It’s still a problem with the piston compressor – the heat exchanger
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The compressors in the plant are piston-type, V-type, with two-stage compression. Recently, the heat exchanger has been leaking and getting clogged frequently. There are no spare parts available for replacement; pipes were made and installed instead. I’m not sure what the consequences will be The compressed materials are R142\R152.
Was the condenser removed and replaced directly with a pipe?
If it is an inter-stage heat exchanger, the inlet temperature of the next stage will definitely be too high. Since such great efforts are being made for production, it would be better to use a shell and tube heat exchanger, which would at least provide some benefit.
The cooler reduces the temperature at the inlet of the cylinder in the next stage, which is highly beneficial for the performance of the materials used in all the components of the compressor； It reduces the power consumption of the compressor, saving electricity!
Use it as a makeshift solution. But it’s not a long-term solution. A cooler must be used; since the fixed tube-sheet type is prone to leakage, it should be replaced with a U-tube type.
Why are fixed tube sheet types more prone to leakage than U-tube types?
You can search for this on Baidu; there are detailed explanations there.
First, the function of the inter-stage cooler in a reciprocating compressor is as follows: 1. To reduce the exhaust temperature of the stage preceding the compressor, thereby minimizing overheating losses； 2. As the temperature rises, the viscosity of the cylinder lubricant decreases, and it may also decompose to form gums, which hinders the proper functioning of the valve components. If the temperature inside the cylinder exceeds the flash point of the lubricating oil, an explosion could even occur. Therefore, the exhaust temperature of a general compressor should be 30~50°C lower than the flash point of the lubricating oil in the cylinder. When compressing air, the exhaust temperature generally should not exceed 160–180°C; for media such as petroleum gas, ethylene, and acetylene, it should generally not go above around 100°C. For the above reasons, it is recommended to closely monitor the temperature between stages during current production operations, submit spare parts as soon as possible, and replace them at an appropriate time.