Industrial heat exchanger mechanisms are subject to pressure and temperature variations, requiring scheduled maintenance to maintain operational and energy efficiency.

Using slim and powerful heavy duty pneumatic cushions instead of bulky high-force metal tools can minimise the risk of machinery damage – and maximise maintenance safety – during lifting, shifting, spreading, and servicing of heat exchangers and boiler technology.

Heat exchangers and boilers are ubiquitous and vital items of plant used throughout industry to transfer thermal energy from a hotter fluid to a cooler one, without the fluids mixing, making them essential for HVAC, refrigeration, and industrial processes.

Because they are subject to continual pressure, expansion, contraction, and corrosion, they require regular maintenance to minimise leaks and curtail the losses of energy and efficiency resulting.

Low-profile Pronal CLT lifting cushions are part of a broad range of Pronal products used for lifting, pushing, wedging, clamping, tilting, and guiding heavy loads across industrial and emergency sectors. CLT cushions can be inflated by a standard 120 bar industrial compressor, or on remote or inaccessible areas, by pressurised cylinder

Air Springs Supply is the Australian national distributor of the tough Pronal elastomer ranges of pneumatic cushions, which are top quality heavy duty equipment also used by military and civil defence organisations for rescue and recovery operations, extending from flood and earthquake, to lifting of damaged aircraft, locomotives and heavy vehicles.

Types such as compact, low-profile CLT lifting cushions – ranging from one to 65 tonnes capacity with heights of 90–515 mm – can be used individually or in multiples for safe, evenly distributed lifting in confined spaces. Their thin profiles and low weights (0.6–22 kg) also make them suitable for multipurpose, repeat, and mobile applications, such as being suitable for vehicle recovery, quarry rock splitting, pipeline lifting, shifting, and positioning, and emergency or rescue services.

Uses in industry

Heavy duty inflatable air cushions are commonly used during heat exchanger and boiler servicing and maintenance as lifting tools, for precise alignment and manoeuvring of heavy components, such as tube bundles or plate packs.

In boiler maintenance, they can also separate tube banks (also called boiler banks or generating banks) which are the primary site for heat exchange and are highly susceptible to performance-degrading issues. Uses include:

• Lifting and Positioning: They are inserted into tight gaps and inflated with standard 7-8 bar industrial compressors, hand pumps, or (in remote applications) air cylinders, to provide controlled, gradual lifting force. “This can be safer and more precise than using traditional heavy mechanical jacks or levers, especially for delicate components,” says Vinh.
• Alignment: During reassembly or installation of new bundles/plates, the controlled lift helps with final alignment before bolting or welding. The rubber construction provides better adherence to smooth surfaces, reducing the risk of slippage and work accidents
• Minimising Damage: The flexible, inflatable material can conform to uneven surfaces, distributing force evenly and reducing the risk of scratching or denting delicate fins, plates, or seals, which can be made of stainless steel or titanium. Unlike hammers or metal wedges, which can cause point forces and damage, the cushions distribute thrust evenly over a larger contact surface, protecting the integrity of the components being moved.
• Access: They can create small gaps to insert other tools or inspection cameras into tight spaces within the unit, enabling better access for cleaning or non-destructive testing. Their thin, flexible nature, when deflated, allows them to be easily inserted into very tight or awkward spaces where conventional lifting or pushing tools cannot fit.
• Efficiency: They can significantly reduce the time required for setup and repetitious maintenance tasks compared to manual or mechanical methods.

Pronal CLT cushions (high-pressure lifting bags) are constructed from multiple layers of aramid fabric reinforcement (known commonly by the brand name Kevlar®) coated with a chemical-resistant elastomer (synthetic rubber). The manufacturing process involves hot vulcanisation in an autoclave, which bonds the materials together into a single, seamless, and highly durable product. This gives the cushions a high strength-to-weight ratio and enables them to withstand high inflation pressures of up to 8 bar (116 PSI). 

Pronal was founded in 1961 and headquartered near Lille in the north of France, PRONAL builds standard and customised flexible products from fabrics coated with elastomer and/or plastomer. In addition to extensive industrial expertise, Pronal also works in the defence, aerospace, civil emergency, and maritime/harbour sectors.

Pronal’s Australian distributor, Air Springs Supply, is Australia’s leading supplier of air springs and associated pneumatic technology for the industrial and transport sectors. Air Springs Supply has more than 50 years’ experience in actuation, isolation, and suspension, with a national distribution and technical service network.