BOWMAN 2-25-3737-4 Owner's manual

EXHAUST GAS HEAT EXCHANGERS
Installation, Operation
& Maintenance Guide
REG NO FM 38224
BS EN ISO 9001-2008

2
Iss A 05/14
Foreword
BOWMAN®has been manufacturing high quality "Exhaust Gas Heat Exchangers" for over 30 years.
Your BOWMAN®Stockist/dealer will be happy to provide you with advice and practical assistance.
Please read these instructions fully and carefully.
Keep the "Installation, Operation & Maintenance Guide" for all future reference to ensure the long
lasting performance from your "Exhaust Gas Heat Exchanger".
All rights reserved
E.J. Bowman (Birmingham) Ltd, reserve the right to change specification andtechnical alteration without prior notice.
No partofthis guide may bereproduced ortransmitted in any form or by anymeans including reproduction orrecording without written
permission from E.J.Bowman(Birmingham) Ltd.

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Iss A 05/14
E X H A U S T G A S H E A T E X C H A N G E R S
Installation, Operation & Maintenance Guide
Contents
Foreword 2
1 . S A F E T Y
1.1 Hazards when handling the heat exchanger 4
1.2 Safety instructions 4
1.3 Approved use 5
1.4 Potential hazards 5
1.5 Safety measures at installation site 5
2 . I N S T A L L A T I O N
2.1 Transport / storage 6
2.2 Installation 6
2.3 Connecting the heat exchanger 7
3 . O P E R A T I O N 7
4 . C O M M I S S I O N I N G 7
5 . M A I N T E N A N C E / R E P A IR
5.1 General Maintenance 8
5.2 Exhaust Gas Heat Exchanger Cleaning 8
6. W A R R A N T Y 8
7. P E R F O R M A N C E 9
8 . S P A R E P A R T S L I S T 10
E.J.Bowman (Birmingham) Ltd
Chester Street • Birmingham • B6 4AP • United Kingdom
Tel: [phone] • Fax: [phone]
Email: [e-mail] • website: www.ejbowman.co.uk

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1 Safety
1.1 Hazards When Handling the Heat Exchanger
BOWMAN®"Exhaust Gas Heat Exchangers" are constructed with current practice and
recognised safety rules. Hazards may still arise from operation, such as:
- Injury of the operator or
- Third parties or
- Damage to the heat exchanger or
- Damage to property and equipment
Any person involved with the installation, commissioning, operation, maintenance or repair of
the heat exchanger must be:
-Physicallyand mentallycapable of performing such work
-Be appropriately qualified.
-Complycompletelywith the installation instructions
The heat exchanger must only be used for its intended use.
In the event of breakdowns which may compromise safety, a qualified technician must
always be contacted.
1.2 Safety Instructions
The following symbols are used in these operating instructions:
This symbol indicates an immediate danger to health.
Failure to comply with this instruction may result in severe injury.
This symbol indicates a possible danger to health.
Failure to comply with this instruction may result in severe injury.
This symbol indicates a possible risk to health.
Failure to comply with this instruction may result in injury or damage to property.
This symbol indicates important information about correct handling of the equipment .
Failure to comply with this instruction may cause damage to the heat exchanger and/or its
surroundings.
danger
caution
take care

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1.3 Approved Use
BOWMAN®"Exhaust Gas Heat Exchangers" are only approved for reclaiming heat from
waste exhaust gases.
Any other use unless specified by BOWMAN®is not approved. BOWMAN®declines all
liabilityfor damage associated or arising from such use.
The maximum permissible operating pressures must not exceed:
Gas (tube side) : 0.5 bar max.
Water (shell side) : 4.0 bar max.
The maximum permissible operating temperature must not exceed:
Gas (tube side) : 700°C
Water (shell side) : 110°C
EuropeanPressureEquipmentDirective
This range of products fall within within Article 3 Paragraph 3
(Sound Engineering Practice) and do not require CE marking.
1.4 Potential Hazards
The heat exchanger may be damaged or leak if themaximum permissible operating
pressure is exceeded.
Connections on the exhaust gas side of the heat exchanger may reach temperatures as high
as 700°C
Connections on the cooling water side of the heat exchanger may reach temperatures as
high as 110°C
1.5 Safety Measures at Installation Site
The heat exchanger should not be used without sufficient cooling water flow through the shell
side.
Ensure the maximum permissible operating pressure on the primary or secondary side
of the heat exchanger is not exceeded. The heat exchanger or surrounding equipment
may be damaged.
While the system is in operation, weekly inspection of the heat exchanger and its
connections should be maintained for leaks and externally visible damage.
take care
caution
take care
caution

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2 Installation
2.1 Transport / Storage
The heat exchanger must be fully drained down prior to transportation. Once drained and
fully dry, the heat exchanger must only be stored indoors within a non-aggressive
atmosphere.
2.2 Installation
Before fitting, check the heat exchanger for visible signs of damage.
a) The heat exchanger must be installed horizontally and levelled accurately, with the
primary circuit through the tubes and the secondary circuit over the tubes. The heat
exchanger should only be connected in ‘counter flow’ with the secondary circuit
connections always being positioned on top (See schematic diagram below). Alternative
installations may also be acceptable; consultation with Bowman should be made prior to
installation.
b) It is very important that the secondary circuit is fully vented via the vent plug fitted in
order to prevent anyaeration taking place which can cause erosion of the tubes.
c) If ethylene glycol or any other heat transfer fluid is used in the secondary circuit,
adequate mixing should be performed prior to filling of the heat exchanger.
d) If temperature control sensors are fitted to either the primary or secondary circuits of the
heat exchanger, they should be fitted to the inlet circuit and not the outlet circuit in order
to provide accurate temperature readings.
e) The pressure relief valve must not be removed or tampered with.
f) Water must always be running through the heat exchanger when the engine is running.
g) No valves are to be incorporated in the circuit which could be accidentally turned off and
prevent water flowing through the heat exchanger.
h) The approach and exit exhaust pipe bore must not be smaller than the heat exchanger
connections.
i) Automatic engine shut down equipment must be fitted.
take care

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2.3 Connecting the Heat Exchanger
Ensure compliance with water qualityand maximum permissible pressure requirements.
When fitting the heat exchanger into the pipe work care must be taken to ensure that no
debris has been introduced into the primary or secondary circuit of the heat exchanger.
See Exhaust Gas Heat Exchanger brochure (available on the Bowman website) for
connection details of each model.
3 Operation
It is essential that the following instructions are followed to prevent corrosion/erosion of the
heat exchanger:
a) Adequate provision should be made to ensure that in the event of the primary circuit
being shutdown, the secondarycircuit continues to operate for a period of time to enable
the dispersal of residual heat to an acceptable level, preventing damage to the heat
exchanger.
b) Adequate provision should also be made to ensure that the secondary circuit pumps are
in continualoperation whenever the primary circuitis in operation.
c) Provision should also be made to ensure that any valves or ancillary equipment
associated with either the primary or secondary side of the heat exchanger cannot be
accidentally turned off, thereby preventing flow through the heat exchanger.
d) It is very important that the secondary circuit is fully vented via the vent plug fitted in
order to prevent anyaeration taking place which can cause erosion of the tubes.
e) Maximum working gas side pressure 0.5 bar
Maximum working water side pressure 4.0 bar
Maximum working gas side temperature 700°C
Maximum working water side temperature 110°C
4 Commissioning
Commissioning of the heat exchanger should not be undertaken until such time that this
document has been fully read and understood.
Adequate provision should be made to ensure that correct operating/service equipment
along with personal protection (PPE) in accordance with current standards/legislation is
utilised prior to the commencement of any working.
caution
take care
take care
take care

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5 Maintenance / Repair
5.1 General Maintenance
The heat exchanger should require little attention in service, however if cleaning the tube
stack the following notes should be used as a guide. Note new gaskets are required if the
end covers are removed.
5.2 Exhaust Gas Heat Exchanger Cleaning
a) Removal of the end covers or access plates, depending on version, allows access
to the tube plates.
b) Wash the tube plates and tubes using a hand held hose or lance. An industrial
steam cleaner can be used if available.
c) Tube brushes can be used to clean through each tube to aid in removing stubborn
deposits. Small diameter rods and brushes for tube cleaning are available from
companies such as Easy Products, www.easyproductsltd.com
d) Detergents or chemicals suitable for use with stainless steels can be used if fouling
is severe. Allow time for the detergent or chemical cleaner to work before hosing
down with plenty of water.
e) The tube stack should be flushed through with clean water to remove all traces of
cleaning chemicals/detergents. If necessary the cleaning fluid should be
neutralised.
f) End covers or access plates should be refitted after cleaning using new gaskets.
6 Warranty
All BOWMAN®Exhaust Gas Heat Exchangers are guaranteed against manufacturing faults
associated with the product for a period of twelve months from the date of invoice.
For full warranty terms, please see the BOWMAN®Conditions of Sale. A copy of which is
available on request or via download from the website.
www.ejbowman.co.uk
caution
take care

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7 Performance
Typical examples of exhaust gas heat exchanger performance. The figures below are a general
guide only and are not based on any particular natural gas engine. They assume an air/fuel
ratio of 10.23 : 1 by volume, a fuel consumption of 0.34m3/kWh (measured at 1.013 bar and
15°C) and an exhaust gas temperature of 600°C and a water temperature of 80°C.
Figures are based on new and clean conditions.
E.J. Bowman (Birmingham) Ltd, reserve the right to change specification andtechnical alteration without prior notice.
Type
Typical
Engine Power
kW
Exhaust Gas Flow
kg/min
Exhaust Gas
Outlet Temp
°C
Heat Recovery
kW
Exhaust Gas
Pressure Drop
kPa
2-25-3737-4
16
1.2
210
9.5
1.6
2-32-3737-5
16
1.2
170
11.5
1.8
3-32-3738-5
32
2.4
210
19
1.5
3-40-3738-6
32
2.4
170
21
1.7
3-60-3738-8
32
2.4
120
23
2.2
4-32-3739-5
60
4.5
210
35
1.3
4-40-3739-6
60
4.5
170
39
1.4
4-60-3739-8
60
4.5
120
43
1.8
5-32-3740-5
90
6.7
210
53
1.2
5-40-3739-6
60
4.5
170
39
1.4
5-60-3740-8
90
6.7
120
65
1.8
6-32-3741-5
140
10.5
210
82
1.3
6-40-3741-6
140
10.5
170
90
1.4
6-60-3741-8
140
10.5
120
101
1.9
8-32-3742-5
250
18.7
210
147
1.3
8-40-3742-6
250
18.7
170
161
1.4
8-60-3742-8
250
18.7
120
181
1.8
10-32-3744-5
400
30
210
236
1.3
10-40-3743-6
400
30
170
256
1.4
10-60-3743-8
400
30
120
288
1.8
12-32-3744-5
600
45
210
353
1.3
12-40-3744-6
600
45
170
388
1.5
12-60-3744-8
600
45
120
425
1.9
15-40-5745-6
950
70
170
604
1.4
15-60-5745-8
950
70
120
670
1.9

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8Spare Parts List
Type
Inlet End Cover
A
Outlet End Cover
B
Pressure Relief Valve
C
Mounting Foot
D
End Cover Gasket
E
2-3737
EX002-3757CI
EX032-4057CI
4028
4476
3787
3-3738
EX003-3758CI
EX033-4058CI
4028
4477
3788
4-3739
EX004-3759CI
EX034-4059CI
4028
4478
3789
5-3740
EX005-3760CI
EX035-4060CI
3795
4479
3790
6-3741
EX006-3761CI
EX036-4061CI
3795
4480
3791
8-3742
EX008-3762CI
EX038-4062CI
3795
4481
3792
10-3743
EX010-3763CI
EX040-4063CI
3795
4482
3793
12-3744
EX012-3902CI
EX042-4064CI
3795
4483
3862
15-5745
EX043-5757CI
EX044-5758CI
3795
4484
5759
Type
Inlet End Cover
A
Outlet End Cover
B
Pressure Relief Valve
C
Mounting Foot
D
End Cover Gasket
E
2-5837
EX062-5334CI
EX062-5334CI
4028
4476
3787
3-5838
EX063-5335CI
EX063-5335CI
4028
4477
3788
4-5839
EX064-5336CI
EX064-5336CI
4028
4478
3789
5-5840
EX065-5337CI
EX065-5337CI
3795
4479
3790
6-5841
EX066-4982CI
EX066-4982CI
3795
4480
3791
8-5842
EX067-4984CI
EX067-4984CI
3795
4481
3792
10-5843
EX068-4987CI
EX068-4987CI
3795
4482
3793
12-5844
EX069-5338CI
EX069-5338CI
3795
4483
3862
15-5845
EX070-5339CI
EX070-5339CI
3795
4484
5759
A
B
C
D
E
C
D
A
B
E
Exhaust Gas Heat Exchangers
with Straight End Covers
Exhaust Gas Heat Exchangers
with Right Angle End Covers

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Exhaust Gas Heat Exchanger webpage: -
http://www.ejbowman.co.uk/products/ExhaustGasHeatExchangers.htm
Bowman products can also be found in the following industries: -
Hydraulic Cooling
Engine Test House Cooling
Mining Industry
Marine Cooling
Swimming Pool & Spa Industry
Fishing Industry Cooling
The product range includes: -
Marine Heat Exchangers
Header Tank Heat Exchangers
Swimming PoolHeat Exchangers
Charge AirCoolers
Stainless Steel Heat Exchangers
Inline Plate Type Heat Exchangers
Fuel Coolers
Shell & Tube Heat Exchangers
Titanium Heat Exchangers
Aftercoolers
Aquatic Heat Exchangers
Non-Storage Calorifiers