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14   

   

   

5.

 

COMMISSIONING   AND   OPERATION   

   

Unsafe   operation   

Commissioning   and   operation   by   unqualified   
personnel   may   result   in   unsafe   operation,   defects   
and   accelerated   corrosion.   

Ø

 

The   box   cooler   may   only   be   commissioned   and   

operated   by   suitably   trained,   qualified   and   
instructed   engineers   and   electricians.   

Ø

 

The   box   cooler   may   not   be   started   or   used   
before   it   is   completely   installed   and   inspected   
according   to   the   instructions   in   this   manual.   

Ø

 

Keep   the   operating   conditions   within   the   
design   limits.   

   

5.1.

 

CHECK   THE   SYSTEM   FOR   SATISFACTORY   

INSTALLATION   

q

 

Verify   that   all   safety   devices   in   the   system   (pressure   

limiting   device,   temperature   control   system)   are   
correctly   set   and   tested   before   start-­‐up.   

q

 

Verify   that   all   piping   and   pipe   fittings   are   properly   

fixed   and   supported   and   allow   for   sufficient   flexibility   
(see   section   4.3.1).   

q

 

Check   all   bolted   connections   for   tightness.   Refer   to   
section   4.4.4   for   tightening   torques.   Verify   also   that   no   

bolts   or   nuts   are   missing   or   broken.   

q

 

Check   also   the   installation   and   working   of   the   ICAF   
system   (when   applicable).      

   

5.2.

 

START-­‐UP   AND   OPERATION   

Do   not   use   the   box   cooler   outside   of   its   specification   
range   (operating   pressure,   operating   temperature,   
flow   speed,   used   fluids)

.

   

1)

 

Open   the   vent   valve   and   fill   the   box   cooler   gradually   
with   the   fluid   for   which   it   is   designed.   

Minimize   

stresses,   ensure   that   the   pressure   rises   slowly   and   
the   box   cooler   heats   up   evenly.

   

2)

 

Allow   all   air   in   the   box   cooler   as   well   as   from   the   
whole   system   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   period   of   operation   the   system   
needs   to   be   inspected   more   frequently.

   

   

Shutdown   the   box   cooler   immediately   in   case   

of   any   possible   defect,   leakage   or   when   the   
operating   conditions   are   not   within   the   design   
limits.   

Investigate   the   cause   (see   section   7)   and   restart   
the   box   cooler   only   when   all   defects   are   fixed   
by   a   qualified   maintenance   engineer.   

5)

 

After   the   initial   8-­‐10   hours   of   operation,   shut   the   box   
cooler   down   (according   to   the   instructions   of   
section   5.3)   and   retighten   all   bolted   connections   (see   
section   4.4.4).   

   

5.3.

 

SHUT-­‐DOWN   

1)

 

Stop   the   equipment   that   is   cooled   by   the   circulating   
liquid.   

2)

 

Wait   until   the   equipment   has   cooled   down   
sufficiently.

   

This   is   to   prevent   overheating   of   both   the   box   cooler   
and   the   equipment   that   is   cooled.   

3)

 

Stop   the   circulation   of   the   liquid.   

Drain   during   shutdown   to   avoid   freezing   

The   medium   will   expand   when   it   freezes   and   this   may   
cause   the   tubes   of   the   box   cooler   to   burst   and   the   
water   covers   to   become   deformed.   

Therefore   drain   the   system   when   freezing   is   expected   
during   shutdown.   Blow   the   water   out   of   the   tubes   
using   compressed   air.   

When   a   suitable   amount   of   antifreeze   is   added   to   the   

stagnant   liquid,   the   box   cooler   does   not   require   to   be   
drained.   (Note   that   the   adding   of   antifreeze   to   the   
cooling   water   may   have   consequences   for   the   
performance   of   the   box   cooler.   Check   the   technical   
specifications   or   contact   Duramax   Marine®   for   advice.)   

Alternatively,   keep   the   liquid   circulating   if   the   system   
must   be   left   full.   

   

   

Содержание Box Cooler

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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