Installation: Ultraliner Boiler Truck: Air System

Ultraliner Boiler Truck: Air System

Important Note: The following boiler truck configuration is used by Ultraliner's Field Service crew and is provided as an example only. Ultraliner, Inc. does not endorse the use of any particular manufacturer's equipment. Ultraliner, Inc. does not specify equipment requirements, but rather offers information regarding the general practice of Ultraliner's installers to provide guidance in a contractor's selection of equipment. The interpretation and application of the following information rests solely with the contractor. Each contractor must independently determine the cost, size, design use, and capacity of their own selection of equipment. Each contractor must independently insure the safety of their equipment and the compliance of their equipment with local and national regulations.

Air compressor:	An air compressor with a minimum output of 175 cubic feet per minute (cfm) is required to process the pipeliner. Such volume is necessary to sufficiently cool the pipeliner prior to depressurization.
Compressed Air Reserve Tank:	A 200 gallon air reserve tank provides compressed air on demand for filling of plugs without constant running of the air compressor. Note, however, that the air compressor MUST be run to have sufficient volume to cool the pipeliner!
After-cooler diversion valves:	These valves are used to divert air flow through the after-cooler when chilled air is required.
After-cooler:	The air from an air compressor is at an elevated temperature and must be chilled to permit proper cooling of the pipeliner. An after-cooler is immediately available and when properly configured can chill the cooling air to as low as 50 degrees F. A manufacturer should be able to properly configure an after-cooler when provided with the air compressor maximum temperature and the cfm output. Proper ventillation of the after-cooler is critical for optimal performance.
Ice Bath:	An ice bath is an excellent supplement to the after-cooler for further cooling of the air and/or as a back-up in case of after-cooler maintenance problems. Ice baths are simple and inexpensive to construct using a drum and copper tubing. When properly used an ice bath can sufficiently cool the pipeliner, however, ice baths can be a hassle for the construction crews and are often not properly used. Due to the simplicity of use for the construction crews, an after-cooler is the preferred air chilling method.
"A" Station Air Valve:	The "A" station air valve (the yellow valve between the two gauges) is used to adjust the volume of air from the air compressor which mixes at this point with the steam from the boiler. By adjusting the air volume at the "A" station, the temperature and pressure of the steam entering the pipeliner can be controlled.
Air hose & connectors:	A retractable air hose and a variety of air hose connectors provide convenient access to compressed air for a variety of uses.

Relevance of the Air System to the Installation Process:

Compressed air is required to inflate the flow-through plugs which are used to send steam through the lumen of the pipeliner.
Compressed air is also used to provide increased processing and blow-molding pressure, while simultaneously controlling the temperature inside the pipeliner.
During the cooling period, the compressed air is used to maintain the internal pressure on the pipeliner while the pipeliner cools.
An air compressor alone, is incapable of sufficiently cooling the pipeliner. Once the "B" station temperature has reached the output temperature of the air compressor (which is always higher than the ambient temperature), an after-cooler is then used to further lower the temperature to at least 90 degrees F. The cooler the pipeliner at the time of depressurization, the tighter the pipeliner will fit. Many crews routinely cool the pipeliner to 80 degrees F or below before depressurization to ensure an exceptionally tight fit.

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Rev: 2/14/2002