BOWMAN EC120 Owner's manual

Heat Exchanger Technology by
Installation, Operation
& Maintenance Guide
CHARGE AIR COOLERS
BOWMAN®
100 YEARS OF HEAT TRANSFER TECHNOLOGY

Thank you, for purchasing a high quality Bowman charge air cooler.
Bowman has been manufacturing charge air coolers for over 50 years and our products are
renowned for their quality, heat transfer performance and durability
Please read this‘Installation, Operation & Maintenance guide’ fully and carefully before installation
to ensure your charge air cooler operates eciently and reliably.
Please keep this guide for future reference to ensure the long term performance of you Bowman
charge air cooler.
Should you require additional advice or assistance, please contact your Bowman stockist or
distributor.
Installation, Operation & Maintenance guides are also available in:
If you require a copy of this guide in one of these languages, visit
https://www.ej-bowman.com/downloads/ where copies are available to freely download.
Introduction
2
2
All rights reserved
E.J. Bowman (Birmingham) Ltd, reserve the right to change specications without prior notice.
All material contained in this brochure is the intellectual property of EJ Bowman (Birmingham) Ltd.
It is protected under copyright and may not be reproduced without prior written consent of the
company.
French German Italian Spanish Polish Russian Chinese

2
3
Contents
Introduction 2
1. Safety 4
1.1 Hazards when handling the cooler 4
1.2 Safety instructions 4
1.3 Approved use 4
1.4 Potential hazards 4
2. Installation
2.1 Transport / storage 5
2.2 Fitting 6
2.3 Connecting the cooler 7
3. Operation 7
3.1 Maximum ow rates 7
3.1 General information 7
4. Commissioning 8
5. Maintenance / Repair 8
5.1 Winter shut-down in areas exposed to frost 8
5.2 General Maintenance 9
5.3 Cleaning 9
5.4 End cover screw tightening sequence 9
5.5 Draining any condensate in the body of the cooler 10
6. Potential Service Issues 10
6.1 Tube failures 10
6.2 End covers 10
7. Warranty 10
8. Spare Parts 11
9. CE Marking Documentation 11

BOWMAN® Charge air coolers are constructed to current practice and recognised safety
standards. Hazards may still arise from operation, such as:
•Injury of the operator or
•Third parties or
•Damage to the cooler or
•Damage to property and equipment
Any person involved with the installation, commissioning, operation, maintenance or
repair of the cooler must be:
•Physically and mentally capable of performing such work
•Appropriately qualied
•Comply completely with the installation instructions
The cooler must only be used for its intended purpose.
In the event of breakdowns which may compromise safety, a qualied person 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.
1.3 Approved use
1. Safety
1.1 Hazards When Handling the Cooler
BOWMAN® charge air coolers are only approved for cooling charge air.
Any other use unless sanctioned by BOWMAN® is not approved.
BOWMAN® declines all liability for damage associated or arising from such use:
The maximum permissible operating pressure must not exceed:
Charge Air: 5.5 bar g (EC120 - GK190)
4.0 bar g (JK190 - RK250)
Water: 16.0 bar g
2
4
Danger
Caution
Take Care

Ensure the maximum permissible operating pressure on the primary or
secondary side of the cooler is not exceeded.
NB: Before the Charge Air Cooler is disconnected it must be allowed to cool and
be depressurized. The supply and returns from the cooler should
be isolated to minimise uid loss.
2. Installation
2.1 Transport / storage
The cooler must be drained prior to transportation. Once drained and dry, the
cooler must only be stored indoors in a non-aggressive atmosphere.
The connections should be capped to avoid ingress of dirt and contaminants.
2.2 Fitting
Before tting, the cooler should be checked for visible signs of damage. The
cooler should be connected in counterow so that the uids ow in opposite
directions, as shown in the illustration below:
A lter with a maximum permeability of 2.0mm should be used in the water
circuit of the cooler. Nothing should be welded to any part of the cooler. Each
unit has threaded mounting holes on its underside. Mounting brackets must
be designed to protect the cooler from the vibration generated during engine
operation. RIGID MOUNTING SHOULD BE AVOIDED. The cooler must not be
operated without adequate water ow and must be mounted so that the water
outlet is uppermost.
1.4 Potential Hazards
Take Care
2
5
The maximum permissible operating temperatures must not exceed:
Charge Air (primary side): 250º C
Cooling Water (secondary side): 110º C
Variants with higher temperature and pressure ratings are available.
Please contact our Sales team for further details.
Caution
Take Care
Water
Inlet
Water
Outlet
Air
Outlet
Air
Inlet
Water
Inlet
Water
Outlet
Air
Outlet
Air
Inlet

When tting the cooler into the pipe work, care must be taken to ensure that
no debris has been introduced into the primary or secondary circuits.
Unsupported lengths of pipework should be avoided so as not to subject the
cooler to excessive loads.
Water side pipework diameter should not reduce to less than the connection
size within a distance of 1m from the cooler.
Measures should be taken to isolate the cooler from excessive vibration. Water
pipe connections are parallel thread. Taper pipe ttings are not recommended
as they can split the end cover if over tightened.
The charge air inlet and outlet are designed to have hose connections using
hose clamps apart from the PK and RK cooler sizes which have ange
connection faces.
Please ensure that the connection ow area is maintained into the cooler and
avoid tight bends to prevent excessive pressure loss.
Type Connection Type Size Water Connections
EC120 Hose 52 mm ¾” BSP
FC100 Hose 52 mm 1” BSP
FG100 Hose 76 mm 1¼” BSP
GL140 Hose 76 mm 1½” BSP
GK190 Hose 89 mm 2” BSP
JK190 Hose 102 mm 2½” BSP
PK250 PN6 Flange 4 x M16 x 32mm on a
170mm PCD
3” BSP
RK250 Flange 4 x M16 x 32mm on a
212mm PCD
8 x 18mm on a 180mm
PCD (PN6-DN100)
Pipework materials must be compatible with the cooler materials.
Stainless steel sea water pipes and ttings should not be used adjacent
to the cooler.
2.3 Connecting the cooler
Take Care
2
6

2
7
3. Operation
3.1 Maximum flow rates
The table below gives maximum ow rates for Charge Air Coolers in either single
two or three pass conguration, using either sea water or fresh water cooling.
Max Recommended Flowrate (I/min) Max Recommended Flowrate (I/min) Max Recommended Flowrate (I/min)
EC range 50 80 170
FC range 80 120 230
FG range 110 170 320
GL range 200 290 560
GK range 300 450 900
JK range 400 600 1200
PK range 650 1000 2000
RK range 900 1400 2800
Max Recommended Flowrate (I/min) Max Recommended Flowrate (I/min) Max Recommended Flowrate (I/min)
EC range 75 120 255
FC range 135 200 380
FG range 180 270 530
GL range 320 470 900
GK range 460 690 1400
JK range 660 1000 2000
PK range 1000 1500 3000
RK range 1400 2150 4300
3.2 General information
It is essential that the following instructions are followed to prevent premature
failure of the Charge Air Cooler due to erosion or corrosion.
a) Always maintain the water pH to correct levels. The ideal water pH
should be kept within 7.4 to 7.6. On no account should it fall below 7.2 or
rise above 7.8.
b) The table above gives the maximum uid velocities through the cooler
and must not be exceeded. If in doubt contact our technical sales team
for guidance.
c) Minimum water velocity of 1m/s should be used.
d) Ensure compliance with water quality and maximum permissible
pressure requirements.
e) Air must be adequately vented from the water circuit.
f ) Stagnant water should not be allowed to accumulate in the cooler. If
it is not in use for any period of time the water should be drained. During
commissioning, shutdown and standby periods, if the cooler has not
been used over a 4-6 day period, it should be drained, cleaned and kept
dry. Where this procedure is not possible, drain the stagnant water and
rell the cooler with clean sea or fresh water, which should be replaced
with oxygenated sea water every 2-3 days to avoid further decomposition.
Take Care
3-Pass 2-Pass 1-Pass
Cooler
3-Pass 2-Pass 1-Pass
Cooler
Sea Water Application (Maximum 2 m/s)
Fresh water Application (Maximum 3 m/s)

4. Commissioning
Commissioning should not be undertaken until 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 used prior to the commencement of any work.
Cooling water should be introduced to the cooler prior to the introduction of
hot charge air.
The water circuit should be vented initially and again when operating
temperatures and pressures are reached. The system should be checked for
leaks.
Copper-nickel alloys have a very good resistance to seawater corrosion due to the
formation of a thin protective lm on the surface of the metal. This lm starts to
develop over the rst few days after the metal has been in contact with“clean,
oxygenated seawater, and requires a further 3 months to develop fully. This is the most
important part of the process to ensure long term corrosion resistance behaviour of
copper nickel. The protective surface lm of cuprous oxide is indicated by either a
brown, greenish brown or blackish brown thin lm layer. The process of ensuring that
copper alloy receives an eective oxide coating prior to service is known as
“conditioning”which is a very important stage for the alloy. Ferrous sulphate can be
used if commissioning in clean sea water is not possible. Schedule cleaning may help
to reduce the risk possibly with non-metallic brushes. Please refer to Copper Alliance
webpage for more information: www.copper.org.
5. Maintenance / Repair
5.1 Winter shutdown in areas exposed to frost
Care should be taken to prevent frost damage from a winter shutdown in conditions exposed
to frost. We recommend fully draining the cooler on the water side or removing the cooler
completely from the installation throughout the duration of the shutdown period.
There is a drain plug on one of the end covers for this purpose.
5.2 General maintenance
While the unit is in operation, weekly inspection of the cooler and its connections should be
made for leaks and externally visible damage.
BOWMAN® recommend that the tubestack should be cleaned and inspected annually
and the O seals renewed at this time.
Removal of the screws around the periphery of each end cover will allow the end covers
and seals to be removed. The tubestack can then be withdrawn from either end of the body.
2
8
Take Care
Danger

5.3 Cleaning
Whilst we strongly recommend that mechanical and chemical cleaning of the heat
exchanger is carried out only by specialised companies, below are some general guidelines
that may be useful;
a) Removing the end covers allows access to the tube stack, which can be removed
from the heat exchanger body.
b) Wash the tube plates and tubes using a hand held hose or lance. An industrial steam
cleaner can also be used if available.
c) Tube brushes can be used to clean through each tube to aid removing stubborn
deposits. Small diameter rods and brushes for tube cleaning are available
from companies such as ; Easy Products www.easyproducts.com or Rico Industrial Services
www.ricoservices.co.uk
d) Detergents or chemicals suitable for use with the tube material* can be used if
fouling is severe. Allow time for the detergent or chemical cleaner to work, before hosing
down with plenty of water. *Please refer to the spare parts list for details of the tube materials.
e) The tube stack should be ushed through with clean water to remove all traces
of cleaning chemicals/detergents. If necessary, the cleaning uid should be neutralised.
f) When retting the end covers after cleaning, new‘O’ seals must be used.
5.4 End cover screw tightening sequence
End covers must be retted in their original orientation and tightened to the torque
gures below, to ensure correct performance.
Cooler Series Screw Size Torque (Nm) Cooler Series Screw Size Torque (Nm)
EC M6 8 GK M12 54
FC M8 22 JK M16 95
FG M8 22 PK M16 130
GL M10 37 RK M16 130
5.5 Draining any condensate in the body of the cooler
Moisture can condense from the air and collect in the charge air cooler. There are drain
plugs which can be removed to allow condensate in the body of the cooler to drain.
If mounting the cooler vertically, always ensure there is a means of draining any
condensate from the unit.
2
9
Take Care

6. Potential Service Issues
6.1 Tube failures
The majority of problems facing a cooler are those of corrosion or erosion on the water
side. Common types of failure are:
a) Impingement attack (or erosion corrosion)
This is caused by water containing air bubbles owing at high speed through the tubes. The
impingement of rapidly moving water may lead to a breakdown of the protective copper oxide lm
built up by the tube thus allowing corrosion/erosion. This is worse with water containing sand or grit.
The eect of these conditions would be pockmarking and pin holing of the tubes. In Charge Air Cooler
applications, erosion problems could occur on the outer surface of the tubes due to localised high
velocity“wet”gas impingement attack, therefore it is important that the risk of overcooling is minimised.
b) Microbial corrosion and pitting corrosion
This is caused by water containing organic matter, such as that found in polluted estuaries, which cause
the surface lms to be predominantly sulphide and less protective. Please avoid extended exposure to
stagnant water which can encourage sulphate reducing bacteria and in the presence of deposits, pitting
corrosion will take place under the deposits.
Titanium tube stacks
Titanium tube stacks are available as a replacement for standard cupro-nickel tube stacks, for
applications where corrosion issues are being experienced. Titanium provides a highly durable, long life
solution for the most demanding applications and comes with a full 10 year guarantee on all titanium in
contact with cooling water.
6.2 End covers
a) Galvanic corrosion
Avoid mixed metal connections where the end covers are more anodic, especially if it has a relatively
small surface area. Alternatively, insulate the connection or coat either the anode or cathode to prevent
electrical connections.
b) Localised corrosion
The end covers can also suer erosion corrosion and therefore ow and velocity guidelines must be
adhered to. Avoid installation with tight angle bends or obstructions which can cause local areas of
turbulence.
This is only a brief introduction to corrosion problems. The subject is complex and the purpose of these
notes is to outline in very general terms what may occur under extreme conditions.
2
10

7. Warranty
All BOWMAN® Charge Air Coolers are guaranteed against manufacturing and material defects for a
period of twelve months from the date of delivery.
BOWMAN® should be contacted immediately if a unit is received damaged. No attempt should be
made to repair a faulty unit as this will invalidate the warranty.
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.ej-bowman.com
8. Spare Parts List
A comprehensive stock of spare parts is always available. Please contact either your nearest stockist, or
our sales oce for price and availability.
9. CE Marking Documentation
Charge Air Coolers are covered by the Pressure Equipment Directive 2014/68/EU which is mandatory
for all EU member states. This manual is part of the compliance and points out all essential safety
requirements to be observed.
2
11

Bowman heat transfer solutions
Bowman heat exchangers and oil coolers can be found in Active Fire Protection Systems,
Automotive Testing, Combined Heat & Power, Hydraulic Systems, Marine Engineering, plus
Mining Equipment and Machinery, in a range that includes:
EJ Bowman (Birmingham) Ltd, reserve the right to change specications without prior notice. K
CHARGE AIR COOLERS
Header Tank
Heat Exchangers
Engine Oil Coolers
Stainless Steel
Heat Exchangers
Transmission Coolers
Swimming Pool
Heat Exchangers
Exhaust Gas
Heat Exchangers Hydraulic Oil Coolers
Plate Heat
Exchangers
FM38224
BOWMAN®
100 YEARS OF HEAT TRANSFER TECHNOLOGY
EJ Bowman (Birmingham) Ltd
Chester Street, Birmingham B6 4AP, UK
Tel: [phone]
Fax: [phone]
Email: [email protected]
www.ej-bowman.com