AIC PS User manual

PSPW-R4 1
USER MANUAL
FOR
PS AND PW-TYPE
HEAT EXCHANGERS
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PSPW-R4 2
INDEX
I. Application
II. Operating Principle
III. Construction (Features & Material)
IV. Operating Parameters & Selection of Heat Exchangers
V. Installation
VI. Startup/Shutdown
VII. Operation
VIII. Maintenance
IX. Storage & Transportation
X. Warranty Terms
XI. Warranty Claims Form
XII. Sales & Service
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PSPW-R4 3
I. APPLICATION
AIC PS and PW-model U-tube heat exchangers are designed for a wide range of liquid to liquid
(PW-model) and steam to liquid (PS-model) applications. We offer products of the highest
quality and reliability to satisfy your most rigorous demands.
Typical Applications:
- Domestic Hot Water
- Oil Temperature Cooling
- Liquid & Gas Cooling
II. OPERATING PRINCIPLE
A heat exchanger is a device in which heat is transferred from one flowing fluid to another.
Thermal energy is transferred through the tube walls and the total heat load is dependent on the
flow parameters of the fluid. Shell and tube heat exchangers are the most common type of heat
exchangers for liquid/liquid service, although many applications also involve steam and certain
gases.
AIC’s PW-line of heat exchangers is designed for liquid to liquid applications, and our PS-line of
heat exchangers is designed for steam to liquid applications. Normally, the heating medium (e.g.
hot water, steam) flows through the shell side, and the heated medium through the tube side,
although this can be reversed depending on the application.
Figure 1. Flow Distribution in PS-model
Figure 2. Flow Distribution in PW-model
3/4"NPT
3/4"NPT
4-Pass
N1 N2
For 4-Pass, N1 and N2 are interchangeable
N
1 - HEATED FLUID IN
N
2 - HEATED FLUID OUT
4-Pass2-Pass
N1
N1
N2
N2
2-Pass
N2
N1
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PSPW-R4 4
III. CONSTRUCTION
FEATURES
Available in 2 or 4 pass construction, our products are enhanced with stainless steel tubes in the
standard construction, rugged cast iron or steel heads, and unique coil and baffle arrangements to
optimize the thermal performance of the heat exchangers.
TUBES- Stainless steel
tubes in standard
construction ensure high
quality performance in a
broad range of
applications.
MOUNTING- saddles
attached with standard
units for quick & easy
mounting.
GASKETS- high quality
compressed fibers
(
reusable
)
TUBESHEET- U-bend
tubes expanded into
tubesheet allow for tube
expansions and contractions
due to thermal fluctuations
HEAD- standard
cast-iron or steel
head for heavy-duty
services.
CONNECTIONS-
standardized sizes for easy
assembly. Additional threads
and surface protection for
clean installation.
TUBE BUNDLE-
unique tube bundle
layout minimizes
buildup problems at the
edges and optimizes
media flow in the units.
BAFFLES- punched
baffles with minimum
clearances between tubes
assure correct fluid flow
and minimized bypass.
MATERIAL
PS and PW-model heat exchangers are manufactured according to the following table, although
optional materials of construction are available to suit specific customer requirements.
Materials of Construction
Sections Standard Construction Optional
Shell Steel SS304; SS316L
Head Cast Iron / Steel SS304; SS316L
Tubes Stainless Steel (304) Copper; SS316L; 90/10 CuNi
Tubesheet Steel SS304; SS316L
Connections Steel SS304; SS316L
Baffle Steel SS304; SS316L
Nuts & Bolts Steel -
Gasket Non-asbestos/pressed fiber -
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PSPW-R4 5
IV. OPERATING PARAMETERS & SELECTION OF HEAT EXCHANGERS
Standard maximum working parameters of the heat exchangers are as follows:
(Units designed to different parameters are available. Please consult the AIC sales office for
details.)
Standard Design Parameters
Pressure (PSI) Temperature (°F)
Shell 150 375
Tube 150 375
Regardless of the application, proper sizing of a heat exchanger is extremely important in
obtaining the desired thermal performance from the unit. In order for AIC to select the most
appropriate product for an application, a customer should specify the following information:
- type of operating medium/fluids
- required heat load
- required inlet/outlet temperatures of the heating medium
- required inlet/outlet temperatures of the heated medium
Selection is made through an internally developed software program and distributed to our
customers.
V. INSTALLATION
Before installing the heat exchanger into the system, ensure that all the proper piping and safety
gauges are in place:
1. Allow enough space around the heat exchanger to provide sufficient clearance to permit
the removal of the tube bundle from the shell (for maintenance or inspection purposes).
2. Provide valves and bypasses in the piping system so that both the shell side and tube side
may be bypassed to permit isolation of the heat exchanger for inspection, cleaning, and
repairs.
3. Provide thermometer wells and pressure gauge pipe taps in all piping to and from the heat
exchanger, as close as possible to the unit to detect operating performance of the unit.
4. Provide necessary air vent valves for the heat exchanger so that it can be purged to
prevent or relieve vapor or gas binding on both the shell and tube side.
5. Install proper liquid level controls and relieve valves and liquid level and temperature
alarms, etc.
6. Install a surge drum upstream from the heat exchanger to guard against pulsation of fluids
caused by pumps, compressors, or other equipment.
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PSPW-R4 6
The PS and PW-models are designed for horizontal installation. If space is a constraint and
vertical installation is required, please inform the AIC sales office.
- Before piping up, inspect all openings in the heat exchanger for foreign material. Remove
all plugs and shipping covers immediately prior to installation. Do not expose the interior
passages of the heat exchanger to the atmosphere as moisture and contaminants may
enter the unit and cause damage to the system.
- Mounting saddles are attached to the standard unit for quick and easy installation.
- When installing, set heat exchanger level to the ground to ensure no excess force is
required to connect to the system. Install the heat exchanger in a manner where it will not
be exposed to mechanical stresses or moments.
VI. STARTUP/SHUTDOWN
In all startup and shutdown operations, fluid flows should be gradual and regulated to avoid
thermal shocking the unit, and every effort should be made to prevent subjecting the heat
exchanger to overpressure or hydraulic hammers, as these conditions may impose stresses on the
unit that could result in structural damages.
Start-Up:
- Valves should be opened gradually in order to achieve a steady increase in flow and
pressure into the unit. The pressure increase/decrease should not exceed 72 psi/min (0.5
MPa/min).
- The cold (heated) fluid should first enter into the system.
- The hot (heating) fluid, water or steam, should be gradually brought into the system.
- Check all connections for leaks.
Shut-Down:
- Shut down hot fluid side first, then the cold fluid side.
VII. OPERATION
Heat exchangers should be used according to the specifications given by AIC, and within
pressure and temperature ranges not exceeding the limits set forth in the section “Operating
Parameters & Selection of Heat Exchangers”.
1. Ensure that the system is clean of debris before starting operation to prevent clogging of
tube and shell side passages.
2. Open vent connections before starting up.
3. Follow the instructions in the section “Startup/Shutdown”.
4. After the system is completely filled with the operating fluid, close all manual vent
connections.
5. Do not operate the heat exchanger under pressure and temperature conditions exceeding
the maximum allowable limit (as specified on the nameplate).
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PSPW-R4 7
6. Prevent any of the fluids form dropping below their freezing point.
7. Drain all fluids when shutting down to prevent possible freezing and corrosion.
Under no circumstances should there be pulsating of fluids, as this causes vibrations that could
damage the structural integrity of the heat exchanger. The system should be designed to prevent
the unit from encountering pressure shocks and rapid temperature changes.
VIII. MAINTENANCE
CLEANING
Clean heat exchangers subject to fouling (scale buildup, sludge deposits, hard water deposits,
tarnishes, etc.) periodically, depending on operating conditions. Fouling in the unit can result in
increased pressure drops, low temperature differential in the heated medium, or a higher exit
temperature on the heating medium side.
To clean or inspect the tubes, it may be necessary to remove the tube bundle from the shell.
When removing the tube bundle, ensure that there is no damage due to improper handling:
- The weight of the tube bundle should not be supported by individual tubes, but should be
carried by the tubesheet, support or baffle plates.
- Do not handle the tube bundle with hooks or other tools that can damage the tubes.
- To withdraw the tube bundle, pass rods through two or more of the tubes and take the
load on the tubesheet, or alternatively, thread a steel cable through one tube and return
through another tube.
- Lift tube bundles horizontally by means of a cradle formed by bending a light-gauge plate
into a u-shape.
- Do not drag the bundles, as this may cause damage to the tubes and baffles.
Cleansing of the heat exchanger can be done without removing the tube bundles or the unit from
the system, although extra connections and bypasses would be required.
The cleaning solutions are readily assessable at businesses carrying chemical cleaning agents for
heat exchangers or tubing and piping applications. As a guideline to purchasing the cleaning
solutions, check for the following product data:
- compatibility with the material of construction (steel, stainless steel, copper, etc.)
- acceptable for use in food processing industries (if applicable)
- effectively removes scale, slag, tarnishes, and hard water deposits
- easily rinsed out of the system
- no objectionable or corrosive fumes
The following fluids are prohibited for use as a flushing agent!!
- Hydrochloric acid up to 0.1% concentration
- Solutions that contain MCl
- Chlorides (MgCl2, NaCl between 0.01-1%, CuCl up to 1%, CaCl2from 5% to
saturation)
- Any fluid that will deposit alkaline residue or phosphorous
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PSPW-R4 8
LEAKS
To locate ruptured or corroded tubes or leaking joints between tubes and tubesheet, the following
procedure is recommended:
- Drain the heat exchanger completely of any fluid or moisture.
- Pressurize the shell side of the unit with fluid (e.g. water, glycol, etc.)
- Observe the tube joints and tube ends for indication of test fluid leakage.
IX. STORAGE & TRANSPORTATION
During transportation of the heat exchangers, ensure that they are not exposed to mechanical
damages. Upon receipt of the heat exchanger, inspect the unit for shipping damages. Notify the
carrier or the AIC sales office immediately in the event that such damages do occur.
Heat exchangers should be stored in a clean, dry, low humidity area away from corrosive
environments or weather elements (e.g. rain, snow, blowing dust). If the unit is not to be placed
in immediate service, take precautions to prevent rusting or contamination. Heat exchangers that
are out of service for extended periods of time should be protected against corrosion.
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PSPW-R4 9
X. WARRANTY TERMS
ADVANCED INDUSTRIAL COMPONENTS INC.
LIMITED WARRANTY INFORMATION
Advanced Industrial Components’ warranty obligations are limited to the terms set forth below:
Advanced Industrial Components Inc. (“AIC”) warrants to the original purchaser that this product will be
free of manufacturing defects in material and workmanship for a period of one (1) year from the original
purchase date, or eighteen (18) months from AIC’s original invoice, whichever expires first. The original
purchase date as used herein shall mean the date stated in the vendor’s original invoice.
AIC will, at its option, repair or replace this product without charge if it is found to be defective during
the limited warranty period specified above. If AIC chooses, at its discretion, to replace any product for
which there is a valid warranty claim, AIC shall replace the product with the same model or, if such
model is not available, with a model which is, in AIC’s reasonable judgment, the nearest compatible
model available at the time of replacement. Note that each purchaser is limited to one (1) product
replacement during the warranty period of the original claim.
NOT UNDER COVERAGE BY THIS WARRANTY
This limited warranty covers defects encountered in normal use of the product while operating according
to the specifications set forth by AIC. The warranty is void and shall not apply to the following,
including, but not limited to:
1. The failure or malfunction results from improper or negligent operation, abuse, misuse or
maintenance or unauthorized alteration.
2. Malfunctions resulting from, or repairs necessitated by, uses of the product for purposes other
than that for which it was designed, or resulting from flood, fire, wind, lightning, freezing, or
any other natural disaster, an act of God, an act of destruction, theft, or accident.
3. Damages to the product that occur during shipment.
4. Damages caused by improper or faulty installation.
5. Products exposed to corrosive elements harmful to the structural integrity and durability of
the product.
6. Products installed outside of Canada and the United States.
AIC shall not be liable for any direct, special, incidental, or consequential damages caused by the use,
misuse, or inability to use this product. AIC is under no legal obligations to rectify, including but not
limited to, lost profits, downtime, goodwill, damages to or replacement of equipment and property.
Purchaser assumes all risk and liability for loss, damage or injury to purchaser and purchaser’s property
and to others and their property arising out of the use, misuse or inability to use this product. This limited
warranty shall not extend to anyone other than the original purchaser of the product.
MAKING A WARRANTY CLAIM
To file a claim under this warranty, the purchaser must do the following during the warranty period:
Before returning the product to AIC for warranty service, the purchaser must complete the Warranty
Claims Form (attached) and fax it to AIC at [phone]. Upon preliminary assessment of the claim,
AIC will send the purchaser a Request for Inspection Form, along with an Inspection Tag and a Return
Merchandise Authorization (RMA) number. The Inspection Tag and RMA number must be clearly
displayed and attached to the product on its return to AIC before it can be processed. Proper packing of
the product in the original container, or equivalent, is the responsibility of the purchaser. This warranty
does not cover expenses or labour for disassembly, removal, shipment, reassembly or reinstallation; the
purchaser will be responsible for such costs.
AIC RESERVES THE RIGHT TO CHANGE SPECIFICATIONS OR DISCONTINUE MODELS WITHOUT NOTICE.
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PSPW-R4 10
XI. WARRANTY CLAIMS FORM
AIC WARRANTY CLAIMS FORM
AIC warrants this product against defects in materials and workmanship for a period of one (1) year from
the original purchase date, or eighteen (18) months from AIC’s original invoice, whichever expires first.
The original purchase date as used herein shall mean the date stated in the vendor’s original invoice.
Should the product fail to perform according to the specifications set forth by AIC during the warranty
period, AIC will repair or replace, free of charge, the products that it finds defective.
If you wish to make a warranty claim, please complete this form. Incomplete forms will not be processed.
To make multiple claims, please fill out one form for each individual unit.
Name:
Company:
Address:
Telephone: Fax:
Product Information:
Model Name:
Comments:
Serial Number:
(indicate source/symptoms of defect)
Purchased From:
Vendor Invoice # :
Vendor Invoice Date:
AIC’s Quotation # : (if applicable)
Product Operating Conditions:
Tube Side Shell Side Chemical Levels
Temperature In Free Chlorine
°C °F pH
Temperature Out Calcium Hardness
°C °F
Alkalinity
Flow
Total dissolved solids
kg/s USGPM
Bromine
Operating Fluids Copper
Chloride
Other (specify)
Thank you for your assistance. Please fax this form back to AIC. You will be contacted once the
information has been reviewed.
AIC FAX NUMBER
[phone]
For pool use, please complete the
f
ollowin
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table:
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PSPW-R4 11
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XII. SALES & SERVICE
Advanced Industrial Components serves its customers through a network of distributors. For
application assistance, performance specifications, pricing, or name of the nearest Authorized
Distributor, contact us at:
ADVANCED INDUSTRIAL COMPONENTS
TEL: [phone]
FAX: [phone]
TOLL FREE:1-888-738-1350