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NRF Instruction Manual

Boxcoolers
Inside mounting
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Table of contents >

Introduction ................................................................................................................................................. 2
Guarantee and liability................................................................................................................................ 2
Receipt of goods ......................................................................................................................................... 2
Preparations before installation ................................................................................................................ 3
Design of the sea chest ................................................................................................................................. 3
Orientation and leveling of the box cooler ............................................................................................... 4
Seawater inlet grids in the ship’s hull ....................................................................................................... 4
Seawater outlet grids in the ship’s hull .................................................................................................... 4
Fittings, piping construction and nozzle loads ....................................................................................... 5
Vents ............................................................................................................................................................. 5
Drains ............................................................................................................................................................ 5
Valves ............................................................................................................................................................ 5
Anodes .......................................................................................................................................................... 5
Clearance for dismantling and cleaning ................................................................................................... 5
Instructions for conservation .................................................................................................................... 5
Unpacking .................................................................................................................................................... 6
Hoisting instructions .................................................................................................................................. 6
Hoisting Tools................................................................................................................................................ 6
Rotating the tube bundle .............................................................................................................................. 6
Installation ................................................................................................................................................... 7
Cut-out in top plate, mounting frame and final painting. ............................................................................ 7
Mounting of the box cooler .......................................................................................................................... 7
Start-up Operation ...................................................................................................................................... 8
Protective plugs and covers: ......................................................................................................................... 8
Dirt removal: ................................................................................................................................................. 8
Start up: ........................................................................................................................................................ 8
Shut down: .................................................................................................................................................... 8
Inhibitors: ...................................................................................................................................................... 8
Bolted joints: ................................................................................................................................................. 8
Maintenance ................................................................................................................................................ 9
Removal of the cover: ................................................................................................................................... 9
Removal of the box cooler: ........................................................................................................................... 9
Inspection: .................................................................................................................................................... 9
Cleaning: ....................................................................................................................................................... 9
Indentifying leaking tubes:............................................................................................................................ 9
Performance Failures ............................................................................................................................... 11
Attachment 1: General Exploded View ................................................................................................... 12
Attachment 2: Hoisting eye bolts ............................................................................................................ 13
Attachment 3: Hoisting Beam .................................................................................................................. 13
Attachment 4: Mounting Frame Installation and Welding Instruction ................................................. 14
Attachment 5: Mounting Frame Installation and Welding Instruction, Square Box Coolers ............ 15
Attachment 6: Mounting Instructions for Box Coolers ......................................................................... 16
Attachment 7: Order form spare parts .................................................................................................... 18

1
Introduction

Read this instruction manual carefully before proceeding.

Please consult the exploded view of the cooler in attachment 1 for an explanation the terms
used in this manual
Important documents besides this instruction manual are:
o the order confirmation
o thermal performance sheet
o final drawing
o factory test certificate

Guarantee and liability

All terms and conditions of sales and services are subject to the latest version of General Conditions
for the Supply of Mechanical, Electrical and Associated Electronic Products, as for The Netherlands,
registration number 119/1998 Country Court Den Haag by the association FME-CWM, as for other
countries applies the latest version of the international conditions ORGALIME S2000. We explicitly
reject all other general conditions.
If required we will send you a copy of these terms free of charge.
Loss of performance and/or damage to the heat exchanger, as a result of the following
circumstances are not covered by the guarantee:
not following the instructions in this manual
replacement with non-original parts

Receipt of goods

Upon receipt of goods, please report any damage or discrepancy to NRF B.V.
Always store the box coolers in a dry room with stable temperature conditions
Follow the instructions for conservation when the box cooler is not put into operation
immediately after receipt.
Compare the data on the nameplate, order confirmation and on the drawings

2
Preparations before installation

Design of the sea chest

The box cooler is suitable for a maximum internal working pressure of 3 bar. The sea chest should
be positioned to ensure that the joint between the box cooler and mounting frame is never more than
30M below the water line. The sea chest should be designed and positioned in the hull to limit the
local seawater velocities at the box coolers to a maximum of 2 m/s during all operations of the
vessel.

The sea chest should be designed to provide a free space of at least 100 mm (4”) on all sides of
each tube-bundle. Large sea chests or interconnected sea chests with partially open frames can
cause locally high seawater velocities that can cause serious damage to the coolers. For this reason
NRF recommends that not more than three box coolers should be installed in one sea chest. The
frames between each sea chest should be completely closed. The frames within one sea chest
should be completely open.

If the cooling system consists of more than one box cooler connected in series or parallel, then each
box cooler must be installed in a separate sea chest.
Installing a low and high temperature cooling system of box coolers in the same sea chest is, in
general, prohibited. Consult NRF B.V. for approval if this arrangement must be considered. If
approved for coolers mounted athwart-ship then the HT section should be located closest to the
outlet grids. If approved for coolers mounted longitudinally then the HT section should be mounted at
the aft end of the sea chest.

Longitudinal orientation Athwart-ship orientation

We recommend that seawater inlet/outlets for other systems should not be positioned in sea chests
used for box coolers. If this can not be avoided then the equipment should be arranged so that it has
no effect on the local seawater velocities at the box coolers.

The top of the sea chest must be constructed to support the complete box cooler. A weak
construction may lead to leakage between the tube-bundle and mounting frame. The top of the
mounting frame, which is welded to the top-plate of the sea chest, must be located below or at the
light-ship waterline.
The shape of the top plate is of great influence for the cooling. Ideally the top plate between the box
cooler and the outlet grid should be inclined (e.g. 10 degrees), sloping upwards towards the
uppermost outlet grids to optimize the cooling water circulation and the de-aeration of the sea chest.
In any case, no flow-restrictions should be positioned on the underside of the top plate (e.g.
stiffening ribs running across the flow direction). Such features will interrupt the flow to the outlet
grids and reduce cooling capacity.

3
Orientation and leveling of the box cooler

The box cooler can be positioned both athwart-ship or longitudinally.

The box cooler must be set level and square so that pipe connections can be made without forcing.
An inclined (>5º) installation of the box cooler is only allowed after consulting NRF B.V.

Seawater inlet grids in the ship’s hull

Location:
The seawater inlet grids should be located at the lowest possible position directly below the
tube-bundle.
Orientation:
Orientation of the inlet grids must be transverse to the sailing direction. This prevents too
much turbulence and high water velocities near the lower end of the bundle
Shape:
The inlet grids should be no larger than 50mm wide and 500mm long. A web distance of not
less than 35mm should be used between the grids.
Alternatively, a pattern of holes ø 50 mm can be used with a minimum hole centre distance
of 85mm. No scoops are allowed!!
Dimension:
The total area of the seawater inlet grids must be between 0,3 dm ²and 0,4 dm²/ per m²
cooling surface of the cooler.

Seawater outlet grids in the ship’s hull

Location:
The seawater outlet grids should be located at the highest possible position, directly under
the top-plate but always below the light-ship waterline
Maximum distance from underside top plate to the uppermost outlet grid is 25mm.

Orientation:
Orientation of the outlet grids must be longitudinal to
the sailing direction.
Shape:
The width of the outlet grids must be no larger than 70
mm. The length approximately 100 mm shorter than
the frame pitch or in any case a maximum of 500mm.
A minimum web distance of 35mm should be used
between grids. A pattern of holes for seawater
outlet grids is strictly forbidden!!
Dimension: The total area of the seawater outlet grids
must be between 0,6 dm² and 1,0 dm² /per m² cooling
surface of the cooler.

The actual cooling surface is mentioned on the thermal specification sheet of the supplied box
cooler.

Smaller inlet or outlet grids than specified above may be possible after consulting with NRF B.V.
Please contact NRF B.V. for an estimate of the total number and size of the grids required. A
drawing of the sea chest with all relevant dimensions should be sent together with your request.

4
Fittings, piping construction and nozzle loads

The pipe work systems must be constructed to give free access for mounting and maintenance of
the box coolers. The piping must be designed and installed in such a way that the flange loads on
the cover are negligible. The box cooler is not designed to serve as an anchor point for piping; this
can result in damage to the box cooler and leakage.

Vents
It is advisable to install vent valves in the piping for de-aeration of the system.

Drains
The piping must be provided with drains near the box cooler. The installation of isolation valves on
all drains is recommended.

Valves
It may be desirable to provide valves in the piping system to permit inspection and repairs without
draining the complete system.

Anodes
NRF supplies 2 to 4 anodes with uncoated coolers. These anodes have to be installed next to each
cooler.
Spare anodes can be obtained at NRF under Part number 07710002.

Clearance for dismantling and cleaning

Provide sufficient clearance above the box cooler to permit withdrawal and replacement of the tube-
bundle. It is advisable to install a hoisting lug above the cooler for use during maintenance (hoisting
instructions are given later in this manual). It may also be desirable to provide extra flange
connections and valves in the piping near the cooler to make an easy dismounting possible.

Instructions for conservation

The box cooler is supplied without any conservation. If the box cooler is not to be installed
immediately, then we advise that you treat the box cooler with a rust preventive liquid of a type
suited for long term conservation. When conservation is necessary, contact a specialize company
and ensure that the treatment used is compatible with the material of the box cooler (see
specification sheet). Be aware that in uncontrolled storage conditions large amounts of water can
accumulate in the heat exchanger as a result of condensation.

5
Unpacking

WARNING!!! The tube-bundle can easily be damaged.

The box cooler should be unpacked near to the job site to reduce the risk of handling damage. Steps
to be followed during unpacking of the box cooler:
1 Remove cover of the wooden packing case.
2 Remove the mounting frame for installation on top of the sea chest.
3 Close the packing case to protect the other parts of the box cooler until needed for installation.
4 Remove cover and sidewalls of the packing case.
5 Rotate the bundle as described in section ‘Hoisting instructions’ below.
6 Attach the hoisting beams or eye bolts to make the bundle suitable for hoisting. Perform the
hoisting as described in section below.

Hoisting instructions

Hoisting Tools
Use hoisting material and tools suitable for the load. The weight of the tube bundles is stated in the
specification sheet for the box cooler. There are two correct methods for hoisting of the tube
bundles;
Use four eye-bolts M12 (DIN580; C15) according to attachment 2. Four threaded holes are
available in the tube sheet for this purpose. Eye-bolts are not supplied with the box cooler.
Make sure that the load is uniformly spread over all of the eye-bolts.
Use a hoisting bar and beam according to attachment 3. These may be used for hoisting the
tube bundle out of the packing and to the job site. These tools are not supplied with the box
cooler.

Rotating the tube bundle

Each tube bundle must be rotated according the hoisting procedure to get it into the mounting
position. This operation must be performed on a flat surface, free from obstacles. Always use a
protective material such as rubber between the surface and tube bundle to prevent damage.

WARNING!!! Do not hoist the tube bundle by using cables/ropes or chains that are run through the
space in the middle of the bundle or connected to a support plate. This will cause severe damage to
the tube bundle. Rotating a tube bundle by pushing it over and let it fall to the floor is not allowed.

6
Installation

Cut-out in top plate, mounting frame and final painting.

The mounting frame must be positioned and welded to the top-plate.
Cut a hole of the correct size in the top-plate of the sea chest. The size of the cut-out is obtained
using dimension E and C as shown in attachments 4 and 5. You should consult the final drawings
supplied by NRF for the values E and C for each box cooler together with attachment 4 or 5. The
radius in each corner of the cut-out should be less than 25mm. The recommended welding
arrangement is shown in attachment 4 or 5.

WARNING!!!! The flatness of the mounting frame after welding must be within the limits stated in
attachment 4 and 5. Machining of the mounting frame after welding is not allowed, so please
take the flatness requirements into account when welding.
Large mounting frames have an extra reinforcement strip between the long sides. Do not remove
this until the mounting frame is welded to the top plate. Round-off all edges after welding – before
the touch-up paint is applied. See also attachment 4 or 5.
The inside of the sea chest and mounting frame must be adequately protected. We advise the use of
an epoxy paint system after welding. This should be taken up in the painting and protection schemes
for the sea chest.

Mounting of the box cooler

Perform the steps as detailed in attachment 6 to mount the box cooler.

WARNING!!!! The order of installation, fastener tightening, the tightening torque and the repeat of
the tightening procedure detailed out in attachment 6 must be followed to ensure proper installation
of the tube bundle and the cover. Machining of the cover is not allowed.

7
Start-up Operation

The equipment is designed for use with the conditions as specified on the specification
sheet/drawing and identification plate. It must not operate at conditions that exceed these
specifications.

Protective plugs and covers:

All nozzle openings must be inspected for foreign material. Protective plugs and covers may not be
removed until just prior to connection of the piping.

Dirt removal:
The entire system should be clean before starting operation. If foreign material can be expected, the
use of strainers in the piping upstream of the heat exchanger is required.

Start up:
During start-up all vent valves should be opened and left open until all passages have been purged
from air and are completely filled with coolant.

Shut down:
When shutting down the system, the box cooler should be drained completely or filled with suitable
antifreeze liquid if there is a possibility of freezing or corrosion damage. The bundle tubes can only
be completely drained by disassembling the box cooler and by pouring the coolant by turning the
pipe bundle upside-down.

Inhibitors:
There can be reasons to add inhibitor to the cooling water circuit of the box cooler. Contact a
specialized company to confirm the compatibility of the inhibitor with the materials of the box cooler
(See specification sheet for materials of the tube bundle) Follow the instructions of the supplier for
use of the inhibitor.

Bolted joints:
Due to normal relaxing of the gaskets, all external bolted joints will require re-tightening after the box
cooler has reached its operating temperature. Re-tightening may only be done when the unit is cold
and depressurized. The same torque wrench moment as mentioned in section ‘Installation’ step 1
and 2 is applicable.

8
Maintenance

Removal of the cover:

Depressurize and drain the cooling system by closing the valves in the inlet- and outlet piping of the
box cooler. The ship must be trimmed in such a way that the top plate of the box cooler is not more
than 0,5M below the waterline. Loosen the hexagon bolts and the nuts on the collar bolts but do not
remove them. Wait until the remaining coolant has leaked out between the tube sheet and the cover.
If water leaks between the tube sheet and the mounting frame, tighten the collar bolts/inside
hexagon socket head screws in such a way that the leaking stops.
Do not proceed if water continues to leak between the tube sheet and the mounting frame.
Never loosen the collar bolts /inside hexagon socket head screws while the ship is in
operation!!!!!
The hexagon bolts and the cover can now be removed.

Removal of the box cooler:

To allow removal of the box cooler the top plate of the box cooler must be at least 0,2M above any
remaining water surrounding the ship. Follow the procedure above, drain the system and remove the
cover. The collar bolts / inside hexagon socket head screws can now be removed and the tube
bundle hoisted to the required position following the hoisting instructions shown in this manual.
The box cooler should never be removed while the ship is in operation!!!!!

Inspection:
At regular intervals i.e. docking periods of the ship, an examination should be carried out to check
the exterior condition of the box cooler. The sea chest should also be inspected for dirt and the
condition of anti-fouling (e.g. paint system and ICAF system). The sacrificial anodes in the sea chest
should be cleaned or replaced. The interior condition of the cooler (inside the cooler) does not
require examination.

Cleaning:
Uncoated and coated coolers can be cleaned with steam or chemical agents:
Steam cleaning:
With steam cleaning the maximum temperature should be limited to maximum 120oC. In
principle, cleaning time of the surface should not exceed more than half an hour.
Chemical cleaning:
We advise that chemical cleaning should only be performed by specialized/certified
companies. The coating is resistant in the range PH 4 – PH14.

The use of a high pressure water installation to clean box coolers is not allowed. This can
damage the cooler when removing barnacles and other objects that stick to the tubes!!!

Indentifying leaking tubes:

Extreme weather conditions, collision and objects entering the sea chest can damage the tube
bundles of the box cooler causing leakage. Such damage can be overcome or repaired:
The ship is afloat;
Remove the cover following the instructions shown above.
Do not proceed if water continues to leak between the tube sheet and the mounting
frame.
Never loosen the collar bolts /inside hexagon socket head screws while the ship is
afloat!!!!! The pressure acting on the outside of the bundle will fill the leaking tube with water
making identification of the leak possible.
Leaking tubes can be plugged-off with brass conical plugs. Do not apply too much of force
when installing a plug. This will cause deformation of the tube sheet that will result in leakage
of the surrounding tubes. Conical plugs of the correct size are obtainable at NRF (Art nr.
07700017).
The ship is in dry-docking:

9
Depressurize and drain the cooling water system by closing the valves of the inlet- and outlet
piping of the box cooler. Remove the cover. The tube that looses water is the leaking one. If
the damage is so small that you cannot trace it visually, then re-install the cover, blind-off the
flanges and connect on one of the blind flanges a compressed air connection. Bring the
cooler under pressure with compressed air (max 3 bar). Depressurize, remove the cover and
check again which tube contains no water.

10
Performance Failures

The failure of the box cooler to perform satisfactorily may be caused by one or more factors, such
as:

A Thermal specification of box cooler does not comply with actual values.

B Excessive fouling at the outside of the tubes.

Solution: clean tube bundle according to section ‘Maintenance’
If fouling becomes a frequent problem then installation of an anti fouling system should
be considered. Contact NRF

C Presence of air or gas resulting from improper piping installation or lack of suitable vents.
Solution: Vent the complete system

D Restricted outboard water flow

Solution: Check the inlet- and outlet openings for restrictions
Check for air-trap in the upper region of the sea chest
Check size of the openings and/or consult NRF B.V.

E Operating conditions differ from design conditions.

11
Attachment 1: General Exploded View

12
Attachment 2: Hoisting eye bolts

Attachment 3: Hoisting Beam

(Note: can not be used to position the outside mounted tube bundle for installation)

13
Attachment 4: Mounting Frame Installation and Welding Instruction

14
Attachment 5: Mounting Frame Installation and Welding Instruction, Square Box Coolers

15
Attachment 6: Mounting Instructions for Box Coolers

Perform the following steps during mounting of the box cooler.

Step 1
Place mounting frame gasket (without web) into position on the mounting frame.

Step 2
Place the tube bundle in position of the mounting frame. For hoisting instructions, see
Instruction Manual section ‘Hoisting instruction’.

Collar bolts version:

Install the collar bolts in the stepped holes of the tube sheet.

Put collar bolt with longest part into stepped holes of tube Screw the collar bolts into the under laying mounting frame by
plate hand

Tighten collar bolts following a diametrically staggered pattern (see drawing for typical example).

9 5 1 3 7 11

14 13

10
12 8 4 2 6

Repeat this pattern at least 3 times until all collar bolts support a torque wrench moment of:
M12: 55 – 65 Nm
M16: 65 – 75 Nm.
To get grip on these bolts you can use a double nut arrangement. After installation it is advised to
conserve the collar bolts and nuts with grease.

Internal hexagon socket head screw version:

Install the internal hexagon socket head screws and washers in the stepped holes of the tube sheet
using the same procedure and order of tightening as described until all bolts support a torque
wrench moment of 55 - 65Nm. After installation it is advised to conserve the screws with grease.

16
 Step 3
Place the cover gasket (with web) on the tube sheet and confirm that the gasket web matches
the position of partition plates on the cover. An extra hole is made in the bolt circle in order to
check the correct position of the gasket and cover versus the tube sheet.

Step 4
Position the cover and install all hexagon bolts.

It is important that these bolts are tightened following a diametrically staggered pattern as shown
here. Repeat this pattern for 2 or 3 times until all bolts support a torque wrench moment of:
M12: 55 – 80Nm
M16: 65 - 80Nm.

Thereafter fit the nuts to the collar bolts and tighten to support a torque wrench moment of:
M12: 55 – 65 Nm
M16: 65 – 75 Nm.
After installation it is advised to conserve the collar bolts and nuts with grease.

Step 5
Connect the piping. Position the piping at the connection points and confirm that the flanges
meet up without loading the cover. If necessary adjust the pipe work to properly match the
installed position of the cooler. Install jointing and tighten according to the recommendations of
the pipe system design.

17
 Attachment 7: Order form spare parts

Example information box cooler references:

Serial number/Reference number “position 1”

Drawing number “position 2”
Quantity Evt. Ref. number
Cover **
Mounting frame **
Bundle **

Cover gasket **
Mounting frame gasket **

** ``On drawing``

Position 2 Position 1

Nederlandse Radiateuren Fabriek B.V. shall expressly retain ownership of goods delivered until full and final
settlement of the price, interest and related expenses. Failure to make any one payment upon due date may
result in a claim for the return of the goods. These conditions shall not prevent the transfer to purchaser, upon
delivery, of all risks of loss or damage to the goods sold or any damage that they may cause. Purchaser shall be
obliged to monitor the good condition of the goods, not to sell pledge or in other way dispose of the goods or part
thereof, until such time as full title shall be transferred to him.

18
Langenboomseweg 64 | P.O. Box 1
NL-5451 JM Mill | 5450 AA Mill
T +31 (0)485 - 476 476
F +31(0)485 - 576 396

www.nrf.eu