Sabroe ECRE Installation Operation and Maintenance Guide

Brand: Sabroe

Model: ECRE

Type: Installation Operation and Maintenance Guide

ECRE cascade cooler

Installation, operation and maintenance manual EN

Vessel manual – ECRE cascade cooler

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Cascade cooler, design type ECRE

The vessel is a horizontal cascade cooler of the “plate and shell” type. It is equipped with an in-

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

HeatPAC, PAC and DualPAC chillers.

The cascade cooler is a fully welded plate heat exchanger where plates are welded together

into cassettes. The refrigerant from the primary circuit (heat pump) evaporates between the

two welded plates which make up the cassettes. The refrigerant droplets are separated from

the vapour in the separator room above the plates.

Function

The discharge gas from the secondary circuit (refrigeration plant) is cooled and condensed in-

side the cassettes.

The upper connection (DN100) is the discharge gas inlet and the bottom connection (DN100)

is the liquid outlet. A cascade cooler minimises the refrigerant charge and eliminates problems

when mixing different oil types.

There is very little volume on the condensing side, which makes the cascade evaporator very

sensitive to non-condensable gasses.

A by-pass with a 2 mm orifice must therefore be installed between the liquid outlet connection

and the low-pressure side of the refrigerant plant. Alternatively, an automatic purge system for

non-condensable gasses can be installed.

The cascade cooler has one or two sets of secondary refrigerant 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 = –40[°C] | Tmax =150 [°C]1

- Secondary side Tmin = –40[°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]

The pressure of your specific vessel is stated on

the name plate sketch delivered with this manual.

- Plate side

Normal version

High pressure version

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

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

The pressure of your specific vessel is stated on

the name plate sketch delivered with this manual.

Function Flooded evaporator (outside)

Condensation (inside)

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

sponding to a maximum dynamic viscosity of ν = 3000 [cSt]. E.g. PAO68,ν=3000[cSt] = –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 C 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

EC Evaporating outside / Condensing inside

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Dimensions

ECRE cascade cooler

1 Mixture inlet, primary side DN 40

2 Gas outlet, primary side DN 125

3, 3a Discharge inlet, secondary side DN 100

4, 4a Liquid outlet, secondary side DN 100

5Safety valve DN 25

6 Oil return DN 25

7 High-level switch G 1

8 Sight glass mm Ø 45/90

A Vessel length mm 300–1800

B Vessel diameter mm Ø 703

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Dimensions

Pos. no. Flange no. Description

1 2342.1002 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 2342.275 Flange welding, DN 100

3a, 4a 1344.388 Flange blind, DN 100

51344.122 Flange DN 25

6 1344.122 Flange DN 25

8 1226.008 Fusite

Pos. no. Gasket no. Description

1 1331.566 O-ring 66.27x3.53

2 1331.588 O-ring 164.69x3.53

3 1331.703 O-ring 126.59 x 3.53

4 1331.703 O-ring 126.59 x 3.53

52356.258 Gasket 39/29x2

6 2356.258 Gasket 39/29x2 2pcs.

8 1331.543 Ring 52x2

Pos. no. Bolt no. Description

1 1424.1009 M16x2x45 4 pcs.

2 1424.320 M24x3x50 4 pcs.

3 1424.1009 M16x2x45 8 pcs.

4 1424.1009 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

protection during normal operating conditions. If, however, the vessel is going to be stored out-

side, 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

transportation 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, in-

stallation 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

absorb external vibrations.

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

expose 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

training 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 fail-

ure. To minimise the risk, all external bolted

joints must be preloaded again after installa-

tion. When the vessel has reached its operat-

ing temperature, 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 recom-

mends an inspection interval of one month during the first six months of operation. A mainte-

nance 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 op-

eration 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 dis-

assemble the bolts, when the vessel is pressurised. Failure to comply with this can lead to se-

vere personal injury.

Disassembly

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

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

START

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Gasket connections

drained, depressurised and thoroughly vented. Any aggressive substances that are dangerous

to personnel must be neutralised or removed.

Gasket connections

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

Excessive scratches and dents on the contact surfaces or reuse of any gasket materials will in-

crease 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.com

Version 3

Sabroe ECRE Installation Operation and Maintenance Guide

Brand: Sabroe

Model: ECRE

Type: Installation Operation and Maintenance Guide

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Sabroe ECRE Installation Operation and Maintenance Guide

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