Service for Engine & Generator Coolers

Charge Air Coolers

As part of marine, off-road and stationary diesel and gas engines charge air coolers particularly are confronted with heavy duties. Over time pollutants in the air or gas mixture can cause corrosion and accumulation of deposits in the tubes. This can lead to pressure loss that can damage the turbocharger and cylinder in the engine room and which can also lead to water leakage. Regular servicing will extend the lifetime as well as prevent downtime of the engines. The Kelvion Service includes cleaning and testing, recoiling, repairs, leak detection, and reverse engineering of this critical component in the engine, and keeps your application running smoothly.

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As part of marine, off-road and stationary diesel and gas engines charge air coolers particularly are confronted with heavy duties. Over time pollutants in the air or gas mixture can cause corrosion and accumulation of deposits in the tubes. This can lead to pressure loss that can damage the turbocharger and cylinder in the engine room and which can also lead to water leakage. Regular servicing will extend the lifetime as well as prevent downtime of the engines. The Kelvion Service includes cleaning and testing, recoiling, repairs, leak detection, and reverse engineering of this critical component in the engine, and keeps your application running smoothly.

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Key Service Solutions

Mechanical Cleaning

Mechanical cleaning of heat exchangers covers a wide range of measures to maintain performance and reliability. It includes internal cleaning – either on the tube side (carried out at the factory or directly on site) or on the housing side (at the factory).
Depending on the application, high-pressure cleaning or brush cleaning of the tube side is applied to remove deposits effectively. By cleaning both the inner and outer sides, the thermodynamic performance of the equipment can be significantly improved. This process not only optimises efficiency, but also contributes to corrosion protection, ensuring long-term durability and safe operation of your heat exchangers.

Chemical Cleaning

Chemical cleaning is a highly effective method for removing deposits, scaling, and corrosion products from heat exchangers. The process uses specially formulated cleaning agents that circulate through the equipment to dissolve unwanted residues without causing damage to the base material.

Depending on the fouling type and material of the heat exchanger, different chemical solutions are applied, such as acidic, alkaline, or neutral detergents.

This method ensures thorough cleaning of even hard-to-reach areas inside the equipment, where mechanical methods may be limited.

Refurbishment Programme

Kelvion provides a full-service offering for heat exchangers. Components are checked against new equipment standards, allowing for sustainable reuse and environmental benefits. Depending on the damage, Kelvion delivers the right solution – from thorough cleaning to retubing or part replacement. If, for example, cleaning is no longer sufficient due to excessive fouling and corrosion, we can go straight to the next level and, for example, carry out any necessary retubing or replacement of parts.

Service Factsheet | Refurbishment

Recoating

Kelvion’s recoating service restores and protects heat exchangers exposed to fouling, corrosion, or aggressive operating conditions. After a thorough inspection and surface preparation, we apply advanced protective coatings that significantly improve resistance against corrosion and chemical or biological attack.

Standard Retubing

Retubing is a proven method to restore the performance and extend the service life of heat exchangers. Over time, tubes can suffer from fouling, corrosion, erosion, or mechanical damage, leading to reduced efficiency or leakage. During retubing, the old tubes are carefully removed, tube sheets are cleaned and prepared, and new tubes are installed, expanded, and sealed to OEM specifications. This process restores the unit to like-new condition, improves reliability,and minimises the risk of unplanned downtime – all without the need to replace the complete bundle or heat exchanger.

Condition Analysis

Our Condition Analysis service for finned tube heat exchangers provides a comprehensive assessment of the condition of your heat exchangers. This includes leak tests as well as a detailed examination and assessment of the fin side and the tube side. Deposits and corrosion are analysed in depth.
Optionally, further analyses such as water testing, the targeted assessment of corrosion issues, and endoscopic inspections to identify fouling, corrosion and erosion can be carried out.

Spare Parts

Spare parts and replacements play a crucial role in maintaining equipment reliability, performance, and longevity.

When your equipment reaches the end of its lifecycle or no longer meets your operational requirements, our replacement service provides a seamless transition to a new, optimised solution.

An effective spare parts management strategy ensures minimal downtime, optimised maintenance schedules, and cost-efficient operations. By keeping critical spare parts readily available, companies can respond quickly to unexpected failures and maintain continuous production. Additionally, using genuine or high-quality replacement parts helps preserve system efficiency, safety, and compliance with technical standards.

Upgrades & Replacements

Upgrading or replacing heat exchangers improves energy efficiency, reliability, and system performance. Modern designs enable higher thermal efficiency,reduced pressure losses, and better integration into existing systems.

When upgrades are no longer sufficient, replacing aging heat exchangers provides a sustainable long-term solution, lowering maintenance needs and supporting current efficiency and regulatory requirements. Both options represent a strategic investment in operational performance and energy efficiency.

MORE SERVICES FOR CHARGE AIR COOLERS

As part of marine, off-road and stationary diesel and gas engines charge air coolers particularly are confronted with heavy duties. Over time pollutants in the air or gas mixture can cause corrosion and accumulation of deposits in the tubes. This can lead to pressure loss that can damage the turbocharger and cylinder in the engine room and which can also lead to water leakage. Regular servicing will extend the lifetime as well as prevent downtime of the engines. The Kelvion Service includes cleaning and testing, recoiling, repairs, leak detection, and reverse engineering of this critical component in the engine, and keeps your application running smoothly.

EARLY LIFE

Assistance to assembly and disassembly, shipping and transport
Supervision of installation by Kelvion experts

SPARE PARTS & SPARE PART SOLUTIONS

Spare parts
Cleaning brushes
Service kits

REPAIRS, OVERHAULS & MAINTENANCE

Complete overhaul, repair or new production
Renewal of corrosion protection and exterior painting
Internal cleaning of the tube and shell side
Cleaning (high pressure, chemical) of Kelvion and non-Kelvion products
Brush cleaning tube side including documentation of results
Pressure testing with 3.1 certificate

UPGRADES & REPLACEMENTS

Modifications and replacements of Kelvion and non-Kelvion products

MONITORING, CONSULTING & TRAINING

Examination and assessment of operating conditions
Endoscopic examination of tube side regarding pollution, corrosion and erosion
Examination of fin side regarding pollution, corrosion and erosion
Analysis of water and other product samples
Investigation of corrosion problems (destructive testing and sample analysis with specialists)
Assessment of deposits or corrosion products which may possibly occur on the tube side
General visual inspection and documentation of results
Pressure test (tube and gas side) acc. to PED / DVGW (category I+II) and PED / DVGW (category III+IV, Kelvion together with 3rd party)

Downloads

Service Factsheet | Charge Air Cooler

PDF, 3 MB

语言: English