ABS Provides User manual

Flooded Heat Exchangers
Operating Instructions

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OUR PRODUCTS

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Index
INDEX
Declaration of conformity to ASME 4
Preliminary remarks 5
Introduction 6
Material inspection 7
Handling and transportation 8
Storage 9
Installation 10
Set-up 18
Start-up and utilization 18
Maintenance and controls by the user
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Safety 25
Disposal 25
Warranty 26
Appendix 28

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1. Declaration of conformity to ASME
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DECLARATION OF CONFORMITY TO ASME
ALL PRESSURE VESSELS MANUFACTURED BY PROVIDES US, INC. MEET ALL OF THE
REQUIREMENTS OF ASME BOILER AND PRESSURE VESSEL CODE. THE DATA PLATE ON
EACH VESSEL WILL BE MARKED WITH THE APPROPRIATE CODE MARKINGSAND
REQUIRED INFORMATION. THE APPROPRIATE "U" FORM WILL ACCOMPANY THE VESSEL.
IF THE INFORMATION IS NOT PROVIDED, PLEASE CONTACT PROVIDES US, INC. FOR
ASSISTANCE.

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2. Preliminary remarks
PRELIMINARY REMARKS
Keep this manual in a place easily accessible to the assigned personnel and diligently follow what is
written in this Operating Instruction manual.
Provides US, Inc. DECLINES ALL RESPONSIBILITIES in case of:
• non-observance of laws in force regarding safety and accident prevention
• inadequate utilization of the pressure equipment
• modifcations to or tampering with the pressure equipment
• modifcations to the pressure equipment issued by personnel notauthorized by Provides US, Inc.
• non-observance of what is written in this Operating Instruction manual

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3. Introduction
INTRODUCTION
3.2 CONDENSER
The main application of PROVIDES condensers is the condensation of the refrigerant that comes out from
the compressor (and from evaporator) in order to make it liquid and ready to begin a new cycle.Through
the thermal cycle of condensation the refrigerant (gas), intended as the primary fluid, transfers heat to the
secondary fluid (generally water) and condenses.
Generally primary fluid gets in the condenser from the top of the shell and it is totally distributed around the
tube bundle.The secondary fluid flows into the tubes of the tube bundle.
On request it is possible to produce totally or partially heat recovery units for sanitary use.
The standard construction materials of PROVIDES condensers consists in:copper for tube bundle; cast iron
or carbon steel for the header; carbon steel for tubesheets,shell, baffles, hydraulic connections and support
brackets.
Refrigerant connections are generally made of copper.
It is possible to supply carbon steel gas side connections.
On request other materials can be used.
3.1 FLOODED EVAPORATOR
The main application of PROVIDES flooded heat exchangers (from here simply“Flooded EV”) is into HVAC
plants,in which through the thermal cycle of condensation and evaporation of the refrigerant,intended as
the primary fluid, transfers heat to the secondary fluid (generally water) condensing or evaporating itself.
Primary fluid gets in the shell of the flooded and is totally distributed around the tube bundle.The
secondary fluid flows into the tubes of the tube bundle.
The standard construction materials of PROVIDES Flooded EV consist in:copper for tube bundle and carbon
steel for header, tubesheets, shell, baffles, hydraulic and refrigerant connections and support brackets.
On request other materials can be used.
3.3 Refrigerants
It is possible to use HCFC, HFO, HFC, NH3 and propane and others,provided they are compatible with
construction materials and certification. Heat exchanger performance depends on the type of refrigerant,so
different refrigerants will yield different capacities under the same conditions.
3.4 Secondary fluids
Heat exchanger’s performance depends on the type of secondary fluid as well.
It’s necessary to check water quality in order to avoid scales or acid etching that may compromise the tube
bundle integrity.
For flooded evaporator, if the evaporation temperature or water temperatures are less than 0°C an antifreeze
solution must be used.
Most common solutions are ethylene or propylene glycol type.
Other types of solutions can be used,unless not compatible with construction materials of the heat
exchangers.Be advised that glycol solution’s viscosity changes as temperature changes,with a consequence
of anincrease of pressure drop as temperature decreases.

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4. Material inspection
MATERIAL INSPECTION
4.1 Documentation
The heat exchanger is always provided with the present Operating Instructions manual and with the
Declaration of conformity.
Before undergoing any operation on the heat exchanger make sure that the delivered equipment is what you
have ordered, verifying the correctness of the nameplate.The general nameplate is located onto the shell and
it is possible to read the model of the heat exchanger, the serial number, the year of construction, the design
and test temperatures and pressures,the volumes and the fluid types.The Notified Body code is also
indicated on the nameplate (CE,ASME, etc.).
In particular, the spacing “TYPE” will be filled as shown below:
- for flooded evaporator: “EVAPORATOR”
- for condenser: “CONDENSER”

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5. Handling and transportation
HANDLING AND TRANSPORTATION
LIFTING AND TRANSPORTATION MUST ALWAYS BE DONE ONLY BY EXPERT PERSONNEL
ATTENTION: DO NOT MOVE THE HEAT EXCHANGER WHEN IT IS UNDER PRESSURE
PROVIDES heat exchangers are internally charged with nitrogen so as to guarantee their perfect
conservation, also in corrosive environments. In case of sea freight the heat exchangers are
individually wrapped.
On request it is possible to supply heat exchangers in wooden cases in compliance with the enforced
norms of the delivering country. The heat exchanger may be pre charged with nitrogen in both water
and refgerant side circuits; make sure to relieve pressure from all circuits before opening.
Verify on the catalog the dimensions and weight supplied by manufacturer before handling, in
order to choose a suitable system of lifting.
Steel chain or synthetic fiber slings, appropriate to the load to move, can be used.
Some heat exchanger models are supplied with appropriate points of anchorage in order to make
the lift easier.
Handle with care and avoid collisions which could compromise the integrity of the heat exchanger.
Before handling, always be sure the paths inside the building are suitable to the dimensions of the
pressure equipment.

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6. Storage
STORAGE
6.1 Rust prevention
PROVIDES heat exchangers’ external surface is protected by a rustproof primer and by a final color
coat.On request it is possible to supply adhesive insulation that covers the whole surface of the
evaporator.
The heat exchanger must be stored preferably indoors and prevented from atmospheric conditions.
In case of outdoor storage, sunlight and cooling during the night may cause the formation of
moisture inside the heat exchanger and/or inside the plastic wrapping.
PROVIDES heat exchangers are, at any rate, purged with nitrogen and upon request, supplied
with silica-gel bags. All openings are protected with plastic caps. If stored for more than 60 days,
make sure all openings are plugged and that nitrogen is present in both circuits (water and
refrigerant).

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7. Installation
INSTALLATION
1 CIRCUIT (MONO) – EVAPORATOR MODEL
THE USE OF THE PRESSURE EQUIPMENT SHOULD BE RESTRICTED TO
PROPERLY INSTRUCTED PERSONNEL
Verify the integrity of the pressure equipment after unpacking.Do not use in case of doubt and contact
Provides US, Inc.
CAUTION:be sure to discharge any nitrogen pressure from both sides before removing plugs.
Installation must allow for the normal operations of maintenance and cleaning.
The place of installation must be supplied with fre extinguishing systems and safety accessories in
order to prevent any overpressure risks.
In case of outdoor installation protect the pressure equipment from accidental impacts.
The heat exchanger must be installed in horizontal position or in any case must rest on supports
provided: any slopes may cause changes in the performance of the heat exchanger.
7.1 Flooded EV connections
The correct installation of refrigerant and water connections is described in the following figures.
7.1.1 Refrigerant side
PROVIDES Flooded EV can have 1 to“n” refrigerant circuits.
The standard layout of 1 circuit flooded consists in one gas outlet on the top of the shell,one liquid inlet on
the bottom of the shell and a series of welded fittings for safety and service accessories.

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2 CIRCUITS (DUAL) – EVAPORATOR MODEL
7. Installation
The standard layout of“n” circuits flooded evaporator consists in“n”refrigerant chambers, each provided
with a series of welded fittings for safety and service accessories.
The connections can be positioned according to client request and constructive feasibility.
Refrigerant connections may be different,depending on the model of flooded and will be mounted
with bolted flanges.
Before installation always remove plastic caps and silica-gel bags from openings.

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7. Installation
• tighten the coupling after you have verified the correct position of the gasket in order to avoid leakage or
break-ups.
7.2 Condenser connections
The correct installation of refrigerant and water connections is described in the following figures.
7.2.1 Refrigerant side
PROVIDES condensers can have 1 or“n”refrigerant circuits.
The standard layout of 1 circuit condensers consists in one gas inlet on the top of the shell,one liquid outlet
on the bottom of the shell and a series of welded fittings to be used for safety accessories,pressure gauges
and cocks.
1 CIRCUIT (MONO)
FITTINGS FOR ACCESSORIES
FITTINGS FOR ACCESSORIES
LIQUID OUTLET
GAS INLET
7.1.2 Water side
Water side connections are exclusively located onto the headers.
Water side connections are available on flooded vessel heads,and can have a variable number of steps.The
type of connection on the water side can be considered from cast iron shells or from carbon steel headers.
The water connections can be threaded,Victaulic (flexible connection) or flanged connection.
Spare kits of flexible joint type (Victaulic®) not assembled on the evaporator may be supplied on request.
Victaulic® kits (see appendix fig. 14.2)
Victaulic® kits consist of 2 coupling connections supplied with EPDM gaskets on the inside and 2 connection
pipes.
• loosen the coupling connection and extract the gasket.
• fit the gasket between the screwed water connection of the flooded vessel and the pipe,only after you
have verified the cleanliness of surfaces (it is useful to wet the gasket with water or lubricant, unless it
is incompatible with the gasket material).
Flange Kits
Flange kits are provided with coupling flanges, gaskets,screws and nuts.

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Refrigerant connections may be placed in different positions (longitudinally) depending on the Client request
and may be different depending on the model of condenser: - they will be mounted with bolted flanges.
Before installation always remove plastic caps and silica-gel bags from openings.
7. Installation
2 CIRCUITS (DUAL)
FITTINGS FOR ACCESSORIES
FITTINGS FOR ACCESSORIES
GAS INLET GAS INLET
LIQUID OUTLET LIQUID OUTLET
The standard layout of“n” circuits condensers consists in“n” independent refrigerant side circuits,
each equipped with refrigerant inlets and outlets and a series of welded connections.

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7.2.2 Water Side
Water side of condensers can vary from 1 up to 4 passes, on tube bundle condensers, while“n”circuits in the
case of compact condensers.The headers can be in cast or iron or carbon steel.
On 1 Pass models the inlet connection is placed on one header and the outlet is on the opposite header.
The water inlet is located on the opposite side compared to refrigerant inlet (that is on the same side as the
refrigerant outlet).
On 2 and 4 Passes models, inlet and outlet connections are both on the same header with the inlet placed in
the lower side.
The following is the layout of the water connections.
1P 2P 4P
FRONTSIDEREARSIDE
7. Installation

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On models with both condensing and heat recovery circuits, (1 Pass + 2 Passes) the inlet connection of the
heat recovery circuit is on the same side of the inlet connection of the condensing circuit (the last one is
placed in the lower side of the header),while the outlet connection of the heat recovery circuit is placed on
the opposite header of the condenser.
On models with both condensing and heat recovery circuits, (2 Passes + 2 Passes), inlet connections of both
circuits are on the same lower side;outlet connections are on the opposite header in the upper side.
Standard water connections consist in threaded nozzles screwed in the headers and formed in order to fit
Victaulic® joint.
Spare kit of flexible joint type (Victaulic®) not assembled on the condensers may be supplied on request.
On request it is possible to supply flanged type of connections.
1P + 1P 1P + 2P 2P + 2P
FRONTSIDEREARSIDE
7. Installation

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Victaulic® kits (see appendix fig. 14.2)
Victaulic® kits consist of 2 coupling connections supplied with EPDM gaskets on the inside and 2 connection
pipes.
For the installation of the kit follow the steps below:
• loosen the coupling connection and extract the gasket.
• fit the gasket between the screwed water connection of the condenser and the connection pipe, only after
you have verified the cleanliness of surfaces (it is useful to wet the gasket with water or lubricant, unless it is
incompatible with the gasket material); make sure the joint between the two pipes lies at the centre of the
gasket.
• tighten the coupling after you have verified the correct position of the gasket in order to avoid leakage.
7. Installation
7.3 Protect from vibrations
We recommend to avoid the transmission of vibrations that may cause damage to the flooded vessel
through anti-vibrating systems.
7.4 Insulation
On request it is possible to supply an external adhesive insulation for the flooded vessel.
Normal maintenance and inspection operations are permitted.
7.6 Static electricity
Adequate precautions must be taken in order to avoid the accumulation of static electricity (according to
current local legislation).
All metallic parts of the equipment should be grounded.
7.5 Heating protection
Permanent joints of connection, obtained by welding or brazing must be made with adequate
heat protection systems; excessive exposure could damage the heat exchanger.
Flange kit
Flange kits are provided with coupling flanges, gaskets,screws and nuts.

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• Do not install any kind of internal variable by-pass (e.g. flow deflectors,filters,etc.) inside the pressure
equipment.
• Always install devices for the regulation of water flow rate in the outlet of the heat exchanger.
• Always remove all air from the water circuits before operation.
• Every time the evaporator is emptied of water or glycol solution (inspection, storage,commissioning and
• Install a safety thermostat before the heat exchanger water side for a max temperature not greater than the
heat exchanger lable indicates.
7. Installation
guarantee an acceptable water limit, we suggest the use of an N25 mesh filter (french numerical), mesh
diameter 0.87 mm.
• Prevent freezing inside the heat exchanger using suitable safety systems (e.g. flow switch, pressure switch,
heating resistance, etc.).
head could damage it.
• Do not expose the heat exchanger to bending stress.
• Always install a filter directly before the water inlet connection of the heat exchanger. In order to
• Always maintain a higher pressure in the outlet water side in order to avoid the entrance of air in
water circuit.
maintenance),it must be dried,purged and filled with nitrogen at 1bar and closed- otherwise corrosion
may occur.
• Each circuit must be equiped with adequate safety accessories to be considered as a separate chamber with
its attached category.
7.7 Warnings
•Do not expose the heat exchanger to localized loadings due to supports (different from the mounting
lugs), stiffening and connection pipes.
• Do not expose the heat exchanger to dynamic and/or localized loads;dynamic overpressures and water

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8. Set-up - 9. Start-up and utilization
SET-UP
START-UP AND UTILIZATION
For a correct use:
damage to the heat exchanger.
THE USE OF PRESSURE EQUIPMENT IS FORBIDDEN BY UNAUTHORIZED/
UNINSTRUCTED PERSONNEL
DO NOT EXCEED THE MAXIMUM FLOW RATE
Test all connections for leakage.
Completely purge the air from the heat exchanger during the water filling through the proper purge
connections placed on the headers.
The presence of air inside may cause damages to the heat exchanger during the operation.
Before use, analyse the water and/or the antifreeze fluids and verify their compatibility with the materials of
the flooded vessel,in order to avoid damage and malfunction due to corrosion or formation of deposits.
Always verify the presence and the correct operation of safety accessories and fire extinguishing systems.
Make reference to current local legislation that regulates the requirements at the start-up and periodical
checks of plants and pressure equipments.Please contact your Notified Body in order to draft a report with
positive result for the start-up.
In the case of SILICONE FREE units, PROVIDES declares that to the best of it’s knowledge and based on
previous findings and information available from it’s suppliers at the time of the request,that the heat
exchanger does not intentionally contain silicone, although there might be traces due to impurities in the
raw materials.
DO NOT EXCEED THE MAXIMUM ALLOWABLE PRESSURE AND TEMPERATURE
INDICATED ON THE NAMEPLATE
• Do not expose the heat exchanger to any kind of excessive vibration;
• Avoid foreign particles entering in to the pressure equipment;
• Avoid the cavitation of the pump and the presence of gas in the hydraulic circuit;
• Do not expose the heat exchanger to pressure and temperature fluctuations;
• Do not expose the pressure equipment to constant or variable loads;
• Use only water and/or brine solutions compatible with the materials of the heat exchanger;
• Avoid the outlet of water from the flooded vessel at the room pressure.
• Maintain the water velocity within recommended limits. Excessive water velocity could cause erosion and

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10. Maintenance and controls by the user
MAINTENANCE AND CONTROLS BY THE USER
Use,when necessary, inhibited brine antifreeze solutions and verify them periodically, avoiding their contact
with air. Always verify the toxicity/danger of antifreeze solutions before handling.Water-glycol mixture with
the passing of time decays and gives rise to acid products that can start corrosion processes.The degradation
of products in the water-glycol mixture may allow biological proliferation also and thus bacteria formation
can give rise to corrosion.For these reason glycol has to be used with suitable corrosion inhibitors.These have
a life span of 1-2 years so it is important to periodically verify the percentage in the water-glycol mixture.
Attention:glycol and inhibitors may be insufficient due to“top ups”of water in the circuit,then it is important
to integrat the right glycol and inhibitors percentage.The parameters to be checked regularly are the
antifreeze concentration and the pH of water-glycol mixture.
For marine heat exchangers,it is necessary to equip the plant with special anodes which must be checked or
replaced regularly.
To determinate the water quality, refer to the following table.
The above mentioned list indicates only some parameters that principally determine the quality of water.The
elements briefly described can be present together and lead to more serious effects.
For all these reasons we recommend to:
DO NOT REMOVE REFRIGERANT FROM PRIMARY CIRCUIT WITHOUT HAVING A
FLOW IN THE SECONDARY CIRCUIT - IF THIS IS NOT POSSIBLE MAKE SURE THAT THE
SECONDARY CIRCUIT IS COMPLETELY EMPTY TO AVOID FREEZING.
DO NOT OPEN THE HEAT EXCHANGER UNDER PRESSURE
10.1 Water quality
Water quality, as regardschemical composition (salinity, pH),is very important for the performance and the
life of the heat exchanger.
Excessive of hardness of water may cause the formation of a layer of deposits on the internal surface of the
tubes that may reduce the performances and the life of the internal parts of the heat exchanger.
Below are some of the main factors that influence the water quality:
Salinity: an increase of salinity causes an increase of electric conductibility and therefore a higher risk of
galvanic corrosion.Be advisedthat, if you use sea water, salinity’s values change depending on the sea.
pH: pH is normal on values around alkalinity (6.8 – 8.4). For a correct work such values have to be maintained.
Dissolved oxygen: an increase of the dissolved oxygen content in water may cause an increase of corrosion.
Bio-fouling: it includes microbiological fouling. Bio-fouling can create anaerobic conditions and make
the attack of sulphate-reducing bacteria possible as well as aeration conditions with the consequence of
localized corrosion.
Suspended solids: may form deposits which decrease performances and may cause corrosion and/or
erosion.

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10. Maintenance and controls by the user
ACCEPTABLE WATER QUALITY LIMITS
pH (25°C) 6.8 – 8.4
Electrical conductivity (µS/cm) (25°C) < 800
Chloride ion (mg CI-/I) < 150
Chlorine molecular (mg Cl2/l) < 5
Sulphate ion (mg SO4
--/l) < 100
Sodium nitrate (mg NaNo3/I) < 100
Alkalinity (mg CaCO3/1) < 100
Total Hardness (mg CaCO3/1) < 200
Iron (mg Fe/I) < 1.0
Copper (mg Cu/I) < 1.0
Sulphide ion (S--/I) none
Ammonium ion (mg NH4
+/I) < 1.0
Silica (mg SiO2/I) 50
Maximum particle size to pass (filtration limit) through heat exchanger (mm) 0.87
Total dissolved solids (mg/l) < 1500
Max Ethylene,Propylene glycol 50%
construction before handling.
• Always install a filter in the water inlet circuit,in order to reduce the entry of solid particles;
• Drain totally the vessel before doing any maintenance operations;
• Do not clean the flooded with non-suitable mechanical systems,e.g. drills or too high pressure jets;
• Do not clean with too aggressive chemical detergents and verify their compatibility with the materials of
FOR HEAT EXCHANGERS WITH ANODES AND ANTI-CORROSION TREATMENT: IF AT
THE FIRST INSPECTION THERE IS AN EXCESSIVE CONSUPTION OF THE ANODES, IT
MEANS THAT THE ENVIRONMENT IS HIGHLY AGGRESSIVE SO IT IS NECESSARY TO
FORMULATE A “MAINTENANCE TIMETABLE”ACCORDING TO THE AGGRESSIVNESS
OF THE WATER (IT IS NOT POSSIBLE TO SUPPLY A “STANDARD” MAINTENANCE
SCHEDULE SINCE THE ANODE CONSUMPTION IS SUBJECT TO MANY FACTORS).
FILL COMPLETELY WITH WATER OR DRAIN TOTALLY THE VESSEL IN CASE OF
LONG NON-WORKING PERIODS.