TURBINE WORKS Ltd. Fax: (00385)/47/648571 Vranova 53, P.0.Box 168 Phone: (00385)/47/648588 CLE as 47000 Karlovac, CROATIA email: infoa@rtkhe e Al VAT No. 3725987 URL: wwwttkne CUSTOMER: Shipyard "BRODOSPLIT" - Split PROJECT: NB 473 FACTORY NO.: 6169 YEAR OF PRODUCTION: 2012. TTK PROJECT No.: P -907/12 CLASS: LR OPERATING MANUAL FOR | SHELL AND TUBE THERMAL OIL/HOT WATER HEAT | EXCHANGER, Type HE 18-16-4 OM.2133-TTK ena eect or ana a [evan D. Lonéarié D. Schiller 1. MRSC February, 2013. A- February, 2013,ors ree ee ee ee ow es eee TVORNICATURBINA Goo. [ome OM.2133-TTK FUPLK Tursine worns tra OPERATING MANUAL CONTENT. Page OPERATING MANUAL 1. Marks and factory number 2. Technical data 3. Description 4. Operating instructions 5. Inspection and maintenance instructions 6. Guarantee 7. Delivered spare parts list Noone naw 8. Heater outline SPARE PARTS CATALOGUE Fresh water heater: - drawing 90.5100.0137 9 - Spare parts list 90.5100.0137 10 amet [enecea by Ronson paz Revaon D, Lonéarié, D. Schiller 1. Mikgié February, 2013. | A- February, 2013.rmaoree ere em ee ere ee ee TVORNIGA TURBINA doo, FTPLIK tureine works ud OM.2133-TTK OPERATING MANUAL aT 1. Marks and factory number Flanges according to Materials: * Shelt ‘* Heating tubes: + Tube plate: + Water chamber: * Gaskets: Protection: * Insulation: ‘Shell (outside coat) Shell (inside): * Water chamber (outside): + Water chambers (inside): Name: ‘SHELL AND TUBE THERMAL OILIHOT WATER HEAT EXCHANGER: Manufacturer: TTK - Turbine Works Ltd. Karlovac-Croatia Type: HE 18-16-4 Fact. No.: 6169 Yard: NB 473 Year of production: 2012. Orderer: Shipyard “BRODOSPLIT" - Split . Technical data * Quantity per ship: 1 piece + Heat exchanger (U-type) HE 18-16-4 Heating surface: 18m? * Capacity: 500 kW + K-margin’ 15% Tube side » Heated medium: fresh water * Fresh water quantity: 22 mith Fresh water inlet temp. 70°C * Fresh water outiet temp.: 90°C + Fresh water design temperature 100°C «Fresh water working pressur 3barg * Pressure drop through the cooler: max 0.2 bar ‘Shell side * Heating medium: thermal oil * Thermal oil quantity: 24 mth © Thermal oil inlet temp.: 180°C: © Thermal oil outlet temp. 140°C * Thermal oil design temperature: 200°C # Thermal oil working pressure: 8barg + Pressure drop through the cooler: max 0.5 bar ISO 7005-1; 1992 for fresh water side ISO 7005-1; 1992 for thermal oii side carbon steel, St 35.8 (DIN) W. Nr.: 1.0305 carbon steel, St 37.0 (DIN) W. Nr.: 1.0254 carbon stee!, St 35.8 (DIN) W. Nr.: 1.0305 welded construction, carbon steel asbestos free sock wool 50 mm lined with galvanized plate 0.75 mm - synthetic fire retardant paint, dry film thickness 120 um - conservation oil ~ Alkyd primer, dry film thickness 80 um Alkyd enamel, dry film thickness 40 um, RAL 6019 - protected with epoxy coat in thickness of 240 um (three dry films of 86 jum thick each) fess D. Longarié D. Schiller ase a Reva 1. Mikgié February, 2013. | A - February, 2013.moe me me rere rere ee oe ee ee TVORNICA TURBINA doo, [ome PUK tureine works ts OPERATING MANUAL 3. Description The device is surface heat exchanger, used for fresh water heating The exchanger is manufactured as welded construction, consisting of cylindrical shell, water chamber, tube bundle with tube plate and connections for thermal oil / fresh water. The tube bundle consist of “U" tubes rolled-in the tube plate. The heated medium (fresh water) enters through the right flange into the water chamber, passes through the tube bundle, and exits the heater through the eft lange on water chamber. ‘The heating medium (thermal oil) enters the exchanger at the upper left flange on the shell, cooling down at the outer surface of cooling tubes and exits the exchanger on the upper right flange on shell, 4, Operating instructions 4.1 General The fresh water heater is mounted on pedestal by screws. Inlet and outlet piping for thermal oi and fresh water should be tightly flanged and should not exert any externally forces on the heat exchanger. Initially gradually increases quantity of fresh water and when full circulation is achieved open valve and let the thermal oil At stop of operation completely drain the fresh water heater to avoid corrosion and freezing. The insufficient heat exchanger performance can mostly depend from: - incorrect installation - excess of scale (pressure, temperature, load) - baffles corrosion and consequent liquid leakage 4.2 Temperature change Operating temperature over the design can originate thermal extension, strains, break, abnormal corrosion and decreases the thermal exchange. 4.3 Pressure change Pressure rise can compromise the mechanical stability and other troubles that are not immediately evident can arise as internal mixing of primary and secondary fluid occurs. 4.4 The heat exchanger works with changing toad ‘The fluid flow increase over the design rates will raise the pressure drop and create corrosion danger. A flow decrease may be dangerous too, for example for excess of scale. Any primary and or secondary flow change will affect the outlet temperature. | D. Lonéarié D. Schiller 1, Mikgi€é February, 2013. | A- February, 2013. Tikeome re ere rere re emesis re er ee ee = FAIS cemenRENN Soo. Pom OM.2133-TTK ‘TURBINE WORKS Ltd. OPERATING MANUAL. To obtain the claimed outlet fresh water temperature it is to advise to put on primary circuit (thermal oil) automatic control equipment piloted from a sensing element in contact with ‘00ling fluid. 4.5 Drain ‘The heat exchanger can be drained via drain valve placed below shell for thermal oil and below water chamber for fresh water. 5. Inspection and maintenance instructions The fluid flow during the time will affect decreasing the performance and may produce total clogging of some tubes. Due to the extreme wideness of operating conditions (temperature, water hardness etc.) itis very difficult to predict the frequency of necessary inspection Experience gives follows: 5.1 Inspection and maintenance before putting in operation - check the inlet and outlet thermal oil valves ~ valves must be closed - check the inlet and outlet fresh water valves - valves must be closed - check the drain and air valves ~ valves must be open 5.2 Inspection and maintenance during operation Check the heating fluid temperature - In case of heating reduction it is necessary to check the tube bundle. - Up to 5% of total number of tubes in a heater may be plugged without affecting normal performance but it is important to install new tube bundle at an early opportunity. For plugging of the tubes use pair of plugs (item 19, code 91.1980,0043-01) per tube. - Clean the inner side of tubes by circulating the solvents inside the tubes. - Outer side of cooling tubes surfaces should be cleaning after extraction of tube bundle. Important: - For major damage tube bundle should be exchanged with new one. - Replacing of tube bundle must be done by service organization. - After replacing the tube bundle, test pressure must be done. 5.3 Monthly and annually maintenance Monthly and annually maintenance are not necessary. 5.4 After each disassembly Afier each disassembling the following parts must be replaced: - gasket (fresh water side) Wem 05 Code 90.5100.0137-05 1 piece - gasket ring (thermal oil side) tem 06 Code 90.5100.0137-06 1 piece [ea ore aie os D. Lonéarié D. Schiller 1. MKB February, 2013, | A- February, 2013.TS REA TURBIASo=. pm OM.2133-TTK OPERATING MANUAL 6. Guarantee TTK guaranties for proper functioning of the heater with correct maintenance according to our instructions and is valid for one (1) year after ship's delivery to the owner or maximum of two (2) years after delivery ex-works. The guaranty shall not be valid in case of: - failure to follow instructions stated within this manual - water hammer - overheating of the heater (if medium temperature is higher then defined in contract) = unpredicted increase in pressure - defective equipment for temperature control + defective draining equipment = unprofessional handling of the equipment by crew - mechanical damages 7. Delivered spare part list Following spare parts were initially delivered with the unit at commissioning: item | Qty | Description Code 1._|_10_| Tube plug 91.1980.0043-01 |2. | "1 Gasket (fresh waterside) ~_ 90.5100.0137-05 3 1_| Gasket ring (thermal oil side) 90.5100.073: [eeearedby ear Baw D. Lonéarié D. Schiller T. MiK&iCé February, 2013. | A- February, 2013.ree re ere meme re owe re ere re ree es ee TVORNIGA TURBINAdoo [Name OM.2133-TTK CUE Oe te OPERATING MANUAL be Pose 10 2750 2490 ‘ ~2400 410 5 7 for disassembly am 1 + i LLLLELL LE. Heat insulation 2000 a 4 | Wo 4 { ros] ~ [se [Pcs| 1 AIR VALVE 7 | Rie 2 7 lone Rie [2 3. [FRESH WATER I petoeuts | 1 4 [FRESA WATER OUT weoeui [4 8 [THERMAL OL INLET DNESPNIG | ot & [THERMAL OL OUTLET ones rs | 1 7 _| GAUGE CONNECTION mixta 4 8 [SAFETY valve ae [4 Mass: ~ 700 ky YARD: NB 473, ee CLIENT: Shipyard "BRODOSPLIT"- Split SHELL AND TUBE THERMAL OIL / HOT WATER INSPECTION: [LR HEAT EXCHANGER, TYPE: HE 18-16-4 CUSTOM a Se Revision iteasurng stat No IDRAWED BY” 1D. Lone] C08: 11.2012 MS.5100.0466mame eee ees re es ee Smee ee re ewe eee ees Oe TORNIGA TURAWA doo, == ‘OM.2133-TTK FIPLIK ture worst SPARE PARTS CATALOGUE mm 40 ee SPARE PARTS CATALOGUE rama [eres Reina os D. Lonéarié D. Schiller 1. Mikgié February, 2013, | A- February, 2013. TKmm rs OS re re est oe re re re re re eS ee ee oe ELIS IVORNICA TURBINA dow [RM KK TURBINE WORKS Lid, SPARE PARTS CATALOGUE OM.2133-TTK [Pass YFaee a) SHELL AND TUBE THERMAL OILHOT WATER HEAT EXCHANGER, Type HE 18-16-4, 90.5100.0137 Checked by D. Schiller Date February, 2013, Revision A. February, 2013.TVORNIGA TURBINA doo. [ore FIPLIK rursine works its SPARE PARTS CATALOGUE OM.2133-TTK SHELL AND TUBE THERMAL OIL/HOT WATER HEAT EXCHANGER Type HE 18-16-4 90.5100.0137 [It No. | Description TNo. of pes. | Code (4 {Shei 1 '90.5100.0137-01 2__| Tube bundle 4 90.5100.0137-02 ‘3._| Water chamber 7 (90.5100.0137-03 | [47] Cock 4 90.5100.0137-04 | 5__| Gasket (fresh water side) 7 90.5100.0137-05 6__| Gasket ring (thermal oil side) 1 | 90.5100.0137-06 i. Name plate (english) _ 1 90.5100.0137-07_ [877 Batt 16 90.5100.0137-08 9 | Plug —__ 2 {90.5100.0137-09 | 10 _| Safety valve 1 90.5100.0137-10 | 74 [Nut i6 90.5100.0137-11.__ 12__| Sealing ring 6 90.5100.0137-12 43_| Safety valve sealing ring = 4 90.5100.0137-13 | 14_| Blind rivet 4 90.5100.0137-14 15 | Insulation 1 90.5100.0137-15 (46 | Connection 4 90.5100.0137-16 | 17_| Bolt 1 {90.5100.0137-17 16 Pin 1 90.5100.0137-18 19 | Tube plug - 70 91.1980.0043-01__| Fanos [event D. Lonéarié D. Schiller February, 2013. A- February, 2013. Teo