Scana

Scana Volda as
Hamneg. 24, P.O.box 205, N-6101 Volda, Norway
Tel: +47 70 05 90 00. Fax: +47 70 05 90 01
Service (after office hrs.): +47 478 24 365
www.scana.no, e-mail: [email protected]

7. BROCHURES, MANUALS, AND DRAWINGS

FROM SUB-SUPPLIERS
- Oil cooler ................................................................Bloksma 508507
- Oil cooler pipeline thermometer................................... SIKA 503717
- Oil pump stand by........................................................ GPM 508557
- Oil pump gear box mounted ...................Commercial WP76 506587
- High pressure filter ....................................................Parker 502628
- Solenoid valve ..............................................................Aron 504357/504404
-
Instructions for installation, start-up
and maintenance of a
Bloksma heat exchanger.

P-type (P/PF, IV/MV)

Article number of this manual: 7ZZ00P0000010

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Instruction manual P-type Heat exchanger

TABLE OF CONTENTS

Page
Glossary………………….……………………………………………... 3
1 Introduction.…………………………………………………………… 4
1.1 Remarks…………………………………………………………………. 4
1.2 Guarantee and liability…………………………………………………... 4
1.3 Environment.……………………………………………………………. 4
1.4 Safety……………..…………………………………………………….. 4
1.5 Inhibitors………………………………………………………………… 4
2 Installation and start-up………………………………………………. 5
2.1 Receipt…………………………………………………………………... 5
2.2 Installation..……………………………………………………………... 5
2.3 Start-up…………………………………….……………………………. 6
3 Maintenance..…………………………………………………………... 7
3.1 Inspection and cleaning intervals….……………………………………. 7
3.2 Anodic protection…….…………………………………………………. 7
3.3 Cleaning of the heat exchanger………….……………………………… 7
3.3.1 Mechanical cleaning of the tubeside…………..……………………….. 7
3.3.2 Chemichal cleaning of the shell-/tubeside………………………………. 7
3.4 Shut down periods………………………………………………………. 8
3.5 Assembling and disassembling of the heat exchanger………………….. 9
3.6 Instructions for gaskets and bolting…..………………………………… 12
3.6.1 Gaskets….……………………………………………………………….. 12
3.6.2 Bolting………………………………………………………..………… 12
4 Trouble shooting & repairs………..………………………………….. 13
4.1 Thermal performance too low..…………………………………………. 13
4.2 Leaking tubes / tube-tubesheet-connection……………………………... 13
4.3 Leaking gaskets….……………………………………………………… 13
5 Spare parts & tools…………………………………………………….. 14
Appendix A: Instructions for conservation
Appendix B: Adresses
Appendix C: Constructional directions for entering a P-type heat
exchanger in a piping design

The P-type heat exchanger can be subdivided into four sizes: P10, P13, P20 and P28.
The number indicates the shell size in centimeters. The construction of the P10 is slightly
different from the others. When necessary this manual has special texts (indicated with: “For
P10 only:”) which apply to the P10 only.

There are two models (P10 only in MV): the IV (Industrial Version) and the MV (Marine
Version). Main difference is the anodes in the tubeside circuit of the MV. It is pointed out in
the text when there are differences between the two models.

In addition this manual applies to P-heat exchangers with plain tubes as well as PF heat
exchangers with bundles with fins.

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Glossary

Refer to the figure(s) in the paragraph “Assembling and disassembling of the heat exchanger”
for an explanation of the designation of parts of the heat exchanger in the text.

Conditioned circuit Closed circuit with a non-corrosive medium.

Unconditioned circuit Open circuit (for instance seawater) or a closed circuit

with a corrosive medium.

Coating Layer protecting the coated material against corrosion.

The coating separates the coated part from the corrosive
medium.

Inhibitor Additive to a medium flowing through the heat

exchanger which –expressly tailored to that medium-
reduces the quickness of chemical reactions like
corrosion.

Anodes / anodic protection Introducing a base metal to a more precious metal (on
purpose) in order to protect this metal. The part serving
as anode is being sacrificed.

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1 Introduction

1.1 Remarks
• Read this instruction manual before proceeding.
• Important documents besides this instruction manual are the order confirmation, the
specification sheet, the drawing(s) and the sheet with constructional directions (appendix
C). In the specification sheet the design pressures and temperatures are listed that must of
course not be exceeded.

1.2 Guarantee and liability

The “General 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 heat exchanger 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 heat exchanger is installed, always
have to be respected.
• Always be on the alert to the possibility of leakage.
• When disposing of the unit at the end of its lifespan, see to it that this takes place
according to the then applicable regulations.

1.4 Safety
Some symbols are used in the text to underline safety aspects:

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

Maintenance and repair: depressurize both circuits of the heat exchanger and let them cool
down to ambient temperature.

In connection with safety every Bloksma heat exchanger is tested under higher pressure than
the design pressure before it leaves the factory. This applies to heat exchangers that are not
tested by a certification agency.

1.5 Inhibitors
There can be reasons to add an inhibitor to one of the circuits of the heat exchanger. Contact a
specialised company, which can also check for harmfulness of the inhibitor to the materials of
the heat exchanger (see specification sheet). Follow the instructions of the supplier for use of
the inhibitor.

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2 Installation and start-up

2.1 Receipt
At receipt check the packaging and the heat exchanger:
• report any damage to Bloksma
• compare the data on the nameplate, confirmation of the order and on the drawing
• 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 heat exchanger in a dry room, free of large temperature changes. When the
heat exchanger is not being put into operation immediately after receipt, follow the
“Instructions for conservation” (Appendix A).

2.2 Installation
Warning: Beware of any rust preventive layers (see “Instructions for conservation”) that
might still be present in the heat exchanger before proceeding.
• Remove all protective plugs and covers from the connecting flanges prior to installation of
the heat exchanger.
• A 1- or 3-pass model (tubeside) has to be mounted in such a way that shell- and tubeside
will be in counterflow.
• Check whether the positions of the vent and drain connections on the heat exchanger
correspond with the mounting position of the heat exchanger.
• In models with body side wire connections, check to see if the couplings with which the
lines are fastened do not touch the bundle.
• Mount the heat exchanger level and square on a flat surface in order for the pipe
connections to be made without forcing.
• Do not weld anything to the heat exchanger.
• Mount one support in a fixed position, while the other one is mounted in such a way that it
is able to slide in the direction of the longitudinal axis of the heat exchanger. The heat
exchanger will thus be able to expand under thermal stress.
• When installing types bigger than P10 vertically, the waterbox at which the position of the
tubesheet is fixed 1 , has to be located on top.
• Before connecting piping to the heat exchanger flanges, make sure that the gasket surface
is clean and free from scratches and other defects. Always use new gaskets, of the correct
type and tighten the bolts crosswise.
• Take care when lifting the heat exchanger. Use at least two hoops around the shell of the
heat exchanger for lifting purposes.
• Check for the presence and correct positions of drain/vent connections in both circuits.
• Install the heat exchanger and the piping in such a manner that there is still enough room
to disassemble (part of) the heat exchanger (tubebundle, drain plugs, etc.).

1
On a 2-pass model the side of the heat exchanger at which the position of the tubesheet is fixed is always the
side where the tubeside medium enters and exits the heat exchanger. On 1-pass models this is the side on which
fixation plates are bolted between waterbox and shell (on the other side distance rings are bolted between shell
and waterbox). Furthermore the side of the heat exchanger where the serialnumber is, is also the side with the
fixed tubesheet.

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2.3 Start-up
Do not exceed the design temperatures and design pressures as stated on the nameplate and
specification sheet. Avoid abrupt temperature fluctuations; these can cause leaking of tube-to-
tubesheet or other connections.

• Make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium.
• Vent both circuits.
• Vent both circuits again when the operating temperatures and pressures are reached.
• Check for leakage.

Do not deviate from the flows as stated on the specification sheet. Higher or lower velocities
can cause erosion or corrosion respectively.

Avoid standstill: at non-conditioned circuits this may cause corrosion. In case of standstill
follow the instructions for shut down periods.

If the heat exchanger is equipped with anodic protection (see specification sheet) you will
have to inspect the anodes (or part that functions as anode) when you are starting up the heat
exchanger after a shut down period.

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3 Maintenance

If necessary refer to “Assembling and disassembling of the heat exchanger” for

(dis-)assembling instructions.

3.1 Cleaning and inspection intervals

Preventive maintenance of the heat exchanger is a user responsibility. The tubeside circuit is
usually the more fouling side of the heat exchanger. Because the degree of fouling strongly
depends on the operating conditions we recommend the following:
• Inspect the tubeside at least quarterly.
• Inspect the shellside at least twice a year.
With the results of these inspections you will be able to determine the required cleaning
intervals. Always keep performing regular inspections.

3.2 Anodic protection

Not applicable for IV models.
The MV models of P-type heat exchangers are fitted with anodic protection: the tubeside
circuit is provided with anodes. When inspecting the tubeside of the heat exchanger also
inspect the state of the anodes (always drain the tubeside circuit before removing the anodes).

3.3 Cleaning of the heat exchanger

3.3.1 Mechanical cleaning of the tubeside

The tubes can be cleaned with a tube brush. Use original Bloksma brushes only; these have
the correct dimensions and are of a suitable material. Other brushes may damage the
protective layer that is in the normal course of events present on the tubewalls.

3.3.2 Chemichal cleaning of the shell-/tubeside

Warning: Chemical cleaning may damage the heat exchanger. Make sure your supplier of a
cleaning agent verifies and confirms the compatibility of his product with the materials of the
heat exchanger (see specification sheet).

Cleaning of the shellside will normally be necessary seldom.

The shell- as well as the tubeside can be cleaned by circulating a chemical solution through
the heat exchanger. Another possibility is disassembling of the heat exchanger and
submerging the tubebundle in a tank filled with a chemical solution. Remove any plastic
partitions (on 2- or 3-pass heat exchangers to divide the tubeside circuit) from the tubesheet(s)
first.

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There are several international companies (example in Appendix B) which supply equipment
and fluids for chemical cleaning of heat exchangers. Their specialized cleaning centres,
situated at ports all over the world, are able to give you a cleaning advise or to clean the heat
exchanger for you. To give an idea of the possibilities, an example of a cleaning procedure is
given below.

Please note: The cleaning advice below is just an example. Cleaning methods and
procedures, as well as fluids for cleaning will differ depending on the materials of the heat
exchanger (see specification sheet) and the application.

This cleaning advise is meant for waterheaters/coolers.

Descalant NF (inhibited cleaning agent)

• Submerge the tubebundle (time is dependend on the degree of fouling)
in a tank with dissolved cleaning agent
• After cleaning neutralize the tubebundle and the cleaning agent with a
special neutralizing fluid
• Flush the tubebundle with fresh water
• Dry the tubebundle

3.4 Shut down periods

During shut down periods longer than a week the heat exchanger has to be drained completely
and dried by means of preheated compressed air. In fact this also has to be done during short
shut down periods (longer than a day) when there is risk of freezing, and it also applies when
a corrosive medium is used in the heat exchanger. After draining a corrosive medium, the heat
exchanger has to be rinsed with fresh water.
Stopping of the flows, cooling down and draining of the heat exchanger has to be done in a
manner to minimize thermal stresses on the heat exchanger.

Never stop one of the flows of the heat exchanger while the other one stays in operation,
because of the risk of boiling.

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3.5 Assembling and disassembling of the heat exchanger

The circumferences of the tubesheets are fitted with three grooves. The two outer grooves
carry O-rings (sealing between shell- and tubeside). At one of the tubesheets the middle
groove is for the fixation of the position of the tubebundle by means of ‘fixationplates’ (this
tubesheet is called the fixed tubesheet).

1 Tubesheet 4 Shell
2 O-ring 5 Tubes
3 Fixationplate
Figure 1: Schematic drawing of tubesheet construction

For P10 only: Instead of fixationplates the P10 has a metal spring ring in the middle groove
of the tubesheet. As soon as the bolts are untightened the position of the tubebundle is no
longer fixated. Tubeside inspection or cleaning remains possible, but extra attention is
required because the tubebundle is not fixed anymore. Except when performinge a pressure
test, we recommend to drain both circuits.

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For tubeside inspection, shellside pressure testing or cleaning of the tubes with a
tubebrush, only the tubeside connections and the waterboxes (these are the parts
on both ends of the shell, on which the tubeside connections are made) need to be
removed (follow step 1 and 3). Pay attention: when the nuts are untightened the
fixationplates are also untightened, so the tubebundle comes loose. In order to fixate the
tubebundle temporarily, fasten the fixationplates with the nuts.

For shellside inspection (for instance), the tubebundle has to be removed completely
(follow step 1, 2 and 3), and both circuits have to be drained.

When assembling as well as disassembling follow the “Instructions for gaskets and bolting”.

Step 1: Tubeside disassembling

• depressurize both circuits

• let both circuits cool down to ambient temperature
• drain the tubeside circuit, by opening the drain in the lowest point and the vent in the
highest point
• mark the position of all parts that will be disassembled, so they can be mounted in the
correct position later on

In case the heat exchanger is placed vertical, disassemble the upper waterbox first. This is the
side with the fixationplates. Fasten the fixationplates immediately with the nuts before
proceeding. For P10 only: A vertically placed P10 will always have to be disassembled
completely because the the tubebundle does not stay in position.

• remove the waterboxes by untightening the nuts (the fixationplates come loose as well)
• 2- or 3-pass heat exchangers have plastic partitions on the tubesheet(s) for dividing the
tubeside circuit; mark their position and remove them
• mount the fixationplates again with the nuts (not necessary when the tubebundle is going
to be removed (see step 2))
• remove the first O-ring from both tubesheets
• only for a pressure test: pressurize the shellside again. Depressurize the shellside again
after the pressure test. For P10 only: Remember that the tubebundle is not fixated!

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Step 2: Removing the tubebundle

• drain the shellside circuit, by opening the drain in the lowest point and the vent in the
highest point
• mark the position of the tubebundle
• move the tubebundle to one side until the second O-ring shows (do not move the
tubebundle further than necessary) and remove this O-ring
• move the tubebundle to the other side and remove the second O-ring on this side as well
• carefully pull the tubebundle from the shell
• support the tubebundle at the baffles when lifting it, but be careful not to bend the baffles
(this will affect the thermal performance of the heat exchanger)

Step 3: Assembling
• assemble the heat exchanger in reversed order (pay attention to the earlier made marks):
Mounting of the tubebundle (only in case it was removed):
• push the tubebundle in the shell (let it stick out of the shell a little bit)
• mount the inner O-ring on the first tubesheet
• move the tubebundle further and let it stick out a little bit on the other side of the shell
• mount the inner O-ring on the second tubesheet
Hint: when it is difficult to move the tubebundle through the shell because the already
mounted O-ring is hard to compress, you can use a strip between tubesheet and waterbox and
then tighten two of the four bolts and nuts
• move the tubebundle in its final position

Tubeside assembly:
• mount the outer O-rings on both sides
• mount the plastic partitions on the tubesheets of 2- or 3-pass models
• mount the fixationplates (for P10 only: mount the metal spring ring)
• mount the waterboxes and all connections

• start-up the heat exchanger again:

• make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium
• vent both circuits
• vent both circuits again when the operating temperatures and pressures are reached
• check for leakage

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3.6 Instructions for gaskets and bolting

3.6.1 Gaskets
Two types of gaskets are being used in this heat exchanger:

O-rings : After disassembling the heat exchanger never use the old O-rings again. Replace
them with original Bloksma O-rings.

Warning: The O-rings have to be lubricated with a special O-ring lubricant (O-ring silicone
paste or Parker O-lube) for easy assembly and a good sealing capacity. Lubricants not suited
for O-rings can affect the sealing capacity of the O-ring (for instance do never use vaseline).
Any warranty claim will be rejected when unsuited lubricants are used.

Soft metal rings : After disassembly of the heast exchanger never use the old soft metal rings
again. Replace them with new ones for good sealing.

3.6.2 Bolting
Check bolts and nuts for damages. Tighten the bolts crosswise (see figure 2). This also applies
to connecting piping to the heat exchanger. Make sure the gasket surface is clean (remove dirt
and any corrosion residues) and undamaged.

Figure 2: (Un-)bolting sequence

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4 Trouble shooting & repairs

4.1 Performance too low

Check:
• whether all connections have been made according to the drawing
• whether the heat exchanger and the system have been properly vented
• whether the flows are according to the specification (check all valves, lines and pumps, as
well as the flow directions)
• whether the shell- as well as the tubeside have been cleaned recently (fouling can cause a
drop in performance and an increased pressure loss; an increased pressure drop is a good
indication that cleaning is necessary)
• whether the heat exchanger has been reassembled properly after disassembly
(the plastic partitions on the tubesheet(s) of 2- or 3-pass heat exchangers; the position
of the tubebundle (this might accidentally be mounted rotated 180° around its axis))

4.2 Leaking tubes / tube-to-tubesheet connection

It is often very hard to determine whether leakage occurs because of a leaking tube or because
of a leaking tube-to-tubesheet connection. The shellside of the heat exchanger can be
hydrotested, after disassembling the tubeside. Follow the instructions in “Assembling and
disassembling of the heat exchanger”. Subsequently pressurize the shellside. After
hydrotesting depressurize and drain the shellside again. Assemble the heat exchanger again.

The tubes are roller expanded into the tubesheet. It is either not possible (finned tubebundles)
or relatively complicated (unfinned tubebundles) to replace a leaking tube, but it can be
plugged with soft copper Bloksma plugs (other materials are too hard and may cause leakage
of the adjacent tube-to-tubesheet connections) in both tube ends. A maximum of
approximately 10% plugged tubes will not influence the thermal performance of the heat
exchanger too much. Contact Bloksma when more than 10% of the tubes is plugged.

4.3 Leaking gaskets

• Check the gasket surfaces.
• Remove dirt or corrosion residues
• Mount new gaskets
It is possible to determine which of the O-rings is leaking, by determining the medium that is
leaking from the heat exchanger.

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5 Spare parts & tools

Available spare parts and tools for P-type heat exchangers:

• Set of gaskets (four O-rings)

• Soft copper plugs
• Nylon tube brush
• Bolts / nuts
• Complete tubebundle
• For P10 only: Metal spring ring
• Fixationplates (for types > P10)
• Plastic partitions (not for 1-pass heat exchangers)
• Water box
• Cover
• Anode

When ordering spare parts, please refer to the Bloksma drawing number (listed on name
plate).

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Appendix A: Instructions for conservation

Standard conservation (controlled conditions)

All heat exchangers supplied by Bloksma are treated with a rust preventive layer (on both
shell- and tubeside). This layer will protect the heat exchanger when it is stored at controlled
conditions, i.e. inside, in a dry room at constant temperature . When these conditions are
met, the heat exchanger 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 heat
exchanger with an inert gas and all openings have to be closed airtight (additionally silica gel
can be added to absorb liquids). Alternatively, the heat exchanger 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 heat exchanger (see
specification sheet) into consideration. Be aware that in uncontrolled storage conditions large
amounts of water can accumulate in the heat exchanger as a result of condensation.

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Appendix C: Constructional directions for including a P-type heat

exchanger in a piping design.
Pay attention to the following points:
• Level and square mounting possibility.
• Bends in the piping have to be located at a distance of at least three times the nominal diameter of
the pipe from the inlet of the heat exchanger.
• When a vaporizing cryogenic medium is used, the heat exchanger has to be placed under an angle
of 3° - 10°, in order for the vapor to be able to exit the heat exchanger, helped by natural
circulation.
• Check if vent and drain connections are present in both circuits of the heat exchanger (when not
on the heat exchanger then make them in the piping).
• Put a filter (with a permeability of 3 mm.) before the inlet of both circuits of the heat exchanger.
• Stress- and vibration free mounting possibility of the connections and the supports (fit expansion
bellows and/or silencer blocks when necessary).
• Disassembling possibility of the tubebundle (and other parts like drain and vent plugs).
• Expansion possibility of lockable liquid circuits.
• Danger of freezing of liquid circuits.
• The design data of the heat exchanger on the specifiationsheet2 and the drawing. For instance the
flows: deviating from them can cause unacceptable high or low velocities. A (temporary) lower
flow is acceptable when caused by a controlsystem and a conditioned circuit is involved. Avoid
standstill (unless the heat exchanger is drained and flushed with fresh water).
• When adding an inhibitor to one of the fluids in the heat exchanger, always check whether this
inhibitor can be harmful for the materials of the heat exchanger (see specification sheet).
• Make sure that in case of flow control (with conditioned circuits only) this is done gradually (no
‘on-off-control’).
• Although this will almost never occur in practice, Bloksma reserves the right (according to TEMA
RGP-RCB-2) to plug a maximum of 1% of the tubes.
• Always check whether both fluids are compatible with the materials of the heat exchanger;
Bloksma chooses the materials judging on the fluids specified by the customer, but is often not
well informed about possible contaminations, higher or lower than normal degrees of acidity and
other for the choice of materials important proprties.
• Check whether the materials of the connecting piping are compatible with the materials of the heat
exchanger (when the materials of the bundle are, from a corrosion point of view, weak in
comparison with the materials of the piping, the bundle will corrode faster than expected).

2
In connection with the applied materials the instruction manuals refer to the specification sheet of the heat
exchanger. Therefore always keep the specification sheet.

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