HIGH-K Heat ExchangerRigging and Installation Instructions

HIGH-K Heat Exchangers should be rigged and installed by contractors or end-users as outlined in thisbulletin. The procedures should be thoroughly reviewed prior to actual rigging to familiarize key

personnel with the methods to be employed and to ensure that all necessary equipment is available at the jobsite.

STANDARD METHOD OF SHIPPINGThe HIGH-K Heat Exchanger is designed and manufacturedto meet shipping, handling, and rigging requirements. Tosimplify rigging and installation all HIGH-K Heat Exchangersship completely fabricated and framed for immediate

GENERAL DESCRIPTIONReview the lifting procedures outlined in this bulletin priorto rigging the HIGH-K Heat Exchanger to ensure properhandling during installation. Refer to the certified drawingfor the unit's weight before selecting the riggingship completely fabricated and framed for immediate

installation by a contractor or end-user. The uniquecompression seal is factory torgued and each unit ispressure tested after fabrication. (Refer to the HIGH-KHeat Exchanger Operating and Maintenance Manual, fordetailed torque requirements.)The fluid connections are covered during shipment toprevent debris from entering the unit. Debris in the HIGH-KHeat Exchanger may hinder performance. DO NOTREMOVE the connection covers until piping the unit--------CHECKING UNIT BEFORE RIGGING .When the HIGH-K Heat Exchanger is delivered to thejobsite, it should be vissually inspected to ensure it is freeof shipping damage prior to signing the Bill of Lading.

ANCHORING .The HIGH-K Heat Exchanger is designed for easy installationon floors, walls, and ceilings. All units ship with mountingholeslocated in the support frame for floor mounting. Inaddition, ceiling-mounted units ship with optional bracketslocated on the support frames for securing to the ceilingstructure. For units installed on walls or ceilings, additionalsupports are recommended to prevent lateral movementof the Heat Exchanger. Refer to the support detail on thecertified drawing for location of the mounting holes.Anchor bolts for floor-mounted units and hanging rods forceiling-mounted units must be provided by others.

for the unit's weight before selecting the riggingequipment. The recommended spreader bar lengths aregiven in this manual based on the HIGH-K shell diameter,unit length and circuiting arrangement. The nominal shelldiameter, nominal tube length, and circuiting arrangementcan be obtained from the HIGH-K Heat Exchanger modelnumber. Figure 1 defines each digit of the model number.

HK8-10-2-3A

Nominal Shell Diameter (inches)

Nominal Tube Bundle Length

(Feet)

Number of Modules(In series per circuit)

Number of Parallel Circuits

Shellside Baffle Arrangement

Figure 1HIGH-K Heat Exchanger Model Number Nomenclature

For example, the HIGH-K Heat Exchanger with modelnumber HK8-10-2-3A has an 8-inch nominal shelldiameter. 10-foot nominal tube bundle length, twoshells in series per circuit, and three parallel circuits on acommon frame. The shellside baffles have an "A" typearrangement. Figure 2 shows a schematic of an HK8-10-2-3A.

Figure 2 -- HK 8-10-2-3A HIGH-K Heat Exchanger

THREE CIRCUITS IN PARALLEL

TWO SHELLS IN SERIES TUBESIDE RETURN WATERBOX

SHELLSIDE CROSS-OVER PIPE

The HIGH-K Heat Exchanger is available in 6, 8, 10, and 14-inch nominal shell diameters. The nominal tube bundle lengths range between 9 and 18 feet depending on the diameter. It is possible to have from 1 to 4 shells in series per circuit and 1 and 7 circuits on a common frame. Table 1 outlines

the nominal tube lengths and pass arrangements available for each shell diameter.

Table 1. HIGH-K Heat Exchanger Size and Configuration Options

Nominal Shell Diameters (Inches)

Nominal Tube Bundle Lengths (Feet)

Number of Shells Per Circuit

Number of Circuits Per Frame

468

10

9,11,139,11,13

10,12,14,16,1810,12,14,16,18

1 to 31 to 31 to 41 to 4

1 to 51 to 51 to 71 to 510

1410,12,14,16,1810,12,14,16,18

1 to 41 to 3

1 to 51 to 4

Rigging Procedures

HIGH-K Heat Exchangers should be lifted using two (2) slings placedbeneath the bottom shells. Locate the slings inside the frame as close tothe vertical support members as possible. The frame should not be used forlifting purposes except for ceiling-mounted units which may be liftedthrough the ceilingmounting brackets. (Note: Take necessary measures toprotect the exterior finish of the unit when liftinf with chain slings). _____

For single-pass, single circuit units, one spreader bar of length "a" (asshown in Figure 3) is needed to hold the slings at the correct locations. Formultiple-pass, single-circuit or multiple-circuit units (Figures 4 and 5respectively), one spreader bar of length "b" or "c" must be placed insidethe slings used at each end of the Heat Exchanger. Depending on the typeof lifting equipment used, additional spreader bars of length "a" may berequired to hold the slings in the correct location while lifting. Table 2contains the spreader bar lengths for single-pass, singlecircuit (a), multiple-pass, single-circuit (a & b) and multiple-circuit (a & c) HIGH-K HeatExchangers. ________________________________________

Figure 3-Recommended Lifting Procedures for a

Single-Pass, Single-Circuit Unit

Place additional spreader bar "c" here

for wider unit.

Figure 4 and 5--Recommended Lifting Procedures for Multiple-Pass, Multiple-Circuit Units

"A"

"B & C"

Table 2. Spreader Bar Lengths (Inches)

HIGH-K Heat Exchanger

Single-PassSingle-Circuit

"a"Optional for other units

Multiple-PassSingle-Cicuit "b"

Multiple-Circuits"c"

2 43 2 3 4 5 6 7

HK 4-9HK 4-11HK 4-13

HK 6-9HK 6-11HK 6-13

HK 8-10HK 8-12HK 8-14HK8-16HK 8-18

HK 10-10HK 10-12HK 10-14HK 10-16HK 10-18

HK 14-10HK 14-12HK 10-14HK 10-16HK 10-18

6490

116

6490

116

7198

124146170

7096

122144168

6490

116139163

18 5/8 30 5/8 42 5/8

18 5/8 30 5/8 42 5/8

24 5/8 40 5/8 56 5/8

30 3/4 50 3/4 70 3/4

34 54 NA

17 1/4

27 7/8

38 1/2

49 1/8

NA NA

171/4

277/8

381/2

491/8 NA NA

245/8

337/8

461/2

591/8

713/4

843/8

263/4

42 3/4

58 3/4

74 3/4

NA NA

35 56 77 NA NA NA

HK 10-18 163

Installation InstructionsGeneral Guidlines

The following guidlines for installation of HIGH-K Heat Exchanger by contractors or end-users are recommended to assure efficientoperation and ease of maintenance. Refer to the HIGH-K Heat Exchanger Operation and Maintenance Manual for detailed start-upprocedures.

A. Space should be provided for access to the unit for routine maintenance (e.g., removal of the tube bundle or mechanicalcleaning).

B. Foundations must be adequate so that the HIGH-K Heat Exchanger will not settle and cause the piping to transmit excessivestrains to the nozzles of the unit.

C. The HIGH-K Heat Exchanger is provided with oplong mounting holes for the foundation bolts. Foundation bolts should becentered in the oblong mounting holes. Foundation bolts should be loosened at one end of the unit to allow for free thermalexpansion of the heat exchanger.

D. System piping should be free of debris prior to connection to the HIGH-K Heat Exchanger.E. Certified print should be checked to insure proper connection of the system piping to the HIGH-K Heat Exchanger.F. Gaskets between inlet and outlet connection flanges should be centered to allow unrestricted fluid flow.G. System piping should be properly supported. UNIT CONNECTIONS SHOULD NOT BE USED TO SUPPORT PIPING. All piping should

be supported independently through the use of pipe hangers or supports. Vibration isolation should be used in accordance withstandard piping practices.

H. Pressure taps and thermometer wells should be installed in the piping entering and leaving the Heat Exhcnagre. To assureaccurate measurements, locate the pressure taps and thermometer wells close to the Heat Exchanger as possible. Pressure tapsshould be at least ten pipe diameters from any fittings.

I. Vent valves should be located at the highest point in the system to allow proper filling, draining and venting.J. Provide throttling valves and a surge drum to prevent damage caused by pulsating fluids in the system piping. The surge drum

should be located upstream from the Heat Exchanger.K. CONTROL OF THE SYSTEM PRESSURE IS ESSENTIAL. Relief valves are necessary where the system pump pressure output exceeds

the design pressure in the Heat Exchanger. (Refer to the Mechanical Specification Sheet for the Heat Exchanger design pressure.)Control valves should be installed in the system piping at the inlets of the Heat Exchanger.

L. To facilitate maintenance, install valves and bypasses to allow isolation between the tubeside and shellside of the HeatExchanger.

M. It is recommended that the HIGH-K Heat Exchanger be installed indoors. UNITS LOCATED OUTDOORS MUST HAVE PROPERM. It is recommended that the HIGH-K Heat Exchanger be installed indoors. UNITS LOCATED OUTDOORS MUST HAVE PROPERFREEZE PROTECTION TO INSURE DAMAGE-FREE OPERATION.

Storage Procedures

When a HIGH-K Heat Exchanger is to be placed in storage for an extended period of time, the procedures listed belowmust be followed:

1) If the unit has been recently shipped from the factory and is unused, disregard statements 2 and 3; followinstructions 4 and 5.

2) If the unit has been used and long term storage is required, it must be completely drained.3) Disassemble the Heat Exchanger. Thoroughly clean the unit internally and externally. Dry the unit. (Blowing dry, hot

air at approximately 150 degrees F on all areas is an excellent method.) Reassemble the Heat Exchanger withoutreplacing gaskets and without torquing bolts. (Refer to the Operating and Maintenance Manual Bulletin M903/1-0for detailed assembly instructions).

4) Install blind flanges with gaskets on all connections.5) Store under cover in a heated area, if possible. The ideal storage environment for Heat Exchangers is indoors, above

grade, in a dry low-humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Avoidwide temperature swings which may cause condensation and "sweating" of steel parts.

SAFETY PRECAUTIONS

Adequate precaustions should be taken to safeguard the equipment and the premises fromdamage and the public from possible injury as appropiate for the installation and location of theseproducts.

NoticeOperation, maintenance and repair of this equipment should be undertaken only by personnelqualified to do so. Proper care, procedures and tools must be used in handling, lifting, installing,operating, maintaining and repairing this equipment to prevent personal injury and/or propertydamage.

WarrantiesPlease refer to the Limitation of Warranties applicable to and in effect at the time of thesale/purchase of these products.

Freeze ProtectionThese products must be proteced against damage and/or reduced effectiveness due to possiblefreeze-up by mechanical and operational methods. Please refer to the Cold Weather Operationguidlines (page 11) or contact the local HIGH-K Representative for recommended protectionalternatives.