11.

0 Maintenance

Preventive Maintenance Work

The maintenance schedule is in Table 11.1

The intervals shown there are a guide based on normal operating conditions. If
operated in a harsh environment, perform the service more frequently. Carry
out the maintenance work, based on either running hours or calendar time
whichever comes first.

Items marked with o should be performed by a user while the other marked
with * should be maintained by the nearest branch.

The actions mentioned in the schedule are repetitive unless otherwise specified,
the actions at 3,000 hours interval, as an instance, shall be carried out again
after 6,000 hours of operation.

Keeping a record is a very good practice for good preventive maintenance.

The record also enables ELGI to find a potential cause of trouble and thereby
perform a suitable repair. Use the attached record form.

Standard Maintenance Schedule

The maintenance instructions are summarized in Table 11.1. Before taking any
maintenance actions, read the concerned section. Time mentioned in the Table
11.1. are not a performance guarantee period.

11.0
 TABLE 11-1 STANDARD CHECK AND MAINTENANCE SCHEDULE

MAI NTENANCE I NSTRUCTI ONS

Every year/
Sl no Activity Description Daily Monthly 2000 hrs Every two year
8000hrs

1 Check Oil Level

2 Check Inter cooler Drain
3 Check After cooler Drain
4 Check Water leakage
5 Check Oil leakage
6 Check Working Parameteres
7 Check Airfilter indicator for Airfilter condition
8 Clean Clean Y type stainer / Orifice
9 Grease Main Motor
clean, If Airfilter chocking indication changes
10 Clean Intake Airfilter
from green to red
Replace ,If Airfilter chocking indications still in
11 Replace Intake Airfilter
red after cleaning
12 Replace CCV Kit
13 Replace Oil Filter
14 Replace Oil
15 clean Oil Strainer
16 Clean Inter and after cooler bundle ( Depends up on water quality)
17 Clean Oil cooler ( Depends up on water quality)
18 Replace Check valve
19 Check Safety valve
20 Check Oil Pump
21 Check / change Solenoid Valve
22 Change Nylon Tube
23 Change Blow Off Silencer
24 Calibrate Switches and Gauges

Pr ecautions
A. I f the compr essor kept idle for mor e than 8 Hour s
1. Close the Inlet and Outlet water valve.
2. Drain the Water from the Compressor System.
3. Close the Main Air outlet Valve.
B. I f the Compr essor kept idle for mor e than a week.
Apart from above points other precautions are
1. Rotate the compressor shaft once in 7 days and ensure free rotation of shaft.
2. Supply dry air at intercooler dry air inlet for 30 min
The above guidelines applicable to normal industrial environment. In the event of changes in the environment, consult ELGI
guidelines
id li on above
b

11.1
11.1 Intake Air Filter

Just after the dust indicator changes from green to red, clean the filter element
or replace it with a new one.

Method of cleaning filter element.

Remove the filter from the suction box panel. (FIG. 11.1)

Attach the suction box cover on the suction box panel to prevent dust or
dirt from entering the compressor inlet.

Disassemble the filter element (FIG. 11.2)

Blow the filter element with compressor air from inside to outside.

Assemble the filter element.

A dirty filter will decrease the suction pressure and will

! increase the compression ratio. It may cause excessive high
CAUTION discharge temperature.

FIG. 11-2 FILTER

FIG. 11-1 INTAKE AIR FILTER

11.2
11. 2 Oil filter (FIG. 11.3, 11.4)

The Oil Filter which has a 10 micron filter screen is located between the oil
cooler and the air end. This is a full flow filter with a replaceable pleated element.
Servicing of oil filter element shall be done every 10,000 hours or 2 years
whichever comes first. The procedure for complete service of this filter is
explained below.

Disassembly
Disassemble the oil housing by removing the four hexagonal bolts holding
the head assembly to the main body.
Remove the body seal from the main body.
Dislodge the element from the head assembly.
Clean the head assembly and housing thoroughly.

Reassembly

Lubricate the new body seal and reposition in main housing.

Replace the new element on to the head assembly.

Place the head assembly with attached filter back into the housing.

Retighten the four hexagonal bolts.

Hex Bolt

Head

Seal

Element

FIG. 11.3 INSIDE OF THE SOUNDPROOF COVER

Spring washer
Housing

Hex. Nut

Drain plug

FIG .11.4 OIL FILTER

11.3
11.3 Oil strainer (FIG. 11.3, 11.5)

In the oil line, an oil strainer and an oil filter are provided.

The oil strainer, which has 150 mesh filter screen, is located in the gear casing.

The cleaning of oil strainer shall be made every 10,000 hours or every 2 years
(whichever comes first) at the same period as oil change.

The oil strainer can be removed from the gear casing containing oil. It is
unnecessary to drain the oil off.

Take off the flexible tube, which connects the gear casing with the oil pump.

Loosen the bolts of rectangular flange and pull the pipe with the oil strainer from
the gear casing.

Clean the oil strainer.

After cleaning it, attach the pipe with the oil strainer on the gear casing.

Oil Fill (FIG. 12.6)

Check the oil level daily. If necessary, fill the oil through the oil filling port at the
side of the gear casing.

Use only recommended oil brands.

DO NOT MIX OIL BRANDS.

Oil Change (FIG. 12.7)

Sample the oil from the gear casing every six months. Change the oil if necessary.

Place a drain pan under the oil drain opening at the left side of the unit.
Remove the cap of the oil filling port and open the oil drain valve.

Remove the plugs from the oil cooler and oil filter. Then drain the oil off.

Completely drain off the old oil. Open the inspection covers at both sides
of the gear casing, and clean and wipe the bottom of the gear casing with
clean cloth.

11.4
Attach the inspection cover and close the oil drain valve. Supply new oil
to the upper line of oil level gauge. Then operate only the oil pump for one
minute and add oil to the upper line.

Attach the cap of the oil filling port.

11.5
11.4 Cooler Drain

Check the drain condition once in a day by opening the drain detection valve.
When a great deal of drainage is discharged from the drain detection valve, it is
considered that the orifice is clogged or the strainer is dirty. Remove the orifice
plate and the strainer and clean them at once. Overhaul the orifice plate and the
Y-type strainer once in a month. The drain increases in the rainy season so
check the drain condition at short intervals such as once in every two to three
hours during the season.

Cleaning Procedure

Slightly close the drain valve, which is attached inside the unit so that the
drain flowing from the orifice hole is slow.

Remove the orifice plate and the Y-type strainer.

Insert a steel wire of 1.5 mm into the orifice hole.

Remove the drain detection valve and the plug. Disassemble the filter
element from the Y-type strainer.

Using an air nozzle held at a suitable distance, blow up and down the
clean side of the filer element.

Inspect the filter element and reinstall it if usable.

11.5 Cooler Maintenance

11.5.1 Cleaning and inspection intervals

Cleaning on the tube side once in every 2500 hrs (for the water quality
mentioned before).

If the water quality can be maintained as per our regular norms then it may
be extended to 5000 hrs also.

Cleaning on the airside once in two years.

11.6
 The above intervals are not mandatory & can vary according to the water
quality.

Cleaning can be done based on the performance of the coolers.

Preventive maintenance of the heat exchanger is a user responsibility.

11.5.2 Cleaning of the heat exchanger

Mechanical cleaning with nylon brushes on tube side

Chemical cleaning where the whole tube bundle is dipped into the chemical
bath to remove scales/dirt

Chemical additives can be used to prevent scale formation based on the

quality of water

Cost of chemical additive is 150 Rs/kg and should be added at 20-60

PPM in the available water. The concentration varies with water quality.

Closed water cooling system can be used where DM water is used for
cooling purposes which avoids formation of scales.

11.5.3 Mechanical cleaning of the tube side

The tubes can be cleaned with a tube brush. Use original Bloksma brushes
only; these have the correct dimensions and are of a suitable material. Other
brushes may damage the protective layer that is in the normal course of events
present on the tube walls.

11.5.4 Chemical cleaning of the shell - / tubeside

Chemical cleaning may damage the heat exchanger. Make sure

your supplier of a cleaning agent verifies and confirms the
! compatibility of his product with the materials of the heat
WA RNING ex c hanger. Cleanin g of th e s hel l s id e wil l no rm all y b e
necessary seldom.

11.7
The shell- as well as the tube side can be cleaned by circulating a chemical
solution through the heat exchanger. Another possibility is disassembling of
the bundle and submerging the tube bundle in a tank filled with a chemical
solution.

To give an idea of the possibilities, an example of a cleaning procedure is given

below.

Cleaning of the shell side will normally be necessary seldom.

The shell-as well as the tube side can be cleaned by circulating a chemical
solution through the heat exchanger. Another possibility is disassembling of
the bundle and submerging the tube bundle in a tank filled with a chemical
solution.

There are several international companies (example in Appendix B) which supply

equipment and fluids for chemical cleaning of heat exchangers. Their specialized
cleaning centers, situated at ports all over the world, are able to give you a
cleaning advice or to clean the heat exchanger for you. To give an idea of the
possibilities, an example of a cleaning procedure is give below.

This cleaning advice is meant for water heaters/ coolers.

Descalant NF (inhibited cleaning agent)

Submerge the tube bundle (time is depended on the degree of fouling) in a

tank with dissolved cleaning agent.

After cleaning neutralize the tube bundle and the cleaning agent with a
special neutralizing fluid.

Flush the tube bundle with fresh water.

Dry the tube bundle.

11.8
11.5.5 Chemicals can be used for cleaning:

A) Product number : 1

Product name: Accepta 2048:Combined scale control &anti-foulant for

cooling systems.

Product description: Combined scale control &anti-foulant for cooling

systems. Designed to inhibit scale formation and fouling in cooling water
systems. Particularly effective against carbonate and Sulphate deposition
and in dispering clay, mud and silt. Accpeta-2048 represents no effluent
problems. Contains carboxylic acid and acrylates.

Add 3 liters of Accepta per 1000 liters system volume. Top up system as
required based on water losses.

B) Product number: 2

Product name: Accepta 3533.

Product description: Scale and corrosion inhibitor for cooling systems.

Compatible with antifreeze.

Ensure the system to be treated is clean, drain and flush. If the system is
heavily fouled consider cleaning the system.

Add 3 liters of Accepta per 1000 liters system volume. Top up system as
required based on water losses.

C) Product number: 3

Product name: Sublime

Product description: Water based solvent containing wetting agents,

corrosion inhibitors and degreasing compounds. It is designed to penetrate
and remove encrusted lime scale, rust and corrosion products and dirt
from water surfaces in process equipment, commercial and industrial
applications.

11.9
 Sublime is most effectively used by circulating through the equipment to
be cleaned. Sublime also is used by filling the equipment to be cleaned
and allowing it to set until scale has disappeared. The cleaning operation
normally takes two to six hours.

Inspection method for SUBLIME:

SUBLI ME comes in a pale yellow color that changes to a deep bluish-

purple when it is spend.

The advantages to this color are:

a) We know when the solution is spent and should be discarded.

b) The color change at a pH of 5.8 to 6.0 which is well within the safe disposal
range of most of the current governmental waste regulations.

c) If the equipment is clean and SUBLIME has not changed color, we can
save it and use it again.

11.10
11.5.6 Shut down periods

During shut down periods longer than a week the heat exchangers has to be
drained completely and dried by means of preheated compressed air. In fact
this also has to be done during short shut down periods (longer than a day)
when there is risk of freezing, and it also applies when a corrosive medium is
used in the heat exchanger. After draining a corrosive medium, the heat
exchanger has to be rinsed with fresh water.

Stopping of the flows, cooling down and draining of the heat exchanger has to
be done in a manner to minimize thermal stresses on the heat exchanger.

Never stop one of the flows of the heat exchanger while the other one stays in
operation, because of the risk of boiling.

11.5.7 Assembling and disassembling of the bundle

The circumference of one of the tube sheets is fitted with three grooves (fixed
tube sheet). The two outer grooves carry O-rings (seating between shell and
tube side). The middle groove of the fixed tube sheet is for the fixation of the
position of the tube bundle by means of fixation plates.

The other tube sheet (floating tube sheet) has no middle groove and is supposed
to slide according to eventual thermal dilatation.

11.11
Step 1: Assembling of the bundle

Move the tube bundle in the shell (let it stick out of the shell a bit). For big
bundle size, it is preferable (when possible) to insert the bundle vertically
in the shell. Tube bundle can be lifted vertically with the help of thread
holes in the tubes plates. For horizontal assembly bundle should be
supported under the baffle or support sheet.

Check position of eventual baffle. Position of the first baffle should be

always at the same side as water inlet.

Mount the inner O-ring on the first tube sheet.

Move the tube bundle further and let it stick out a bit on the other side of
the shell.

Mount the inner O-ring on the second tube sheet.

11.12
Hint : when it is difficult to move the tube bundle through the shell because the
already mounted O-ring is hard to compress, you can use a strip between tube
sheet and channel and then tighten bolts and nuts.

Move the tube bundle in its final position.

Tube side assembly:

Mount the outer O-rings on both sides

Mount the fixation plates to secure the bundle in the shell. Note that the
fixation plates of the cooler with an even number of tube passes should
always be mounted on the same side as the channel.

Mount the water boxes and all connections

Start-up the heat exchangers again

Make sure that the cold medium circulation is established first, followed
by the gradual introduction of the hot medium.

Vent both circuits

Vent both circuits again when the operating temperatures and pressures
are reached.

Check for leakage.

Step 2: Tube side disassembling

Depressurize both circuits

Let both circuits cool down to ambient temperature

Drain the tube side circuit, by opening the drain in the lowest point and the
vent in the highest point

Mark the position of all parts that will be disassembled, so they can be
mounted in the correct position later on

Remove the water boxes by un-tightening the nuts (the fixation plates
come loose as well)

11.13
 Mount the fixation plates again with the nuts (not necessary when the
tube bundle is going to be removed (see step 4))

Remove the outer O-ring from both tube sheets

Only for a pressure test: pressurize the shell side again.

Depressurize the shell side again after the pressure test.

Step 3: Removing the tube bundle

Drain the shell side circuit, by opening the drain in the lowest point and the
vent in the highest point.

Mark the position of the tube bundle

Move the tube bundle to one side until the inner O-ring shows (do not
move the tube bundle further than necessary) and remove this O-ring.
Refer methods.

Move the tube bundle to the other side and remove the outer O-ring on this
side as well.

Carefully pull the tube bundle from the shell

Support the tube bundle under the baffles or support sheet when lifting it,
but we should handle careful not to bend the baffles (this would affect the
thermal performance of the heat exchanger)

11.5.8 Removal Of Cooler Tube From The Housing

11.14
11.15
11.16
Remarks

Copper fin is very fragile part of the cooler and should be handled with a
lot of caution

For casting design with a blind side, bundle is designed with a small and a big
tube sheet. The small tube sheet is inserted at first in the casting with the 4 O-
rings already mounted. Fixed tube sheet has to be placed always at the channel
side (for 2 pass execution).

Instructions for gaskets and bolting

O-rings: After disassembling the heat exchanger never use the old O-rings
again. Replace them with original Bloksma O-rings.

The O-rings have to be lubricated with a special O-ring lubricant

(O-ring silicone paste of Parker O-lube) for easy assembly and
a good sealing capacity. Lubricants not suited for O-rings can
! affect the sealing capacity of the O-ring (for instance never use
WA RNING
Vaseline). Any warranty claim will be rejected when unsuited
lubricants are used.

11.5.9 TROUBLE SHOOTING AND REPAIRS

Performance too low

Check :

Whether all connections have been made according to the drawing.

Whether the heat exchanger and the system have been properly vented

Whether the flows are according to the specification (check all valves,
lines and pumps, as well as the flow directions)

11.17
 Whether the shell-as well as the tube side have been cleaned recently
(fouling can cause a drop in performance and an increased pressure loss;
an increased pressure drop is a good indication that cleaning is necessary).

Whether the heat exchanger has been reassembled properly after

disassembly (the position of the tube bundle (this might accidentally be
mounted rotated 180degree around its axis))

Leaking tubes/ tube-to-tube sheet connection

It is often very hard to determine whether leakage occurs because of a leaking

tube -to-tube sheet connection. The shell side of the heat exchanger can be
hydro-tested, after disassembling the tube side. Follow the instructions in
Assembling and disassembling of the bundle. Subsequently pressurize the
shell side. After hydro testing depressurize and drain the shell side again.
Assemble the heat exchanger again.

The tubes are roller expanded into the tube sheet. It is either not possible
(finned tube bundles) or relatively complicated (un-finned tube bundles) to replace
a leaking tube, but it can be plugged with soft copper plugs (other materials are
too hard and may cause leakage of the adjacent tube-to-tube sheet connections)
in both tube ends. A maximum of approximately 10% plugged tubes will not
influence the thermal performance of the heat exchanger too much.

11.6 Oil Pressure Regulator (FIG. 11.9)

The oil pressure regulator maintains oil pressure adequate for the oil system.
At the correct setting, oil pressure gauge indicates 1.5 2.2 kgf/cm2.

If proper adjustment of oil pressure is lost, proceed as follows to re-establish

the correct setting.

When the pressure is lower, turn the adjustment control knob clockwise.

If the oil pressure drops to 1.1 kgf/cm2, the pressure switch shuts down the unit
automatically due to low oil pressure.

11.18
 Fig 11.9 OIL PRESSURE RELIEF VALVE

11.7 Capacity Control Device

Apply grease on the pinion gear and the rack of piston rod every six months

11.19
11.8 Blow-off Silencer

Check the blow-off silencer every 10,000 hours or every one and a half years,
whichever comes first. Replace the sound absorbing material or the entire blow-
off silencer with a new one if necessary.

Disassembling Procedure
Remove the top panel from the soundproof cover by loosening the corner
bolts.
Remove the blow-off silencer from the ventilation box.
Loosen the bolt installed at the top cover of the blow-off silencer.
After removing the top cover, check it for warping, deflection or cracks.
Remove the cartridge of sound absorbing material from the blow off silencer.
Check the dispersing condition of the sound absorbing material.
If a lot sound absorbing material is lost, it is necessary to replace the
sound absorbing material with a new one.
Assemble the blow-off silencer in the reverse order.

FIG11.11 REMOVAL OF BLOW-OFF SILENCER

FIG11.12 BLOW-OFF SILENCER

11.20
11.9 Disassembly of Soundproof Cover

The soundproof cover consists of several panels, doors and shaped steel.
They are bolted to each other so that it is easy to assemble or disassemble
them.

To make maintenance work easy, it is recommended to remove the concerned

panel or door.

FIG11.13 DISASSEMBLY OF SOUNDPROOF COVER

11.21