HYDAC Cooler Routine Inspection

Brand

HYDAC/Germany

Type

Plate Cooler

Structure

Vertical

Application Areas

Environmental Protection, Bio-industry, Petroleum, Pharmaceutical/Biopharmaceutical, Comprehensive

HYDAC Sensors, HYDAC Filters, HYDAC Filter Elements, HYDAC Coolers, HYDAC Detectors

After the HYDAC cooler is put into operation, operators should regularly inspect the heat exchanger to determine if it is operating normally.

(1) Check process parameters; operation under excessive temperature or pressure is strictly prohibited.

(2) Check for leaks in the partition tank, boiler, and interface flanges.

(3) Check the stability of the foundation support.

(4) Check the vibration of the cooler and pipelines.

(5) Regularly check the oil color and temperature changes after heat exchange.

HYDAC Cooler Daily Maintenance

HYDAC coolers use cooling water that mostly contains calcium, magnesium ions, and acidic carbonates. When the cooling water flows over metal surfaces, carbonates are generated. Additionally, dissolved oxygen in the cooling water can cause metal corrosion, forming rust. Scale buildup reduces heat exchange efficiency. In severe cases, it becomes necessary to spray cooling water onto the exterior of the casing. Excessive scale buildup can clog pipes, rendering heat exchange ineffective. Research data shows that scale deposits significantly impact heat transfer losses, increasing energy costs as deposits accumulate. Therefore, saving energy, extending equipment lifespan, and reducing production time and expenses are crucial.

Traditional cleaning methods such as mechanical methods (scraping, brushing), high-pressure water cleaning, and chemical cleaning (acid washing) have long presented numerous problems: they fail to remove scale and other deposits; acid corrodes equipment, creating leaks; residual acid causes secondary corrosion or under-deposit corrosion, ultimately leading to equipment replacement; and cleaning wastewater is toxic, requiring substantial investment in wastewater treatment.

HYDAC cooler cleaning agent from Germany is ideal for cleaning condensers.

HYDAC coolers from Germany are highly efficient, environmentally friendly, safe, and non-corrosive. They provide excellent cleaning results without corroding the equipment, ensuring the long-term use of the condenser. Fushitek cleaning agent, with the addition of wetting and penetrating agents, can effectively remove the most stubborn scale (calcium carbonate), rust, grease, sludge, and other deposits generated in water-using equipment. It is harmless to the human body and will not cause corrosion, pitting, oxidation, or other harmful reactions to materials such as steel, copper, nickel, titanium, rubber, plastic, fiber, glass, and ceramics, thus greatly extending the service life of the equipment.

When shutting down the HYDAC cooler, the hot flow should be stopped first, followed by the cold flow. If maintenance is required, the medium inside the tube shell should be cleaned according to the line cleaning procedure, and maintenance can only be carried out after the equipment body temperature has dropped to the permissible temperature.

HYDAC Cooler Usage Precautions

(1) When the cooler is put into operation, the vent valve on the cooling line should be opened to release air. Close it after water is seen to prevent air resistance from affecting the cooling effect.

(2) When the cooler is shut down for line cleaning, stop the cooling water supply and open the cooling water vent valve at the same time to avoid pressure buildup and damage to the equipment. (3) When adjusting the temperature of the cooled oil, the cooling water outlet valve should be used first. While using the inlet valve to control the water flow can save cooling water, it can cause a short circuit or slow down the flow rate within the cooler, resulting in a hot top and cold bottom, affecting heat exchange efficiency. Therefore, inlet control is not recommended.

HYDAC Cooler Troubleshooting Methods

1. Insufficient Coolant

Add Coolant

2. Radiator Fin Blockage

Find the cause of the blockage and clean the radiator

3. Poor Radiator Ventilation

Increase the effective ventilation area according to installation requirements to ensure smooth ventilation

4. Coolant Fan Malfunction

Check the fan belt tension and replace the belt if necessary

5. Damaged Fan

Repair or Replace

6. Damaged Water Pump

Repair or Replace

7. Thermostat Malfunction

Replace

8. Fuel Injection Pump Malfunction

Have authorized personnel repair or replace

9. Incorrect Fuel Injection Timing

Check the fuel injection pump data and have authorized personnel repair and adjust

10. High Ambient (Intake) Temperature

Maintain proper ventilation in the engine room to reduce the temperature. 11. Severe overload of the generator set

Control the load and prohibit prolonged overload operation of the generator set.

12. Coolant alarm switch (sensor) or instrument malfunction

Inspect the control panel, instruments, and engine body sensors; repair or replace them to eliminate the fault.

14. Cooling Water

HYDAC Cooler Overview

During the operation of a diesel generator set, friction exists between various components, generating heat. If this heat cannot be dissipated or cooled in time, it will seriously affect the lifespan and operating efficiency of the generator set. Cooling water is a liquid used to lower the temperature of the generator set.

The cooling water used to directly cool the diesel engine should be clean fresh water, such as rainwater, snow water, good quality tap water, or clarified river water. If well water or other groundwater is used directly, because they contain more minerals, scale can easily form in the diesel engine's water chamber, affecting the cooling effect and causing malfunctions. If only hard water is available, it must be softened before use.

The following are two common methods for softening cooling water for HYDAC coolers:

① Boiling method – Boiling the water to allow sediment to settle.

② Add 0.67s caustic soda (sodium hydroxide) to each liter of water, stir to allow sedimentation, and use the clear water from the top.

We especially remind you: Seawater must never be used to directly cool the diesel engine.

Furthermore, after the diesel engine has finished running, the cooling water should be completely drained to prevent the cooling water from freezing and expanding, which could damage the generator set.

HYDAC Cooler Maintenance

How to maintain the cooling water used in the diesel engine at a certain temperature or ensure it performs its cooling function properly, timely water replacement and circulation, and protection of the generator set during use to prevent overheating are detailed below.

HYDAC coolers use clean soft water. Soft water typically includes rainwater, snowmelt, and river water. These waters contain low levels of minerals, making them suitable for engine use. Well water, spring water, and tap water, on the other hand, have high mineral content. These minerals, when heated, easily deposit on the walls of the water tank, water jacket, and water passages, forming scale and rust. This reduces the engine's cooling capacity and can easily lead to overheating. The water added must be clean; impurities in the water can clog water passages and accelerate wear on components such as the water pump impeller. If hard water is used, it must be softened beforehand. Softening methods typically include heating and adding an alkaline solution (commonly caustic soda).

Do not start the engine before adding water to the HYDAC cooler.

In winter, some drivers, for ease of starting or because water sources are far away, often start the engine first and then add water. This method is extremely harmful. After a dry start, because there is no coolant in the engine compartment, all engine components heat up rapidly, especially the cylinder head and the water jacket outside the fuel injectors in diesel engines. If coolant is added at this time, the cylinder head and water jacket are prone to cracking or deformation due to sudden cooling. When the engine temperature is too high, the engine load should be removed first and the engine should be idled at low speed. Coolant should only be added when the water temperature returns to normal.

Prevent burns when the engine boils over. After the radiator boils over, do not blindly open the radiator cap to avoid burns. The correct procedure is to let the engine idle for a while before turning it off. Wait until the engine temperature drops and the radiator pressure decreases before unscrewing the cap. While unscrewing, cover the cap with a towel or car cloth to prevent hot water and steam from spraying onto your face or body. Never look directly down at the radiator. After unscrewing, quickly remove your hand and wait until there is no more hot air or steam before removing the cap. Take precautions to prevent burns.

------------ The company primarily deals in European and American brands, and can source brands from any European country. For example, its key German brands include: BURKERT, DEMAG, HAWE, REXROTH, HYDAC, PILZ relays, FESTO, IFM sensors, E+H, HEIDENHAIN, P+F sensors, SICK, TURCK, HIRSCHMANN industrial switches, Henschler, MURR, SCHMERSAL, SAMSON, and EPRO (a subsidiary of Emerson).

American brands include MOOG, ASCO solenoid valves, MAC solenoid valves, NUMATICS, PARKER pneumatics and hydraulics, VICKERS, and ROSS.

British brands include Norgren. Italian brands OMAL, ATOS, CAMOZZI, UNIVER, and Camozzi.