EVC Turflow Heat Exchangers: Installation and Maintenance Instructions
EVC Turflow Heat Exchangers: Installation and Maintenance Instructions
EVC Turflow Heat Exchangers: Installation and Maintenance Instructions
TES Issue 3
EVC
Turflow Heat Exchangers
Installation and Maintenance Instructions
1. Safety information
2. Storage
4. Installation
5. Commissioning
6. Maintenance
The products listed on the adjacent table comply with the requirements of the EU Pressure
Equipment Directive/UK Pressure Equipment (Safety) Regulations and carry the mark
when so required.
The products fall within the specified Pressure Equipment Directive categories as shown in Table 1.
Turflow type heat exchangers fully comply with the requirements of the ASME Boiler and Pressure
Vessel Code and carry the "U" ASME Stamp when so required.
i) The products have been specifically designed for use on steam, air or water which are in Group
2 of the above mentioned Pressure Equipment Directive. Spirax Sarco should be contacted to
confirm the suitability of the product for use on alternative fluids and applications.
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which it
is being fitted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced
by any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
v) Remove protective covers from all connections and protective film from all name-plates, where
appropriate, before installation on steam or other high temperature applications.
Each name-plate is fixed to the shell of the unit and confirms the following information:
- Serial number, year of manufacture and heat exchanger type and name-plate.
- Fluid group, both shell and tube side according to the directive.
- Design condition: both shell and tube side maximum allowable pressure and temperature.
Note: A different kind of approval with certification from a notified body may be possible for bespoke units.
Note:
This document refers only to the mechanical installation and commissioning of the heat exchanger
and should be used in conjunction with the relevant IMIs for other system components and
supplementary safety information for all the system components.
Warning
This product is designed and constructed to withstand the forces encountered during normal use.
Use of the product for any purpose other than its intended use could cause damage to the product
and may cause injury or fatality to personnel.
Before any installation or maintenance procedure, always ensure that all primary steam and
condensate return lines and secondary water lines are isolated.
Ensure any residual internal pressure in the system or connecting pipework is carefully relieved.
Allow hot parts to cool before commencing work, to avoid the risk of burns.
Always wear appropriate safety clothing before carrying out any installation or maintenance work.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
- Where a formal 'permit to work' system is in force it must be complied with. Where there is no
such system, it is recommended that a responsible person should know what work is going on
and, where necessary, arrange to have an assistant whose primary responsibility is safety.
1.14 Freezing
Provision must be made to protect products which are not self-draining against frost damage in
environments where they may be exposed to temperatures below freezing point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, thisproduct is recyclable
and no ecological hazard is anticipated with its disposal providing due care is taken.
2.1.1 On receipt of the heat exchanger, inspect all protective covers for shipping damage.If damage is
evident, inspect for possible contamination and replace protective covers as required. If damage is
extensive, notify the carrier immediately and Spirax Sarco.
2.1.2 If the heat exchanger is not to be placed into immediate service, take precautions to prevent
oxidisation or contamination.
If it is planned to install the heat exchanger after two weeks from delivery it is recommended that
the following procedure is implemented:
- Remove the possibility of humidity from both tube side and shell side by circulating hot air.
- Install a manometer.
- Fill the tube and shell side with nitrogen up to 0.5 bar (7 psi).
2.1.3 Remove any accumulation of dirt, water, ice or snow and wipe dry before moving exchangers from
outside to inside storage. If the unit was not filled with nitrogen or other preservative, open the drain
plugs to remove any accumulated moisture, then reseal. Accumulation of moisture could indicate
oxidisation has already started and remedial action should be taken.
2.1.4 Store under cover in a heated area, if possible. The ideal storage environment for heat exchangers
and accessories is indoors, above ground, in a dry, low humidity atmosphere which is sealed to
prevent entry of dust, rain or snow. Maintain temperatures between 20 °C and 50 °C (68 °F to
122 °F) and humidity at 40% relative humidity or lower.
Note: Ambient temperature of the place where the unit will be installed must be between -10 °C
and 50 °C (14 °F to 122 °F).
2.1.5 In tropical climates, it may be necessary to use trays of renewable desiccant (such as silica gel),
or portable dehumidifiers, to remove moisture from the air in the storage area. Thermostatically
controlled portable heaters (vented to outdoors) may be required to maintain an even air temperature
inside the storage area.
Note: Advisable to inspect the heat exchangers and accessories frequently while in storage.
Notes:
1. The above information is relevant for standard Turflow heat exchangers, for further product technical
data see Technical Information sheet TI-P222-02.
2. For bespoke Turflow heat exchangers appropriate documentation will be supplied with the unit.
Warning: Bespoke units can be designed according to different criteria than standard units, always
refer to the data on the name-plate for the ultimate design limits.
Fig. 3
4.1 Transport
Each unit is individually packed in a special carton box with suitable legs for lifting with a fork lift truck.
Suitable spacers are put in the box to avoid damage during transit.
The total weight is indicated outside of the box.
For length out of standard special pallets are used to allow fork lifting or the units are fitted with lifting
legs attached to the heat exchanger to provide a means for lifting and moving the units.
4.3 Follow the in-out connections of fluids as per the project system design.
Hot side – cold side
If the primary fluid is steam, superheated water, or diathermic oil, note that the system design has
been made providing connection on the shell side.
This principle becomes mandatory as the operating conditions approach the limits specified on the
name-plate, and as the difference in temperature increases.
Should such circumstances arise, Spirax Sarco can only accept responsibility for the system design
when these conditions are adhered to. lf these conditions are not met by the purchaser or his agent,
the manufacturer’s guarantees and responsibilities will also be automatically invalidated.
4.4 Due to the design features, this Series of heat exchanger can be installed in almost any position
and with any direction of secondary flow. However, for maximum performance, countercurrent flow
is advisable. To minimize the space required, the system should be positioned vertically. A vertical
installation with tube side flow from top downwards will make it more difficult for substances to adhere
to the walls and make it easier to expel the lime scale and ditritus from the heat exchanger. This
provides an effective trap for impurities and encrusted sedimentation. Figures 3 and 4 illustrate all
possible installation positions.
Warning: A suitable space around the heat exchanger is to be advisable for maintenance, in
accordance with local current legislation.
Fig. 3
Atmospheric vent
Steam inlet
Condensation
output
Steam input Atmospheric vent
7 no
Fig. 4
Fig. 4 and 5 - Position when the shell side fluid is condensing steam
Warning: Only one end of the heat exchanger must be fixed. The other end must be allowed to move axially
on a specially constructed sliding guide (Figure 6), to allow for the normal expansion of the heat exchanger
tubes, which results in the system lengthening axially, and varies depending on the operating temperature.
Guide Guide
Fig. 6
Table 2 displays the axial expansion that can result, depending on the temperatures to which the heat
exchanger tubes are subjected.
Moving side
Caution: Provision must be made to isolate the heat exchanger from any external vibration sources that
could cause tube failures within the heat exchanger. Neglecting this provision, internal leakage and mixing
of the hot and cold media could happen.
Fig. 8
Fig. 9
Caution: All system piping on the heat exchanger’s moving side must allow the axial movements of the heat
exchanger. Failure to do so will result heat exchanger leakage and mixing of the two fluids.
4.10 To protect the expansion joint from external damage and optimise energy consumption, it is advisable
to use a polyurethane insulating jacket as shown in Figure 11.
4.12 Inspect all flanges on the heat exchanger for foreign material. Remove all plugs and shipping pads
just before installing.
4.13 Ensure that the entire system is clean before commissioning to prevent blocking of the tubes. The
use of strainers in settling tanks in pipelines leading to the unit is recommended.
4.14 Ensure adequate isolation valves are installed for inspection, cleaning or repair work to be carried out.
4.15 Provide thermometer wells and pressure gauge connections in all piping to and from the unit and
located as near to the unit as possible.
Moving
point
Fixed
point
Fig. 10
Fig. 11
5.1 Do not operate equipment under conditions in excess of those specified on the name-plate.
Warning: Failure to operate the heat exchanger within the design pressure and temperature limits
(as specified on the name-plate) may result in damage to the heat exchanger and potential injury to
adjacent personnel.
Fluid and/or steam velocities in excess of the design operating conditions on either the shell or tube
side of the heat exchanger can cause damage (tube erosion and/or vibration). The direct result of this
is internal leakage and mixing of the hot and cold media. Proper setting of system controls is required.
Warning: The heat exchanger is not provided with safety devices against overpressure, as it is
included in the piping. Therefore the risks due to overpressure must be avoided by installing suitable
safety valves along the piping connected to the heat exchanger.
5.3 Retighten the bolting on all gasket joints after the heat exchanger has reached operation temperatures
to prevent leaks and gasket failures. Retightening should be done uniformally and in a diametrically
staggered pattern as illustrated in Figure 14 and in compliance with Section 6.6 'Bolting'.
5.4 On high pressure and high temperature applications it is recommended that the gasketed joints of
the heat exchanger be retightened to the required torque after 24 hours at operating pressures and
temperatures to compensate for relaxation or creep that may have occurred (refer to Table 2).
5.6 A heat exchanger that has, or will be, out of service for an extended period of time should comply
with that written in Section 2 of this document.
For 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 prevent stagnant water conditions
that can ultimately cause oxidation.
Vent Drain
Fig. 12
6.1 Do not loosen the connection flanges until all pressure has been relieved from the equipment, the
unit drained of all fluids, and the equipment surfaces cooled to ambient temperature.
6.2 Do not blow out the heat exchanger with air when fluids normally handled are inflammable.
Warning: Proper precautions must be taken (special clothing, equipment, etc.) to protect
personnel from injury due to escaping fluids or hot heat exchanger surfaces.
6.3 Cleaning
Heat exchangers subject to fouling or scaling should be cleaned periodically. Sludge and scale
greatly reduce heat transfer effectiveness and increase pressure drops. Since the difficulty of
cleaning increases rapidly as the scale thickens or deposits increase, the interval between cleanings
should not be excessive. Regularly inspect the interior and exterior surface of the tubes and keep
the unit clean. This will help in preserving the performance and the mechanical integrity of the unit.
Frequency of cleaning should be according to scale build-up.
Warning: Neglect in keeping all tubes clean may result in complete stoppage of flow through
some tubes with consequent over-heating of these tubes, severe expansion strains and
leaking tube joints.
6.3.1 The tube side of the heat exchanger can be inspected by sight while optical means can be used
for shell side inspection.
6.3.2 Provide convenient means for frequently cleaning heat exchangers as suggested below:
- Circulating hot wash oil or light distillate through tubes or shell at good velocity will
effectually remove sludge or other similar soft deposits.
- Soft salt deposits may be washed out by circulating hot fresh water.
- Some chemical cleaning compounds on the market may be used to advantage for
removing hard scale, provided hot wash oil or water, as described above, does not
give satisfactory results.
Contact Spirax Sarco for more information if required
- If the above methods are ineffective for removal of hard scale, mechanical means
may be used on the tube side.
Warning: Care must be exercised when handling certain fluids. Follow the manufacturer
instructions. Use eye and skin protection. Wear a respirator when required.
6.3.3 Do not attempt to clean tubes by blowing steam through individual tubes. This overheats the tube
and results in tube expansion strains and sometimes leaking tube joints.
6.3.4 If scaling or other fouling were expected, connections in the piping could be provided for flushing
out or chemical circulation cleaning.
- Pressurize the shell side of the heat exchanger with a cold fluid, preferably water.
- Observe all tube joints and tube ends for indication of test fluid leakage.
If a leak is detected, please contact Spirax Sarco service, an engineer will be able to support you
in solving the problem.
6.5 When a heat exchanger is dismantled for any reason, before reinserting the unit into the line
Fig. 13
1 16
6 11
9 8
Warning: It is extremely important
t o f o ll ow a p ro p e r t i g h t e nin g
14 3 sequence. If this sequence is
neglected, flange deformation and
Fig. 14
gasket damage are possible and
4 13 this could result in leakage. Any
gasket leak can result in potential
injury to adjacent personnel.
7 10
12 5
15 2
6.6.2 It is essential that the installer follows the gasket manufacturers installation guidelines when installing
gaskets. Metallic gaskets, such as the spiral wound gaskets, usually have special installation
instructions. 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.
b. Same as a, the bolts/studs should be torqued to 2/3 of the recommended tightening torque.
c. Same as a, the bolts/studs should be torqued to the recommended torque value shown in the
above chart.
d. Following the staggered tightening pattern the bolts/studs torques should be checked for
equilibrium since the tightening of one bolts/studs can relieve the stress on adjacent bolts/studs.
If after following the gasket manufacturers recommended tightening procedure a leak still occurs,
the bolts/studs should be tightened in the torque increments shown until the leaks stops.
6.6.3 Refer to section 'Commissioning' Steps 5.3 and 5.4 regarding bolt retightening after start-up.
6.6.4 Where frequent disassembly of the heat exchanger is encountered, the use of new bolting in
conformance with dimension and specifications of the original design is recommended.
6.7 When contacting Spirax Sarco for any issue about the heat exchanger refer to the following data
stamped on the name-plate:
- Serial number
- Model
- Year
REPAIR
Please contact our nearest Branch Office or Agent or directly Spirax-Sarco S.r.l. - Ufficio resi Via per Cinisello,
18 - 20054 Nova Milanese (MB)
Tel.: +39 0362 49 171
Fax: +39 0362 49 17 307
LOSS OF GUARANTEE
Total or partial disregard of above instructions involves loss of any right to guarantee.