Sabroe ESRE Installation Operation and Maintenance Guide

Brand: Sabroe

Model: ESRE

Type: Installation Operation and Maintenance Guide

ESRE evaporator

Installation, operation and maintenance manual

Vessel manual - ESRE evaporator

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Evaporator, design type ESRE

The vessel is a horizontal evaporator of the “plate and shell” type. It is equipped with an internal

liquid separator and finalised with welded heads. The vessel is used as a component for ChillPAC,

HeatPAC, PAC and ComPAC.

Function

The evaporator is a fully welded plate heat exchanger where plates are welded together into cas-

settes. The refrigerant evaporates between the two welded plates, which make up the cassettes,

and water/brine is cooled in the channels inside the cassettes. The refrigerant droplets are sepa-

rated from the vapour in the separator room above the plates.

The evaporator has one or two sets of brine connections depending on size and operating

conditions.

A sight glass is mounted at the end cover.

Note: The refrigerant liquid level must never be visible in the inspection glass.

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Application

Refrigerant R717, (R507, R134a, R22, R404 or R410A)

Ambient temperature 0 – 55 [°C]

Capacity 55 – 1800 [kW]

Temperature sides

- Evaporator Tmin = –30[°C] | Tmax =150 [°C]1

- Secondary side Tmin = –30[°C] | Tmax =150 [°C]

Pressure

- Shell side

Normal version

High pressure version

Pmax = 22.0 [bar ] | Pmin = –1.0 [bar]

Pmax = 26.0 [bar ] | Pmin = –1.0 [bar]

- Plate side Pmax = 16.0 [bar ] | Pmin = –1.0 [bar]

Heat transfer fluid Water and glycol-based fluids.

Function Flooded evaporator system.

1The operating temperature must not be less than the compressor oil temperature corresponding

to a maximum kinematic viscosity of ν= 20,000 [cSt]. E.g. PAO 100,ν=20,000 = -25 [°C]

Designation code

Materials

Description Material

Shell P265GH EN10028-2

End cover P295GH EN10028-2

Plate stack AISI 316L DIN 17440

Connections P265GH EN 10028-2 / S235JRG2 EN10025-2

E S R E 7 0 0 9 0 2 2 Number of passes on brine side

090 Number of cassettes in plate stack

70 Nominal element diameter [cm].

E Type designation

R Stainless steel plates

ES Evaporating outside with built-in separator

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Dimensions

ESRE evaporator

1Mixture inlet DN 40

2Gas outlet DN 125

3, 3a Brine outlet DN 100 DIN 2633 C / DIN 2527 B

4, 4a Brine inlet DN 100 DIN 2633 C / DIN 2527 B

5Safety valve DN 25

6Oil return DN 25

7High-level switch G 1

8 Sight glass mm Ø 45/90

AVessel length mm 300–1800

BVessel diameter mm Ø 703

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Dimensions

Pos. no. Flange no. Description

12342.1002 Flange DN 40

2 2342.260 Flange DN 65

2 2342.261 Flange DN 80

2 2342.1011 Flange DN 100

2 2342.261 Flange DN 125

3, 4 1344.184 Flange welding, DN 100

3a, 4a Flange blind, DN 100

51344.122 Flange DN 25

6 1344.122 Flange DN 25

8 1226.008 Fusite

Pos. no. Gasket no. Description

11331.566 O-ring 66.27x3.53

2 1331.588 O-ring 164.69x3.53

3 2357.016 Gasket 162/115x2

42357.016 Gasket 162/115x2

52356.258 Gasket 39/29x2

6 2356.258 Gasket 39/29x2 2pcs.

8 1331.543 Ring 52x2

Pos. no. Bolt no. Description

11424.1009 M16x2x45 4 pcs.

2 1424.320 M24x3x50 4 pcs.

3 1424.1009 M16x2x45 8 pcs.

41424.1009 M16x2x45 8 pcs.

51424.332 M14x2x45 2 pcs.

6 1424.332 M14x2x45 4 pcs.

8 1424.190 M10x1.5x20 6 pcs.

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Shipping

The vessel is delivered primed and with blinded connections. This ensures sufficient surface pro-

tection during normal operating conditions. If, however, the vessel is going to be stored outside,

the surface must be protected against corrosion. If operation is disengaged and vessel storage is

needed, preventive measures must be taken to eliminate any contamination through open ports.

Mobility

The vessel may only be relocated in an empty state. Any excessive impact suffered during trans-

portation or relocation may damage the vessel substantially. If the vessel should be craned on its

own, slings must be used, and they must be strapped around the vessel arch.

Installation

Safety on site and the safety of personnel must be in compliance with the EN 378-3 standard.

Post-transport inspections must be carried out on arrival. In case of damage to the vessel, instal-

lation must be aborted immediately.

When relocating the vessel on site, make sure to leave sufficient space for inspection, mainte-

nance and emergency escape routes.

The bedplate or foundation must be robust to withstand the strains inflicted by the vessel and ab-

sorb external vibrations.

During installation, all vessel ports and openings must be protected against impurities. Do not ex-

pose any ports or openings until their services are needed.

Before the vessel is taken into service, make sure that the entire system is clean of impurities and

foreign substances. Piping connections must not induce further mechanical stress in the vessel,

under any circumstances. Vibrations should be minimised by using vibration dampers or the like.

Welding or other externally induced thermal stress is not permitted. Protective measures must be

taken to safeguard the vessel from exceeding the maximum allowable pressure and temperature.

If the vessel is going to be installed in a harsh environment, further corrosive protection must be

applied to all exposed areas.

Safety equipment

The site operator is responsible for all personal and site related safety equipment needed to safely

relocate, install and operate the vessel. Safety equipment is not part of the delivery. The vessel

manufacturer cannot be held liable for any defective or missing safety equipment.

Initial start-up and operation

Upon commissioning of the vessel, it is the site manager’s responsibility to ensure that all rele-

vant personnel and staff are briefed and trained in compliance with EN 378-3. This includes train-

ing in maintenance of the vessel construction and operation of the vessel.

Refrigerant charging and draining must be carried out according to the instructions in the unit

documentation. Always perform leak testing before any charging.

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Bolted connections

Yielding may occur over time in the gasket

joints, thus enhancing the risk of gasket failure.

To minimise the risk, all external bolted joints

must be preloaded again after installation.

When the vessel has reached its operating tem-

perature, the preloading procedure must be

repeated.

All bolts are preloaded in a diametrically stag-

gered pattern, see Figure 1. The bolts are pre-

loaded to approximately 90 percent of the

yielding strength relative to the specific bolt

quality (i.e. 8.8, 10.9, 12.9).

Fig. 1: Diametrically staggered bolt preload pattern.

Metric thread (ISO 8.8)

M 4 5 6 8 10 12 14 16 18 20 22 24 27

[Nm] 2.7 5.2 9.2 22 40 69 108 147 225 295 375 510 670

[Kpm] 0.28 0.53 0.94 2.2 4.1 7.0 11 15 23 30 38 52 68

[ft.lbf.] 2.1 3.9 6.8 16 30 50 80 110 170 220 270 370 490

Metric thread (ISO 12.9)

M 4 5 6 8 10 12 14 16 18 20 22 24 27

[Nm] 4.1 7.6 14 31 60 98 157 225 335 430 540 745 980

[Kpm] 0.42 0.78 1.4 3.2 6.1 10 16 23 34 44 55 76 100

[ft.lbf.] 3.0 5.7 10 23 44 75 120 160 240 320 400 550 720

Maintenance

Competent personnel must inspect the vessel regularly. Johnson Controls Denmark recommends

an inspection interval of one month during the first six months of operation. A maintenance plan

must then be made based on the service needed during the first six months. The maintenance

plan must meet the requirements of EN 378-2 at all times.

If any weakening of the vessel is detected (e. g. corrosion, erosion, dents or cracks) the vessel

must be taken out of operation immediately. The circumstances and immediate danger posed by

the defect(s) must be assessed by a third party, and the third party must decide whether opera-

tion with the vessel can continue.

For further information on water quality in secondary water systems, please see the guide Water

quality in secondary systems – Guidelines to avoid corrosion and scaling in heat exchangers.

Danger!

Do not, under any circumstances, decrease the bolt tension of the connections, and never disas-

semble the bolts, when the vessel is pressurised. Failure to comply with this can lead to severe

personal injury.

Disassembly

Some vessel types can be disassembled for cleaning and inspection purposes. Before initialising

disassembly, the operator must make absolutely certain that the entire vessel has been drained,

depressurised and thoroughly vented. Any aggressive substances that are dangerous to person-

nel must be neutralised or removed.

START

Vessel manual - ESRE evaporator

0008941 en 2020.12 9/9

Gasket connections

To ensure gas tight connections, the gasket contact surfaces must be clean of any impurities. Ex-

cessive scratches and dents on the contact surfaces or reuse of any gasket materials will increase

the risk of leakage. Always use a fresh set of gaskets when reassembling any gas tight

connections.

Spare parts and replacements

Please refer to the manufacturer for further information about spare parts.

Final disposal of the vessel

To make reusing materials from the vessel easy, the variety of material is kept to a minimum. The

vessel contains no asbestos, rare-earth materials, mercury or any other heavy metal in any form.

After depressurising, thorough bleeding and correct disposal of the refrigerant the vessel can be

scrapped or used as a cast component.

Johnson Controls Denmark ApS

SABROE Factory

Christian X's Vej 201 ∙ 8270 Højbjerg

Denmark

Phone +45 87 36 70 00

www.sabroe.comVersion 4

Sabroe ESRE Installation Operation and Maintenance Guide

Brand: Sabroe

Model: ESRE

Type: Installation Operation and Maintenance Guide

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Sabroe ESRE Installation Operation and Maintenance Guide

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