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2   

   

   

2.1.1.

 

Mounting   arrangement   

The   box   cooler   can   be   mounted   in   2   different   ways:   

§

 

Transversely   (athwartships)

:   this   is   the   most   common   

way   to   mount   box   coolers   (see   fig.   1a).   

§

 

Longitudinally,   parallel   with   fore   and   aft   centerline   

(see   fig.   3b).   

Whichever   mounting   method   is   chosen,   the   sea   chest   
requires   inlet   and   outlet   slots   to   allow   uninterrupted   water   
flow   (see   also   section   4.1).   

There   are   also   different   methods   for   installation,   from   
above   (top-­‐mounted)   or   from   below   (bottom   pull).   See   
section   4.2.      
For   the   specific   details   of   the   supplied   box   cooler,   see   the   
attached   technical   specifications   and   the   supplied   drawing.   

   

Figure   1b.   Refer   to   the   supplied   drawing.   

   

2.1.2.

 

Preventing   biological   marine   growth   

While   Duramax   Marine®   box   coolers   require   very   little   
maintenance   they   are   exposed   to   seawater   and   can   
potentially   become   fouled.   The   build-­‐up   of   biological   
marine   growth   (such   as   algae,   mussels,   barnacles   and   
other   shellfish)   on   the   external   surfaces   of   the   tube   bundle   
may   seriously   reduce   the   thermal   efficiency.   

Marine   growth   is   a   greater   problem   in   coastal   waters   than   

in   the   open   sea.   

An   electrolytic   anti-­‐fouling   system   (ICAF   system

2

)   is   often   

needed   to   reduce   this   undesirable   marine   growth.   An   ICAF   
system   releases   copper   ions   into   the   seawater   which   
prevents   the   settlement   of   macro   marine   fouling.   

An   ICAF   system   can   be   mounted   in   the   sea   chest,   below   
the   box   cooler.   Or,   alternatively,   the   box   cooler   can   be   

supplied   with   an   integrated   ICAF   system.   See   section   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   of   the   box   cooler   require   
that:   
a)

 

the   box   cooler   is   used   as   intended   and   when   in   
proper   working   order   

b)

 

the   operating   conditions   are   kept   within   the   
design   limits   

c)

 

all   installation,   operating   and   maintenance   
instructions   are   observed.   

§

 

The   box   cooler   may   only   be   installed,   operated   and   

maintained   by   suitably   qualified,   capable   and   
instructed   engineers,   operators   and   electricians.   

§

 

The   box   cooler   is   intended   for   use   by   professional   
personnel   only.   

§

 

It   is   assumed   that   the   liquid   circulates   in   a   closed   
system   and   that   inhibitors   are   added   (when   required)   
to   prevent   internal   corrosion   and   fouling.   (Note   that   
the   adding   of   inhibitors   may   have   consequences   for   
the   performance   of   the   box   cooler.   Check   the   

technical   specifications   or   contact   Duramax   Marine®   
for   advice.)   

§

 

The   user   is   responsible   for   ensuring   that   the   intended   
contents   of   the   box   cooler   will   be   compatible   with   the   
materials   used   to   construct   the   box   cooler.   The   
material   used   for   the   tube   sheet   is   CuZn38SnAl   and   for   
the   tubes   CuZn20Al2   (aluminium   brass).   

§

 

No   special   measures   are   taken   to   protect   the   box   
cooler   against   cyclic   loads,   resonance   or   vibrations   
(causing   fatigue),   impact   loads,   water   hammer,   
surging,   shocks,   fire   or   lightning   stroke.   

§

 

Misuse   or   failure   to   observe   the   instructions   in   this   
manual   may   invalidate   the   warranty.   Duramax   
Marine®   also   rejects   any   liability   for   personal   injury   or   
material   damage   resulting   from   misuse   or   from   failure   

to   observe   the   instructions   in   this   manual.   

   

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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