G03. Explain the necessity of intercoolers on a multi-stage compressor.

What
attention is required to keep them safe and in good working order? Sketch and
describe an intercooler suitable for a 2400 kPa compressor and state materials used.
For maximum efficiency, compression should follow the isothermal law as close as
possible. The only way to achieve this is with cooling of the air between stages.

Intercoolers and after-coolers need to be cleaned and serviced regularly, especially if

seawater is circulated. Any fouling or decline in efficiency of the cooler directly affects
the efficiency of the entire compressor. In addition if the temperature of the air is
insufficiently cooled, the high temperatures may also affect the lubrication of the piston
and liner resulting in increase wear and damage. If the temperature is allow to continue to
climb it could reach a point where there is a risk of self ignition of any possible oil
vapour in the compressor. During the service of the coolers the following should also be
checked,

a) Condition of any zinc fitted

b) Correct operation/condition of the safety valve or burst disk
c) All coolant pumps and associated drives should also be checked/inspected for
correct operation.

On H.P. coolers, there is less chance of leakage taking place between the tubes and the
tube plate, as the high pressure in the tubes tends to expand the tubes, one end is fixed
and the other end is free to expand as it is sealed with an O-ring

The tubes would most likely be Copper–nickel alloy and the casing would be cast iron.