Submittal Sheet - National Pump Supply
Contents
1. OPERATION 1 When placing a unit in operation open the vent connec tions and start to circulate the cold medium only Be sure that the passages in the exchanger are entirely filled with cold fluids before closing the vents The hot medium should then be introduced gradually until all passages are filled with liquid close vents and slowly bring the unit up to temperature 2 Start operation gradually Do not admit hot fluid to the unit suddenly when empty or cold Do not shock unit with cold fluid when unit is hot CAUTION Fluids must be gradually introduced to the unit Failure to do so can cause damage to the heat exchanger 3 Do not operate equipment under conditions in excess of those specified on nameplate WARNING Failure to operate the heat exchanger within the design pressure and temperature on the nameplate may result in damage to the heat exchanger and potential injury to adjacent personnel CAUTION Fluid and or steam velocities in excess of design operating conditions on either the shell or tube side of the heat exchanger can cause damaging tube erosion and or vibrations Result is internal leakage and mixing of the hot and cold media Proper setting of system controls is required In all installations there should be no pulsation of fluids since this causes vibration and strain with resulting leaks Retighten bolting on all gasketed joints after the heat exchanger has reached operation temperatures2. Tube bundle removal Frequently and at regular intervals observe interior and exterior condition of all tubes and keep them clean Fre quency of cleaning should be according to scale build up a During bundle removal the dead weight of bundle should never be supported on individual tubes Rest the bundle on the tube sheet support plates or wood blocks cut to fit periphery of the bundle CAUTION Neglect in keeping all tubes clean may Tube bundles may be raised using slings formed by result in complete stoppage of flow through some bending light plates into a U form and attaching lifting tubes with consequent overheating of these tubes result lugs to the ends of the sheets Baffles can be easily ing in severe expansion strains leaking tube joints and bent and damaged if dragged over rough surfaces damage to the heat exchanger 6 Exchangers subject to fouling or scaling should be cleaned periodically A light sludge or scale coating on the tube greatly reduces it effectiveness A marked increase in pressure drop and or reduction in performance usually indicates cleaning is necessary if the unit has been checked for air or vapor binding and this has been found not to be the cause Since the difficulty of cleaning increases rapidly as the scale thickens or deposits increase the interval between cleanings should not be aes CAUTION When cleaning a tube bundle tubes 7 At times it may be necessary to locate a ruptured t
3. Typical installation of a SU DSU Heat Exchanger when used as an Instantaneous Heater TO HOT pP WATER FIXTURES HOT WATER STORAGE TANK RELIEF VALVE AIR VENT OR VACUUM BREAKER B amp G ALL BRONZE BOOSTER CONDENSATE TO TRAP FIGURE 3 Typical installation of a SU DSU Heat Exchanger when used with a storage tank B amp G COMPRESSION TANK B amp G COMPRESSION TANK PRESSURE GAUGE PRESSURE GAUGE B amp G FLO CONTROL B amp G FLO CONTROL VALVE a k VALVE y h ft B amp G AIRTROL 4 gt TANK FITTING peee ee eS h TO TANK TO TANK B amp G PRESSURE 4 i REDUCING VALVE GOLD WATER SUPPLY pressure cauae O US BY asc BOOSTER DRAIN PLUG B amp G BOOSTER FOR BOILER WATER For proper sizing of Airtrol System consult B amp G Representative FIGURE 4 Typical installation of a WU DWU Heat Exchanger when used as a Convertor NOTE All valves pumps tanks vents etc shown as part of a TYPICAL INSTALLATION are supplied by others Contact your ITT Bell amp Gossett Representative for these items TYPICAL INSTALLATIONS cont RELIEF VALVE TO WATERMIXER AND FIXTURES B amp G WU DWU HEAT EXCHANGER CONTROL When the WU DWU is installed on a hot water boiler as shown a B amp G Flo Control Valve prevents gravity circulation of boiler water when Booster is not running RELIEF VALVE FLO CONTROL TO WATERMIXER AND FIXTURES 4 PUMP C
4. before installing Do not expose units to the elements with pads or other covers removed from nozzles or other openings since rain water may enter the unit and cause severe dam age due to freezing 10 Be sure the entire system is clean before starting operation to prevent plugging of tubes with sand or refuse The use of strainers in settling tanks in pipe lines leading to the unit is recommended Drain connections should not be piped to a common closed manifold Steam hammer can cause serious damage to the tubes of any heat exchanger A careful consideration of the fol lowing points before an installation is made can prevent costly repairs which may be caused by steam hammer A vacuum breaker and or vent should be used in accordance with the type of steam system installed The proper trap for the steam system installed should be used The trap and condensate return line to the trap should be properly sized for the total capacity of the convertor The trap should be sized for the pressure at the trap not the inlet pressure to the steam controller Condensate should be piped and pitched to a conden sate receiver condensate return pump or drain at an elevation below the heat exchanger CAUTION During times of shutdown volumetric h oco can occur We recommend the installa tion of a properly sized relief valve on both sides of the the heat exchanger Failure to do so can cause damage to the heat exchanger
5. the bolt center to be adjusted after the foundation has set WARNING All system piping to the heat ex changer must be adequately supported Failure to do so will result in excessive loads on the heat exchanger connections causing damage and or leakage and poten tial injury to adjacent personnel WARNING When installing a Diamondback heat exchanger above a ceiling or workststion where personnel are present it may be necessary to install a drip pan to collect any tell tale drip due to internal tube failure Failure to do so may result in damage to the ceiling and potential injury to personnel 7 Loosen foundation bolts at one end of unit to allow free expansion of shells Oval holes in foundation brackets are provided for this purpose CAUTION Provision must be made to isolate the heat exchanger from any external vibrations that cause tube failures within the heat exchanger Result is internal leakage and mixing of the hot and cold media 8 Set exchangers level and square so that pipe connections may be made without forcing q be i en CAUTION It is up to the installer to provide A adequate support for tank heater units 2 two feet or longer when installing them in a tank Failure to provide adequate support may result in premature tube failure and or failure of the tube tubesheet mechanical roll joint 9 Inspect all openings in exchanger for foreign material Remove all wooden plugs and shipping pads just
6. BELL amp GOSSETT SU DSU WU DWU n HT 50B SM and HTWU DHTWU Series Installation Operation and Maintenance M anual for B amp G U Senes Heat Exchangers Removable Bundle Design Single Wall Diamondback Double Wall and Hi Temperature Units INSTALLER PLEASE LEAVE THIS MANUAL FOR THE OWNER S USE A SAFETY INSTRUCTION This safety alert symbol will be used in this manual to draw attention to safety related instructions When used the safety alert symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED FAILURE TO FOLLOW THESE IN STRUCTIONS MAY RESULT IN A SAFETY HAZARD LT Bell amp Gossett COPYRIGHT 1984 1997 BY ITT INDUSTRIES INC ITT Fluid Technology Corporation STORAGE NOTE If the heat exchanger cannot be installed and put into operation immediately upon receipt at the jobsite certain pre cautions are necessary to prevent deterioration during stor age Responsibility for integrity of the heat exchangers must be assumed by the user ITT Bell amp Gossett will not be responsible for damage corrosion or other deterioration of heat exchanger equipment during transit and storage Good storage practices are important considering the high costs of repair or replacement and the possible delays for items which require long lead times for manufacture The fol lowing suggested practices are provided solely as a conve nience to the user who shall make his own decision on whether
7. ONTROL B amp G WU DWU HEAT EXCHANGER When installed on a steam boiler note that boiler water is pumped into the WU DWU Heater from the bottom of the boiler FIGURE 5 Typical installation of a WU DWU Heat Exchanger when used as an Instantaneous Heater TO FIXTURES ee eee B amp G TANK AND HEATER UNIT OR B amp G TANK HEATER INSTALLED IN SEPARATE TANK Heating with Steam B amp G HIGH PRESSURE RELIEF VALVE COLD WATER SUPPLY TO TRAP OR CONDENSATE RECEIVER See itom 10 under Installation Instructions FIGURE 6 Typical installation of a TCS DTCS Tank Heater TO FIXTURES TO SYSTEM Heating with Boiler Water B amp G HIGH PRESSURE RELIEF VALVE nr anes fgg oana FROM SYSTEM WATER HEATER BOILER FIGURE 7 Typical installation of a TCS DTCS Tank Heater NOTE All valves pumps tanks vents etc shown as part of a TYPICAL INSTALLATION are supplied by others Contact your ITT Bell amp Gossett Representative for these items REPLACEMENT PARTS When replacement parts are required refer to part identified in the drawing of the proper unit When ordering be sure full nameplate information is given including Nat l Bd No and or Serial No Catalog and Factory Number EXAMPLE One replacement tube bundle for Serial No 97C77001 01 1 Catalog No SU 64 2 Factory No 5 260 06 048 001 Note Gaskets are always furnished with replacement tube bundles and need not be o
8. for equilibrium since the tightening of one bolt stud can relieve the stress on adjacent bolts studs If after following the gasket manufacturer s recommended tightening procedure a leak still occurs the bolts studs should be tightened in the torque increments shown until the leak stops The staggered tightening pattern is still followed NOTE When using spiral wound gaskets both the head and the shell tank gaskets must be spiral wound You can not mix one spiral wound and one compressed fiber gas ket on a heat exchanger Refer to OPERATION steps 5 and 6 regarding bolt re tightening after start up Where frequent disassembly of the heat exchanger is encountered the use of new bolting in conformance with dimension and ASTM specifications of the original design is recommended TYPICAL INSTALLATIONS SLIGHT GLASS TAPPINGS B amp G ASME EXPANSION TANK DRAIN O TANK n B amp G ASME B amp G AIRTROL a RELIEF VALVE TANK FITTING r CONTROL VACUUM BREAKER CONDENSATE OUT ie N ay B amp G ASME PRESSURE B amp G TRIPLE DUTY VALVE gt REDUCING VALVE B amp G PUMP x THERMOMETER B amp G ASME ROLAIRTROL FIGURE 1 Typical installation of a SU DSU Heat Exchanger when used as a Convertor AUTOMATIC STEAM REGULATING my lt gt HOT WATER AIR VENT OR VACUUM BREAKER TYPE SU DSU HEAT EXCHANGER CONDENSATE TO TRAP See Item 10 under Installation Instructions FIGURE 2
9. mar Som depasite The result of either of the above conditions can lead to Soft salt deposits may be washed out by circulating failure of the tube and a leaking bundle hot fresh water Some cleaning compounds on the market such as Oakite may be used to advantage for removing sludge or coke provided hot wash oil or water as described above does not give satisfactory results e If an emergency repair of a tube is required use suit able tube plugs to seal off both ends of the U bend tube Some loss of performance will result until a new replacement tube bundle is obtained Consult your local If the above methods are ineffective for removal of hard ITT Bell amp Gossett Representative for proper replace scale a mechanical means may be used ment of the bundle WARNING Care must be exercised when handling CAUTION Field repair of Diamondback double certain fluids Follow manufacturers instructions wall heat exchangers is not recommended Re Use eye and skin protection Wear a respirator when rolling of the tube joints may result in the closing of the required leak detector flow paths between the two tube walls pre venting the heat exchanger from providing a positive Do not attempt to clean tubes by blowing steam through indication of potential cross contamination individual tubes This overheats the tube and results in ti xpansion strains an metimes leaking tubes ube expansioistrains and sometimes leaking 8
10. n tightening flanges with spiral wound gaskets if cocking occurs the result can be deformation and non repairable damage to the gaskets in addition to a resultant leak Any gasket leak can result in potential injury to adjacent personnel TIGHTENING TORQUES COMPRESSED FIBER GASKETS Recommended Torque Torque ft lbs Increment 40 5 80 5 SPIRAL WOUND GASKETS Recommended Bolt Stud Torque Torque Max Dia ft lbs Increment Torque Ya 40 5 60 5 a 80 5 120 3J 120 5 200 fa 200 10 320 1 300 10 490 T s 450 10 710 Lf 600 10 1000 Tightening tip It is essential that the installer follows the gasket manufacturer s installation guidelines when installing gaskets Metallic gaskets such as the spiral wound gaskets usually have special installation instruc tions One of these instructions includes a special proce dure for tightening bolts studs when installing new gas kets The procedure recommends that the bolts studs be torqued in four stages a Following the staggered tightening pattern the bolts studs should be torqued to 1 3 of the recommended tightening torque Same as a the bolts studs should be torqued to 7 3 of the recommended tightening torque Same as a the bolts studs should be torqued to the recommmended torque valve shown in the above chart Following the staggered tightening pattern the bolts studs torques should be checked
11. orage environment for heat exchangers and accessories is indoors above grade in a dry low humidity atmos phere which is sealed to prevent entry of blowing dust rain or snow Maintain temperatures between 70 F and 105 F wide temperature swings may cause condensation and sweating of steel parts Cover windows to prevent temperature variations caused by sunlight Provide ther mometers and humidity indicators at several points and maintain atmosphere at 40 relative humidity or lower In tropical climates it may be necessary to use trays of renewable dessicant such as silica gel or portable dehu midifiers to remove moisture from the air in the storage enclosure Thermostatically controlled portable heaters vented to outdoors may be required to maintain even air temperatures inside the enclosure Inspect heat exchangers and accessories frequently while they are in storage If paint deterioration begins as evidenced by discol oration or light rusting consider touch up or repainting If the unit is painted with our standard shop enamel areas of light rust may be wire brushed and touched up with any good quality air drying synthetic enamel Units painted with special paints when specified on customers orders may require special techniques for touch up or repair Obtain specific information from the paint manufacturer Painted steel units should never be permitted to rust or deteriorate to a point where their st
12. rdered separately SU DSU WU DWU and HTWU DHTWU HEAD GASKET REPLACEMENT TUBE BUNDLE TANK GASKET TCS DTCS and TCW DTCW TANK GASKET HEAD HEAD GASKET REPLACEMENT TUBE BUNDLE TANK COLLAR For further information contact ITT Bell amp Gossett Heat Transfer Products 175 Standard Parkway Cheektowaga NY 14227 Phone 716 862 4171 Facsimile 716 862 4176 http fhs ittind com LT Bell amp Gossett ITT Fluid Technology Corporation
13. rength will be impaired A light surface rust on steel units which can be repainted after installation will not generally cause any harm See Items 3 and 4 for internal surface preservation If the internal preservation Items 3 and 4 appears inade quate during storage consider additional corrosion pre vention measures and more frequent inspections Interiors coated with rust preventive should be restored to good condition and recoated promptly if signs of rust occur INSTALLATION 1 Provide sufficient clearance at the head of the unit to per mit removal of tube bundle from shell Provide valves and by passes in the piping so that both the shell and tube bundle may be by passed to permit iso lation of the unit for inspection or repairs Provide thermometer wells and pressure gauge connec tions in all piping to and from the unit and located as near the unit as possible Provide convenient means for frequently cleaning the unit as suggested under MAINTENANCE Provide necessary air cocks for units so they can be purged to prevent or relieve vapor binding of either the tube bundle or the shell Foundations must be adequate so that exchangers will not settle and cause piping strains Foundation bolts should be set to allow for setting inaccuracies In concrete foot ings pipe sleeves at least one size larger than bolt diame ter slipped over the bolt and cast in place are best for this purpose as they allow
14. revent stagnant water conditions that can ultimately cause corrosion MAINTENANCE Following the procedures previously mentioned for A front head removal remove the head and replace it with 1 Do not open heads until all pressure is off equipment the a companion flange that mates with the shell body unit drained of all fluids and the equipment surfaces flange Replace the nuts and bolts studs cooled to ambient temperature i PRN b Pressurize the shellside of the heat exchanger with a 2 Do not blow out heat exchangers with air when operating cold fluid preferably water fluids are of a flammable or otherwise hazardous nature ae ia ee Observe all tube joints and tube ends for indication of test fluid leakage WARNING Proper precautions must be taken To tighten a leaking tube joint use a suitable parallel special clothing equipment etc to protect per roller tube expander sonnel from injury due to escaping fluids or hot heat exchanger Sullaces A CAUTION When tightening leaking tube joints 1 Do not roll tubes beyond the back face of the tubesheet 3 Provide convenient means for frequently cleaning heat Maximum rolling depth should be the tubesheet thickness exchangers as suggested below minus t s a Circulating hot wash oil or light distillate through tubes 2 Do not re roll tubes that are not leaking since this will or shell at good velocity will effectually remove sludge thin the tube wall gro ther Si
15. to prevent leaks and gasket failures Retightening should be done uniformally and in a diametrically staggered pattern as illustrated in MAINTENANCE On high pressure and high temperature applications where an HTWU DHTWU heat exchanger is used or any appli cation where spiral wound gaskets are required it is rec ommended that the gasketed joints of the heat exchanger be retightened to the required torque see MAINTE NANCE after 24 hours at operating pressures and tem peratures to compensate for any relaxation or creep that may have occurred In shutting down flow of hot medium should be shut off first If it is necessary to stop circulation of cooling medium the circulation of hot medium should also be stopped by by passing or otherwise Drain all fluids when shutting down to eliminate the possi bility of freezing and corrosion To guard against water hammer condensate should be drained from steam heaters and similar apparatus both when starting up and when shutting down Heat exchangers that are out of service for extended periods of time should be protected against corrosion as described in the storage requirements for new heat exchangers Heat exchangers that are out of service for short periods and use water as the flowing medium should be thoroughly drained and blown dry with warm air if possible If this is not practical the water should be circulated through the heat exchanger on a daily basis to p
16. to use all or any of them 1 On receipt of the heat exchanger inspect for shipping damage to all protective covers If damage is evident inspect for possible contamination and replace protective covers as required If damage is extensive notify the car rier immediately If the heat exchanger is not to be placed in immediate ser vice take precautions to prevent rusting or contamination Heat exchangers for oil service made of ferrous materials may be pressure tested with oil at the factory However the residual oil coating on the inside surfaces of the exchanger does not preclude the possibility of rust forma tion Upon receipt fill these exchangers with appropriate oil or coat them with a corrosion prevention compound for storage The choice of preservation of interior surfaces during stor age for other service applications depends upon your sys tem requirements and economics Only when included in the original purchase order specifications will specific preservation be incorporated prior to shipment from the factory Remove any accumulations of dirt water ice or snow and wipe dry before moving exchangers into indoor storage If unit was not filled with oil or other preservative open drain plugs to remove any accumulated moisture then reseal Accumulation of moisture usually indicates rusting has already started and remedial action should be taken Store under cover in a heated area if possible The ideal st
17. ube or should not be hammered on with any metallic tool a leaking joint between the tubes and the tubesheet of a and in case it is necessary to use scrapers care should single wall heat exchanger The following procedure is be exercised that the scraper is not sharp enough to cut recommended the metal of the tubes 9 Before reinserting the tube bundle into the shell or collar of a tank place the ring tank gasket over the end of the tube bundle and bring forward to the backside of the tubesheet TUBE BUNDLE PARTIALLY REMOVED HEAD GASKET TANK GASKET 10 The tube bundle can be replaced using the tools and reverse procedure given for bundle removal 11 When installing a Diamondback double wall tube bun dle make sure the leak path drain hole in the spacer ring between the two tubesheets is in the lowest position of the tubesheet circle SPACER RING SHELLSIDE TUBESIDE TUBESHEET TUBESHEET MECHANICALLY ROLLED TUBE J OINT DOUBLE WALL TUBE J OINT 12 When replacing the heads use a torque wrench to tighten the bolts studs and nuts Use the following chart as a guide All torque values apply to well lubricated nut bearing surfaces All bolted joints should be tightened uniformally and in a diametrically staggered pattern as illustrated below START WARNING It is extremely important to follow a proper tightening sequence If it is not followed the flanges can become cocked and a leak will result Whe
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