. Check always water quality
if treated circuit water or sea water.
6.1 Leaking gasket. Drain water is Retighten cover
treated water and connections, see
water lost in header torque value on data
tank. sheet. If necessary
In case off sea replace gasket.
water coolant drain
water is sea water.
6.2 Leakage between Use tube expander
tubes and tube to secure tube in
plate. tube plate.
6.3 Cooler tubes Leaking tubes have
leaking. to be plugged on
both ends.

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

9 Tube Leaks
9.1 Repair of Water Leakage's

Cause of a water leakage may be corroded tubes or a leaking rolled in tube end. To find out the
leaking tube it is helpful to remove the bundle and to deposit it on suitable benches.

The removed bundle has to be filled up with water and should be put under water pressure. The
area of the leaking can be estimated by the dripping water. To find out the real leaking tube it
could be necessary to do an individual pressure test of single tubes of the identified area.
Therefore the headers have to be dismantled.

10. Tightening Torque [Nm]

WITHOUT GASKET OR
SIZE WITHOUT GASKET OR KLINGERSIL – GASKET
KLINGERSIL - GASKET WITH NORD – LOCK – WASHER

M 10 42 50
M 12 75 90
M 16 180 220
M 20 360 430

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

11. Stack cooler with housing

1. Air cooler housing

2. Fin tube bundle
3. Tube plate
4. Nozzle header brush
5. Return header
6. Cover
7. Water mist catcher
8. Cover
9. Sealing groove
10. Tube cleaning brush

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 GEA Maschinenkühltechnik GmbH
Geschäftsbereich Südstraße 48
Wärmetechnik D-44625 Herne

12. Block cooler

1. Nut
2. Flange
3. Gasket
4. Bolt
5. Nozzle header
6. Header Bolt
7. Nozzle header
Gasket
8. Tube brush
9. Return header
Gasket
10. Return header
11. Header bolt
12. Drain / vent
13.
14. Tube plate
15.

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