Chromalox DirectConnect User manual

1
Installation and
Operating Instructions
DirectConnectTM Medium
Voltage Process Heaters
PD466
161-307073-001
March 2015

2
Table of Contents
Title Page
Scope.................................................................................................................................... 3
Precautions and Warnings.................................................................................................. 3
Handling ............................................................................................................................... 4
Storage ................................................................................................................................. 4
Installation............................................................................................................................ 5
Startup and Operation ........................................................................................................ 6
Heating Element and Bundle Removal.............................................................................. 7
General Maintenance & Preservation................................................................................ 9

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1.
These guidelines are provided to assist in the
handling, storage, installation and maintenance for
a medium voltage heater system manufactured by
Chromalox. Instructions are provided to prevent
work site injury and aid in the handling, installation
and commissioning of this equipment. Please refer
to manual 0037-75532 for system startup, operation
and safety checks of the control panel.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heater. Failure to do
so could result in personal injury or property dam-
age. Heater must be installed or serviced by a quali-
fied person in accordance with the National Electri-
cal Code, NFPA 70.
1.
All personnel working on medium voltage electrical
equipment shall adhere to OSHA, NEC, NFPA 70E
and local specifications and standards. Failure to
adhere to proper medium voltage safety standards
including proper use of PPE may result in injury or
even death. Chromalox will not be liable for failure of
customer to adhere to governing standards.
2. De-energize all equipment before opening junction
boxes and control panels. Do not work on live cir-
cuits.
3. This equipment was specifically designed for its in-
tended purpose and shall not be used for any other
application without a complete re-evaluation by the
manufacturer. The operator shall ensure these instruc-
tions are kept with the equipment to prevent any mis-
use for which the equipment has not been designed.
4. The system owner must provide for suitable pressure
relief measures and procedures to avoid dangerous
discharge of pressure relief blow off and to protect
against exceeding the vessel maximum design pres-
sure. The operator must ensure that momentary
pressure surges be kept to 10% of maximum allow-
able pressure.
5. The heater is provided with over temperature protec-
tion devices. The over temperature protection devic-
es are connected to the appropriate over tempera-
ture monitoring device in the control panel. These
devices must be tested and their correct operation
verified prior to applying power to the heater.
6. The equipment is not to be disassembled while un-
der pressure or vacuum. The operator must provide
devices to prevent physical access whilst pressure or
a vacuum exists.
7. The system owner must provide devices and warn-
ings to prevent physical contact of personnel with hot
surfaces.
8. The system owner must provide adequate means of
draining and venting of pressure equipment.
ELECTRIC SHOCK HAZARD. Any installation in-
volving electric heaters must be performed by a
qualified person and must be effectively grounded
in accordance with the National Electrical Code to
eliminate shock hazard.
EXPLOSION HAZARD. When heating in closed ves-
sels, controls and back-up controls must be used to
regulate build-up of temperature and/or pressure.
9. The system owner must make provision to ensure
proper sealing and pressurization integrity at all con-
nection points.
10. Where necessary, the system owner must provide
suitable accessories to meet damage-limitation re-
quirements in the event of external fire.
11. Where necessary, the system owner must provide
for sampling of the vessel from time to time to allow
evaluation of the properties of the fluid so as to avoid
risks related to deposits and/or corrosion.
12. Where necessary, the system owner must provide
means of safe removal of residual heat after shut-
down.
13. The system owner must ensure that steps are taken
to avoid a dangerous accumulation of ignitable mix-
tures of combustible substance that could result in
explosion or fire..
14. Lifting eyes and lugs must be regularly checked for
corrosion and appropriate measures taken to reme-
dy corrosion such that the integrity of the lifting eyes
and lugs are not compromised.
15. The paint corrosion protection condition of the
equipment must be checked periodically to ensure
the corrosion allowance is not exceeded.
16. Before contemplating fill/pressurization, discharge or
disconnection, the Installation, Operation, and Main-
tenance instructions must be read fully.
17. Pressurization of the system shall be gradually ap-
plied, if possible, in order to allow for pressure con-
nection integrity and minimize risk in the event of im-
proper sealing of connections.
18. The heater shall be allowed to cool off to approxi-
mately 20-50°C prior to the elimination of flow through
the system in order to eliminate the risk of over tem-
perature due to latent heat in the elements/system.
19. If the electric bundle is to be removed please follow
the proper electrical isolation and disconnection pro-
cedures.
Scope
Precautions & Warnings

4
Note: Equipment that is not going to be immediately
installed should be kept in the original packaging and
stored per instructions.
1. The following steps shall be followed for unpacking:
A. All nails to be removed with nail extractor tool only.
B. Extract nails from top of case and remove battens.
C. Remove all top lumber securing equipment from
top.
D. Extract nails from one side panel and remove bat-
tens.
E. Remove all lumber securing equipment from side.
F. Extract nails from front panel and remove battens.
G. Remove all lumber securing equipment from front.
H. Extract nails from second side panel and remove
battens.
I. Remove all lumber securing equipment from sec-
ond side.
J. Extract nails from back panel and remove battens.
K. Remove all lumber securing equipment from back.
L. Remove any polythene covering using sharp knife,
taking care not to damage equipment or paintwork
with knife blade.
M. Equipment can now be lifted from base utilizing
lifting lugs or eyes placed as per the equipment
drawing.
N. Ensure equipment is lowered gently to clean and
level ground to prevent damage.
2. Inspect the equipment/system to ensure no damage
has occurred.
3. Handle the systems with care to avoid damage to the
heater terminal enclosure.
4. Know the capabilities of the lifting equipment avail-
able to handle the weight of the system.
5. Keep the system secured to the shipping skid to
prevent distortion of the frame during moving and to
minimize tipping.
6. Exercise care during any movement and placement
operations to prevent falling or unintentional rolling or
tipping.
Unpacking and Handling
1. Any system that is not installed and energized im-
mediately shall be stored in a clean, dry space
where a uniform temperature prevents condensa-
tion. It shall be stored in a heated building with ad-
equate air circulation and protected from dirt and
water. In non-humidity controlled environments,
an anti-condensate heater or desiccant shall be
used in the heater junction box to prevent mois-
ture intrusion into the heating elements. Shipping
containers are temporary protective covers. The
systems should not be stored outdoors for more
than 24 hours. If the system remains outdoors, the
entire system must be protected from the outdoor
elements with appropriate coverings.
2. Short and Long Term Storage of Heaters and
Heater Junction Boxes:
A. Unit shall be stored in a clean, dry environment.
B. Unit shall be stored off the ground.
C. All openings shall be properly covered by caps,
plugs, water-proof tape, etc.
D. All fragile parts, sharp edges, and projection
shall be properly cushioned.
E. The desired storage area for the heater shall be
an indoor heated facility.
F. The heater junction box shall be opened monthly
and silica gel bags with color saturation indica-
tors shall be inspected. Replace when warning
indicators indicate a change is required.
G. If the unit is to be left standing in the open, it
shall be suitably covered for protection against
adverse weather, using a tear-free waterproof
membrane such as a tarpaulin. The equipment
shall stand on dry ground, or on blocks to lift it
clear of any possible water.
H. If the covered area is not heated, desiccant
should be removed from the terminal housing
and an anti-condensation heater shall be in-
stalled and connected to a suitable supply and
kept in operation.
I. If flanges are opened for inspection during stor-
age, mating faces shall be cleaned and the
gaskets renewed before covers are replaced.
Nozzles and flanges shall be blanked with a full
face gasket and plate blank flange (coated with
primer) secured by 4 bolts minimum, (coated
with preservative).
J. All spare heater elements shall be stored secure-
ly, in a humidity controlled environment to pre-
vent moisture ingress.
Storage

5
1. Electrical Sensor Installation
A. Verify thermocouple and transmitter wires are
connected to the correct terminals.
B. Ensure anti-condensate heater wiring is con-
nected properly to prevent moisture intrusion
into the heating elements.
2. Heater Junction Box Installation
A. All silica gel packs, internal packing, caps, plugs,
wrappings, etc. need to be removed before op-
eration.
B. Medium voltage cable connections must be
installed in accordance with all local electrical
codes. The specific local specifications and
codes define the code of practice for electri-
cal apparatus for use in potentially hazard-
ous atmospheres. The operator installing the
heater must either be fully conversant with
local specifications or have access to it to en-
sure the heater is correctly installed.
C. The kirk key lock system is used on both the
control panel and heater junction box. The key
must be removed from the control panel which
will disable power to the system before either the
control panel and/or the heater junction box can
be opened. The key for the control panel will be
used to open the heater junction box.
D.
When opening the heater junction box, the poly-
carbonate panel must be removed and/or rotated
out of the way in order to access the connections.
E. Ensure cables connecting the control panel to
the heater junction box are rated for the line volt-
age of the system per NEC and NFPA 70E.
F. Customer cables entering the junction box shall
be secured to prevent damage and stress to the
heater wire connections.
G. The only connections that require checks for
tightness are the leadwires from the heating el-
ements to the copper bus. Verify lead wires are
isolated from and are not making contact with en-
closure surfaces or any other electric conduction
materials. Connections at the heating element
termination are water tight and do not require any
further checks. Recommended torque values for
#8 & #10 screws at the bus bar connections are
15 in-lbs. and 20 in-lbs., respectively.
H. Check that the electrical circuits agree with the
heater wiring diagram and all electrical con-
nections are tight. Sufficient clearance shall ex-
ist between live and electrical parts and live to
the ground. For voltages up to 7500kVAC, the
distance between phases and phase to ground
shall be verified. Spacing requirements: (other
than enclosure walls) (air clearance: 2in; creep-
age: 3.5in) to walls of enclosure (air clearance:
3in; creepage: 4in).
I. Ensure that the electrical protection is satisfac-
tory. Leadwires, cables and glands shall show no
signs of damage and shall be adequate for the
stated electrical duty.
J. Ensure cables connecting the control panel to
the heater junction box are installed in conduit
and all openings & transitions are protected to
prevent moisture intrusion.
K. Ensure cables and conduits are bonded correctly
and secured to prevent damage and stress to the
connections.
L. Verify junction box is free of metal chips and
shavings if drilling or punching is necessary.
3. General Electrical Safety
A. Ensure that the equipment is appropriate to the
installed area classification.
B. Ensure that the equipment is appropriate to the
surface temperature class and the heater tem-
perature class stamped on the terminal box la-
bel.
C. Check that the apparatus carries the correct cir-
cuit identification. The electrical details of the
heater are stamped on the nameplate.
D. Check that all enclosures, seals and joints are
satisfactory. Water and other corrosive fluids
must not get into threaded connections. These
shall be lightly lubricated with a conductive lubri-
cation compound (i.e. copper-based grease) as
needed.
E. Check that the grounding/earthing is satisfac-
tory. Perform a ground integrity test if necessary
to verify sufficient bonding.
F. Any persons about to perform installation pro-
cedures with any electric heater shall first sat-
isfy themselves as to the nature and extent of
any potential hazards that may be encountered.
These hazards shall be identified by a risk analy-
sis undertaken by the responsible person within
the installation team prior to commencement of
the installation process.
G. Only qualified, trained electrical personal shall
perform any activity on energized equipment.
Lockout/tagout shall always be performed prior
to entering electrical panels. Main disconnect
switch will lock and remove all power in the panel
except very low level DC control circuits being
input by the DCS.
H. With large amounts of fault current available,
there is always the possibility of “arc flash”. Take
all necessary precaution and use appropriate
Personnel Protection Equipment (PPE). Never
open junction boxes or never work on live circuits
unless the equipment has been de-energized.
I. Operating personnel must at all times observe all
safety precautions. Do not replace components
or make adjustments inside the equipment with
the high voltage supply turned on. Under certain
conditions, dangerous potential exists when the
power control is off, due to charges retained by
capacitors. To avoid electrical shock or injury,
always remove power and discharge capacitors
before touching a circuit.
Installation