AFTCLRSEP-SA After-Cooler/Separator- Semiannual

Application:                                                Man Hours 6

This applies to the after-cooler/separator utilizing
chilled water to condense moisture from large compressed air systems.  These are
different than the mechanical/chemical air dryers that are serviced using PM

Special Instructions:

1.  Review manufacturer's instructions and the Standard Operating Procedure for
    "Controlling Hazardous Energy Sources."
2.  Schedule outage with operating personnel.
3.  Provide an alternate source of air, if necessary.
4.  Schedule Preventive Maintenance (PM) on associated
    equipment if possible.
5.  Secure air and chilled water valves and tag them.
6.  Secure, lockout and tag electrical supply to
7.  Wear appropriate protective equipment.
8.  Use caution when disassembling.  Check for and relieve
    pressure where found.

Items to Check & Initial Completion:

1. ___ Unbolt and remove supply and discharge water lines.
2. ___ Unbolt supply and discharge air flanges and lower
3. ___ Remove tube bundle assembly.
4. ___ Check tube bundle for deterioration or ruptured tubes.
5. ___ Clean exterior of the tube of all scale buildup.
6. ___ Flush out the tube bundle shell.
7. ___ Visually inspect the shell, flanges, piping, etc. for deterioration,
       cracks, etc.
8. ___ Clean the trap orifice of all carbon and heavy grease buildup.
9. ___ Reassemble the tube bundle in the shell using new gaskets and seals.
10.___ Replace assembly and separator in pipe line, using new gaskets.
11.___ Reconnect the supply and discharge water lines.
12.___ Remove tags, open air and water valves, restore power, and
       start air compressor.
13.___ Check operation of unit.  Check the air and water inlet and outlet
14.___ Check all connections for leaks.
15.___ Wire brush, treat with rusticide and primer rusted areas.  Consult the
       Material Safety Data Sheet (MSDS) for hazardous ingredients and proper
       personal protective equipment (PPE).  Consult the Material Safety Data
       Sheet to ensure that the paint lead level is 0.06% or less.

Tools & Materials:

1.  Standard Tool kit.
    Plus Pipe wrenches to 24"
         Tubing cutters
         Flaring tool
         Small acetylene outfit
         Packing tool kit and packing
         3/4" socket set
         Crescent wrenches to 14"
2.  Ladder
3.  Vacuum and Tube Cleaning Equipment
4.  Gasket material and Seals
5.  Lifting device (hoist, come-a-long, hydraulic lift etc.)
6.  Length of garden hose.
7.  Rusticide, primer and paint supplies.  Consult the MSDS for hazardous
    ingredients and proper personal protective equipment (PPE).

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