Sabroe CONC/COKC/COSB/CORB/COTB Installation Operation and Maintenance Guide

Brand
Sabroe
Model
CONC/COKC/COSB/CORB/COTB
Type
Installation Operation and Maintenance Guide
CONC, COKC, COSB, CORB and COTB
Condensers
Installation, operation and maintenance manual
en
Vessel manual - CONC, COKC, COSB, CORB and COTB condensers
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CONC, COKC, COSB, CORB and COTB
Installation, operation and maintenance manual for condenser
Design
In principle the condenser consists of a cylindrical shell with a steel tube insert. The condenser
has inlet and outlet branches in the shell, the water inlet and outlet are positioned in one of the
end covers. The end covers are welded. The tube insert consists of two tube plates into which a
number of tubes are fit.
Function
The condensers are designed for condensing refrigerant. In the gas phase, the refrigerant is led
into the top of the condenser and out at the bottom in the liquid phase. The cooling water is led
through the connection at the bottom and through several passes. Depending on the choice of
condensate outlet form, the pressure equalizing nozzle may be used at the top of the condenser.
r g e
e /
o u t l e t
/
o u t l e t
W a t e r i n l e t
W a t e r o u t l e t
Discharge gas inlet
Condensate/refrigerant outlet
Condensate/refrigerant outlet
Water outlet
Water inlet
C O
K
C
80
38
02
Number of passes on water side
Nominal element length (dm)
Nominal element diameter in
cm : up to ø 1000 mm
dm : from ø 1000 mm
C: Enhanced shaped tubes (SfCu and CuNi)
B: Smooth tubes (steel and stainless steel)
G: Smooth tubes ø10 (steel and stainless steel)
K: Copper tubes
N: Copper-nickle tubes
S: Steel tubes
R: Stainless steel tubes
T: Titanium tubes
CO: Condensation outside the tube
Designation code
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Application
A condenser is designed for condensing refrigerant. The choice of condenser is dependent on the
type of refrigerant selected and quality of cooling water basically to avoid corrosion on the water
side of the condenser.
Refrigerant
Refrigerant type Suitable condenser type
Ammonia COSB, CORB, COTB
HCFC, HFC All types
Other refrigerants Contact Johnson Controls
Type and size
By choosing COKC or CONC instead of COSB, COTB or CORB in connection with HCFC and HFC,
the external measurements can be minimised.
The number of pass variants with the same diameter and length makes it possible to choose the
most efficient condenser at a given required performance.
Cooling water
The correct combination of material, cooling water, fouling and velocity are very important for a
satisfactory performance.
For further details, please consult technical reference books. A general summary, however, is giv-
en here:
Primarily the condenser is designed for recirculating cooling systems, including closed circuit (no
oxygen/air admittance) and systems with open cooling towers.
The necessary corrosion inhibitors must be added with respect to the latter. For systems with an
open cooling tower, depending on permitted fouling, it is recommended to use treated water for
make-up.
Technical description
COKC CONC COSB CORB/COTB
Secondary refrigerant Water Sea water Treated water Any water
Primary refrigerant R22, R134a, R404A, R507 R717
Shell covers (welded) Generally, P235GH, P265GH or similar
Covers (casted) G-CuAl 10 Ni DIN 1714, GGG 40 DIN 1693
Connections Generally, P235GH, P265GH or similar
Painting Min. 30 u primer
Cover gaskets EPDM
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Type Tube types Dimensions Material (tube) Material
(tube plate)
Corrosion
plugs
COKC Enhanced shaped
inside/outside
Diameter
19x0.7 (min.)
Sf-Cu
DIN 1787 P265GH None
CONC CuNiMOFe
DIN 17664
P265GH coated
with CuNi (90/10) Zink#
COSB Smooth longitudi-
nally welded
Diameter
19x1.5
st 37.0 DIN 1626
E235+N
EN 10305–4
P265GH None
COTB Smooth Diameter
19x0.7 (min.)
Titanium SB-338
Grade 2
P265GH coated
with titanium Zink#
CORB
Smooth seamless
Diameter
19x0.9 AISI316 CrNiMo 17-12-2
Zink#
CORB Diameter
19x1.0 SAF 2205 Cr Ni Mo 22-5-3
CORB Diameter
19x0.9 SAF 2507 Cr Ni Mo 25-7-4
# Excluding type 16, 2 and 4-pass and end-out.
Selection of condensers
The selection of condensers must be based on the following operating conditions.
Medium
shell side HCFC/HFC Ammonia
Secondary
refrigerant
Treated cooling
tower water
and closed
systems
Sea
water
Treated cooling
tower water
and closed
systems
Untreated
cooling tower
water
Sea
water
Sea
water
Type COKC CONC COSB CORB
AISI316
CORB
SAF
2205
COTB
and
CORB
SAF
2507
Max. Cl content, ppm
150
(Max. temp.
30°C)
1000
Ph 8-10 8-10
Max. sea water
temperature 35°C 40°C
Gas inlet max.
temperature 130°C
Max. water velocity m/
s inside tube 2.3 a) 2.3 a) 2.5 2.5 4.0 4.0
Min. water velocity m/s
inside tube 1.0 b) 1.0 1.0 b) 1.0 1.5 1.5
a) Max. allowable velocities. Must be reduced if the secondary refrigerant is highly polluted.
b) Min. velocity for closed systems, 0.3 m/s.
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Cooling tower water and closed systems
• Necessary corrosion inhibitors must be added. For systems with an open cooling tower,
we recommend using treated water for make-up, depending on permitted fouling factors.
• For refrigeration systems with cooling tower water of varying and/or less favourable qual-
ity, we recommend type CORB or CONC.
Sea water
Use CONC CuNi, COTB titanium or CORB with SAF 2507.
The stainless steel materials in SAF 2205 and SAF 2507 belong to the Ferrit-Austenitic steel types,
which, compared to the traditional Austenitic steel (AISI 304, AISI 316 etc.), are far more corro-
sion resistant in a chloride environment.
To ensure the corrosion resistance of the materials, it is important to observe the minimum veloc-
ity at full load as well as part load if there is risk of considerable fouling, in order to observe the
stated max./min. temperatures and the chloride content (Cl).
COMP 1 - Computer calculation programme
To be able to select the correct condenser for your specific operating conditions, we recommend
using the SABROE calculation program, COMP 1.
To get the highest heat transfer coefficient and the lowest fouling, adjust the water flow to give a
tube velocity equal to (or slightly lower than) the max. velocity.
When a condenser with a higher capacity is needed, it is better to increase the length than in-
creasing the diameter. This will be the most economic solution.
Fouling
To be able to select the correct condenser, the fouling in the cooling system must be known. The
fouling factors experienced by TEMA and Johnson Controls Denmark are shown below:
Types of water Fouling
Natural water
Sea water 0.0001 units
Brackish water 0.0002 units
River water:
Minimum
Average
Muddy or silty
Hard (above 0.25 g/l)
0.0002
0.0004
0.0004
0.00005
units
units
units
units
City or well water
(such as great lakes) 0.0002 units
Cooling tower and artificial spray pond,
Treated make-up water 0.0002 units
Untreated water 0.0005 units
The fouling factor is very important for a proper selection of condenser. Too high fouling factors
result in too high prices. Too low fouling factors result in too low capacities, meaning increased
condensing temperature.
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Element dimensions – COKC and CONC
Elements for COKC and CONC
DNi = Inlet connection (not illustrated)
Li = Inlet connection
DNo = Outlet connection (not illustrated)
Lo = Outlet connection
Size DNi Li DNo Lo Size DNi Li DNo Lo
1615 50 130 32 120 7031 150 410 200 410
161S 50 130 32 120 7038 200 410 200 410
1623 40 130 32 120 7050 200 410 200 410
1627 40 130 40 130 7060 150 410 200 410
2115 50 150 32 150 8031 200 470 20G 470
2119 65 160 40 130 8038 200 470 250 450
2123 50 150 50 170 8050 200 470 250 450
2127 50 150 50 170 8060 200 470 250 450
2715 65 190 50 180 1031 250 550 250 550
2719 80 190 50 180 1038 250 550 300 560
2723 65 190 65 190 1050 250 550 300 560
2727 65 190 55 190 1060 250 550 300 560
2731 65 190 65 190 1238 300 660 300 660
3219 80 220 65 210 1250 300 660 300 660
3123 80 220 65 210 1260 300 660 300 660
3227 80 220 80 220 1438 400 760 300 760
3231 80 220 80 220 1450 400 760 300 760
3238 80 220 100 220 1460 400 760 300 760
4119 100 270 80 270
4123 80 270 100 270
4127 100 270 100 270
4131 100 270 100 270
4133 100 270 125 270
4150 100 270 125 270
4160 100 270 125 270
5023 100 310 125 310
5027 125 310 125 310
5031 125 310 125 310
5038 125 310 150 320
5050 125 310 200 320
5060 125 310 150 320
6023 125 360 150 370
6027 125 360 150 370
6031 150 370 T50 370
6038 150 370 200 370
6050 150 370 200 370
6060 150 370 200 370
ISO228
G 3/4ISO228
G 3/4
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Unit size 15 19 23 27 31 38 50 60
Unit length
(excl. covers) A 1582 1962 2342 2722 3102 3862 5000 6000
Inlet connection
spacing C 0 0 760 760 1520 2280 1520 1520
Inlet connections no. 1 1 2 2 2 2 3 4
Outlet connection
spacing B 1300 1660 1750 1750 1750 2280 3040 2280
Outlet connections
no. 2 2 2 2 2 2 2 3
Support spacing R 450 650 650 650 1050 1400 1900 1900
Diameter size 16 21 27 32 41 50 60 70 80 10 12 14
Shell diameter D1 168 219 273 324 419 509 610 700 813 1016 1220 1420
Shell plate diameter
D2 270 310 370 425 550 650 750 810 915 1138 1340 1562
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Element dimensions – CORB, COTB and COSB
DNi = Inlet connection (not illustrated)
Li = Inlet connection
DNo = Outlet connection (not illustrated)
Lo = Outlet connection
Size DNi Li DNo Lo Size DNi Li DNo Lo
2115 32 150 32 150 1050 200 570 150 570
2120 32 150 32 150 1060 200 570 150 570
2125 40 150 32 150 1240 200 670 150 670
2720 40 180 32 180 1250 200 670 200 670
2725 50 180 40 180 1260 250 650 200 670
2730 50 180 40 180 1440 250 750 200 770
3220 50 200 40 200 1450 250 750 200 770
3225 65 210 50 200 1460 300 760 200 770
3230 65 210 50 200
3240 50 200 50 200
4120 80 270 50 250
4125 80 270 50 250
4130 80 270 65 260
4140 65 260 65 260
4150 80 270 80 270
4160 50 270 80 270
5025 100 310 100 310
5030 100 310 100 310
5040 80 310 80 310
5050 100 310 100 310
5060 100 310 100 310
6025 125 360 80 360
6030 125 360 80 360
6040 100 360 100 360
6050 125 360 100 360
6060 125 360 100 360
7030 150 410 150 410
7040 125 410 125 410
7050 125 410 125 410
7060 150 410 150 410
8030 150 470 100 460
8040 125 470 125 470
8150 150 470 125 470
8160 150 470 150 470
1030 200 570 125 570
1040 150 570 150 570
Unit size 15 20 25 30 40 50 60
Unit length
(excl. covers) A 1495 1995 2495 2995 3995 4995 5995
Inlet connection
spacing C 0 0 0 0 2280 2500 3040
Inlet connections no. 1 1 1 1 2 2 2
Outlet connection
spacing B 1300 1660 1750 1750 2280 3040 4000
Outlet connections
no. 2 2 2 2 2 2 3
Support spacing R 450 650 650 1150 1625 2000 2500
Nominal diameter 16 21 27 32 41 50 60 70 80 10 12 14
Shell diameter D1 168 219 273 324 419 509 610 700 813 1016 1220 1420
Shell plate diameter
D2 270 310 370 425 550 650 750 810 915 1138 1340 1562
ISO228
G 3/4
ISO228
G 3/4
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Cover dimensions with end-out connections
Without corrosion plugs - only 1-pass size 16-14
Nominal
diameter 16 21 27 32 41 50 60 70 80 10 12 14
Cover length 150 170 198 225 370 526 528 635 638 710 845 990
Connection
DN 100 125 150 200 250 300 #400 #500 #500 #700 #800 #900
# Connections may be optimised according to actual running conditions. This means that the cus-
tomer can specify the required connection size on the questionnaire.
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Cover dimensions with side-out connections
With or without corrosion plugs
Size 16-14
1-pass covers
Nominal
diameter 16 21 27 32 41 50 60 70 80 10 12 14
Cover
length L 240 280 320 410 490 570 730 870 870 1170 1360 1520
Connection ref. DN 100 125 150 200 250 300 #400 #500 #500 #700 #800 #900
Length M 100 125 150 200 250 300 400 500 500 700 800 900
Length G 210 240 270 310 370 410 470 520 580 700 810 920
Total depth P 399 452 512 587 717 799 912 1030 1140 1362 1577 1792
Total depth Q 270 310 370 425 550 650 750 880 980 1180 1390 1600
2-4-pass covers
Nominal
diameter 16 21 27 32 41 50 60 70 80 10 12 14
Cover
length L 195 234 255 290 330 385 450 570 670 870 1030 1170
Cover
length K 80 116 144 175 210 260 310 310 370 470 580 670
Connection
sec. ref. DN 50 80 100 125 150 200 250 300 #350 #500 #600 #700
Length M 115 134 145 165 1B5 215 245 300 350 500 600 700
Length N 85 105 112 130 150 200 200 -----
Length Q 167 197 227 256 322 377 432 520 580 700 810 920
Total depth P 349 404 466 468 652 766 880 -----
Total height Q 335 410 444 510 670 810 900 1024 1134 1360 1577 1792
General for connections
All connections are delivered with flanges and counterflanges, including gaskets and bolts
- counterflange welding connection according to DIN 2448.
For connections <= DN 250 DIN 2633 (PN 16) form C.
# Connections may be optimised according to actual running conditions. This means that the cus-
tomer can specify the required connection size on the questionnaire.
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2-4 pass, size 16-32
2-4 pass, size 41-60
2-4 pass, size 70-14
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Supports
S, Saddle plate
Nominal diameter 16 21 27 32 41 50 60 70 80 10 12 14
Length S 85 90 95 110 120 125 13S 140 145 175 190 205
Height T 91 116 143 168 218 263 313 358 417 520 625 728
Depth U 156 200 253 295 387 468 561 641 745 931 1131 1302
Angle V 138 133 136 132 135 134 134 133 133 133 136 133
U, Foot
Nominal diameter 16 21 27 32 41 50 60 70 #80 #10 #12 #14
Length S 65 70 75 90 100 110 110 120 120 150 150 150
Height T 115 133 152 241 279 315 356 420 480 610 730 850
Depth U 140 180 240 280 350 400 400 450 550 700 800 950
Bolts V 70 90 12D 140 170 200 200 300 400 550 650 800
Bolt hole 0 22 22 22 22 22 22 22 25 25 25 25 25
# These U-consoles are solid.
R, Foot
Nominal diameter 16 21 27 32 41 50 60 70 80 10 12 14
Length S 80 80 80 100 100 120 120 120 150 175 175 175
Height T 225 250 280 350 435 525 630 680 735 835 935 1035
Depth U 278 328 384 449 569 680 816 925 1025 1237 1450 1650
Bote V 178 228 284 329 449 560 641 750 850 1007 1220 1420
Free height W 100 100 100 130 150 180 205 205 205 205 205 205
Depth - foot X 100 100 100 120 120 120 175 175 175 230 230 230
Bolt hole O 25 25 25 25 25 25 25 25 25 25 25 25
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Bolted connections
Normal relaxing of the gasketed joints may occur in the interval between testing at the manufac-
turer’s and installation on site. Therefore, all external bolted joints may require retightening after
installation and, if necessary, after the vessel has reached operation temperature. It is important
that all bolted joints are tightened uniformly and in a diametrically staggered pattern.
Bolts must be tightened evenly with a torque wrench.
START
Temporary seal cap.
Std. thickness
DIN 2448
OD
Cut off = Standard marking line
X Cut off = SCH 40
Y Cut off = SCH 80
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Connection
nominal
diameter
Connection
external
diameter
OD
Standard
connection
thickness
DIN 2448
Connection possibilities
DN inch ANSI SCH40
x cut off
ANSI SCH80
y cut off
15 1/2 21.3 2.3 7 11
20 3/4 26.9 2.3 7 11
25 1 33.7 2.6 8 13
32 1 1/4 42.4 2.6 9 14
40 1 1/2 48.3 2.6 9 15
50 2 60.3 2.9 9 16
65 2 1/2 76.1 2.9 20 22
80 3 88.9 3.2 14 23
100 4114.3 3.6 15 25
125 5 139.7 4 15 27
150 6 168.3 4.5 15 31
200 8 219.1 6.3 15 31
Type
COxx
Bolts
End cover Torque
16 M14 37 Nm
21 M14 38 Nm
27 M16 45 Nm
32 M16 63 Nm
41 M20 95 Nm
50 M22 122 Nm
60 M22 138 Nm
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Installation
On delivery
On delivery, the condenser is primed with temporary seal caps. Before storing the condenser, the
customer should check the caps to avoid condensed moisture in the vessel and check for trans-
port damage. Johnson Controls recommends top coating the condenser before storing or
installation.
Installation
The condenser must be mounted horizontally in either saddle plates or consoles.
Note:
• The foundation must be stable and free of extraordinary vibrations.
• Forces and moments of the external tube connections must not damage the condenser.
• The condenser installation must enable easy mechanical cleaning and replacement of
tubes.
• The condenser must be secured against excess pressure to avoid exceeding the design
pressure (see name plate).
• If the condenser is equipped with corrosion plugs, it is necessary to perform a dry or wet
function test:
1. Cover 1 is cleaned of coating to obtain a clean metallic surface.
2. Corrosion plug (2) is mounted with 0-ring (3).
3. Corrosion plug including 0-ring is mounted in the end cover.
4. Cover (1) is placed over the corrosion plugs (2).
5. Three bolts (4) are mounted.
6. Cable (5) is mounted with clips suited for bolts (6 and 4).
7. The cable with clips (7) is mounted together with the last bolt (4) between cover
(1) and tube plate/bolt/nut (8, 6 and 9).
8. All bolts (4) and bolt/nut (6 and 9) with dips are tightened.
9. Make sure there is an effective connection between corrosion plug (2) and cover
(1) and between corrosion plug (2) and tube plate (8).
10. This is done by measuring the resistance and the voltage drop as shown in Fig. 1.
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Fig. 1
With cover without water < 0.5 Ω
Cover filled with water < 10 mV
Each corrosion plug has to be tested
To be tested on cover and on tube plate
Cable
Nut
Tube plate
Corrosion plug
End cover
O-ring
Bolts
Cable
Bolts
mV
Leak hole
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Starting up
Before charging refrigerant to the system, a few things need to be checked:
1. Check the operating conditions
Medium
shell side HCFC HFC Ammonia
Secondary
refrigerant
Treated
cooling tower
water for
closed
systems
Sea water
Treated
cooling tower
water
Untreated
cooling tower
water
Sea water Sea water
Type COKC CONC COSB CORB
AISI316
CORB
SAF 2205
COTB or
CORB
SAF 2507
Max. Cl content
ppm
150
(Max. temp.
30°C)
1000
Ph 8-10 8-10
Max. sea water
temperature 35°C 40°C
Gas inlet max.
temp. °C130°C 130°C 130°C 130°C 130°C 130°C
Max. water
velocity m/s
inside tube
2.3 a) 2.3 a) 2.5 2.5 4.0 4.0
Min. water
velocity m/s
inside tube
1.0 b) 1.0 1.0 b) 1.0 1.5 1.5
a. Max allowable velocities. Must be reduced if the primary refrigerant is highly polluted.
b. Min. velocity for closed systems, 0.3 m/s.
2. The condenser is filled with brine (water). Do not forget to purge the system.
3. In case of treated cooling tower water, it is important to supply extra water synchronously
with inhibitors.
4. Ph-values of closed systems must be checked regularly to avoid corrosion damages.
5. The oxide film on the tube surface of CONC condensers must not be removed when the
condenser is started up. The condenser must be started up with pure water without accel-
erant corrosives (meaning harbour water cannot be used). Only after the condenser has
been operating with clean water for approximately two days can you change to sea water.
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Sea water condensers, standstill
A continuous water flow through the condenser is very important. If the condenser has to be stop-
ped the following must be observed:
Type Max. standstill
before draining off sea water
Max. standstill
before dismantling covers
CONC 4 weeks * 1 year
CORB SAF 2205 1-2 weeks
(depending on water temperature) 2 months
CORB SAF 2507
COTB 4 weeks 2 months
* Do not forget to add Fe oxides in order to reestablish the protective oxide film on the tube
surface.
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Maintenance
Operation experience will show how often the condenser has to be checked. It depends on the op-
erating conditions. Johnson Controls recommends that the condensers are inspected at monthly
intervals during the running-in period. The inspection includes:
• Check for impurities, fouling and so on
• Corrosion plugs
• Safety devices
• Corrosion
• Copper tubes (are the ends intact?)
• Coating on covers.
After a running-in period of six months, a maintenance plan must be made. As a minimum John-
son Controls recommends inspection every third month.
A. Check for impurities and fouling
Mechanical cleaning is carried out with nylon or brass tube cleaners (Note that CORB condensers
must only be mechanically cleaned by means of nylon brushes. Steel brushes will damage the
protective oxide film on the tube surface). Heavy-handed cleaning may damage the tubes. Some-
times it may prove necessary to clean chemically. Johnson Controls recommends a so-called
"shock chlorination", which is 2-3 mg Cl2 added to one litre of water during continuous operation
for about one hour (when on board a ship, large amounts of mussels must be removed from vari-
ous filters).
B. Corrosion plugs
Corrosion plugs will "cry" when they need replacement.
C. Safety devices
Safety devices must be function tested according to existing national and/or classification rules.
D. Corrosion
Visual inspection is required.
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Sabroe CONC/COKC/COSB/CORB/COTB Installation Operation and Maintenance Guide

Brand
Sabroe
Model
CONC/COKC/COSB/CORB/COTB
Type
Installation Operation and Maintenance Guide
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