Instruction manual for the installation, operation and maintenance of Bloksma Boxcoolers.

Bloksma B.V. P.O. Box 1003 1300 BA Almere The Netherlands Tel. +31 (0)36 5492300 Fax +31 (0)36 5492390 E-mail: service@bloksma.net Internet: www.bloksma.net
Version 03.12. Article number: 7ZZ00K0000010

Instruction Manual Boxcooler

TABLE OF CONTENT.

1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.6 3.7 3.7.1 3.7.2 4 4.1 4.2 4.3 5

Table of content Definitions Introduction Remarks Guarantee and liability Environment Safety Inhibitors Use of systems to prevent biological fouling Installation and start-up Receipt Handling the boxcooler Position of the boxcooler in the sea chest Installation Welding instructions for the mounting ring Start-up Maintenance Prevention of bio fouling Inspection and cleaning intervals Anodes in the sea chest for cathodic protection Cleaning the boxcooler Cleaning on the inside of the tubeside Mechanical cleaning on the outside of the tubes Chemical cleaning on the outside of the tubes Shut down periods in freezing conditions Assembly and dis-assembly of the boxcooler Instructions for gaskets and bolts Gaskets Bolts Troubleshooting & repairs Insufficient thermal performance Leaking tubes / tube-to-tubesheet connections Leaking gaskets Spare parts & tools Appendix A: Instructions for conservation Appendix B: Addresses

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Instruction Manual Boxcooler

Definitions.
Refer to the figure(s) in paragraph 3.6 Disassembly and assembly of the boxcooler for an explanation of the parts of the boxcooler. Conditioned circuit Unconditioned circuit Closed circuit with a non-corrosive, non-fouled fluid. Open circuit (for instance seawater) or a closed circuit with a corrosive and/or fouled fluid. Layer on the tubes to protect the less noble metal the carbon steel sea chest against corrosion. Additive to the water flowing in the tubes of the box cooler in order to prevent or limit chemical reactions like corrosion.

Coating

Inhibitor

Anodes / cathodic protection Connecting a less noble metal (the anode) to a noble metal (the cathode) in order to protect this cathodic metal. The part serving as anode is being sacrificed. ICAF Impressed Current Anti Fouling system. A small current is applied to copper anodes mounted in the sea chest. This prevents biological fouling on the boxcooler. The space in the ship in which the box cooler is placed. The water in which the vessel is sailing flows through the space in the ship where the box cooler is placed, serving as a coolant. Part that is welded onto or into the top of the sea chest to fix the boxcooler to the hull. Although there are both round and rectangular box coolers, this part is called a mounting ring in both cases.

Sea chest

Mounting ring

Instruction Manual Boxcooler

1 Introduction.
1.1 Remarks. Read this instruction manual before proceeding. This manual deals only with the boxcooler itself. If the boxcooler is provided with an anti fouling (ICAF) system, the separate ICAF manual must be read too. 1.2 Guarantee and liability. The General sales conditions of Bloksma B.V. are applicable. Also refer to the confirmation of the order for possible additions. Not covered by the guarantee are loss of performance and/or damage to the boxcooler as a result of: not following the instructions in this manual replacement with non-original parts 1.3 Environment. The environmental laws and rules of the area where the boxcooler is installed, always have to be respected. The rules of the classification societies if applicable have to be respected. Always be on the alert to the possibility of leakage. 1.4 Safety. Some symbols are used in the text to underline safety aspects:

Pay attention: depending on the application the boxcooler will be hot during operation

Maintenance and repair: depressurise the boxcooler and let it cool down to ambient temperature. General Note: Most boxcoolers contain fluids, which can be irritating or dangerous to humans. These fluids could cause problems in case of leakage. Since one fluid in the boxcooler is at a higher temperature, any leaks might cause burns of the skin. A boxcooler is a pressure vessel designed for operation at certain specific limits of pressure and temperature. All operating personnel should be made aware of this specific design pressure and temperature.

Instruction Manual Boxcooler

1.5 Inhibitors. Sometimes inhibitors are added to the cooling water in the boxcooler. Contact the supplier of the inhibitor, which can also check for compliance of the inhibitor with the materials of the boxcooler (see specification sheet). Without proper prevention, micro organisms in the cooling water may grow excessively and may cause corrosion on metals. Bacteria also give an accumulation of slurry / mud, forming a viscous film on the tubes and blocking the water flow, both causing insufficient cooling. Follow the instructions of the supplier for use of the inhibitor and maintenance procedures. 1.6 Use of systems to prevent biological fouling. As mentioned in 3.1 a system could be used to prevent biological fouling. Some of these systems can interact with the materials of the boxcooler, resulting in a negative effect on the reliability or lifetime of the boxcooler. Notably systems that use hypochlorite by electrolysis of seawater can damage the material of the boxcooler. Anti fouling systems supplied by Bloksma have a guarantee for proper functioning for the complete anti fouling / boxcooler combination.

2 Installation and start-up.

2.1 Receipt. At receipt check the packaging and the boxcooler: report any damage to Bloksma compare the data on the nameplate, the drawing and the Bloksma confirmation of the order. check whether or not the correct instruction manual is present by comparing the article number on the cover sheet with the article number of the instruction manual on the confirmation of order Always store the boxcooler in its original wooden box in a dry room, free of big temperature changes. When the boxcooler is not being put into operation immediately after receipt, follow the Instructions for conservation (Appendix A). Although in practice this will virtually never occur, Bloksma retains the right to plug off maximally 1% of the tubes (as per TEMA RGP-RCB-2). 2.2 Handling the boxcooler. Remove the top cover from the wooden case. Lift the boxcooler on the water box. The bigger boxcoolers are supplied with special lifting lugs on top of the water box. The smaller boxcooler can be lifted on the water connections. Some boxcoolers depending on total weight are supplied with steel frames, bolted to the 2 sides of the boxcooler. These frames protect the fragile bundle during handling of the boxcooler. Remove this frame only just before the installation of the boxcooler in the sea chest. Be careful not to damage the tubes at the u-bends during lifting. When the boxcooler needs to be put down, put some soft material on the floor first, let the u-bends rest on this material first and then lay down the boxcooler.

Instruction Manual Boxcooler

2.3 Position of the boxcooler in the sea chest. The thermal performance of the boxcooler is depending on the shape and layout of the sea chest and the area, position and orientation of the inlet and outlet openings. The design of the sea chest in combination with the applied boxcoolers has to be discussed with Bloksma; this subject is not included in this instruction manual. Please contact Bloksma regarding the rules for a proper sea chest design. Below is a typical drawing of a sea chest; this drawing is for orientation only.

Instruction Manual Boxcooler

2.4 Installation.

Note: There may still be some rust preventive fluid present in the boxcooler (see appendix: Instructions for preservation).

Check if Bloksma has approved the sea chest design. Ensure that there is enough space above the boxcooler to lift the boxcooler for maintenance. For bigger boxcoolers, 2 steel frames are bolted at each side of the boxcooler to protect the tubes against damage and to ease handling of the boxcooler. Please remove these frames, otherwise the boxcooler will not fit into the mounting ring. Check if there is a drain and a vent facility in the piping of the tubeside circuit. Lift the complete boxcooler to the place where is has to be installed. Mark the orientation of the water box, gasket and tubebundle relative to each other with a marking pen to ensure that the components are re-assembled with the right orientation afterwards. Remove the water box from the boxcooler. Remove all protective plugs and covers of the connecting flanges. If the mounting ring is not delivered separately: remove the mounting ring from the boxcooler. Never weld the mounting ring while the tube bundle is attached! Weld the mounting ring of the box cooler in according to the welding instructions as described in paragraph 2.4. Position the gasket (without partitions) over the mounting flange. Handle the boxcooler with extreme care when hoisting the bundle into position. The tubesheet of the boxcooler is provided with threaded holes (M16) for hoisting purposes. Use all holes at the same time. Mount the box cooler vertically in the sea chest. Mount the internal hexagonal bolts first. See also paragraph 3.6. The gasketing and bolting must be done in accordance with the instructions as mentioned in paragraph 3.7. Assemble the other components of the box cooler, ensuring that the relative positions are according to the markings. Clean and inspect the gasket surfaces of the flanges before connecting the pipelines. Always use new gaskets of the correct type and tighten the bolts crosswise. Always check if the fluid that flow through the boxcooler is consistent with the materials of the boxcooler. Bloksma makes its material choices on the basis of the fluids specified by the client, but is often not informed of possible contamination, higher/lower acid levels than normal, additives and other aspects relevant to the choice of materials.

Instruction Manual Boxcooler

2.5 Welding instructions of the mounting ring. PLEASE READ THIS INSTRUCTION CAREFULLY BEFORE WELDING Cut the proper dimensions out of the top plate. The actual dimensions depends on the type of weld(see next item), the weld size and the thickness of the top plate. Weld the mounting ring of the box cooler IN (Figure 1b) or ON (Figure 1c) the top plate of the sea chest. Which weld to use depends also on the requirements of the classification societies? Please make sure that the sides of the rectangular mounting ring are kept parallel and do not deform over the length to ensure that the bolting with the tube plate and water box still matches. Never weld the mounting ring while the tube bundle is attached!

Instruction Manual Boxcooler

2.6 Start-up. Do not exceed the design temperature and pressure as specified on the nameplate, specification sheet and drawing. Avoid abrupt temperature fluctuations; these can cause leaking of the tube-to-tubesheet connections or other connections. Establish the circulation of the warm medium gradually. Vent the tubeside circuit. Vent the tubeside circuit again when the operating temperature and pressure have been reached. Check for leakage.

Respect the flow as specified on the specification sheet. Higher speeds can cause erosion. Avoid water standing still in the boxcooler in freezing conditions because this can cause damage to the tubes. Drain the boxcooler for these cases and remove any remaining water in the tubes by pressed air.

Note: In most cases some threaded BSP connections are welded on the water box. These are for internal use at Bloksma only to simplify drainage of the cooler. As the waterbox has internally some provisions for automatic venting through the water connections, these threaded connections dont need to be used for venting.

Instruction Manual Boxcooler

3 Maintenance.
If necessary see Assembly and disassembly of the boxcooler for (dis-) assembly instructions. 3.1 Prevention of biological fouling. In general, the boxcooler system is for most of the applications a maintenance free system. However depending on the area of sailing and depending on several operational conditions, bio fouling must be anticipated for. Bloksma can supply a so called ICAF (Impressed Current Anti Fouling) system. Normally this system is built in together with the boxcooler(s), but also retrofitting is possible. The ICAF system uses copper anodes under the boxcooler. A small current is applied to the anode, which dissolve the copper to Cu+ ions in the seawater. The Cu+ ions prevent any biological growth. 3.2 Inspection and cleaning intervals. The end user is responsible for (preventive) maintenance. The tubeside circuit of the boxcooler will rarely need to be cleaned as the fluid in the tubes is always conditioned. The outside of the bundle in the sea chest is the part most subject to bio fouling. Because the degree of fouling strongly depends on operating conditions, we recommend the following: At least once a year inspect the exterior. Depending on the results of the inspections you can determine the definitive cleaning intervals. However always continue to carry out regular inspections. 3.3 Anodes in the sea chest for cathodic protection. In the rare case for fresh water service - when the bundle of the box cooler does not have a coating, anodes must be used to protect the hull. How many anodes have to be used and where the anodes have to be placed can be checked with the supplier of the anodes. When inspecting the bundle also inspect the condition of the anodes. In case of a coated tubebundle no anodes are required. However we recommend still to use some anodes; they are useful in case the external coating is damaged over a big surface or when brass components are fitted in the sea chest.

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Instruction Manual Boxcooler

3.4 Cleaning the boxcooler. 3.4.1 Cleaning on the inside of the tubes. The tubeside circuit of the boxcooler will rarely need to be cleaned as the fluid in the tubes is always conditioned. The bends of the U-tubes can only be cleaned chemically. The straight parts of the tubes can be cleaned, if necessary, with a brush. Use only original Bloksma brushes; they have the proper dimensions and are made of a suitable material. 3.4.2 Mechanical cleaning on the outside of the tubes. The exterior of the bundle can be rinsed clean with the aid of the deck wash or compressed air. Use only soft water with low pressure. Note: the maximum temperature of the external coating is 150 C. Never use hard materials which can damage the tubes and/or coating. Protect the boxcooler in case the sea chest is cleaned internally. 3.4.3 Chemical cleaning on the outside of the tubes. Note: Chemical cleaning can damage the boxcooler. Let the supplier of the chemical cleaning agent determine whether the agent is suitable in combination with the materials of the boxcooler (see specification sheet). All boxcoolers with coated tube bundles (see specification sheet) the temperature may not exceed 150 C, and no bleach may be used, because of the coating. After disassembly the tube bundle can be submerged in a tank containing a chemical solution. There are various international companies (example in Appendix B) who can deliver products for the chemical cleaning of boxcoolers. They have world-wide offices in harbours and can give you cleaning advice or can clean the boxcooler for you.

3.5 Shut down periods in freezing conditions. During shut down periods, bear in mind the possibility of freezing. Avoid the boxcooler standing still in freezing conditions: this can cause damage to the tubes. The outside of the boxcooler is normally never in danger; it is the tube side fluid which freezes and can damage the tubes. Drain the boxcooler internally in these cases, for instance by applying compressed air.

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Instruction Manual Boxcooler

3.6 Assembly and disassembly of the boxcooler.

Mark the orientation of the water box, gasket and tubebundle relative to each other with a marking pen to ensure that the components are re-assembled properly afterwards.

The tubesheet of the box cooler is fastened with internal hexagon screws to the mounting ring. The water box is fastened on top of this with bolts (see figure 2).

1 2 3 4

Bolt Water box Partition gasket Tubesheet

5 6 7 8

Gasket Mounting ring Top plate sea chest Internal hexagon screw

Figure 2: Fastening tubesheet and waterbox For tubeside inspection or to check for leakage when the ship is sailing, or to clean the tube with a brush, only the tubeside connections and the water box need to be removed (as per steps 1 and 3). The bundle remains fixed by the internal hexagon bolts. Please take care: When the internal hexagonal bolts are not fixed sufficiently, leakage could occur ! To remove the bundle (only when the waterline is below the mounting ring or when the ship is in dry-dock) follow steps 1,2 and 3.

Both at assembly and disassembly follow the Instructions for gaskets and bolts.

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Instruction Manual Boxcooler

Step 1: Tubeside disassembly.

Depressurise the tubeside circuit. Let the tubeside circuit cool down to ambient temperature. Drain the tubeside circuit by opening the drain at the lowest point and the vent at the highest point. Mark the relative position of all parts that will be disassembled, so that they can later be assembled in the correct positions. Remove the water box by loosening the bolts (1). Do not remove the internal hexagonal bolts (8) ! Remove the partition gasket (3). After cleaning and drying the tubesheet you can check for leakage.

Step 2: Removing the bundle. The bundle can only be removed when the ship is dry and docked. Mark the position of the bundle. Loosen the internal hexagonal bolts. Carefully pull the bundle out of the sea box using the 2 threaded holes in the tubesheet. Remove the gasket.

Step 3: Assembly. Assemble the boxcooler in the opposite order (note the marks that you have made): Assembly of the bundle (only if it had been removed): Mount a new gasket. Slide the bundle into the sea box. Fasten the internal hexagon screws. Tubeside assembly: Mount a new partition gasket. Mount the water box and the connections. Place the boxcooler back in operation: Gradually establish the circulation of the warm medium. Vent the tubeside circuit. Vent the tubeside circuit again when the operating temperature and pressure has been reached. Check for leakage.

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Instruction Manual Boxcooler

3.7 Instructions for gaskets and bolts.

3.7.1 Gaskets. Always make sure the gasket surface is clean (remove remains of old gaskets), and free of any damage. Never re-use old gaskets. Always use original Bloksma gaskets (cheap alternatives have a shorter life span and are much likelier to leak). See spare parts & tools for order information. Check before assembly if the dimensions of the gasket surface and the gasket correspond. Warning: Gaskets must be applied completely dry (i.e. mounted without any sealing aid, jointing compound, molykote, graphite, grease or other lubricant). Any sealingaid will affect the sealing capacity of the gasket. Any warranty claim will be rejected when sealing-aid is used. The gasket must be lined-up correctly and it may not cover any tubes. Note that the partitions of the partition gasket are in the proper position; compare the partitions of the gasket with those in the water boxes. For storage of gaskets see chapter 5.

3.7.2 Bolts. Check the bolts and nuts for damage. Tighten the bolts with a torque of 50 N.m. As the gasket has a wide surface, is very flexible and as the water box will deform slightly, some local leakage may still occur. In this case please re-tighten the bolts until leakage stops. Treat the bolts with an anti-corrosion and/or anti friction application to ease removal of the bolts after long periods. For a round box cooler: Tighten the bolts cross-wise (see figure 3). For a rectangular box cooler: Tighten the bolts by working from the centre to the corners (see figure 3). This is very important !

Figure 3: Tightening sequence

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4 Troubleshooting & repairs.

4.1 Insufficient thermal performance. Check the following items: Sea chest: Is the sea chest design explicitly approved by Bloksma Is the area of the inlet and outlet opening OK see specification Is the orientation of the in- and outlet grids OK Is the outlet opening below the empty waterline Are the openings not obstructed by any foreign material Is the sea chest under all conditions submerged (stern-wave, rolling/pitching) Boxcooler Is the orientation of the water box relative to the tubesheet OK Is the orientation of the gasket relative to the water box OK Is any product in the water box obstructing the water flow Is the outside of the tubebundle free from fouling Process Is the actual engine heat load acc. to the Bloksma specification Is the calculating condition (sailing, still-standing, tug) on the spec. correct Is the amount of fresh water flow correct Is the freshwater circuit free from bacterial contamination (inhibitor) Is the thermostatic valve installed properly Is the thermostatic valve completely open Is the piping vented properly Is the piping connected properly (counter current)

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Instruction Manual Boxcooler

4.2 Leaking tubes / tube-to-tubesheet connection. It is often very difficult to determine whether leakage is occurring due to a tube that is leaking or due to a leaking tube-to-tubesheet connection. In addition to checking the tube-to-tubesheet connections (see Assembly and disassembly of the boxcooler) it is also possible after complete disassembly to hydro test the boxcooler. So this is only possible when the ship is dry and at the dock. To do this, after disassembly of the boxcooler assemble the water box on the bundle (using the normal screws). Assemble a blind flange on the one opening of the boxcooler, and put pressure (max. 5 bar) on the other opening. The tubes are expanded in the tubesheet. A leaking tube cannot be replaced but it can be plugged with Bloksma soft copper plugs (other materials are too hard and can cause leakage of the surrounding tube-to-tubesheet connections) in both ends. At most some 5% of the tubes can be plugged without affecting the thermal performance of the boxcooler too much. Contact Bloksma if more than 5% of the tubes are plugged. 4.3 Leaking gaskets. Check the gasket surfaces. Remove soil and corrosion deposits. Mount new gaskets. Check if the tightening sequence was correct and the proper torque has been applied.

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Instruction Manual Boxcooler

5 Spare parts and tools

Spare parts and tools for boxcoolers that are available: Set of gaskets (*) Soft copper plugs Bolts / nuts Water box Mounting ring Complete U bundle

When placing orders please specify the nameplate data.

(*) Flat gaskets contain some rubber and are subject to ageing. Recommendations for storage: Dry non-freezing environment at a constant temperature of about 20C Constant humidity level Dark place (no direct sunlight) Lying down (not hanging on hooks)

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Instruction Manual Boxcooler

Appendix A: Instructions for conservation.

Standard conservation (controlled conditions) All boxcoolers supplied by Bloksma are treated with a rust preventive layer on the tubeside. This layer will protect the boxcooler when it is stored at controlled conditions, i.e. inside, in a dry room at constant temperature. When these conditions are met, the boxcooler can be stored without special treatment for a longer period (up till 24 months). The rust preventive layer can be removed with a mineral solvent (petroleum). Advise for conservation (uncontrolled conditions) When the above mentioned storage conditions are not met, you will have to fill the boxcooler with an inert gas and all openings have to be closed airtight (additionally silica gel can be added to absorb liquids). Alternatively, the boxcooler can be treated with a rust preventive liquid of a type suited for long term conservation. When necessary contact a specialised company. Take the materials of the boxcooler (see specification sheet) into consideration. Be aware that in uncontrolled storage conditions large amounts of water can accumulate in the boxcooler as a result of condensation.

Appendix B: Addresses.
Chemical cleaning and products for chemical cleaning Ashland Chemical Netherlands B.V. Drew Marine Division Malledijk 20 3208 LA Spijkenisse The Nederlands Telephone : + 31 (0)181-457074 Telefax : + 31 (0)181-625792 Website: www.ashchem.com

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