3500B Marine Propulsion Engines Heat Exchanger - Inspect Caterpillar


Heat Exchanger - Inspect
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3500B Marine Propulsion Engines [SEBU7253]
COOLING SYSTEM
HEAT EXCHANGER GP
3500B Marine Propulsion Engines Heat Exchanger - Inspect
1.1. Shell and Tube Heat Exchanger
2.2. Cleaning the Shell and Tube Heat Exchanger
3.1. Plate Type Heat Exchanger
4.2. Cleaning the Plate Type Heat Exchanger

------ WARNING! ------

Personal injury can result from hot coolant, steam and alkali.

At operating temperature, engine coolant is hot and under pressure. The heat exchanger and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.



NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.


Shell and Tube Heat Exchanger

The interval for the maintenance of the shell and tube heat exchanger depends on the operating environment of the vessel and on the operating time. The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items:

  • Cleanliness of the tubes for the heat exchanger

  • Effectiveness of the heat exchanger system

Operating in water that contains the following will adversely affect the heat exchanger system: silt, sediment, salt and algae. In addition, intermittent use of the vessel will adversely affect the heat exchanger system.

The following items indicate that the heat exchanger may require cleaning:

  • Increased coolant temperature

  • Engine overheating

  • Excessive pressure drop between the water inlet and the water outlet

An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range. Inspection and maintenance of the heat exchanger are required if the engine is overheating.

Cleaning the Shell and Tube Heat Exchanger

Refer to the Disassembly and Assembly Manual for the engine.

  1. Drain the heat exchanger.

  2. Remove the heat exchanger.

  3. Turn the heat exchanger core upside-down in order to remove debris.


    NOTICE

    Do not use a high concentration of caustic cleaner to clean the core. A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage. Only use the recommended concentration of cleaner.


  4. Back flush the core with cleaner.

    AVSpare recommends the use of Hydrosolv liquid cleaner. Table 1 lists Hydrosolv liquid cleaners that are available from your AVSpare dealer.

    Table 1
    Hydrosolv Liquid Cleaners(1) 
    Part Number  Description  Size 
    1U-5490  Hydrosolv 4165  19 L (5 US gallon) 
    174-6854  Hydrosolv 100  19 L (5 US gallon) 
    (1) Use a two to five percent concentration of the cleaner at temperatures up to 93°C (200°F). Refer to Application Guide, NEHS0526 or consult your AVSpare dealer for more information.

  5. Steam clean the core in order to remove any residue. Flush the tubes of the heat exchanger core. Remove any other trapped debris.

  6. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

    ------ WARNING! ------

    Personal injury can result from air pressure.

    Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

    Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.


  7. Dry the core with compressed air. Direct the air in the reverse direction of the normal flow.

  8. Inspect the core in order to ensure cleanliness. Pressure test the core. Many shops that service radiators are equipped to perform pressure tests. If necessary, repair the core.

  9. Install the heat exchanger. Refer to the Service Manual for the procedure.

For more information on cleaning the core, consult your AVSpare dealer.

Plate Type Heat Exchanger

The interval for the maintenance of the plate type heat exchanger depends on the operating environment of the vessel and on the operating time. The sea water that is circulated through the heat exchanger and the amount of operating time of the vessel affects the following items:

  • Cleanliness of the heat exchanger plates

  • Effectiveness of the heat exchanger system

Operating in water that contains the following will adversely affect the heat exchanger system: silt, sediment, salt and algae. In addition, intermittent use of the vessel will adversely affect the heat exchanger system.

The following items indicate that the heat exchanger may require cleaning:

  • Increased coolant temperature

  • Engine overheating

  • Excessive pressure drop between the water inlet and the water outlet

An operator that is familiar with the normal operating temperature of the coolant can determine when the coolant temperature is out of the normal range. Inspection of the heat exchanger and maintenance of the heat exchanger are required if the engine is overheating.

Your AVSpare dealer has the equipment and the personnel in order to measure the pressure drop across the heat exchanger.

Consult your AVSpare dealer or refer to the Service Manual for service information for the heat exchanger.

Cleaning the Plate Type Heat Exchanger

Refer to the Disassembly and Assembly Manual for the engine. The heat exchanger must be disassembled in order to be cleaned. The Disassembly and Assembly Manual will contain instructions for cleaning the heat exchanger prior to reassembly. The following general guidelines are for cleaning a plate type heat exchanger. Refer to Table 2 for types of cleaners.


NOTICE

Do not use hydrochloric acid to clean stainless steel plates.

Do not use hydrofluoric acid to clean titanium plates.

Water that contains more than 300 ppm of chlorine should not be used to prepare cleaning solutions.

Do not use Ketones such as Acetone and Methyletyketone.

Do not use esters such as Ethylacetate and Butylacetate.

Do not use Halogenated hydrocarbons such as Chlorothene and Carbon Tetrachloride

Do not use Aromatics such as Benzene and Toluene.


Table 2
Problem  Source  Cleaners(1) 
Scaling  Calcium carbonate
Calcium sulphate
Silicates 
Nitric acid
Sulfamic acid
Citric acid
Phosphoric acid
Complexing agents
Sodium polyphosphates 
Sediment(2)  Corrosion products
Metal oxides
Silt
Diatomic organisms  
Gross fouling  Seaweed
Chips of wood and fibers
Mussels
Barnacles 
Biological growth  Bacteria
Nematodes
Protozoa 
Residue  Oily films
Asphalt
Fats 
Paraffinic or Naphtha based solvent such as Kerosene.(3)(4) 
(1) Cleaners should be mixed at a maximum concentration of 4 percent by weight. The temperature of the cleaning solution should be less than 60 °C (140 °F).
(2) The addition of surfactants to the cleaning solution may ease cleaning.
(3) Do not mix the solvent with water for cleaning. Dry the plates with a cloth or rinse the plates with water.
(4) Gaskets that are made from natural rubber, butyl rubber and EPDM rubber will swell in these solvents. Do not allow the solvent to contact the gasket more than half an hour.

  1. Drain the heat exchanger.

  2. Disassemble the heat exchanger and remove the plates. Keep the plates in order.

  3. Clean the plates with a cleaning solution and a soft brush. Pressurized water may also be used. Do not use steel wool or a wire brush, which may scratch the plate. Any iron scratches on the plates can lead to corrosion of the plates. Rinse the plates with water.

  4. Assemble the heat exchanger.

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