OPERATING INSTRUCTIONS
Contents
1. ba HYDRAULIK OPERATING INSTRUCTIONS Shell and tube heat exchanger Dipl Ing K Dietzel GmbH LeedenstraBe 10 D 04626 Beerwalde Page 1 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 36602 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de HYDRAULIK Contents 1 Implementation 3 1 1 USS eect ered oc ences EEE erected tesa cen te dente E E E 3 1 2 PS Sel SUS CS ee ee Benin nee ee 3 1 3 Warnanty and OBO ciara heen seb ee eignet 3 2 Safety precautions 4 2 1 Safety symbols used in the instructions ccccccececeseeseeceeeeeeeaeeeeeeceeeeeesesaaeeeeeeeeeessaaaaeeseeees 4 2 2 Standards and direelives sense naeh heuer een heine he 4 2 3 FAS Sana AD SS ee es ern nee nee 5 2 3 1 Safety symbols used in the instructions u00ss0000000nnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnne nennen 5 2 3 2 INAIDED AUCH een Eee 5 2 3 3 Prefill pressures SWITCHING points a aaa 5 2 3 4 FOO UCT KO ee ee ee ee ee 6 2 4 General SAlely INIOrmalloON essen rennen een 7 2 4 1 Requirements to be met by the personnel ccccsssscccccceeeeeceeeeeeeeeeeeeaeeseeeeeseaaeeeessaeeeeeeeeeaas 7 2 4 2 Safety precautions for the technical condition 222000000220000nnnnnnennnnnnnnnnnnnnne nennen 9 2 4 3 Safety precautions for transport erection and installation uuss002404000ennennnne nennen 9 2 4 4 Safety Precautions for operation2. Dipl Ing K Dietzel GmbH Windm hlenstra e 6 D 04626 Beerwalde 8 1 Maintenance intervals A CAUTION Risk of losing performance Define the maintenance intervals so as to ensure that there will be no loss of heat exchanger performance which may endanger the operation of your plant The service life of your heat exchanger depends on the quality of the fluids and on their components The performance parameters determined during operation should be used for defining the maintenance intervals which are the sole responsibility of the owner Please note the following Define the inspection intervals according to the corrosion damage detected during the first visual inspection The stationary zinc anode needs to be replaced when it has lost approx 70 of its zinc quantity CAUTIONG Risk of damage to components due to aggressive coolants When it is used to prevent against electrolytic corrosion check the wear of the zinc anode during the first two weeks after the initial start up of the unit Determine the service life and the inspection intervals on the basis of this amount of wear 63 HYDRAULIK 8 2 Replacing pullable tube bundles WZ WZS WTE A To replace the tube bundle proceed as follows 1 ze wy gt 9 CAUTION Risk of damage to the tube bundle To avoid damage to both the tube bundle and the lamellas prevent canting the tube bundle during assembly or disassembly NO
3. close every port with a plug and to apply preservative agent in order to protect your heat exchanger against corrosion Penn NOTE i For information on the selection and use of preservative agents please contact Dipl NOTE Ing K Dietzel GmbH Do not exceed a storage period of 2 years Safety heat exchanger under pressure should not exceed a storage period of 6 Month 63 HYDRAULIK 6 Erection or disassembly DANGER Accident and injury hazard Before assembling or removing the heat exchanger shut down the plant and lock it out to prevent its inadvertent restarting DANGER Accident and injury hazard due to improper assembly or disassembly work N The total weight of a heat exchanger of the WTE series may be up to 150 kg Use lifting gear or sling equipment which has been dimensioned sufficiently to carry this weight when performing any assembly or disassembly work NOTE Risk of contamination by escaping fluids If your heat exchanger is part of a system with a tank or reservoir please check whether the tank level is higher than the installation level of your heat exchanger before starting its assembly or disassembly If so you must drain the tank beforehand 6 1 Erection conditions To benefit from the unit s full capacity please observe the following precautions during assembly and installation To guarantee the free passage of fluids inspect your heat exchanger for any contamination
4. corrosion Select materials which are not very far from one another in the electrochemical series or use a zinc anode Bronze and copper nickel alloys ensure good durability against sea water Brackish water Mix of sea and river water Mostly presents a high ammonia and chloride content so use brass High content of NaCl providing for a good electrolyte Mating different materials leads to a risk of electrolytic corrosion Select materials which are not very far from one another in the electrochemical series or use a zinc anode 63 HYDRAULIK 4 Technical Description Construction The pipe bundle heat exchanger is primarily comprised of the following components 01 Casing pipe with inlet and outlet nozzles 02 Pipe bundle with aluminum fins 03 Tube plates 04 Dismountable connection cover 05 Dismountable redirection cover 06 Drain screw on casing side 07 Drain screw on pipe side 08 Screw on bracket for mounting 09 Pressure sensor switch safety heat exchanger 10 Membrane reservoir safety heat exchanger 11 filler coupling check valve safety heat exchanger 3 1 2 3 5 Figure 4 WNZ top WNZS bottom Dipl Ing K Dietzel GmbH LeedenstraBe 10 D 04626 Beerwalde Page 15 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 36602 140 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de ha HYDRAULIK 4 2 Connections
5. exchanger unless by personnel which has been duly trained instructed and authorised for such work The area of responsibility of every person should be clearly defined Before initiating any activity the personnel must have been familiarised with the hazards involved in using the shell and tube heat exchanger This heat exchanger may cause a risk of injury if operated by any untrained person Every person put in charge with operating or servicing the shell and tube heat exchanger must have read and understood the complete operating instructions and be familiar with all safety precautions described therein Please observe the following Every safety precaution included in these operating instructions and in every further applicable document must be observed and adhered to without any restriction at all times This shell and tube heat exchanger must not be operated unless by trained personnel which has been duly instructed on the technical aspects of safety 63 HYDRAULIK Such personnel must not present any physical limitation which may temporarily or permanently limit its attention or judgement This heat exchanger must not be operated and no maintenance assembly repair or cleaning work must be carried out by any person who is under age overtired or under the effect of alcohol drug or medication The personnel must have sound knowledge of the following operational sequences regulations practical procedures and component
6. gt HYDRAULIK CAUTION Risk of damage to the system Ensure that the inlet and outlet lines are connected each to the correct ports Please observe the piping layouts CAUTION Risk of cracking The use of calking strip on pipe threads leads to a higher risk of cracking in cast elements because it increases the resistance between the parts connected Do not tighten the threads too firmly CAUTION Risk of destroying components of the shell and tube heat exchanger by exposure to seawater or brackish water Install a zinc anode to prevent electrolytic corrosion in a heat exchanger which is used in a cooling circuit running with seawater or brackish water CAUTION Warning against reduced performance Horizontal installation with the drain outlet pointing downward is preferred for heat exchangers belonging to the BU series A reduced performance should be expected when these heat exchangers are mounted in an upright or oblique position If this mounting position is selected the drain outlet must always be installed at the lower side because no drainage of the heat exchanger will be possible otherwise When a heat exchanger of the BTU series is installed in a horizontal position make certain to turn the heat exchanger so that the drain outlet points downward gt p CAUTION A Risk of cracking To avoid any risk of cracking tighten the fastening screws of the connecting flanges evenly in a crosswise order To in
7. instructions for the diaphragm accumulator which are included in the delivery must be stored with the heat exchanger documents and must be complied with The operating instructions can be downloaded from the link provided below Link addresses Pressure sensor PP7553 without display http www ifm com products de ds PP7553 htm Pressure sensor PN7003 with display http www ifm com products de ds PN7003 htm Programming and display unit PP2001 http www ifm com products de ds PP2001 htm ELM hydraulic accumulator http www olaer de pdf anleitungen doc6120_ betriebsanleitung hydrospeicher pdf ba HYDRAULIK 4 6 Tank insert cooler WTE For heat exchangers in the WTE series Medium 2 medium to be cooled is led into the heat exchanger through an inlet nozzle on the casing and directly into the tank through redirection segments Figure 11 WTE model 4 7 Screw in cooler WES Heat exchangers in the WES series are screwed directly into the tank Figure 12 WES model Dipl Ing K Dietzel GmbH LeedenstraBe 10 D 04626 Beerwalde Page 22 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 86602 140 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de HYDRAULIK 5 Transport storage and preservation DANGER Risk of injury by improper transport The total weight of a heat exchanger of the WNZ or WTE series may be up to 150 kg When transporting a shell and tu
8. or brackish water or any other aggressive liquid as a coolant in a standard model Such aggressive coolant requires the use of specific material CAUTION Risk of damage to components due to aggressive coolants To prevent electrolytic corrosion a heat exchanger using a coolant like e g seawater or brackish water must be equipped with a zinc anode at the cooling water inlet end Specific materials must be used if seawater or brackish water is used as fluid 1 cooling fluid in a heat exchanger If you intend any use under such conditions please contact Dipl Ing K Dietzel GmbH HYDRAULIK 8 Maintenance repair and cleaning a i i NOTE Risk of contamination by escaping fluids If your heat exchanger is part of a system with a tank or reservoir please check whether the tank level is higher than the installation level of your heat exchanger before starting its assembly or disassembly If so you must drain the tank beforehand NOTE No repair must be performed on the tube bundles of the heat exchanger unless in an emergency and unless by authorised personnel If any such event occurs please always contact Dipl Ing K Dietzel GmbH Analyse any sign of failure and communicate it to the manufacturer NOTE All warranty or liability claims will be void when using any spare part or wearing part other than those approved by the manufacturer Please contact the manufacturer to order spare parts or wearing parts
9. the sensor the signal lines may not be interrupted and the heat exchanger may not have a leak between the pressure chambers The working of the sensor is checked by programming the switch points during filling and setting of the pressure of the intermediate space Thus the sensor is ready to operate as soon as the operating voltage is applied The pressures set such as the nitrogen prefill pressure membrane reservoir the fill pressure and the programmed switch points can be found on the label on the casing of the heat exchanger or the technical drawing 63 HYDRAULIK Pressure Checks of the sealing medium must take place via the pressure sensor The filler coupling must only be used to fill in the sealing medium The connection and specifications of the pressure switch can be found in the operating manual and the datasheet of the sensor see link addresses A change to the pressure sensor programming is only possible using the programming and display unit provided for this purpose see link addresses The programming and display unit required for maintenance as well as the other necessary tools can be loaned from Dipl Ing K Dietzel GmbH for a separate charge Dipl Ing K Dietzel GmbH also offers employee training on request WARNING Danger of loss of the safety function Even a small amount of leaked liquid can impair the safety function 4 5 3 Diaphragm accumulator hydraulic accumulator The operating
10. to material resistance The heat is taken from medium 2 the medium to be cooled through the surface of the aluminum fins and transferred to medium 1 the coolant medium and brought out with its fluid flow c elzel HYDRAULIK Pipe bundles with a fin block additionally expand the heat transmission surface on the casing side This makes this type of pipe bundle heat exchanger particularly suitable for oil water applications For water water applications due to the fact that the material values heat conductivity heat capacity are the same pipe bundles without fins are more suitable The heat transfer performance is calculated as the product of the average log temperature difference between the two media the heat transfer area and the heat transfer coefficients The heat transfer coefficient is a specific value that depends on the materials used the material values of the media and the flow conditions A variety of application cases or conditions of use required special layout of the pipe bundle heat exchanger The layout and calculation tune the variable parameters to one another in such a way that the desired heat transfer performance can be achieved with the smallest possible component size Adaptation to conditions of use is done primarily using the nominal width length of the pipe bundle number of redirection plates fin spacing and the number of channels in the pipe With the options listed here the pipe bundle heat ex
11. value Assessment criterion Chloride Sulphate Nitrate Free aggressive carbonic acid Ammonium Iron dissolved Available chloride Sulphide Value Value mg sem O o p00 SSS woo o HE so CP T CdS Tab 5 Assessing cooling water quality by water components Explanations on the assessment table column O N in the water Good durability under normal conditions Corrosion may occur especially when several factors have been assessed as 0 Its use is not recommended Deoxidized copper proves best when no dissolved oxygen and no sulphide is present 63 HYDRAULIK NOTE H Values higher than those indicated in table 5 apply to copper nickel tubes as a general rule 3 3 4 Types and special characteristics of cooling water Industrial water Untreated water no drinking water often presents a high amount of impurities Have the water analysed to assess its quality Copper bronze and steel provide for a high resistance to industrial water Water from brooks or rivers Dipl Ing K Dietzel GmbH recommends the use of copper nickel tubes To protect against corrosion a suitable coating must be applied to steel elements Untreated water no drinking water often presents a high amount of impurities Have the water analysed to assess its quality Sea water High content of NaCl providing for a good electrolyte Mating different materials leads to a risk of electrolytic
12. TE For disassembly 2 threaded holes for inserting forcing screws are located at the flange end of tube bundle Switch off and lock out the plant to prevent its unintended restart Shut off every fluid lines and depressurize the heat exchanger Drain all fluids and drain the tank if necessary Remove all pipework from the cover Remove the fastening screws from the cover and pull the tube bundle out of the shell Clean the shell space of the heat exchanger see chapter 8 4 Provide a new tube bundle with a new O ring and carefully slide the tube bundle into the shell Mount the cover with a new flat gasket and tighten the fastening screws evenly in a crosswise order Reinstall and purge vent all fluid lines 8 2 1 Replacing a zinc anode optional To replace the zinc anode proceed as follows 1 2 Switch off and lock out the plant to prevent its unintended restart Shut off both the cooling water inlet and outlet lines and the inlet and outlet lines of fluid 2 fluid to be cooled fluid cooled at the heat exchanger Depressurise the heat exchanger and drain fluid 1 cooling fluid Unscrew the zinc anode assess its wear and replace it if necessary Purge the lines before restarting the plant 8 3 Cleaning The heat exchanger tube bundles may be cleaned from the inside and for pullable variants also from the outside To determine the cleaning intervals please refer to the performance parameters determined d
13. The heat exchanger is equipped with inlet and outlet nozzles on the casing as well as inlets and outlets on the connection cover Due to the increased heat transmission area from the aluminum fins medium 1 coolant medium see 3 2 4 is led through the pipes while medium 2 medium to be cooled such as hydraulic oil flows through the casing space The heat exchanger is connected as a counter flow or cross counter flow arrangement as shown in Figure 5 In comparison with the parallel flow arrangement this provides a larger average logarithmic temperature difference leading to greater heat transmission performance In the multi way variant with an even numbers of channels 2 4 and 6 way the inlet and outlet of both media may be connected arbitrarily In these cases the heat exchanger is operated independent of the connection inlet and outlet direction by counterflow and parallel flow to equal extents Medium t Medium Figure 5 Connections There are also drain screws both on the casing and on the connection or diversion cover that are provided for the emptying of the heat exchanger 4 3 Functional description The pipe bundle heat exchanger is a pressure container consisting of two pressure chambers casing side and pipe side that are separate from one another The pipe bundle expands the heat transmission area and permits heat transmission between different media by means of appropriate material pairs with respect
14. and limb by exposure to poison CAUTION A N Warning against possible damage to property or equipment 2 1 Safety symbols used in the instructions NOTE Important general note NOTE Important note on environmental protection 2 2 Standards and directives The heat exchanger has been constructed according to the technical rules and standards as currently applicable and it is safe to operate The fundamental requirements in terms of safety and health have been observed during the development and construction of the heat exchanger as defined in the applicable laws standards and directives All safety related information included in these operating instructions refer to the national laws and EU directives as currently applicable The relevant regulations governing accident prevention and environmental protection need to be observed in addition to the safety precautions indicated in these operating instructions 63 HYDRAULIK 2 3 Plates and labels 2 3 1 Safety symbols used in the instructions The surface temperature of the heat exchanger at the shell tube and shell connections can reach the maximum operating temperature of 95 depending on the operating conditions Figure 1 Warning against a hot surface sign DANGER AN an or injury hazard due to missing or damaged safety signs Damaged or missing safety symbols at the shell and tube heat exchanger may lead to human errors and consequent personal injury or dama
15. be heat exchanger do not use any lifting gear or sling equipment unless it is dimensioned sufficiently to carry this weight No person to be under suspended loads CAUTION Warning against possible leaks from damaged seal faces When moving the equipment make certain not to scratch the seal faces of the connecting flanges CAUTION A N Warning against possible frost damage Drain the cooling water from the heat exchanger to avoid frost damage during storage at subzero temperatures CAUTION Warning against possible damage to tube bundles When tube bundles are transported or stored make certain not to damage or bend the lamellas or tubes NOTE Risk of contamination by preservative agents When they are used for treatment preservative agents must neither penetrate into the ground nor reach the sewer system They must be disposed of in accordance with the applicable regulations for environmental protection The same applies to the removal of preservative agents Depending on its weight a heat exchanger will be transported either in cardboard boxes oron pallets All openings in the heat exchanger are closed by plugs Bare surface as at the shell side inlet and outlet connections are protected with high performance corrosion protection This long term corrosion protection needs not be removed before commissioning due to the compatibility with most mineral oil based lubricants NOTE For storage please remember to
16. cccccccsesseseececeeeeeaeseeeeceeeeeesaeeeeceeeeeeseaeeeeceeeeeessuaaeeeeeeees 9 2 4 5 Safety precautions for maintenance uuuuessnnssssnnnneeennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnn 10 3 Technical data 11 3 1 Operating pressure and operating temperature cccccccccecceeeeseeeeeeeeeeaeeeseeeeeeeeeeaaaneeeeeeees 11 3 2 PACS NANG resne es E EEE E A E E AER 11 3 3 Water quality requirements cccccssscccccesseecceeseecceeseeeceauececseueceeseaeeessaeeessuseesssaseeessagseees 12 3 3 1 Water ARON CSS innen are enge Erde EEE ER 12 3 3 2 DIE VA nenne rear age EEE Renee EEE 12 3 3 3 Cooling water assessment by its componeniS uussnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 13 3 3 4 Types and special characteristics of cooling water u0020000020nnenennnenennnnnennnnnnnnenennn 14 4 Technical Description 15 4 1 OMS UC TON ener a ee nee 15 4 2 CONA CONN cece REDEN EEE NERE EINER NINE EE E EEAO EEEE E 16 4 3 FUNC TOM eNOS SCA TOMA een een ee ee ee 16 4 4 WNZ and WZ series universal series us 0400000200nnnnnnnnnnnnnnnnnnennnnnnnnnennnnnnnnnennnnnn nenn 18 4 5 WNZS and WZS series safety heat exchanger cccccccsseesseeeeeeeeeeeeeseeeeeeeeesaaesseeeeeeeeeeaas 19 4 5 1 Filling sealing Medi ee neueren 20 4 9 2 FS SS GOING Or anne an a ee een ae Rene regen 20 4 5 3 Diaphragm accumulator hydraulic accumulator ccecceeceeeeeeceeeeeeeeeeeeeeeue
17. changer can be adapted very well with a cross flow arrangement to the specific application Figure 7 WNZS cross section For WNZS and WZS model heat exchangers both media are also separated from one another by a sealing medium shown in yellow in Figure 7 This ensures that in case of leaks the two media cannot mix together ruling out contamination In this model series the pipes of the bundle are double walled thus consist of an inner and an outer pipe The space thus created between them is filled with a harmless food suitable glycol water mixture that serves as a sealing medium The membrane reservoir is used for volume compensation required due to temperature changes and keeps the pressure in the intermediate space which is monitored by a pressure sensor constant A leak on one side or the other pipe space or casing space would cause a pressure change in the intermediate space which would then be registered by the pressure sensor 63 HYDRAULIK 4 4 WNZ and WZ series universal series Design features for WNZ Straight interior pipes Pipe bundle with aluminum fins Tube plates are welded to the casing pipe 1 2 4 or 6 way variants on pipe side can be implemented Drain screws on pipe except for 6 way variants and casing side Holding plates are screwed to the tube plates Figure 8 WNZ model Design features for WZ Straight interior pipes Extractable pipe bundle with a
18. e the safety aspects when performing any work Shut down the heat exchanger immediately whenever you become aware of any risk which may cause personal injury or damage to property or the environment In addition to the safety precautions included in these operating instructions the owner must also observe the general regulations applicable to safety and accident prevention as defined in the country in which this equipment is used Make certain to exclude any mishandling which may lead to a loss of use or impair the environment The personnel must have read and understood the operating instructions prior to erection or start up This includes in particular knowledge about how to avoid any risk of injury for users or third persons Every safety precaution included in these operating instructions and in every applicable document need to be observed and complied with Observe the regulations applicable to safety at work and environmental protection when performing any work on this heat exchanger including e g erection disassembly transport cleaning or maintenance Every spare part or wearing part should be ordered from Dipl Ing K Dietzel GmbH as a basic rule Dipl Ing K Dietzel GmbH does not assume any liability whatsoever for any damage which may result from the use of a spare part made by another manufacturer 2 4 1 Requirements to be met by the personnel No work must be performed on the shell and tube heat
19. ed by Water hardness pH value of the water 3 3 1 Water hardness Water hardness indicates the content of hardness components carbonates and bicarbonates Hardness components will deposit on the tube surfaces especially at a higher temperature thus reducing the performance of the heat exchanger A temperature of 63 is considered critical If the water is very hard these deposits need to be taken into account in the heat exchanger design Millimole of calcium Degree of hardness in dH carbonate per litre German hardness degree lt 8 4 OH 1 5 25 8 4 14 dH gt 140H Tab 3 Water quality classification by hardness ranges A rule of thumb which may be used for converting values into German hardness is as follows 10 mg l of hardness components correspond to 10H 3 3 2 pH value The following rule applies to shell and tube heat exchangers with copper and copper nickel tubes pH value not less than 6 Corrosion may occur if the value is smaller Rule for alkaline water Water hardness not less than 6 H Corrosion may be caused by free carbonic acid if the value is lower a e E a5 fionyaci 6 0 68 weakyacia A rm 63 HYDRAULIK Tab 4 Classification of water quality by pH value 3 3 3 Cooling water assessment by its components The table indicated below provides an overview of the resistance of copper tubes to water components contained in non drinking water Assessment criterion pH
20. eeeeecceeseeecsueeeeseseeessseeessageeeessgeeesssaeeeeees 32 8 4 Maintenance of the safety function only WNZS us02222200000200n0nnnnnnnnnnnnnnnnnnnnnne nennen 33 9 Disposal 33 63 63 HYDRAULIK 1 Implementation 1 1 Notes These operating instructions describe the functionality and handling of shell and tube heat exchangers made by Dipl Ing K Dietzel GmbH Any modification in the product will be reserved to further technical development For further information please refer to the data sheets contact Dipl Ing K Dietzel GmbH or go to www dietzel hydraulik de 1 2 Use as intended The heat exchangers made by Dipl Ing K Dietzel GmbH have been designed for use with specific fluids pressures temperatures and other parameters For the technical data and conditions of use applicable to every heat exchanger please refer to its nameplate or data sheet The installation operation and maintenance of the heat exchangers is not allowed unless to trained specialist personnel observing both the safety precautions and the operating instructions The safe operation of the heat exchangers is guaranteed provided that they are used in accordance with their intended purpose and specifications Any use other than that shall be deemed contrary to the intended use Liability for any personal injury or damage to property resulting from any such use contrary to the intended purpose shall not be assumed by the man
21. eeeeeneeeeessneeeens 21 4 6 Tank meert cooler WT Eseese es anregen 22 4 7 DELEW IN COOLEST WE G une rorat nenies ird sogo Mnao De ES ASETE Ea E aA DES o e 22 5 Transport storage and preservation 23 6 Erection or disassembly 24 6 1 Erection conditions cccccceecccceeeecceececeeececeeeeeceeeeeseucesseuceesaeeessueeeseeeesaeeeseeessaeeesseeeetsneeesaes 24 6 2 Installing and connecting theheat ExCNANGEL ccccccsseeeeceeeeeeseeseeeseeeeeeeeeeeeeesaeeesaeeeeeeens 24 6 3 Disassembling the heat exchanger ccccccseseeecseeeeeeeeeeeeeeeeeeeeseeeeeeeeeeesseeeeessegeeessseeeeeeas 26 7 Operation 27 8 Maintenance repair and cleaning 28 8 1 Maintenance intervals ae a En eh a area aaa naeh 28 8 2 Replacing pullable tube bundles WZ WZS WTB uus22222200000nennnnn nn nnnnnnnnnnnnennnnnn nennen 29 8 2 1 Replacing a ZINC anode optional cccccsseeeceeeceeeeeeeeeeeeeeeeesseeeeeeeeseeceeeeeeseeeeeeeesseeeeeeeeeas 29 8 3 CEN ame ee ee ne ie ee ee eee 29 8 3 1 Safety Precautions for CIEANING cccccccccssseseeccceeeeceeeeeeeceeeeseeaeeeeeeeeeessaeeeeeeeeessaaaeeeeeeess 30 8 3 2 Cleaning a tube bundle caccscti seve scisncetedsecnsecdelsnensstceiedasteraisssterscuwsadeat ccey nee heran euere 30 8 3 3 Cleaning the shell space ccccssescccccssseeceecceeeeeceeceeeeseeeeceeaeceeseseaeeeeessuaaseeeesseageeeessaaeeeees 32 8 3 4 Reinstallation after cleaning cccccsssccccsseeecseeeeec
22. g work please make certain to remove all cleaning agents from the shell leaving no residue if possible before putting your heat exchanger back into operation 8 3 4 Reinstallation after cleaning A CAUTION Risk of fluid escape under pressure Avoid damaging seal faces Do not use any sharp tools to clean a seal face Tool marks on a seal face may cause a leak Before installing a new gasket carefully clean any sealing remains from the seal face Soiled seal faces may cause injuries e g to eyes when fluid escapes under pressure after restarting the plant 1 Remove the old flat gaskets 2 Clean the seal faces and remove all sealant residues while carefully avoiding any damage to the seal faces 3 Insert new flat gaskets ensuring their proper fit Flat gaskets may be ordered by indicating the item number of the heat exchanger A sealant like Loctite 518 or Loctite 5188 may be applied to increase the sealing effect Put on the cover in its correct position Tighten the screws evenly in crosswise order Recommended torque values M6 9Nm M8 25Nm M10 44Nm 6 To secure the screws we recommend to apply a locking liquid like e g Loctite 243 or Loctite 2400 7 Itis not necessary to re tighten the screws 63 HYDRAULIK 8 4 Maintenance of the safety function only WNZS Warning Danger of floss of performance lt is not at all recommended to do maintenance work except pressure checking at the safety f
23. ge to property Do not remove any danger sign or information sign Replace any danger sign or information sign which may have become damaged scratched or illegible Use water and soap but no fuel or solvent to clean danger signs or information signs 2 3 2 Nameplate The heat exchanger has a nameplate for identification chelzel HYDRAULIK Equipment WNZ 125 4 0600 5 G112 G034 01 02 02 08 Item number WT 00048 Serial number 000319 Consignment number 172710 Date 11 10 Tube end Shell end Maximum operating 16 40 Maximum operating 95 Dipl Ing K Dietzel GmbH Windm hlenstra e 6 D 04626 Beerwalde Tel 49 36602 140 0 Fax 49 36602 34727 www dietzel hydraulik de Figure 2 Nameplate Warranty claims will become void when this nameplate is removed The designation engraved in this nameplate allows the unambiguous identification of the heat exchanger s dimension material composition and use 2 3 3 Prefill pressures switching points The type plates for the WNZS and WZS model heat exchangers safety heat exchangers also include the following specifications Nitrogen prefill pressure Fill pressure for the sealing medium Output function NO NC and switching limits for the pressure sensor HYDRAULIK 2 3 4 Product key WNZ 125 4 0800 5 S112 G034 01 02 02 07 L A B jej E GS eK A Type of construction SSS 80 125 175 250 mm Number
24. hat they will not be disposed of improperly under no circumstances The regulations governing environmental protection in every country must be observed for disposal on a mandatory basis gt gt 8 3 2 Cleaning a tube bundle DANGER Accident and injury hazard When cleaning a tube bundle be sure to observe the safety precautions as indicated in chapter 8 3 1 in every case CAUTION Risk of corrosion No hydrochloric acid must get on any aluminium lamella when cleaning a tube bundle CAUTION Risk of corrosion by scratches Any scratch on the inner surface of a tube bundle may cause increased corrosion To avoid this risk please use a brush with soft bristles for inside cleaning NOTE Regarding the use of cleaning agents please consult Dipl Ing K Dietzel GmbH D gt e o Before it may be cleaned a tube bundle must be removed from the heat exchanger only possible for pullable variants Please observe the following precautions for cleaning 63 HYDRAULIK To remove furring on the inner tube side use a mix comprising 50 of hydrochloric acid with inhibitors and 50 of water To clean the inner surfaces of a tube bundle with tubes having a diameter of lt 5 mm use an ultrasonic bath or rinse the tube bundle with hydrochloric acid Use a brush to clean the inner surfaces of a tube bundle having a tube diameter of gt 5 mm Use a brush having soft bristles to avoid scratching that the tube wall
25. lde Deutschland ee 4 HYDRAULIK Phone 49 36602 140 0 Fax 49 36602 34727 e mail info dietzel hydraulik de Internet www dietzel hydraulik de Revision Issue 12 2014 2014 Dipl Ing K Dietzel GmbH These operating instructions are subject to copyright Any disclosure or reproduction of these operating instructions or of any document pertaining thereto or any use or communication of its contents are prohibited unless with the express written consent of Dipl Ing K Dietzel GmbH All rights are reserved for the registration of any patent utility model or industrial design Dipl Ing K Dietzel GmbH LeedenstraBe 10 D 04626 Beerwalde Page 34 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 86602 140 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de
26. luminum fins 2 4 or 6 way variants on pipe side can be implemented Drain screws on pipe except for 2 and 6 way variants and casing side Holding plate screwed on flange side welded on closure side Figure 9 WZ model Dipl Ing K Dietzel GmbH LeedenstraBe 10 D 04626 Beerwalde Page 18 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 36602 140 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de ha HYDRAULIK 4 5 WNZS and WZS series safety heat exchanger Design features for WNZS Straight interior pipes Pipe bundle with aluminum fins Inner tube plates are welded to the casing pipe 1 2 4 or 6 way variants on pipe side can be implemented Drain screws on pipe except for 6 way variants and casing side Holding plates are screwed to the tube plates Figure 10 WNZS model Dipl Ing K Dietzel GmbH LeedenstraBe 10 D 04626 Beerwalde Page 19 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 36602 140 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de HYDRAULIK 4 5 1 Filling sealing medium The intermediate space in the safety heat exchanger is filled with a sealing medium using the filler coupling EMA3 R 1 4 A 40 propylene glycol water mixture is used as the sealing medium The product specifications and safety instructions for the medium can be found in the Technical Datasheet and the Safety Data
27. ly with the statutory requirements at all times The personnel must report any change which occurs on the heat exchanger and may affect safety to the owner without any delay Do not connect the heat exchanger unless exclusively to the feed lines intended and designed for it Safety precautions for transport erection and installation The corresponding freight carrier is responsible for the transport of the shell and tube heat exchanger as a general rule The following security requirements should be observed during the transport erection and installation of the shell and tube heat exchanger 2 4 4 No erection or installation work must be performed unless by duly trained and instructed specialist personnel Do not carry out any erection or installation work without proper authorisation For transport secure the components of the heat exchanger as indicated in the specifications applicable to the transport equipment used Do not use any lifting gear or sling equipment unless it has been dimensioned sufficiently for your transport Stay out from under suspended loads Wear a safety helmet Safety precautions for operation Make certain to observe the following safety precautions when operating the shell and tube heat exchanger Do not operate the heat exchanger unless all safeguards are in place The owner should provide safeguards including e g safety valves heat protective covers temperature probes etc depending o
28. n the operational requirements The functionality of the safeguards should be checked on a regular basis Any defect which may occur must be corrected immediately To avoid unauthorised or accidental contact and unauthorised access it is absolutely necessary to provide this heat exchanger with a mechanical protection Do not expose this heat exchanger neither to overtemperature nor to overpressure 63 HYDRAULIK The operating safety of this heat exchanger must be guaranteed at all times The operational conditions must correspond to the intended use of this heat exchanger Shut down the plant immediately whenever a change is detected at the heat exchanger during operation including e g an excessively high operating pressure 2 4 5 Safety precautions for maintenance The personnel employed for maintenance inspection or fault correction must have the qualifications required for performing such work No maintenance work must be performed unless by duly trained and instructed specialist personnel Please observe the following Do not carry out any work on this heat exchanger unless the plant is stopped Attach a sign at the position where the plant is switched on warning that work is in progress on the heat exchanger Lock out the plant to prevent its unauthorised restart Do not use any spare part wearing part service fluid or cleaning agent unless approved by Dipl Ing K Dietzel GmbH Dipl Ing K Die
29. of ways 1 2 3 4 6 Wege E Standard length and selectable length from tube plate to tube plate l Material tube plate 401 02 04 05 06 SS S M L X Fin size Fin type O without fins Figure 3 Product key Type of construction WNZ Heat exchanger not extractable WZ Heat exchanger extractable WTE Heat exchanger tank installation WES Heat exchanger screw in without fins WNZS Heat exchanger not extractable safety heat exchanger Circuit points S SAE 3000 PSI connection G Threaded end 034 Ya 100 1 114 114 112 1 Ye 200 2 212 2 Ve 300 3 312 3 Ye Other connections DIN Flange or CEL CES Connections optional on demand Material code 01 Steel 02 Stainless steel 03 Grey cast iron 04 CuNi 90 10 05 Brass for WES screw in cooler 06 Bronze saltwater proof 07 Chemically nickel plated steel 08 Steel ZnNi8 coated Dipl Ing K Dietzel GmbH Leedenstra e 10 D 04626 Beerwalde Page 6 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 36602 140 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de 63 HYDRAULIK 2 4 General safety information Do not use this heat exchanger other than according to its intended use Do not remove any safety or warning notice attached and keep them in a legible condition This heat exchanger must not be installed operated or serviced unless by authorised specialist personnel Work with care and observ
30. or foreign material in its inlet and outlet ports When establishing connections do not use any tubes or fittings unless they are of the same or of a compatible material Make certain to avoid any stress or tension at the connecting branches when connecting the unit to a the pipe system If necessary provide supports for pipework or use flexible tubing When connecting your heat exchanger ensure that the drain openings for fluid 1 cooling fluid points downward and that the drain openings of fluid 2 fluid to be cooled fluid cooled are located at the bottom side lf itis used an automatic water throttle valve should be installed at the inlet to the heat exchanger Route the cooling water outlet pipe so as to ensure that cooling water is flowing through your heat exchanger at all times When installing a heat exchanger of the WTE series make certain that the flange counterpart at the tank fits precisely and has a planar surface The tank mounting flange must be firmly connected to the tank When installing a heat exchanger of the WTE series make certain that your heat exchanger is not exposed to any strong forces or vibrations To ensure vibration absorption install a corresponding spring system for your heat exchanger 6 2 Installing and connecting the heat exchanger Make certain that your heat exchanger is firmly installed at its intended location and that the pipe connections are properly mounted Tr eu ea
31. s Operational sequences in the interplay between heat exchanger and plant Safeguards of the heat exchanger and their proper function Delimitation protection and identification of danger zones regarding the heat exchanger Behaviour and action to be taken in the event of an emergency As are required for the work to be performed personnel should wear protective clothing and safety gloves and if necessary goggles and respiratory equipment Immediately switch off the plant into which the heat exchanger is integrated whenever a hazard is detected which may cause personal injury Do not eat drink smoke or use any naked flame at the location of the heat exchanger The operating instructions must always be available to the personnel We recommend that the owner has a document signed by the personnel to confirm that they have taken note of the content of these operating instructions The owner or the personnel trained by the owner is responsible for ensuring accident free operation 63 HYDRAULIK 2 4 2 Safety precautions for the technical condition Please observe the following 2 4 3 Do not make any modification or structural alteration to the heat exchanger Inspect the heat exchanger for damage and ensure it is in a proper condition prior to every start up The owner must not operate this heat exchanger unless it is ina faultless and operationally reliable condition Its technical condition must comp
32. s through the drain plug or drain openings provided drain the tank if necessary Disconnect the inlet and outlet lines for fluid 2 fluid to be cooled fluid cooled from the connecting branches at the shell side Disconnect the cooling water inlet and outlet lines from the connecting branches at the covers Disassemble the heat exchanger 63 HYDRAULIK 7 Operation When it has been installed properly the heat exchanger may be put in operation without taking any further preliminary measure Check the heat exchanger for correct operation after its initial start up To do so perform the following checks Check the connection points for tightness Check the available filters valves and fittings for free passage Check the correct function of the heat exchanger CAUTION N Risk of plant damage due to loss of performance A loss of heat exchanger performance may be caused by furring on the tube side or oil sludge e g due to a defective filter on the shell side end Please refer to chapter 8 2 on this point CAUTION To define the maintenance intervals Dipl Ing K Dietzel GmbH recommends that all i parameters be recorded for recently installed heat exchanges in order to allow conclusions with regard to their performance Particular features of heat exchangers having a seawater or brackish water cooling circuit CAUTION Risk of damage to components due to aggressive coolants Do not use seawater
33. sheet see link addresses WARNING Danger of loss of performance lt is not at all recommended that you fill the safety heat exchanger with sealing medium yourself Incorrect filling media or improper filling can lead to a loss of performance WARNING Danger of escape of media under pressure When opening the closing screws the filler coupling or the membrane reservoir expect the sealing medium to escape under pressure Link addresses Technical datasheet http www terra calidus de media produkte frostschutz glykol pdf Technisches 20DB 20Terra 20Gelu 20L pdf Safety datasheet http www terra calidus de media produkte frostschutz glykol pdt SDB 20 Terra 20Gelu 20L pdf 4 5 2 Pressure sensor The pressure of the sealing medium in the intermediate space is preset The pressure depends on the system pressures pipe side casing side The pressure of the sealing medium is preferably between the two system pressures so that two switch points can be defined above and below the preset pressure Two switch points include the information regarding which of the two pressure chambers is leaking because the system pressure of the defective side will establish itself in the intermediate space The sensor is preconfigured as normally closed NC by default The outputs Out 1 and Out 2 thus permanently emit a diagnostic signal Thus three conditions must be met to receive a signal The operating voltage must be applied to
34. stall your heat exchanger proceed as follows Drain the tank if necessary Fasten the heat exchanger Firmly bolt the WTE series to the tank using a tank mounting flange Proceed as shown on the pipe connection diagram to connect the inlet and outlet lines of fluid 1 cooling fluid to the corresponding connecting branches at the covers inserting the corresponding gaskets Connect the inlet and outlet lines for fluid 2 fluid to be cooled fluid cooled with the corresponding gaskets to the connecting branches at the shell side tightening the fastening screws at the covers and at the flanges of the feed lines evenly in a crosswise order Take the precautions described below to ensure the proper functioning of your heat exchanger in different systems To protect your heat exchanger against contamination and sludge accumulation Dipl Ing K Dietzel GmbH recommends the installation of the filter unless the cooling water is obtained from your municipal water supply system or from a cieilzel HYDRAULIK closed circuit system Have a water analysis performed before starting operation if necessary o avoid contamination Dipl Ing K Dietzel GmbH also recommends not to conduct fluid 2 fluid to be cooled fluid cooled through your heat exchanger unless it is filtered beforehand To protect the heat exchanger against strong variations in flow or pressure Dipl Ing K Dietzel GmbH recommends the installation of safet
35. surface Clean the outer surfaces of the tube bundle in an ultrasonic bath or rinse the tube bundle with trichloroethylene Before using any other cleaning agent to remove furring please consult Dipl Ing K Dietzel GmbH After completing your cleaning work please make certain to remove all cleaning agents from the tubes leaving no residue if possible before putting your heat exchanger back into operation For cleaning perform the following steps Toe SYS Switch off and lock out the plant to prevent its unintended restart Shut off the cooling water inlet and outlet ends at the heat exchanger Depressurise the heat exchanger and drain the cooling water Remove the cover Perform cleaning Reinstall the cover using new flat gaskets see 8 3 4 Purge the lines before restarting the plant 63 HYDRAULIK 8 3 3 Cleaning the shell space A DANGER Risk of injury When cleaning the shell space be sure to observe the safety precautions as indicated in chapter 8 3 1 in every case Sludge may accumulate and require cleaning in the shell space of the heat exchanger To allow cleaning the heat exchanger needs to be dismantled and the tube bundle must be removed Please observe the following precautions for cleaning Depending on the degree of contamination flush the shell space once or several times using a commercially available solvent like e g trichloroethylene After completing your cleanin
36. tzel GmbH LeedenstraBe 10 D 04626 Beerwalde Page 10 of 34 Status 12 2014 Phone 49 36602 140 0 Fax 49 36602 140 34727 K Nees E Mail info dietzel hydraulik de www dietzel hydraulik de 63 HYDRAULIK 3 Technical data 3 1 Operating pressure and operating temperature Maximum shell operating pressure 40 bar 16 bar WZ WZS Minimum maximum shell operatin Minimum 5 C Maximum 95 ee Covel p g Avoid steam formation at the water end higher p temperatures are available on request Minimum maximum tube operating min 5 C max 95 temperature Tab 1 Technical data For different data please refer to the nameplate 3 2 Materials Standard heat Seawater heat CuNi 90 10 CuNi 90 10 Stainless steel 1 4404 Bea Stainless steel only heat angle bracket Steel Steel y exchanger without fins bypass valve Steel evened DIESEL Stainless steel 1 4404 plated Bronze Flat gasket Flat gasket C4400 C4400 Tab 2 Materials used for the heat exchanger HYDRAULIK 3 3 Water quality requirements NOTE All information regarding water quality requirements is given as a recommendation Unforeseen reactions may occur in exceptional cases when a particular concentration of component substances is present Both the water quality and the components contained are important when assessing the cooling water available for its use in the shell and tube heat exchanger Water quality is determin
37. ufacturer but rather by the owner of the heat exchangers 1 3 Warranty and liability Every product made by Dipl Ing K Dietzel GmbH shall be subject to the general terms and conditions as indicated on www dietzel hydraulik de Any warranty and liability claim for personal injury or damage to property shall be excluded whenever such injury or damage may be attributed to one or more of the following causes Use of the heat exchanger contrary to its intended use Improper start up installation operation servicing or maintenance of the heat exchanger Any structural alteration carried out on the shell and tube heat exchanger without the manufacturer s written permission Heat exchanger operation with improper plant connection or defective safety appliances or when safety appliances or safeguards have not been installed properly Failure to observe the safety regulations and notes included in these operating instructions Improper repair Use of any spare part wearing part service fluid or cleaning agent other than those approved by the manufacturer Dipl Ing K Dietzel GmbH shall assume no warranty and no liability other than exclusively for material or manufacturing defects 4 HYDRAULIK 2 Safety precautions DANGER N Warning against possible hazards to life and limb DANGER A Warning against possible hazards to life and limb due to a hot surface DANGER Warning against possible hazards to life
38. unction without training by Dipl Ing K Dietzel GmbH Warning Danger of escape of media under pressure When opening the closing screws the filler coupling or the membrane reservoir expect the sealing medium to escape under pressure Even a small amount of leaked liquid can impair the safety function Warning Danger of floss of performance Even a short term exceeding of the operating parameters may lead to changes in pressure Dipl Ing K Dietzel GmbH advises you to check the pressure of the sealing fluid at regular intervals Performance parameters determined during operation should be used to define maintenance intervals The pressure of the sealing fluid must be checked exclusively at the pressure sensor Dipl Ing K Dietzel GmbH offers training for maintenance of the safety function on request The programming and display unit required for maintenance as well as the other necessary tools can be loaned from Dipl Ing K Dietzel GmbH for a separate charge 9 Disposal NOTE J Make certain that neither lubricants service fluids cleaning agents nor their containers are disposed of as household waste or penetrate the subsoil Be sure to observe the instructions given in the corresponding data sheets and in the environmental protection regulations applicable in every country The heat exchanger must be treated as hazardous waste when it is disposed of Dipl Ing K Dietzel GmbH LeedenstraBe 10 04626 Beerwa
39. uring operation and to the performance indications Define the intervals so as to avoid any loss of heat exchanger performance which might endanger a plant operation HYDRAULIK 8 3 1 Safety precautions for cleaning DANGER Risk of injury by chemical burns or poisoning Chemical burns of body parts or eye injuries may occur by a failure to observe the applicable occupational health regulations when cleaning the tube bundle using e g hydrochloric acid or the shell space using e g trichloroethylene The applicable safety at work regulations must be observed on a mandatory basis when handling any cleaning agent Wear protective clothing safety gloves goggles and respiratory protection when working whether any aggressive cleaning fluid CAUTION Risk of damage to components of the shell and tube heat exchanger Properly purge the system connected before restarting it CAUTION Risk of contaminating the fluid Check that your cleaning agent is compatible with the fluid since experience suggests that it is hardly possible to remove a cleaning agent without leaving any residue CAUTION Risk of destroying heat exchanger components To avoid damage which might be caused by wrong treatment please always contact Dipl Ing K Dietzel GmbH before using any other aggressive cleaning agent HINWEIS Risk of contamination by cleaning agents When using any cleaning agent including e g hydrochloric acid make certain t
40. y valves and automatic throttle valves in the inlet lines of fluid 1 cooling fluid and fluid 2 fluid to be cooled cooled fluid o avoid the electrolytic corrosion of any heat exchanger components a zinc anode should be installed either at the inlet end in the cover or at the inlet line Disassembling the heat exchanger DANGER Injury hazard due to pressurised fluids To avoid any injury during disassembly depressurise the system as defined in the accident prevention regulations before starting any work DANGER Injury hazard by a falling shell and tube heat exchanger Before disassembling secure the heat exchanger using adequately dimensioned lifting gear and sling equipment to prevent it from falling down DANGER Burn hazard by hot components Burns may be caused when touching any heated component Allow the components to cool down before disassembling the heat exchanger or its feeding lines NOTE Risk of contamination by drained fluids Catch and dispose of drained fluids using reservoirs intended for this purpose pursuant to the regulations applicable to environmental protection No fluid must neither enter the subsoil nor reach the sewer system To disassemble your heat exchanger proceed as follows Shut down and lock out the plant properly to prevent its unintended restart Depressurise both your heat exchanger and every system line connected and shut off the corresponding valves Completely drain the fluid
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