Instruction manual for the installation,

operation and maintenance of

Bloksma Boxcoolers.

Bloksma B.V.
P.O. Box 1003
1300 BA Almere
The Netherlands

Tel. +31 (0)36 5492300

Fax +31 (0)36 5492390

E-mail: service@bloksma.net
Internet: www.bloksma.net

2006-12 Article number: 7ZZ00K0000010

 Instruction Manual Boxcooler

TABLE OF CONTENT.

Page
Table of content 2
Definitions 3
1 Introduction 4
1.1 Remarks 4
1.2 Guarantee and liability 4
1.3 Environment 4
1.4 Safety 4
1.5 Inhibitors 5
1.6 Use of systems to prevent biological fouling 5
2 Installation and start-up 5
2.1 Receipt 5
2.2 Handling the boxcooler 5
2.3 Position of the boxcooler in the sea chest 6
2.4 Installation 7
2.5 Welding instructions for the mounting ring 9
2.6 Start-up 11
3 Maintenance 12
3.1 Prevention of bio fouling 12
3.2 Inspection and cleaning intervals 12
3.3 Anodes in the sea chest for cathodic protection 12
3.4 Cleaning the boxcooler 13
3.4.1 Cleaning on the inside of the tubeside 13
3.4.2 Mechanical cleaning on the outside of the tubes 13
3.4.3 Chemical cleaning on the outside of the tubes 13
3.5 Shut down periods in freezing conditions 13
3.6 Assembly and dis-assembly of the boxcooler 14
3.7 Instructions for gaskets and bolts 16
3.7.1 Gaskets 16
3.7.2 Bolts 16
4 Troubleshooting & repairs 17
4.1 Insufficient thermal performance 17
4.2 Contamination on bundle during final assembly of the hull 17
4.3 Leaking tubes / tube-to-tubesheet connections 18
4.4 Leaking gaskets 18
5 Spare parts & tools 19
Appendix A: Instructions for conservation 20
Appendix B: Addresses 20

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 Instruction Manual Boxcooler

Definitions.

Refer to the figure(s) in paragraph 3.6 “Disassembly and assembly of the boxcooler”
for an explanation of the parts of the boxcooler.

Conditioned circuit Closed circuit with a non-corrosive, non-fouled fluid.

Unconditioned circuit Open circuit (for instance seawater) or a closed

circuit with a corrosive and/or fouled fluid.

Coating Layer on the tubes to protect the less noble metal –

the carbon steel sea chest – against corrosion.

Inhibitor Additive to the water flowing in the tubes of the box

cooler in order to prevent corrosion or increase
lifetime.

Anodes / cathodic protection Connecting a less noble metal (the anode) to a

noble metal (the cathode) in order to protect this
cathodic metal. The part serving as anode is being
sacrificed.

ICAF Impressed Current Anti Fouling system. A small

current is applied to copper anodes mounted in the
sea chest. This prevents biological fouling on the
boxcooler.

Sea chest The space in the ship in which the box cooler is
placed. The water in which the vessel is sailing
flows through the space in the ship where the box
cooler is placed, serving as a coolant.
Mounting ring Part that is welded onto or into the top of the sea
chest to fix the boxcooler to the hull. Although there
are both round and rectangular box coolers, this
part is called a mounting ring in both cases.

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 Instruction Manual Boxcooler

1 Introduction.
1.1 Remarks.
• Read this instruction manual before proceeding.
• This manual deals only with the boxcooler itself. If the boxcooler is provided with
an anti fouling (ICAF) system, the separate ICAF manual must be read too.
• The design pressures and design temperatures as stated in the specification
sheet and on the nameplate may never be exceeded.

1.2 Guarantee and liability.

The “General sales conditions of Bloksma B.V.” are applicable. Also refer to the
confirmation of the order for possible additions.

Not covered by the guarantee are loss of performance and/or damage to the
boxcooler as a result of:
• not following the instructions in this manual
• replacement with non-original parts
• every form of corrosion

1.3 Environment.
• The environmental laws and rules of the area where the boxcooler is installed,
always have to be respected.
• The rules of the classification societies – if applicable – have to be respected.
• Always be on the alert to the possibility of leakage.

1.4 Safety.
Some symbols are used in the text to underline safety aspects:

Pay attention: depending on the application the boxcooler will be hot during operation

Maintenance and repair: depressurise the boxcooler and let it cool down to ambient
temperature.

General Note:
Most boxcoolers contain fluids, which can be irritating or dangerous to humans.
These fluids could cause problems in case of leakage. Since one fluid in the
boxcooler is at a higher temperature, any leaks might cause burns of the skin.

A boxcooler is a pressure vessel designed for operation at certain specific limits of

pressure and temperature. All operating personnel should be made aware of this
specific design pressure and temperature, which are stated on the name plate.

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 Instruction Manual Boxcooler

1.5 Inhibitors.
Normally inhibitors are added to the cooling water in the boxcooler. Contact the
supplier of the inhibitor, which can also check for compliance of the inhibitor with the
materials of the boxcooler (see specification sheet). Without proper prevention, micro
organisms in the cooling water may grow excessively and may cause corrosion on
metals. Bacteria also give an accumulation of slurry / mud, forming a viscous film on
the tubes and blocking the water flow, both causing insufficient cooling.
Follow the instructions of the supplier for use of the inhibitor and maintenance
procedures.

1.6 Use of systems to prevent biological fouling.

As mentioned in 3.1 a system could be used to prevent biological fouling. Some of
these systems can interact with the materials of the boxcooler, resulting in a negative
effect on the reliability or lifetime of the boxcooler. Notably systems that use
hypochlorite by electrolysis of seawater can damage the material of the boxcooler.
Anti fouling systems supplied by Bloksma have a guarantee for proper functioning for
the complete anti fouling / boxcooler combination.

2 Installation and start-up.

2.1 Receipt.
At receipt check the packaging and the boxcooler:
• report any damage to Bloksma
• compare the data on the nameplate, the drawing and the Bloksma confirmation of
the order.
• check whether or not the correct instruction manual is present by comparing the
article number on the cover sheet with the article number of the instruction
manual on the confirmation of order

Always store the boxcooler in its original wooden box in a dry room, free of big
temperature changes. When the boxcooler is not being put into operation
immediately after receipt, follow the “Instructions for conservation” (Appendix A).

Although in practice this will virtually never occur, Bloksma retains the right to plug off
maximally 1% of the tubes (as per TEMA RGP-RCB-2).

2.2 Handling the boxcooler.

• Remove the top cover from the wooden case.
• Lift the boxcooler on the water box. The bigger boxcoolers are supplied with
special lifting lugs on top of the water box. The smaller boxcooler can be lifted
on the water connections.
• Some boxcoolers – depending on total weight – are supplied with steel
frames, bolted to the 2 sides of the boxcooler. These frames protect the fragile
bundle during handling of the boxcooler. Remove this frame only just before
the installation of the boxcooler in the sea chest.
• Be careful not to damage the tubes at the u-bends during lifting.
• When the boxcooler needs to be put down, put some soft material on the floor
first, let the u-bends rest on this material first and then lay down the boxcooler.

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2.3 Position of the boxcooler in the sea chest.

The thermal performance of the boxcooler is depending on the shape and layout of
the sea chest and the area, position and orientation of the inlet and outlet openings.
The design of the sea chest in combination with the applied boxcoolers has to be
discussed with Bloksma; this subject is not included in this instruction manual. Please
contact Bloksma regarding the rules for a proper sea chest design.
Below is a typical drawing of a sea chest; this drawing is for orientation only.

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2.4 Installation.

Note: There may still be some rust preventive fluid present in the boxcooler (see
appendix: “Instructions for preservation”).

• Check if Bloksma has approved the sea chest design.

• Ensure that there is enough space above the boxcooler to lift the boxcooler for
maintenance.
• Check if there is a drain and a vent facility in the piping of the water circuit.
• Move the complete boxcooler to the place where it has to be installed.
• Mark the orientation of the water box, gasket and tubebundle relative to each
other with a marking pen to ensure that the components are re-assembled with
the right orientation afterwards.
• Remove all protective plugs and covers from the connecting flanges.
• When the mounting ring is not delivered separately: remove the mounting ring
from the boxcooler. Never weld the mounting ring while the tube bundle is
attached!
• Remove the water box from the boxcooler. The nuts are used for transport only
but the flat washers have to be re-used under the bolts.
• Weld the mounting ring of the boxcooler in accordance with the welding
instructions as described in paragraph 2.4.
• Position the gasket (without partitions) over the mounting flange.
• Handle the boxcooler with extreme care when hoisting the bundle into position.
The tubesheet of the boxcooler is provided with threaded holes (M16) for hoisting
purposes. Use all threaded holes to lift the bundle.
• Mount the box cooler vertically in the sea chest.
• Mount the internal hexagonal bolts first. See also paragraph 3.6. Be sure to use
all the bolts and tighten them securely: these bolts must guarantee a watertight
sealing when the waterbox is removed !
• The gasketing and bolting must be done in accordance with the instructions as
mentioned in paragraph 3.7. Please use the tightening sequence as mentioned in
paragraph 3.7.2.
• Assemble the other components of the boxcooler: the gasket with partitions and
the waterbox: ensure that the relative positions are according to the markings.
Especially ensure the partitions on the gasket corresponds with the partitions of
the waterbox.
• Clean and inspect the gasket surfaces of the flanges before connecting the
pipelines. Always use new gaskets of the correct type and tighten the bolts
crosswise.
• Always check if the fluid that flows through the boxcooler is consistent with the
materials of the boxcooler. Bloksma makes its material choices on the basis of
the fluids specified by the client, but is often not informed of possible
contamination, higher/lower acid levels than normal, additives and other aspects
relevant to the choice of materials.

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 Instruction Manual Boxcooler

Please note that there is also a special version of the boxcooler: the bottom-pull. In
this case the boxcooler is mounted through the sea chest from the underside of the
hull. The mounting ring (or welding frame) is adapted for this version. Please read the
special welding instructions, which are delivered together with this welding ring.

Exploded view of the boxcooler components – typical example only.

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 Instruction Manual Boxcooler

2.5 Welding instructions of the mounting ring.

PLEASE READ THIS INSTRUCTION CAREFULLY BEFORE WELDING

• Cut the proper dimensions out of the top plate. The actual dimensions depends
on the type of weld(see next item), the weld size and the thickness of the top
plate.
• Weld the mounting ring of the box cooler IN (Figure 1b) or ON (Figure 1c) the top
plate of the sea chest. Which weld to use depends also on the requirements of
the classification societies? Please make sure that the sides of the rectangular
mounting ring are kept parallel and do not deform over the length to ensure that
the bolting with the tube plate and water box still matches.
• Never weld the mounting ring while the tube bundle is attached!

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 Instruction Manual Boxcooler

There are 2 aspect to consider when welding the rectangular mounting ring to the top
plate of the hull:

1. Sealing.
The flatness of the mounting ring after welding, as well as of the tube sheet and the
water box must be within limits to guarantee a proper watertight sealing. The surface
of the mounting ring is machined, so completely flat. The tube sheet and water box
have a flatness of 1.5 mm for each meter length. Maintaining this value also for the
mounting ring after welding is required to prevent sealing problems.

2. Alignment of the bolt holes.

Due to welding, the mounting ring can get deformed resulting in not parallel and
straight sides. This can cause problems with the bolt holes alignment. The bolts are
size M12 with 14 mm holes, so only a tolerance of less than +/- 1 mm is acceptable.
When the welding is done by an experienced, professional welder, this is normally
sufficient. To limit the deflection, an extra bar could be temporarily tack-welded in the
middle of the ring before welding, to prevent any excessive deformation. Also the
dimension of the weld and particularly the sequence of welding is important.

Orientation of round mounting ring for welding:

The rectangular mounting ring can be rotated over 180 degrees without any
consequences.

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 Instruction Manual Boxcooler

2.6 Start-up.
Do not exceed the design temperature and pressure as specified on the nameplate,
specification sheet and drawing. Avoid abrupt temperature fluctuations; these can
cause leaking of the tube-to-tubesheet connections or other connections.

• Establish the circulation of the warm medium gradually.

• Vent the tubeside circuit.
• Vent the tubeside circuit again when the operating temperature and pressure
have been reached.
• Check for leakage.

Respect the flow as specified on the specification sheet. Higher speeds can cause
erosion.

Avoid water standing still in the boxcooler in freezing conditions because this can
cause damage to the tubes. Drain the boxcooler for these cases and remove any
remaining water in the tubes by pressed air.

Note:
In most cases some threaded BSP connections are welded on the water box. These
are for internal use at Bloksma only to simplify drainage of the cooler. As the
waterbox has internally some provisions for automatic venting through the water
connections, these threaded connections don’t need to be used for venting.

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 Instruction Manual Boxcooler

3 Maintenance.

If necessary see “Assembly and disassembly of the boxcooler” for (dis-) assembly
instructions.

3.1 Prevention of biological fouling.

In general, the boxcooler system is for most of the applications a maintenance free
system. However – depending on the area of sailing and depending on several
operational conditions, bio fouling must be anticipated for. Bloksma can supply a so
called ICAF (Impressed Current Anti Fouling) system. Normally this system is built in
together with the boxcooler(s), but also retrofitting is possible. The ICAF system
uses copper anodes under the boxcooler. A small current is applied to the anode,
which dissolve the copper to Cu+ ions in the seawater. The Cu+ ions prevent any
biological growth.

3.2 Inspection and cleaning intervals.

The end user is responsible for (preventive) maintenance. The tubeside circuit of the
boxcooler will rarely need to be cleaned as the fluid in the tubes is always
conditioned.
The outside of the bundle in the sea chest is the part most subject to bio fouling.
Because the degree of fouling strongly depends on operating conditions, we
recommend the following: At least once a year inspect the exterior. Depending on the
results of the inspections you can determine the definitive cleaning intervals.
However always continue to carry out regular inspections.

3.3 Anodes in the sea chest for cathodic protection.

In the rare case – for fresh water service - when the bundle of the box cooler does
not have a coating, anodes must be used to protect the hull. How many anodes have
to be used and where the anodes have to be placed can be checked with the
supplier of the anodes. When inspecting the bundle also inspect the condition of the
anodes.

In case of a coated tubebundle no anodes are required. However we recommend still

to use some anodes; they are useful in case the external coating is damaged over a
big surface or when brass components are fitted in the sea chest.

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 Instruction Manual Boxcooler

3.4 Cleaning the boxcooler.

3.4.1 Cleaning on the inside of the tubes.

The tubeside circuit of the boxcooler will rarely need to be cleaned as the fluid in the
tubes is always conditioned. The bends of the U-tubes can only be cleaned
chemically. The straight parts of the tubes can be cleaned, if necessary, with a brush.
Use only original Bloksma brushes; they have the proper dimensions and are made
of a suitable material.

3.4.2 Mechanical cleaning on the outside of the tubes.

The exterior of the bundle can be rinsed clean with the aid of the deck wash or
compressed air. Use only soft water with low pressure. Note: the maximum
temperature of the external coating is 150 °C.
Never use hard materials which can damage the tubes and/or coating.
Protect the boxcooler in case the sea chest is cleaned internally.

3.4.3 Chemical cleaning on the outside of the tubes.

Note: Chemical cleaning can damage the boxcooler. Let the supplier of the chemical
cleaning agent determine whether the agent is suitable in combination with the
materials of the boxcooler (see specification sheet).
All boxcoolers with coated tube bundles (see specification sheet) the temperature
may not exceed 150 °C, and no bleach may be used, because of the coating.

After disassembly the tube bundle can be submerged in a tank containing a chemical
solution.

There are various international companies (example in Appendix B) who can deliver
products for the chemical cleaning of boxcoolers. They have world-wide offices in
many harbours and can give you cleaning advice or can clean the boxcooler for you.

3.5 Shut down periods in freezing conditions.

During shut down periods, bear in mind the possibility of freezing.
Avoid the boxcooler standing still in freezing conditions: this can cause damage to
the tubes.
The outside of the boxcooler is normally never in danger; it is the tube side fluid
which freezes and can damage the tubes. Drain the boxcooler internally in these
cases, for instance by applying compressed air.

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 Instruction Manual Boxcooler

3.6 Assembly and disassembly of the boxcooler.

Mark the orientation of the water box, gasket and tubebundle relative to each
other with a marking pen to ensure that the components are re-assembled
properly afterwards.

The tubesheet of the box cooler is fastened with internal hexagon screws to the
mounting ring. The water box is fastened on top of this with bolts (see figure 2).

1 Bolt 5 Gasket
2 Water box 6 Mounting ring
3 Partition gasket 7 Top plate sea chest
4 Tubesheet 8 Internal hexagon screw
Figure 2: Fastening tubesheet and waterbox

For tubeside inspection or to check for leakage when the ship is sailing, or to
clean the tube with a brush, only the tubeside connections and the water box
need to be removed (as per steps 1 and 3). The bundle remains fixed by the
internal hexagon bolts. Please take care: When the internal hexagonal bolts
are not fixed sufficiently, leakage could occur !

To remove the bundle (only when the waterline is below the mounting ring or
when the ship is in dry-dock) follow steps 1,2 and 3.

Both at assembly and disassembly follow the “Instructions for gaskets and bolts”.

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 Instruction Manual Boxcooler

Step 1: Tubeside disassembly.

• Depressurise the tubeside circuit.

• Let the tubeside circuit cool down to ambient temperature.
• Drain the tubeside circuit by opening the drain at the lowest point and the vent at
the highest point.
• Mark the relative position of all parts that will be disassembled, so that they can
later be assembled in the correct positions.
• Remove the water box by loosening the bolts (1). Do not remove the internal
hexagonal bolts (8) !
• Remove the partition gasket (3).
• After cleaning and drying the tubesheet you can check for leakage.

Step 2: Removing the bundle.

• The bundle can only be removed when the ship is dry and docked.
• Mark the position of the bundle.
• Loosen the internal hexagonal bolts.
• Carefully pull the bundle out of the sea box using the 2 threaded holes in the
tubesheet.
• Remove the gasket.

Step 3: Assembly.

• Assemble the boxcooler in the opposite order (note the marks that you have
made):
Assembly of the bundle (only if it had been removed):
• Mount a new gasket.
• Slide the bundle into the mounting ring.
• Fasten the internal hexagon screws.

Tubeside assembly:
• Mount a new partition gasket.
• Mount the water box and the connections.

• Place the boxcooler back in operation:

• Gradually establish the circulation of the warm medium.
• Vent the tubeside circuit.
• Vent the tubeside circuit again when the operating temperature and pressure
has been reached.
• Check for leakage.

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3.7 Instructions for gaskets and bolts.

3.7.1 Gaskets.
Always make sure the gasket surface is clean (remove remains of old gaskets), and
free of any damage. Never re-use old gaskets. Always use original Bloksma gaskets
(cheap alternatives have a shorter life span and are much likelier to leak). See “spare
parts & tools” for order information. Check before assembly if the dimensions of the
gasket surface and the gasket correspond.

Warning: Gaskets must be applied completely dry (i.e. mounted without any sealing
aid, jointing compound, molykote, graphite, grease or other lubricant). Any sealing-
aid will affect the sealing capacity of the gasket. Any warranty claim will be rejected
when sealing-aid is used.

The gasket must be lined-up correctly and it may not cover any tubes. Note that the
partitions of the partition gasket are in the proper position; compare the partitions of
the gasket with those in the water boxes. For storage of gaskets see chapter 5.

3.7.2 Bolts.
Check the bolts and nuts for damage. Tighten the bolts with a torque of 50 N.m. As
the gasket has a wide surface, is very flexible and as the water box will deform
slightly, some local leakage may still occur. In this case please re-tighten the bolts
until leakage stops. Treat the bolts with an anti-corrosion and/or anti friction
application to ease removal of the bolts after long periods.

For a round box cooler: Tighten the bolts cross-wise (see figure 3).
For a rectangular box cooler: Tighten the bolts by working from the centre to the
corners (see figure 3). This is very important !

Figure 3: Tightening sequence

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4 Troubleshooting & repairs.

4.1 Insufficient thermal performance.

Check the following items:

Sea chest:
• Is the sea chest design explicitly approved by Bloksma
• Is the area of the inlet and outlet opening OK – see specification
• Is the orientation of the in- and outlet grids OK
• Is the outlet opening below the empty waterline
• Are the openings not obstructed by any foreign material
• Is the sea chest under all conditions submerged (stern-wave, rolling/pitching)

Boxcooler
• Is the orientation of the water box relative to the tubesheet OK
• Is the orientation of the gasket relative to the water box OK
• Is any product in the water box obstructing the water flow
• Is the outside of the tubebundle free from fouling or contamination

Process
• Is the actual engine heat load acc. to the Bloksma specification
• Is the calculating condition (sailing, still-standing, tug) on the spec. correct
• Is the amount of fresh water flow correct
• Is the freshwater circuit free from bacterial contamination (inhibitor)
• Is the thermostatic valve installed properly
• Is the thermostatic valve completely open
• Is the piping vented properly
• Is the piping connected properly (counter current)

4.2 Contamination on bundle during final assembly of the hull.

In case the hull is still standing in river water for final assembly over a longer period
of time, accumulation of dirt can be built up on the boxcooler tubes. Especially when
there is much mud in the water, this risk is increased.
During the thermal testing of the engines, this could lead to insufficient thermal
performance. It is advised to check the condition of the bundle and – when
appropriate - to clean the tubes.
As soon as the vessel is used regularly, dirt cannot accumulate and this
phenomenon will not occur.

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4.3 Leaking tubes / tube-to-tubesheet connection.

It is often very difficult to determine whether leakage is occurring due to a tube that is
leaking or due to a leaking tube-to-tubesheet connection. In addition to checking the
tube-to-tubesheet connections (see “Assembly and disassembly of the boxcooler) it
is also possible – after complete disassembly – to hydro test the boxcooler. So this is
only possible when the ship is dry and at the dock.
To do this, after disassembly of the boxcooler assemble the water box on the bundle
(using the normal screws). Assemble a blind flange on the one opening of the
boxcooler, and put pressure (max. 5 bar) on the other opening.

The tubes are expanded in the tubesheet. A leaking tube cannot be replaced but it
can be plugged with Bloksma soft copper plugs (other materials are too hard and can
cause leakage of the surrounding tube-to-tubesheet connections) in both ends. At
most some 5% of the tubes can be plugged without affecting the thermal
performance of the boxcooler too much. Contact Bloksma if more than 5% of the
tubes are plugged.

4.4 Leaking gaskets.

• Check the gasket surfaces.

• Remove soil and corrosion deposits.
• Mount new gaskets.
• Check if the tightening sequence was correct and the proper torque has been
applied.

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5 Spare parts and tools

Spare parts and tools for boxcoolers that are available:

• Set of gaskets (*)

• Soft copper plugs
• Bolts / nuts
• Water box
• Mounting ring
• Complete U bundle

When placing orders please specify all data as stated on the nameplate.

(*) Flat gaskets contain some rubber and are subject to ageing.
Expected lifetime of spare gaskets is approx. 5 years when stored according to the
rules below.
Rules for storage:
• Dry, non-freezing environment at a constant temperature of about 20°C
• Constant humidity level
• Dark place (no direct sunlight)
• Lying down (not hanging on hooks)

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Appendix A: Instructions for conservation.

Standard conservation (controlled conditions)
All boxcoolers supplied by Bloksma are treated with a rust preventive layer on the
tubeside. This layer will protect the boxcooler when it is stored at controlled
conditions, i.e. inside, in a dry room at constant temperature. When these
conditions are met, the boxcooler can be stored without special treatment for a longer
period (up till 24 months).
The rust preventive layer can be removed with a mineral solvent (petroleum).

Advise for conservation (uncontrolled conditions)

When the above mentioned storage conditions are not met, you will have to fill the
boxcooler with an inert gas and all openings have to be closed airtight (additionally
silica gel can be added to absorb liquids). Alternatively, the boxcooler can be treated
with a rust preventive liquid of a type suited for long term conservation.
When necessary contact a specialised company. Take the materials of the boxcooler
(see specification sheet) into consideration. Be aware that in uncontrolled storage
conditions large amounts of water can accumulate in the boxcooler as a result of
condensation.

Appendix B: Addresses.
Chemical cleaning and products for chemical cleaning

Ashland Chemical Inc.

Drew Marine Division
Boonton NY - USA

Telephone : +1 973 263 7600

Telefax : +1 973 263 4485
E-mail : drewmarine@ashland.com
Website : www.ashchem.com

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