Serial Number:: Document Type

16660
Serial Number:
Document Type:
Compressor Data Sheet - Section 1
Installation - Section 2
Lubrication - Section 3
Controls - Section 4
Operation - Section 5
Maintenance - Section 6
Recommended Parts List - Section 7
Drive and Coupling - Section 8
Lube System - Section 9
Heat Exchangers - Section 10
Control Valves - Section 11
Vibration Equipment - Section 12
Controllers - Section 13
Switches and Gauges - Section 14
Miscellaneous - Section 15
Compression Systems
3101 Broadway, PO Box 209
Buffalo, NY14225-0209 USA
Tel. 716.896.6600
Fax 716.896.1233
Fri Apr 30 08:02:28 2010 Heat Exchanger Specification English Units
Customer: El Nazr Fertilizers and
Job No.: CB-16660
Chemical Industries
Indust Co.
Service of Unit: TAE-100M6R3/30 :
Cooper PN: A3802998 - 06070
I/C #1
Size: 33.5 / 14 X 12 X 112.0 Effective Surface: 5611.0 Sq.Ft.
Performance
Fluid Allocation Shell Tube
Fluid Name Air Water
Fluid Quantity, Total 12065.9 ICFM* 420.2 GPM
Vapor (In/Out) LB/Hr 746.9 / 746.9
Liquid LB/Hr 208944.3
Condensate LB/Hr 0.0
Non Condensables LB/Hr 49880.1
Temperature (In/Out) Deg F 293.4 / 110.0 86.0 / 97.0
Specific Heat BTU/LB*Deg F 0.24 1.0
Inlet Pressure PSI(abs) 37.2
Core Velocity Ft/Min 6.95
6.7 Ft/Sec
Pressure Drop PSI 0.585 6.056
6.58
Fouling Resistance Hr.Sq.Ft.Deg.F/BTU 0.0010 0.0030
Heat Ex.: 2299576.9 BTU/Hr // LMTD: 82.0
Deg F // Transfer Rate: 5.0
BTU/Hr.Sq.Ft.Deg.F
Construction
Design/Test Pressure PSI(gage) 102.0 / 133.0 150.0 / 195.0
Design Temperature (min/max)Deg F -20.0 / 350.0 -20.0 / 150.0
Number of Passes 1 2
Corrosion Allowance in 0.0625 0.0625
Connections: Size (In/Out) in 12.0 / 12.0** 6.0 / 6.0**
Connections: Rating 150 PSIG**
Tube No.: 162 OD: 0.6250 in** Thk: 18.0 BWG**
Length: 112.0 in Pitch: 1.5 in ---> 30 deg. triangular
Tube/Fin Arrangement:BARE with ALUMINUM fins // Tube Material: 304 SSTL
Shell: 304 SSTL Shell Cover: N/A ID / OD: 32.8 in / 33.5 in
Bonnet, Supply: STEEL // Bonnet, Return: 304 SSTL
Tubesheet, Stationary: 304 SSTL // Tubesheet, Floating: 304 SSTL
Bypass Seal: Silicone Rubber Tubesheet Joint: Rolled Expansion Joint: O-Ring
Gasket, Shell: Non-Asbestos // Gasket, Tube: Non-Asbestos // Gasket, Floating Head: Non-Asbestos
Code Requirements: A.S.M.E. Section VIII Division 1
Weights-Dry: 4500.0 Lb // Wet: 4810.0 Lb
// Bundle: 1480.0 Lb
Remarks: * Measured @ 14.36 PSI(abs); 89.6 Deg F; 50.0 %RH
** ASME Nominal Values
*** Phenolic Coated Fins. *** 304 SSTL Bundle Casing.
Notes:
Continue
VRN Friday, April 30, 2010

Compression Systems
Tel. 716.896.6600
Fax 716.896.1233
Fri Apr 30 08:48:21 2010 Heat Exchanger Specification English Units
Job No.: CB-16660
Industries Co.
Chemical Indust
Cooper PN: A3802999 - 06070
I/C #2
Performance
Core Velocity Ft/Min 7.3 Ft/Sec
BTU/Hr.Sq.Ft.Deg.F
Construction
Shell: 304 SSTL Shell Cover: N/A ID / OD: 32.8 in / 33.5 in
Notes:
Continue

Compression Systems
Tel. 716.896.6600
Fax 716.896.1233
Tue May 4 10:43:48 2010 Heat Exchanger Specification English Units
Job No.: CB-16660
Chemical Industries
Indust Co.
Cooper PN: A3803000 - 06070
I/C #3
Performance
BTU/Hr.Sq.Ft.Deg.F
Construction
Shell: 304 SSTL Shell Cover: STEEL ID / OD: 32.8 in / 33.8 in
Notes:
Continue
VRN Tuesday, May 04, 2010

Compression Systems
Tel. 716.896.6600
Fax 716.896.1233
Tue May 4 10:55:57 2010 Heat Exchanger Specification English Units
Job No.: CB-16660
Chemical Industries
Indust Co.
Cooper PN: A3803001 - 06080
I/C #4
Performance
BTU/Hr.Sq.Ft.Deg.F
Construction
Shell: 304 SSTL Shell Cover: STEEL ID / OD: 23.2 in / 24.2 in
Tubesheet Joint:
Bypass Seal: Silicone Rubber Expansion Joint: O-Ring
Rolled/Grooved
// Bundle: 750.0 Lb
Notes:
Continue

Compression Systems
Tel. 716.896.6600
Fax 716.896.1233
Fri Apr 30 08:39:11 2010 Heat Exchanger Specification Metric Units
Job No.: CB-16660
Industries Co.
Chemical Indust
Cooper PN: A3802998 - 06070
I/C #1
Size: 850.9 / 14 X 12 X 2844.8 Effective Surface: 521.5 m^2
Performance
Fluid Quantity, Total 20498.8 m^3/Hr* 95.4 m^3/Hr
Vapor (In/Out) Kg/Hr 338.8 / 338.8
Liquid Kg/Hr 95414.1
Condensate Kg/Hr 0.0
Non Condensables Kg/Hr 22625.5
Temperature (In/Out) Deg C 145.2 / 43.3 30.0 / 36.1
Specific Heat Kcal/KgC 0.24 1.0
Inlet Pressure BAR(abs) 2.6
Core Velocity m/s 2.12
2.0 m/s
Pressure Drop BAR 0.040 0.454
0.418
Fouling Resistance Hrm^2C/Kcal 0.0002 0.0006
Heat Ex.: 579822.7 Kcal/Hr // LMTD: 45.6
Deg C // Transfer Rate: 24.4 Kcal/Hrm^2C
Construction
Design/Test Pressure BAR(g) 7.0 / 9.2 10.3 / 13.4
Design Temperature (min/max)Deg C -28.9 / 176.7 -28.9 / 65.6
Corrosion Allowance mm 1.5875 1.5875
Length: 2844.8 mm Pitch: 38.1 mm ---> 30 deg. triangular
Shell: 304 SSTL Shell Cover: N/A ID / OD: 831.8 mm / 850.9 mm
Weights-Dry: 2041.2 Kg // Wet: 2181.8 Kg
// Bundle: 671.3 Kg
Remarks: * Measured @ 0.99 BAR(abs); 32.0 Deg C; 50.0 %RH
Notes:
Continue

Compression Systems
Tel. 716.896.6600
Fax 716.896.1233
Fri Apr 30 08:48:56 2010 Heat Exchanger Specification Metric Units
Job No.: CB-16660
Chemical Industries
Indust Co.
Cooper PN: A3802999 - 06070
I/C #2
Performance
Core Velocity m/s 2.2 m/s
Construction
Shell: 304 SSTL Shell Cover: N/A ID / OD: 833.1 mm / 850.9 mm
// Bundle: 671.3 Kg
Notes:
Continue

Compression Systems
Tel. 716.896.6600
Fax 716.896.1233
Tue May 4 10:45:02 2010 Heat Exchanger Specification Metric Units
Job No.: CB-16660
Chemical Industries
Indust Co.
Cooper PN: A3803000 - 06070
I/C #3
Performance
Construction
Shell: 304 SSTL Shell Cover: STEEL ID / OD: 833.1 mm / 858.5 mm
// Bundle: 675.9 Kg
Notes:
Continue

Compression Systems
Tel. 716.896.6600
Fax 716.896.1233
Tue May 4 10:57:16 2010 Heat Exchanger Specification Metric Units
Job No.: CB-16660
Chemical Industries
Indust Co.
Cooper PN: A3803001 - 06080
I/C #4
Performance
Construction
Shell: 304 SSTL Shell Cover: STEEL ID / OD: 589.3 mm / 614.7 mm
Tubesheet, Stationary: 304 SSTL //
Tubesheet, Floating: 304 SSTL
Tubesheet Joint:
Bypass Seal: Silicone Rubber Expansion Joint: O-Ring
Rolled/Grooved
// Bundle: 340.2 Kg
Notes:
Continue

Heat Exchanger
I.O.M. Instructions
INSTALLATION
Drying of Coolers
On compressors used in nitrogen and dry air service the following is recommended prior to
commissioning of machine.
1. Remove drain plug(s) from bottom of cooler shell and shell cover assembly, if
applicable. See cooler assembly drawing, in this section, for drain locations.
2. With drain plugs removed, purge machine with dry air for a minimum of 24 hours.
3. Remove purge from compressor and replace drain plugs.
Bundle Removal
Clearance must be provided at the water nozzle end of the cooler to remove the tube
bundle. Refer to the Compressor Installation Arrangement drawing for clearance
dimensions.
Water Piping
If the cooler water manifold is not provided by Cameron, refer to the Water Schematic
drawing for recommendations and definition of Cameron’s scope of supply. Control valves
should be provided on the discharge line of each cooler. The manifold should include
couplings for temperature and pressure gauges on both inlet and discharge lines close to
the heat exchanger.
Drain piping should be isolated for each cooler and not piped to a closed manifold system.
Before connecting piping, inspect all openings of the coolers and piping for contaminants.
CAUTION
Piping should be suitably supported so that forces
are not directly applied to the heat exchanger.
Condensate Removal
Condensate will accumulate during normal operation of some heat exchangers. Refer to
the Condensate Flow Schematic drawing for recommendations and definition of
Cameron’s scope of supply.
CAUTION
Condensate piping should drain to an open sump
and never piped to a closed manifold system.
1
Heat Exchanger
I.O.M. Instructions
OPERATION
Start-Up
1. Check water piping system for cleanliness to prevent blockage of tubes.
2. Loosen water side vent plugs before admitting water to the cooler.
3. Check all flange bolting for tightness.
4. Start flow of water, gradually at first. When the system is completely filled and all
air vented, tighten vent plugs.
WARNING
Never operate the heat exchanger at pressures,
temperatures or flows in excess of those specified
on the nameplate.
Shut-Down
Caution must be taken to avoid subjecting the heat exchanger or the compressor to
thermal shock. Excessive temperature could impose stresses resulting in catastrophic
damage to the heat exchanger and/or the compressor.
WARNING
Never stop water flow to the heat exchanger before
shutting down the compressor.
Winter Protection During Shut-Down

If it becomes necessary to shut-down the compressor in a location subject to freezing
conditions the following procedure must be implemented to prevent coil damage.
1. Thoroughly drain water by removing vent and drain plug from supply channel.
2. Replace drain plug.
3. Add two gallons (minimum) of antifreeze solution through vent in supply channel.
4. Replace vent plugs.
Performance
When performance does not meet specified requirements check the following:
1. Fouled tubes caused by sludge or scale.
2. Incorrect piping connections. Refer to the Installation Arrangement and Water

Flow Schematic drawings.
2
Heat Exchanger
I.O.M. Instructions
3. Air locks caused by improper venting.
4. Operating at conditions other than design; refer to the Heater Exchanger

Specifications.
5. By-passing of either air or water. Check partition gaskets and seal strips.
MAINTENANCE
WARNING
Do not attempt to loosen any bolting until all
pressures have been relieved and fluids drained.
Cleaning
A regular inspection program is important to determine frequency of cleaning. A reduction
in performance and/or a marked increase of pressure drop usually indicates that cleaning
is required.
NOTE
Cameron’s heat exchangers are designed to be
mechanically cleaned without removing the bundle
from the shell.
Water Side. Interior surfaces of the tubes can be cleaned by back-flushing to remove
sludge and other soft deposits. A rotary brush with brass or nylon bristles will be more
effective. If more severe fouling exists, contact a Cameron Compression Systems
Representative.
Gas Side. The extended surfaces (aluminum fins) should only be cleaned with detergent
and high pressure steam.
CAUTION
If all tubes are not clean, flow may be partially
blocked in some tubes causing overheating or
cooling. This condition could develop severe
stresses that can loosen tube joints and fracture
tubes.
Special Draining Instructions for High Pressure Heat Exchanger (Design Pressure ≥
150 PSIG)
When fluid is added to the gas side of a fully assembled high pressure heat exchanger
some of the fluid will be trapped between the shell cover and return channel. It is
necessary to remove the vent and drain plugs located on the shell cover to insure
thorough draining. (See Heat Exchanger Assembly drawings for vent and drain locations.)
3
Heat Exchanger
I.O.M. Instructions
Bundle Removal
1. Remove lantern-ring (or shell cover) and O-ring from return water header O.D.
2. Remove return water header.
3. Remove supply water header.
4. Inspect for inoperative roller guides – replace if required.
5. Insert eyebolt in tapped hole provided on top of front tube sheet.
6. Supporting bundle from eyebolt, begin sliding bundle out of shell.
WARNING
Do not completely remove bundle from shell. Do
not rest bundle on lower bypass seal.
7. After sufficient bundle is exposed, support and lift bundle with a nylon mesh sling
as its center of gravity.
WARNING
Protect bottom bypass seal (silicone) with 4x4
timbers on both sides.
8. Complete removal from shell.
Handling of Tube Bundles

Do not grasp bundles with hooks or other sharp tools which may damage the tubes or fins.
Nylon mesh slings or straps are suitable for lifting the bundles in a horizontal position.
Always take care to protect the lower bypass seal with 4x4’s in the area of the sling.
The bundles should not be dragged and should only be moved about on cradles or skids.
Reassembly
1. Inspect upper and lower bypass seals for possible damage. If replacement is
required, refer to Cameron Engineering Specification IL-2401.
2. Spray top sheet of bundle and shell channel with silicone spray.
CAUTION
Failure to comply could destroy the bypass seals.
3. Position front tube sheet gasket on mating flange. Hold with tape or glue.
4. Remove top row of studs in rear tube sheet to prevent possible damage to upper
bypass seal.
4
Heat Exchanger
I.O.M. Instructions
5. Support bundle with sling near its center of gravity. (Protect bypass seal with
4x4’s.)
6. Position bundle in shell. Align rollers on shell channel with guide legs on either
side.
7. Partially inert bundle to point of lift.
8. Transfer support to eyebolt on front tube sheet.
WARNING
Do not reset bundle on lower bypass seal.
9. Complete installation of bundle in shell.
10. Reinstall top row of studs in rear tube sheet.
11. Position return water header gasket and install return water header.
NOTE
Refer to Cameron’s Engineering Specification IL-
2401 for torque values and sequence.
12. Position supply header gasket and install supply water header. (Torque per IL-
2401)
13. Position o-ring on O.D. of return header and install lantern ring. (Torque per IL-
2401)
5
Heat Exchanger
I.O.M. Instructions

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16660

Compressor Data Sheet - Section 1

Recommended Parts List - Section 7

Drive and Coupling - Section 8

Lube System - Section 9

Heat Exchangers - Section 10

Control Valves - Section 11

Vibration Equipment - Section 12

Switches and Gauges - Section 14

VRN Friday, April 30, 2010

VRN Friday, April 30, 2010

VRN Tuesday, May 04, 2010

VRN Tuesday, May 04, 2010

VRN Friday, April 30, 2010

VRN Friday, April 30, 2010

VRN Tuesday, May 04, 2010

VRN Tuesday, May 04, 2010

3. Remove purge from compressor and replace drain plugs.

3. Check all flange bolting for tightness.

Winter Protection During Shut-Down

2. Replace drain plug.

4. Replace vent plugs.

1. Fouled tubes caused by sludge or scale.

2. Incorrect piping connections. Refer to the Installation Arrangement and Water

3. Air locks caused by improper venting.

4. Operating at conditions other than design; refer to the Heater Exchanger

2. Remove return water header.

3. Remove supply water header.

4. Inspect for inoperative roller guides – replace if required.

5. Insert eyebolt in tapped hole provided on top of front tube sheet.

6. Supporting bundle from eyebolt, begin sliding bundle out of shell.

8. Complete removal from shell.

Handling of Tube Bundles

7. Partially inert bundle to point of lift.

8. Transfer support to eyebolt on front tube sheet.

9. Complete installation of bundle in shell.

10. Reinstall top row of studs in rear tube sheet.

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