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

3
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

6
J. Under no circumstances shall any person reach
into an enclosure for the purpose of servicing or
adjusting the equipment except in the presence
of someone who is capable of rendering aid.
Verify equipment is de-energized.
K. If desired, perform a pre-operational continuity
check on the heater circuits. If continuity check
indicates an open circuit, check individual heater
connections and retighten as necessary. The to-
tal resistance of the heater will be a slightly lower
value before the system is energized. Consult the
factory for the estimated resistance after the sys-
tem has been energized.
L. Perform an insulation resistance test on each
heater circuit. The test voltage shall be applied
between one of the phases on each circuit and
ground. A minimum insulation resistance of 5 MΩ
shall exist. Disconnect cables from control panel
before performing test. In the event the cold in-
sulation resistance falls below 5 MΩ, the flanged
heater shall be baked in an oven between 150-
200°F for a minimum of 24 hours. Junction box
panel door shall remain open during bake out.
M.A factory performed dielectric withstand voltage
test has been performed on the elements and
flanged heaters. No further dielectric testing is
necessary on the system.
4. Mechanical Installation
A. The heater skid shall be adequately protected
against mechanical damage, extreme tempera-
tures and other adverse conditions.
B. Ensure that all precautions are taken regarding
the weight of the heater. Lifting equipment shall
have capacity for the given weight. Personnel in-
volved in the installation shall be aware that one
end of the heater will be heavier than the other
and that this will affect the lifting.
C. When positioning the heater, sufficient clearance
shall be provided for the removal of the tube
bundle from the vessel, for servicing purposes.
D. A new gasket shall be used whenever the heater
is removed and re-installed.
E. The foundation must be sufficiently strong to
prevent the heater from settling, which could
cause the piping to transmit excessive strains to
the heater nozzles. It is recommended that for
concrete footings pipe sleeves shall be fitted on
each foundation bolt. These shall be at least one
size larger than the bolt diameter, as they allow
the bolt center to be adjusted after the founda-
tion has cured.
F. Foundation bolts on a single ended heater shall
allow free expansion of the shell. The support
foot at the cap end is slotted for this purpose.
G. All heater openings shall be inspected for foreign
material. Protective plugs, covers and silica gel
desiccant shall not be removed until just prior
to startup. When connecting flanged joints, only
nuts, bolts and gaskets in accordance with the
applicable piping specification shall be used and
tightened to the recommended torque as speci-
fied in the piping specification.
H. The entire system shall be clean before starting
up. Use of filters and/or strainers may be required
where elements face exposure to materials other
than that for which the heater is designed (par-
ticles, foreign matter, etc.). The process or main-
tenance supervisor shall assess this thoroughly
before installation, and ensure that filtering/
straining provision is adequate.
I. General safety precautions listed in the plant
Safety Manual shall be closely complied with to
prevent injury to personnel or damage to equip-
ment.
J. Ensure that the area safety supervisor and others
in the vicinity are aware that work is being under-
taken and post warning notices. Ensure that the
appropriate PPE and clothing is worn. Beware of
wet or slippery ladder rungs and working areas if
working aloft.
K. Where possible hazards have been eliminated or
reduced as far as is reasonably practicable by
design but the additional warnings listed below
shall be followed to ensure continued safe use.
1. Consult the control panel manual for system start-
up, operation and general control panel safety
checks.
2. Starup of both heater and control panel shall only
be performed by Chromalox Personnel. Please
contact Chromalox Service at 1-800-443-2640
Startup and Operation

7
1. Heating Element Replacement
A. If element to flange connections are made via
compression fittings, the heaters can be individ-
ually replaced.
B. If element to be replaced is on the outer circum-
ference of the heater bundle, replacement may
be possible without removing the junction box
and standoff plate.
C. Remove service cables to junction box and un-
bolt bus bars from insulators. Stow remaining el-
ement leadwires to prevent damage.
D. Remove junction box, standoff plate and water
tight fittings.
E. Disconnect bus heating element to be replaced.
F. The compression fittings at the flange are bored
through fittings with a compression nut, front and
back ferrules and a welded in or NPT threaded
insert. When replacing an element, loosen the
compression nut, replace element and install
new ferrules. The welded in or NPT insert can
remain in the flange during replacement. Ensure
the surface of the new heating element where
ferrules are installed is free of any burrs. Tighten
the compression nut hand tight and then an ad-
ditional 1-1/4 turns. Additional turns may be nec-
essary to ensure adequate sealing. Reconnect
leadwires to the appropriate bus bars.
G. Reinstall water tight fittings and junction box
onto gland plate.
H. Reinstall bus bars onto insulators and recheck
insulation resistance per Installation section.
2. Heating Bundle Removal and Replacement
FIRE/EXPLOSION HAZARD. No operation involving
the use of an open flame or other source of igni-
tion shall be attempted until the condition has been
made safe (gas free) by the control of the flammable
material that may give rise to the risk. Electrical test
equipment can constitute a hazard and shall not be
used in the presence of a flammable material, un-
less specifically designed for the purpose and suit-
ably certified.
A. Flange faces shall be thoroughly cleaned and
inspected. Surface marks extending across the
joint face or heavy pitting are not acceptable.
B. The alignment of the flanges shall be in accor-
dance with the tolerance quoted in the vessel
code and manufacturing standard.
C. The gasket or sealing ring shall be inspected im-
mediately prior to use.
D. The immersion heater can be installed either by
use of a crane or by a running block and tackle at-
tached to an overhead stiffener beam (reference
Figure 3 as an example). Longer bundles shall be
lifted by two cranes (or two sets of blocks and
tackles).
E. Multiple slings shall be placed under multiple
spacer/baffle (span not to exceed 84”) to evenly
distribute the weight of the bundle. DO NOT PO-
SITION SLINGS OR SUPPORTS UNDER THE
ELEMENTS AS THIS WILL CAUSE IRREPARA-
BLE DAMAGE.
F. Hook the chains of lifting device to lifting eyes
on bundle flange, and tension. Locate lifting eyes
with the aid of the drawings provided.
G.
If applicable, hook the chains of the second lifting
device to a baffle along the length of the bundle.
H. Fit gasket.
I. Carefully begin inserting bundle, ensuring both
lifting devices are moving in synchronization and
taking extreme care to avoid finger jams.
J. As the bundle progresses into the vessel, remove
each successive sling at the entry point into the
vessel.
K. Continue slowly inserting bundle.
L. When bundle is fully inserted, bolt bundle flange
to vessel flange.
M.Remove chains from flange lifting eyes.
N. Insert stud bolts and fit the nuts so they are fin-
ger tight, checking that there is an equal protru-
sion of stud bolt or two threads showing passed
the nut.
O. Stud bolt tightening shall be carried out in stages
to predetermined sequence. Acceptable tighten-
ing sequences are shown in Figures 1 and 2. The
sequences shown in Figure 2 shall be used until
any flange misalignment is taken up.
P. Throughout the stud bolt tightening sequence,
frequent checks shall be made to ensure parallel
‘pull-up’ of the flanges.
Q. Final tightening shall be carried out by torque
measurement to the value given in Table 1. To
ensure its accuracy, the torque wrench shall be
calibrated regularly.
R. After final assembly of the flanges, the screw
thread protruding beyond the nut faces shall be
protected against corrosion. The use of flange
protectors shall also be considered. The immer-
sion heater shall be lifted with care, after ensuring
that lifting equipment is of the correct capacity.
Customer must install lifting eyes into the thread-
ed openings provided in the main bundle flange.
Care shall be taken to ensure that the bundle is
lifted in such a way that when it slants it receives
no damage from the ground or other obstacles.
S. The unit is now ready for electrical connection
from the junction box to the control panel.
T. This procedure shall be followed in reverse for
removal of bundle.
Heating Element and Bundle Removal

8
Figure 1: Typical Bolt Tightening Sequence
A tightening sequence similar to that shown in Figure 2
is recommended for use until any angular misalignment
is taken up. When flange faces are parallel the tighten-
ing sequence shown in Figure 1 shall be used.
Figure 2: Typical Bolt Tightening Sequence to Take
Up Angular Misalignment
Table 1: Bolting Torque
Bolt
Diameter
(In)
Recommended
Minimum Torque
(lbf/ft)
Maximum
Permitted Torque
(lbf/ft)
1/2 48 66
5/8 96 133
3/4 170 232
7/8 273 380
1 413 568
1-1/8 597 848
1-1/4 837 1199
1-1/2 1497 2157
1-5/8 1932 2806
1-3/4 2430 3529
1-7/8 3027 4395
2 3695 7325
2-1/2 5402 10945
Notes:
1. The recommended minimum torque figures given
above are considered to be sufficient for normal
purposes and take into account permitted mis-
alignment between flanges.
2. If necessary, a torque greater than the recommend-
ed minimum may be used but the maximum per-
mitted torque shall not be exceeded.
Figure 3: Example Removal Procedure
(for reference only)

9
1. Contact the Chromalox Service Department for ad-
ditional questions regarding maintenance, repair
and startup.
2. Preventative maintenance consists of inspections,
tests and cleaning of equipment at scheduled in-
tervals. It helps detect and correct conditions that
could cause equipment malfunction. The scheduled
maintenance instructions in this manual are recom-
mendations; it is the responsibility of the owner to
ensure that all local codes are met.
3. The control panel and junction box use high volt-
age. It is important that only experienced and au-
thorized technicians who observe standard safety
precautions perform all phases of installation, op-
eration, and maintenance. Before conducting any
preventive maintenance, fully de-energize and
ground the equipment. Tag the controller OUT OF
SERVICE only after it has been fully de-energized.
4. Make sure that you are not grounded whenever you
adjust equipment or use measuring equipment. Do
not use test equipment known to be in poor condi-
tion.
5. Equipment shall be kept clean, both inside and out-
side. Do not allow any water vapor ingress, as this
will precipitate corrosion of the electrical compo-
nents and promote carbon tracking.
6. Ensure that the air surrounding the control panels
does not exceed the maximum design temperature
of 40°C.
7. At 6 month intervals, check the exterior and interior
of all enclosures for visible signs of damage, corro-
sion, and discoloration and any lose connections in
the wiring. Retighten as necessary. Touch-up any
paintwork damage to prevent corrosion.
8. Isolate heater and disconnect cabling and busbars
from element terminations.
9. Periodically inspect all terminal connections and
visible insulation for damage, looseness, fraying
and other defects. Retighten any loose terminal
lugs and replace or repair damaged or deteriorated
insulation. Temperature sensors shall be checked
for accuracy and replaced if necessary.
10. Check all cabling for visible damage and check
tightness of termination nuts, fittings and glands.
11. During annual shutdown periods (or as scheduled)
unbolt heater from its mating flange and check the
condition of the heating elements. Discoloration
due to overheating shall be investigated further to
ascertain the cause. Any product build-up on the
surface of the element shall be cleaned off using
high pressure steam, water jets or suitable solvent.
The chloride content of steam or water shall not ex-
ceed 20 ppm, otherwise the element sheath can fail
through stress corrosion cracking.
12. Check that the ohms per phase on each stage are
within tolerance. If they are not, check each ele-
ment individually to establish those with unaccept-
able readings which will need replaced.
Note: Individual elements may temporarily be elec-
trically isolated from a circuit. This can allow the
heater to run in a temporary condition while re-
placements are ordered.
13. Equipment shall be installed at the earliest oppor-
tunity. In areas of adverse environmental conditions
(for example, very hot or very wet conditions), ad-
vice shall be sought from the manufacturer regard-
ing appropriate storage times.
14. Pieces of equipment prone to damage, such as
thermocouples, shall be protected from mechani-
cal damage.
15. Mating surfaces and bolting shall be evaluated for
potential corrosion and if necessary covered with
a rust-preventative suited for the materials and as
recommended by the manufacturer.
General Maintenance & Preservation

10
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
© 2015 Chromalox, Inc. All rights reserved.
Chromalox
103 Gamma Drive
Pittsburgh, PA 15238
[phone]
www.chromalox.com