Page 1 of 5 Tudor House Tudor Industrial Estate Ashton Street Dukinfield Cheshire SK16 4RN Telephone: 0845 519 2116 Email: enquiries@worldheat.co.uk Web: www.worldheat.co.uk Reg. In England Number 6744323 VAT Reg Number 976 2483 78 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Applicable to the following products:- ( a ) NON STORAGE STEAM/WATER CALORIFIERS ( b ) NON STORAGE WATER/WATER CALORIFIERS ( c ) SEMI-STORAGE CALORIFIERS ( d ) COPPER, CARBON STEEL, STAINLESS STEEL, GALVANISED STEEL STORAGE VESSELS AND CALORIFIERS ( e ) SWIMMING POOL CALORIFIERS. ( i ) INSTALLATION Foundations must be adequate to ensure that the unit will not settle and cause pipe strain or distortion of the shell etc. Ensure that the nameplate is readily accessible for later reference, inspection and maintenance purposes. It is recommended that the exchanger be installed in a level position, with ample clearances around for future inspection and maintenance. In the case of units having removable tube bundles, it is necessary to ensure that ample room exists for withdrawing the bundle clear of the shell. Tightening of bolts should be evenly distributed over flanges each bolt being gradually tightened diagonally opposite, in succession. The equipment has protection on nozzle branches but damage can occur during transit and it is essential that an examination be carried out for any foreign material which may have found its way into the vessel. Distortion can occur to pipe connections during transit/handling especially extended types. If this does happen they can be straightened by insertion of a threaded pipe and pulling square (copper only) If an anti-stratification pump set is fitted, the pipe work and circulator may be supplied loose for fitting on site, (this is to avoid damage in transit). The pump should be installed to circulate water from the top of the cylinder to the bottom. Reference should be made to the manufacturers specific instructions. Trafford Semi-Storage Calorifiers are normally supplied with the circulating pump fitted. The unit should be flushed thoroughly with clean water prior to operation. Pasteurisation (where necessary) should be carried out in accordance with the latest Codes of Practice and Water Bylaws. Before carrying out water treatment ensure that the materials of construction of the unit are suitable for chemicals utilized otherwise aggressive attack (corrosion) of components is liable to occur and this may only become evident by reduction in the anticipated lifespan. For example do not use Chlorine where Stainless Steel materials are incorporated.
Page 2 of 5 Great care should be exercised when fitting and/or handling bursting discs. These are usually graphite composition and are easily damaged if mishandled. They would usually be supplied loose for customer fixing. Please refer to manufacturers details. Galvanised steel cylinders containing hot water should be fitted with magnesium Anodes. These will protect the zinc coating of the steel from attack (Also see Section iv). Ensure that, in the case of swimming pool calorifiers, pool water flow rates are no more than these indicated in our equipment specification. If excess flow is intended this should bypass the calorifier. Swimming pool water treatment should be injected into the system downstream of the calorifier so that the solution is passed through the pool prior to the return of the calorifier, in dilute form. Excesses of treatment may cause damage. Steam heated calorifiers should (whenever possible) be installed to allow gravity drainage of condensate, thus eliminating undesirable back pressures which could affect the operation of the unit. All units are pressure tested hydraulically (cold) at works, as stated on the nameplate and test certificate. Under no circumstances must a pressure (in excess of the designated working pressure) be applied, otherwise damage may result. It is critcal to ensure the unit construction is compatible with types and grades of materials to which it is connected, both directly and indirectly. Generally, dis-similar materials may lead to corrosion by electrolytic action. ( ii ) CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH Our investigations have realised that there are no specific items to highlight during normal operating conditions. During our manufacturing process a red dye penetrant is used on internal surfaces of vessels for preinspection of welds. It if therefore essential that adequate flushing and sterilization is carried out (as described in section i) and that the quality of water produced is to acceptable standards. ( iii ) OPERATION Do not operate the equipment at pressures or temperatures (or other conditions) in excess of those specified on the name plate. Open all vents to prevent air locking. Slowly introduce secondary fluid into the shell and when all spaces are filled, close vents and slowly raise to required operating pressure. Gradually admit the primary fluid into the exchanger and when all spaces are filled close vents and slowly allow the unit to reach operating temperature. In the event of the secondary operating pressure being higher than the primary pressure, the primary tubes must never be emptied exposing them to secondary pressure. This could result in collapse of the primary
Page 3 of 5 tubes. In the event of pulsations occurring under star-up conditions, reduce the fluid flow until pulsations disappear. Check that all gaskets are effective when unit is operating. If leaks are evident remove heat and pressure, then tighten bolts (in a diagonally opposite fashion and in rotation) as necessary. In steam vapour heated units, ensure that the vessel is drained of cold condensate before admitting hot vapour. Cylinders fitted with anti-stratification pump sets should have circulators wired to run continuously. Please refer to manufacturers instructions for details. For details of bursting discs please refer to manufacturers literature. If a rattling noise is evident from shell and tube heat exchangers it is likely that the shell side fluid flow is in excess of that permitted. This is particularly relevant to potentially high flow units such as swimming pool calorifiers. If this situation occurs the flow must be regulated as necessary. In the case of swimming pool calorifiers a regulated bypass pipe may be required. All warranties will be void if the unit is subjected to pressures/temperatures greater than those indicated on our nameplate and test certificate. ( Also refer to page 2). ( iv ) MAINTENANCE The shell should be periodically cleaned of all dirt and sludge and sterilised thereafter (as Bylaw Regulations and Codes of Practice dictate). Inspect internal surfaces for pitting and corrosion. All cleaning etc to be carried out in accordance with current legislation. When draining vessels ensure an adequate secondary vent is provided, and that it is open to atmosphere prior to opening drain valve. The inside and outside surfaces of all tubes should be periodically inspected to ensure that the tubes are clean and the bores unblocked. Blocked tubes prevent fluid from circulating and can cause overheating resulting in extremes of expansion which can weaken the tube joints. Any gradual fall off in performance or increases in pressure indicates that:- (a) An air or vapour lock exists which can be rectified by cracking the vents. (b) A coating of scale deposit is present on the tube walls which prevents the effective transfer of heat through the tubes. The thickness of the deposit is related to the actual loss of heat transmission. Inspection of the outside surface of a fixed coil can be through the inspection opening (where fitted) or by removal through the bolted end (where fitted).
Page 4 of 5 To gain access to the tubes of a removable battery reduce all pressures and drain all fluids from the unit, (open all vents and drain cocks). Remove header to expose tubes and tubeplates. It is advisable to mark all relative positions of covers, etc, to ensure correct reassembly. Inspect tube joints and tubeplates for leaks. By removal of the bundle or through the inspection opening (where fitted) inspect all tubes for deterioration/leakage. Pressure test if visual inspection does not highlight fractures. Leaks between tubes and tubeplates may be effectively sealed by releasing the pressure in the shell and lightly expanding the defective tube. Do not apply undue pressure when expanding and do not attempt to re-expand tubes which are not leaking. Always use parallel roller type expanders. Great care should be taken where facilities exist for removing tube bundles from shells since it is important that no distortion or damage is caused by careless or improper handling. When withdrawing or handling the tube bundle do not use hooks or similar tools as these are liable to cause damage to the tube. Avoid damaging gasket seating surfaces of flanges. When lifting bundle horizontally, always ensure even distribution of weight along the length. The withdrawn bundle is to be entirely supported by the tube plate and support plates resting on wooden blocks cut to fit the curvature of the tube bundle, under no circumstances allow the tube bundle to be supported on the tubes. Take great care not to bend or distort baffles in any way as they are a close fit in the shell and if clearance is increased, the performance of the unit may be seriously affected. Methods of cleaning tube deposits includes:- (a) Mechanical means involving brushes and scrapers. Care should be take not to cut into metal surfaces. (b) Chemical cleaning using acid solution containing inhibitors. (c) Water soluble deposits are best removed by circulation of hot fresh water or condensate. (d) Soft deposits can be removed by rapid circulation of hot wash oil or solvent. Do not blow steam through single tubes since this may cause the tube to expand and disrupt the tube joint. Do not blow air through units when fluids normally circulating are of an inflammable nature. It is recommended that a complete new set of gaskets be fitted when reassembling a heat exchanger, bolted head or inspection opening cover plate. Gasket material should be E.P.D.M. (W.R.C. approved) for bolted heads and inspection openings; and nonasbestos fibre for tube bundles. E.P.D.M. gaskets should be made dry whereas non-asbestos fibre gaskets may require a suitable jointing paste applied to both faces. After reassembly, the unit may be hydraulically tested up to the working pressures shown on the nameplate, although a visual inspection at working conditions should suffice. For details of cylinders fitted with anti-stratification pump sets refer to the pump manufacturers instructions.
Page 5 of 5 Galvanised steel vessels (and copper in certain instances) may have anodes fitted. If they are of a replaceable type inspect the rod, by removing it. The period for inspection can be determined by noting the amount of wear after the initial inspection. This period should not be greater that 12 months. In order to protect the zinc coating of steel vessels (and inner surface of copper vessels) it is essential to retain anodes and not allow them to fully dissolve. Should you require spares, replacements etc, please refer to our sales office quoting the serial number of the equipment.