Pressure vessels: Water-cooled condensers and oil coolers Translation of the original Operating Instructions English PDF

Description
DB2005 Pressure vessels: Watercooled condensers and oil coolers Translation of the original Operating Instructions English... 2 Druckbehälter: Wassergekühlte Verflüssiger und Ölkühler Originalbetriebsanleitung

Please download to get full document.

View again

of 43
All materials on our website are shared by users. If you have any questions about copyright issues, please report us to resolve them. We are always happy to assist you.
Information
Category:

Health & Medicine

Publish on:

Views: 191 | Pages: 43

Extension: PDF | Download: 0

Share
Transcript
DB2005 Pressure vessels: Watercooled condensers and oil coolers Translation of the original Operating Instructions English... 2 Druckbehälter: Wassergekühlte Verflüssiger und Ölkühler Originalbetriebsanleitung Deutsch Réservoirs sous pression : Condenseurs à eau et refroidisseur d'huile Traduction des instructions de service d'origine Français K033N/H(P).. K4803T(P) K033N/HB(P).. K4803TB(P) OW401.. OW941 OW401B.. OW941B Installer Monteur Monteur Table of contents 1 Introduction Safety Authorized staff Residual hazards Safety references General safety instructions Application ranges Plant registration Conformity Mounting Transporting the pressure vessel Installation location Plant design Refrigerant / oil side Coolant side Delivery condition Connecting the pipelines Mounting the pressure relief valve Connection for pressure gauge Connections for watercooled condensers and oil coolers Connection dimensions for coolant pipes Coolant passes Commissioning Checking tightness Charging refrigerant Coolant Operation Standstill Maintenance Cleaning Extracting the refrigerant Draining the oil Decommissioning DB2005 1 Introduction This pressure equipment is designed for installation in refrigeration systems according to the EC Machinery Directive 2006/42/EC and the Pressure Equipment Directive 2014/68/EU. They may only be put into operation if they have been installed in the machines according to these Assembly/Operating Instructions and if the overall system complies with the applicable legal provisions (applied standards: see Declaration of Conformity). The pressure equipment has been built in accordance with stateoftheart methods and current regulations. Particular importance was placed on user safety. Always keep these operations instructions near the refrigeration system for the whole lifetime of the pressure vessel. 2 Safety 2.1 Authorized staff All work done on the pressure equipment and refrigeration systems may only be performed by qualified and authorized staff who have been trained and instructed accordingly. Local regulations and guidelines apply with respect to the staff's qualification and expertise. 2.2 Residual hazards The pressure equipment may present unavoidable residual risks. That is why any person working on this device must carefully read these Operating Instructions The following regulations shall apply: the relevant safety regulations and standards (for example, EN 378) generally accepted safety rules, EU directives, national regulations. 2.3 Safety references are instructions intended to prevent hazards. Safety references must be stringently observed NOTICE Safety reference to avoid situations which may result in damage to a device or its equipment. CAUTION Safety reference to avoid a potentially hazardous situation which may result in minor or moderate injury. WARNING Safety reference to avoid a potentially hazardous situation which could result in death or serious injury. DANGER Safety reference to avoid an imminently hazardous situation which may result in death or serious injury General safety instructions State of delivery CAUTION The pressure equipment is filled with a holding charge: Overpressure bar. Risk of injury to skin and eyes. Depressurise the pressure equipment Wear safety goggles DANGER Risk of bursting the pressure device due to mechanical stress. Serious injuries are possible. Connect the pipeline to the pressure unit without stress DANGER Risk of bursting of components and pipelines due to hydraulic overpressure. Serious injuries are possible. Make sure not to exceed maximum admissible pressures DB2005 3 For work on the pressure vessel after having put the system into operation CAUTION Surface temperatures of more than 60 C or below 0 C. Risk of burns or frostbite. Close off accessible areas and mark them. Before performing any work on the pressure device: switch off the installation and let it cool down. For work on the pipework of the coolant, the following is applicable WARNING Coolant can burn skin and eyes Wear safety goggles WARNING The pressure equipment is under pressure Serious injuries are possible Depressurise the pressure equipment Wear safety goggles CAUTION Refrigerant can be very cold Risk of severe frostbite. Avoid any contact with the refrigerant. CAUTION Oil can be very hot. Serious burns are possible. Allow the oil to cool. 4 DB2005 3 Application ranges Type Fluid group according to 2014/68/EU (PED) Safety group according to EN 378 PS Maximum permitted pressure TS Maximum and minimum permitted temperature K033N/H(P)(B).. K4803T(P)(B) A1, A2, A2L, A3 33 bar 120 C / 10 C OW401(B).. OW941(B) A1, A2, A2L, A3 28 bar 120 C / 10 C OW401(B).. OW941(B) Tab. 1: Permitted fluids Oil according to ISO 67433, DIN bar 120 C / 10 C Type Coolant PS K033N/H(P).. K4803T(P) OW401.. OW941 K033N/H(P)B.. K4803T(P)B OW401B.. OW941B Tab. 2: Coolants Maximum permitted operating pressure TS Maximum and minimum permitted temperature Water or brine 10 bar 95 C / 10 C Seawater, water or brine For brine concentration see the BITZER SOFTWARE. Antifreeze NOTICE Risk of corrosion The coolant must not react aggressively with the pipe material of the pressure vessel or the material of the end covers. K033N/H(P).. K4803T(P) / OW401.. OW941 (Standard design) pipes: copper, end covers: grey cast iron K033N/H(P)B.. K4803T(P)B / OW401B.. OW941B (seawater design) pipes: coppernickelalloy, end covers: coated plastic As a free service, BITZER will examine the suitability of pipe materials if a water analysis is provided. The basis for the examination is the current status of knowledge. However, due to the complexity of the situation, no absolute guarantee can be given that materials will be corrosion proof. 3.1 Plant registration Condensers and oil coolers are pressure vessels according to the Pressure Equipment Directive 2014/68/ EU. For this reason the entire plant must be registered with the supervisory authority and duly approved in accordance with the local regulations. The category for the conformity assessment of each pressure vessel is listed in the following table. For the inspection before commissioning and recurring inspections, national regulations must be considered (for example the Industrial Safety Regulation (BetrSichV) in Germany). In non EU countries local regulations must be complied with. DB2005 5 3.2 Conformity Type Reservoir fluid capacity dm 3 (l) Category according to 2014/68/EU (PED) Fluid group 2 Category according to 2014/68/EU (PED) Fluid group 1 K033N/H(P)(B) 3.8 I II A2 K073H(P)(B) 3.4 I II A2 K123H(P)(B) 5.1 I II A2 K203H(P)(B) 11.8 II III B + D K283H(P)(B) 11.3 II III B + D K373H(P)(B) 14.5 II III B + D K573H(P)(B) 29.4 II III B + D K813H(P)(B) 27.7 II III B + D K1053H(P)(B) 40.0 III IV B + D K1353T(P)(B) 37.0 III IV B + D K1973T(P)(B) 76.0 III IV B + D K2923T(P)(B) 67.0 III IV B + D K3803T(P)(B) IV IV B + D K4803T(P)(B) 98.0 III IV B + D OW401(B) 10.5 II III B + D OW501(B) 14.0 II III B + D OW781(B) 18.0 II III B + D OW941(B) 24.0 II III B + D Tab. 3: Category and evaluation of conformity Conformity assessment depending on the module 4 Mounting 4.1 Transporting the pressure vessel Transport the pressure vessel screwed on a pallet. Lift it using the eyebolts or the upper fastening brackets if available. DANGER Suspended load Do not step under the machine 4.2 Installation location For outdoor installation, take suitable measures to protect the pressure vessel against corrosion (e.g. caused by seawater or aggressive atmosphere) and low outside temperatures. Consultation with BITZER is recommended. NOTICE Danger of freezing It is necessary to ensure that the temperature at the location is high enough above the freezing point of the coolant. 4.3 Plant design If a compressor is mounted on the condenser: NOTICE No vibrations should be transmitted to the condenser Do not use the condenser as loadbearing element Mount the compressor on the condenser only with damper elements The discharge line must be sufficiently elastic so that a minimum of vibrations and movement is transferred to the condenser. It may be necessary to fit flexible vibration dampers. 6 DB2005 Extreme pressure pulsations should be damped by fitting pulsation mufflers. 4.4 Refrigerant / oil side The whole system should be designed and operated in order to guarantee that the maximum operating pressure in the pressure vessel cannot be exceeded. Pressure relief valves are essential if it is to be expected that the maximum operating pressure will be exceeded due to external heat sources (e.g. fire), or if the entire refrigerant charge of the plant is more than 90% of the receiver volume at 20 C (charge capacity). Receiver volume means the volume between operationally lockable valves before and after a pressure vessel. In case of two vessels being mounted in series, it is the volume of both vessels and the connecting pipe. In these cases relief devices should be installed that lead the refrigerant or the oil to the lowpressure side of the plant (emission reduction). Safety switching device According to the local regulations, safety switching devices for pressure limiting must be provided. 4.5 Coolant side The coolant should contain neither solids nor gases: Any solids must be separated out using suitable filters. The presence of gas should be avoided through suitable design measures. Open circuits: The pressure vessel must not drain off while not in use. For this reason, fit either a coolant regulator at the coolant outlet of the pressure vessel, or a swanneck at the outlet. When using tapwater as a coolant, it is necessary to check whether the installation of a pipe disconnector is stipulated. When cooling with seawater: If, due to local conditions, the seawater in use can lead to scale or shell deposits, suitable filters should be fitted. This also serves to protect the pipe lines from shell deposits. 4.6 Delivery condition The pressure vessel is sealed in the delivery condition and filled with inert gas. The inert gas overpressure is bar. All Rotalock and flange connections are closed by blanking plates. These plates must be removed before commissioning. 4.7 Connecting the pipelines The pipe connections are suitable for pipes in all common dimensions in millimetres and inches. Brazed connections have stepped diameters. The pipe will immerge more or less depending on its dimensions. If not required the end with the largest diameter can be cutoff. DANGER Risk of bursting the pressure device due to mechanical stress. Serious injuries are possible. Connect the pipeline to the pressure unit without stress First relieve the excess pressure from the pressure vessel: Open the connections carefully. WARNING The pressure equipment is under pressure Serious injuries are possible Depressurise the pressure equipment Wear safety goggles Remove shutoff valves and/or solder connections. NOTICE Potential chemical reactions due to air penetration Install the open pressure vessel immediately in the system. Reseal the pressure vessel during installation breaks. NOTICE Do not overheat the shutoff valves Cool the valve body during and after the brazing operation. Maximum brazing temperature 700 C When brazing or welding, rinse the corresponding conductive parts with inert gas. DB2005 7 Clean the pipes Use only pipelines and system components which are clean and dry inside (free from slag, metal filings, rust and phosphate coatings) and which are delivered with an airtight seal Mounting the pressure relief valve Internal thread 3/818 NPTF: Screw in the pressure relief valve. External thread 1 1/412 UNF: Screw the pressure relief valve into the adaptor. Then fasten the adaptor at the pressure vessel with the union nut. Available adaptors see figure 1, page 8. 1/2 14 NPTF SW 12 SW 22 G 1/2 SW 22 1/2 14 NPTF G 1/2 SW 12 3/8 18 NPTF SW /4 12 UNF 1 1/4 12 UNF 1 1/4 12 UNF 1 1/4 12 UNF 1 1/4 12 UNF Fig. 1: Adaptors for the pressure relief valve Connection for pressure gauge Only use it for maintenance work, not during operation. Never connect a pressure limiter to it 8 DB2005 # & & & = % % % = 4.8 Connections for watercooled condensers and oil coolers $ % $ 7. = 6 2 = Fig. 2: K033N/H(P)(B).. K373H(P)(B) $ % $ 7. = 2 = I I 1 = = Fig. 3: K573H(P)(B) + K1053H(P) = 2 = I I 1 # $ % $ 7. = Fig. 4: K1053H(P)B + K1353T(P)(B).. K4803T(P)(B) DB2005 9 # $ $ % $ 7. = ' % $ 7. = Fig. 5: OW401(B).. OW941(B) Connection positions 2a 3a 3b 4a 4b 1 Refrigerant or oil inlet 2 Refrigerant or oil outlet Alternative refrigerant outlet (only for sea water version) 3 Coolant inlet 4 or 6 pass 2 or 3 pass 4 Coolant outlet 4 or 6 pass 2 or 3 pass 5 Coolant drain 6 Connection for pressure gauge 7 Connection for pressure relief valve Internal thread 3/818 NPTF, external thread 1 1/412 UNF 8 Sight glass 9 Oil drain 10 End cover, removable 11 Fixing rail, bottom 12 Fixing rail, top Tab. 4: Connection positions Dimensions (if specified) may have tolerances according to EN ISO 13920B. The legend applies to all watercooled BITZER condensers and oil coolers and contains connection positions that do not occur in every series. 10 DB2005 4.9 Connection dimensions for coolant pipes Screw the pipes in and make sure that the screwed nipples do not turn. Joining threads (3) and (4): Standard design internal thread (G..) or flange (DN..), seawaterresistant design nipple with internal thread (G..) or flange (DN..) Types K033N/H(P) (B) 1 Ø mm / inches 2 Ø mm / inches 2a 3 4 pass 3b 2 pass 4a 4 pass 4b 2 pass 5 9 Ø 12 / 1/2 10 3/8 G 1/2 2 x G 1/2 G 1/2 G 3/4 K073H(P)(B) 12 / 1/2 10 3/8 G 1/2 2 x G 1/2 G 1/2 G 3/4 K123H(P)(B) 16 / 5/8 12 1/2 (1 1/4 K203H(P)(B) 16 / 5/8 16 5/8 (1 1/4 K283H(P)(B) 22 / 7/8 22 7/8 (1 1/4 K373H(P)(B) 28 / 1 1/8 22 7/8 (1 3/4 K573H(P)(B) 35 / 1 3/8 (1 3/4 K813H(P)(B) 35 / 1 3/ /8 (1 3/4 K1053H(P) (B) K1353T(P) (B) K1973T(P) (B) K2923T(P) (B) K3803T(P) (B) K4803T(P) (B) 42 / 1 5/ /8 (1 3/4 42 / 1 5/ /8 (1 3/4 54 / 2 1/ /8 (2 1/4 54 / 2 1/ /8 (112 x 112) 76 / 3 1/ /8 (140 x 140) 76 / 3 1/ /8 (140 x 140) G 1/2 2 x G 1/2 G 1/2 G 3/4 G 3/4 2 x G 3/4 G 3/4 G 1 G 3/4 2 x G 3/4 G 3/4 G 1 G 3/4 2 x G 3/4 G 1 1/4 G 1 G 1 1/4 G 2 G 3/4 G 2 G 1/4 G 1 1/4 G 2 G 1 1/4 G 2 G 1/4 G 1 1/4 G 2 G 1 1/4 G 2 G 1/4 G 1 1/4 G 2 G 1 1/4 G 2 G 1/4 G 2 DN 65 G 2 DN 65 G 1/4 G 2 DN 65 G 2 DN 65 G 1/4 DN 80 DN 100 DN 80 DN 100 G 1/4 DN 80 DN 100 DN 80 DN 100 G 1/4 OW401(B) 22 / 7/8 22 7/8 G 3/4 2 x G 3/4 G 3/4 G 1 10 OW501(B) 22 / 7/8 22 7/8 G 3/4 2 X G 3/4 G 3/4 G pass 3 pass 6 pass 3 pass OW781(B) 28 / 1 1/ /8 G 1 2 x G 1 G 1 G 1 1/2 G 1/4 OW941(B) 35 / 1 3/ /8 G 1 2 x G 1 G 1 G 1 1/2 G 1/4 Tab. 5: Connection dimensions for coolant pipes mm DB 4.10 Coolant passes Depending on the end covers, the coolant passes the pressure vessel 2, 3, 4, or 6 times. K573H(B).. K4803T(B): 4pass end covers are mounted as standard. Alternative: 2pass end cover At all other devices it can be chosen between 4 or 2 and 6 or 3 passes at the same end cover. This depends the positions to which the coolant pipes are mounted. DANGER Risk of bursting due to excessive pressure The pressure applied during the test must never exceed the maximum permitted values Test pressure: 1.1fold of the maximum allowable pressure (see name plate). Make a distinction between the highpressure and lowpressure sides 5.2 Charging refrigerant Use only allowed refrigerants, see chapter Application ranges, page 5. Fig. 6: K033N/H(P)(B).. K373H(P)(B): 4 or 2 passes at the same cover is possible depending on the connection, OW781(B).. OW941(B): 6 or 3 passes at the same cover is possible depending on the connection DANGER Risk of bursting of components and pipelines due to hydraulic excess pressure while feeding liquid. Serious injuries are possible. Avoid overcharging the system with refrigerant under all circumstances Fig. 7: K573H(P)(B).. K4803T(P)(B): different end covers for 4 or 2 passes Fig. 8: OW781(B).. OW941(B): 6 or 3 passes at the same cover is possible depending on connection 5 Commissioning The pressure equipment was tested in the factory as a single unit. After installation, the tightness of the connections and of the piping system must be tested again. 5.1 Checking tightness Check the refrigerant circuit (assembly) for tightness, as a whole or in parts, according to EN 3782 (or other applicable equivalent safety standards). For this, create an overpressure, preferably using dried nitrogen. WARNING Risk of bursting due to counterfeit refrigerants Serious injuries are possible Purchase refrigerants only from reputable manufacturers and reliable distributors NOTICE Risk of wet operation during liquid feeding Measure out extremely precise quantities Keep the oil temperature above 40 C. Before charging with refrigerant: Put the coolant circuit into operation. Otherwise the coolant might freeze. Check the oil level in the compressor. Charge condenser or receiver, on systems with flooded evaporator, maybe also the evaporator directly with liquid refrigerant. Blends must be taken out of the charging cylinder as a solid liquid. After commissioning, it may be necessary to add refrigerant: While the compressor is running, charge with refrigerant on the suction side, preferably at the evaporator inlet. 5.3 Coolant The maximum permitted coolant volume flow is indicated in the BITZER SOFTWARE. This value refers to clean and gasfree water with a flow velocity of 2.5 m/s. The pressure vessel can be operated with water containing a slight amount of solids or gases with a flow 12 DB2005 speed of up to about 1.5 m/s. However, positive experience must first have been gained from comparable applications. Pressure test / test operation A pressure test should be carried out with a closed coolant circuit (maximum operating pressure: 10 bar). With an open circuit a short test run is sufficient. Corrosion If the plant is not operated for a long time after pressure test or test run, the pipes must be protected against corrosion by: pressure test with clean water or dry gas, test run with clean water. If this is not possible, the pipes must be cleaned: Flush pipes and dry them or fill them with clean water. Runningin time with open cooling circuits (corrosion protection) Within the first months, coolant should constantly flow through the pressure vessel so that a protective layer can be built up. During the shutoff periods, a low flow rate is sufficient. 6 Operation The pressure equipment must be checked at regular intervals by qualified and authorised staff. The test intervals depend on the mode of operation. They must be defined by the system operator. 6.1 Standstill NOTICE Risk of corrosion During shutoff periods, the coolant side of the pressure vessel must be protected against corrosion This applies especially with aggressive coolants, e.g. brackish water, water containing solids or liable to biofouling. Any contamination of the coolant pipe system should be removed before any long shutoff periods. This applies especially in cases of organic materials and shell deposits. With aggressive or corrosive coolants, the pipe system must be cleaned and dried or filled with clean water. 7 Maintenance The pressure vessels are designed for a maintenancefree operation. However, it is advisable to clean the coolant pipes regularly. The contamination depends directly on the quality of the coolant used. Materials in the coolant in dissolved or solid form can deposit in the pipes, e.g. lime, sand, algae or silt. Organic materials such as algae can build up local elements. In the worst case, this can lead to pitting. With seawater cooling, shells can also grow on the insides of the pipes. 7.1 Cleaning WARNING The pressure equipment is under pressure Serious injuries are possible Depressurise the pressure equipment Wear safety goggles WARNING Coolant can burn skin and eyes Wear safety goggles Suitable cleaning methods and cleaning intervals depend on the type and extent of contamination. NOTICE Risk of corrosion Cleaning agent must not re
Related Search
Similar documents
View more...
We Need Your Support
Thank you for visiting our website and your interest in our free products and services. We are nonprofit website to share and download documents. To the running of this website, we need your help to support us.

Thanks to everyone for your continued support.

No, Thanks