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13   

4.5.

 

ICAF   SYSTEMS   

Box   coolers   may   be   affected   by   marine   fouling   (algae,   
mussels,   barnacles   and   other   shellfish)   on   the   external   
surfaces   of   the   tube   bundle.   In   the   long   run   this   will   
seriously   reduce   the   heat   transfer.   
This   undesirable   marine   growth   on   the   tube   bundle   can   be   
reduced   by   installing   an   

Impressed   Current   Anti-­‐Fouling   

(ICAF)   system.      

An   ICAF   system   is   an   electrolytic   antifouling   system.   It   
consists   of   copper   rods,   the   anodes,   and   carbon   steel   
plates,   which   are   mounted   below   the   box   cooler   (see   
fig.   13).   

A   power   unit   in   the   engine   room   maintains   a   minor   current   

(the

   impressed   current

)   between   the   anodes   and   the   

cathodes   in   order   to   release   the   required   minimum   
amount   of   copper   ions.   The   copper   ions   mix   with   the   
seawater   in   the   sea   chest   and   de-­‐regulate   the   local   
environmental   balance,   thus   suppressing   marine   growth   
on   the   box   cooler.   

To   simplify   the   installation,   Duramax   Marine®   can   supply   

the   box   cooler   with   an   integrated   ICAF   system   from   
Corrosion   &   Water   Control   (see   fig.   14a).   

In   that   case   the   copper   anodes   are   clamped   to   a   frame   that   
is   fixed   to   the   box   cooler.   Each   copper   anode   is   provided   
with   a   6   m   cable.   The   cables   are   protected   by   tubes   
(conduits)   and   led   through   the   tube   sheet   by   means   of   
cable   glands   (see   fig.   14b).   
Install   the   power   unit   and   connect   the   cables   according   to   
the   installation   manual   from   

Corrosion   &   Water-­‐Control   bv

   

and   observe   all   relevant   instructions.   

The   electrical   installation   shall   only   be   carried   out   by   
suitably   qualified,   capable   and   instructed   electricians.   

Do   not   coat   the   anode   rods   and   cathode   plates!

   

Note   that   the   copper   anodes   are   calculated   for   a   specific   
dry-­‐docking   cycle   (e.g.   3   or   5   years).   

Figure   13.   Copper   rods   (anodes)   and   steel   (cathode)   plates   

of   the   ICAF   system   mounted   separately   

in   the   sea   chest   below   the   box   cooler.   

Figure   14a.   Box   cooler   with   integrated   

ICAF   system.   

Figure   14b.   Cable   gland   and   conduit   for   the   cables   of   the   

ICAF   system,   leading   to   the   copper   anodes.

   

cable   

gland   

Summary of Contents for Box Cooler

Page 1: ...HEAT EXCHANGE SYSTEMS Duramax Marine is an ISO 9001 2015 Certified Company Box Cooler Installation Manual...

Page 2: ...Do not install operate or service this box cooler without having read and fully understand all information enclosed in this manual...

Page 3: ...hest design 5 4 2 Welding the mounting frame in position 6 4 3 Mounting 7 4 4 Fixing the process piping 11 4 5 ICAF systems 13 5 COMMISSIONING AND OPERATION 14 5 1 Check the system for satisfactory in...

Page 4: ...n manual of the ICAF system may be supplied with the box cooler Study this manual as well and follow all relevant instructions 2 PRODUCT DESCRIPTION INTENDED USE WARRANTY 2 1 PRODUCT DESCRIPTION The p...

Page 5: ...ion 4 5 2 ICAF system Impressed Current Anti Fouling system 2 2 INTENDED USE The box cooler is custom built according to the order and the attached technical specifications Safe and trouble free use o...

Page 6: ...the total weight of the box cooler in kg 4 The minimum maximum design temperature Refer to the attached technical specifications for the values 5 The minimum maximum design pressure in barg 3 Refer t...

Page 7: ...n of the eyebolts must be adjusted with suitable washers Do not insert the point of a hook in an eyebolt but use a shackle Lift only by using all 4 eyebolts simultaneously see fig 2 Do not insert the...

Page 8: ...w the special sea chest to be installed see fig 3b 3 Ensure that the top plate of the sea chest is on or below the waterline when the ship is empty This is to make sure that the tube bundle is fully s...

Page 9: ...he tube bundle and the sea chest where the sea water serves as an electrolyte To protect the sea chest from galvanic corrosion all metal areas of the sea chest shall be well preserved Furthermore it i...

Page 10: ...ube bundle against paint Do not coat the cathode plates of the ICAF system when applicable 4 3 MOUNTING The box cooler can be mounted in two different ways From above top mounted see section 4 3 1 Fro...

Page 11: ...ating may reduce the lifetime of the box cooler and will accelerate galvanic corrosion of the sea chest 6 Position the supplied collar bolts in the appropriate bolt holes of the tube plate and fasten...

Page 12: ...inspect and clean the parts according to the instructions of section 4 3 1 3 Position the gasket that is used between frame 2 and the tube sheet on top of frame 2 Make sure the gasket and the gasket...

Page 13: ...any other agent when installing the SBR gasket 3 Lift the tube bundle refer to fig 2 until just below the header frame but leaving sufficient space to remove the eyebolts See 1 of fig 10c 4 Then take...

Page 14: ...oad and piping vibrations to the box cooler Install safety devices to prevent overpressure and overheating see section 4 4 2 4 4 1 Piping design Ensure that the piping is well supported independently...

Page 15: ...einforced graphite ring gaskets 6 Make sure the gaskets are properly centred and tighten up the stud bolts of the flanges alternate and crosswise to guarantee an even setting of the gaskets see sectio...

Page 16: ...lation Duramax Marine can supply the box cooler with an integrated ICAF system from Corrosion Water Control see fig 14a In that case the copper anodes are clamped to a frame that is fixed to the box c...

Page 17: ...to escape then close the vent valve 3 Allow the circuit to pressurize and open the return valve so the liquid can flow through 4 Regularly carry out the inspections of section 6 1 During the initial...

Page 18: ...cted values and are within the permissible design limits If the outlet temperature of the liquid is increasing throughout longer periods of time this may be an indication that the box cooler has becom...

Page 19: ...ces of the flanges 4 Inspect the interior for fouling or signs of corrosion It is not expected that internal cleaning of the tubes will be necessary because the liquid should be conditioned and circul...

Page 20: ...ith full characteristics of used water the materials of the box cooler and its use When required contact Duramax Marine for advice External cleaning of the tube bundle Excessive marine fouling will si...

Page 21: ...ent valve at the highest point to bleed off the air that is present in the system 2 Fill the box cooler through a feeder with a suitable non corrosive unheated liquid while the air vent is open Close...

Page 22: ...ng flanges not flat or face surfaces damaged see section 4 2 Re tighten the bolts see section 4 4 4 Contact Duramax Marine if this does not succeed pressure and or temperature too high see section 5 2...

Page 23: ...20 8 TECHNICAL SPECIFICATIONS Please refer to the technical specifications as supplied with the order documents...

Page 24: ...Bearings DX 490 Rudder Bushings DURAMAX HEAT EXCHANGE SYSTEMS DuraCooler Keel Coolers Duramax Demountable Keel Coolers Duramax BoxCoolers Duramax Plate Heat Exchangers DURAMAX IMPACT PROTECTION SYSTEM...

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