hydro THERMAL K500 Instruction manual
Version 3.5
Revised 8/2016
K500
Hydroheater
your smart ENERGY investment™
Page 2 of 87
K500 Auto Hydroheater –3.5 Rev: 8-2016
© Hydro-Thermal Corp., 2014. All rights reserved
Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
Printed copies of this document are not controlled by the Hydro-Thermal ISO Quality
System. The latest version of this document can always be found on www.hydro-
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this document by logging onto the Knowledge Center with your log-in and password.
for more information. Level 2 access will assure you have the most up-to-date Manual
available.
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K500 Auto Hydroheater –3.5 Rev: 8-2016
© Hydro-Thermal Corp., 2014. All rights reserved
Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
TABLE OF CONTENTS
1.0 K500 Automatic Hydroheater –General Information ....................................... 5
1.1 your smart ENERGY investment™ ............................................................. 5
1.2 Purpose of the Manual ............................................................................. 5
1.3 Principles of Direct Steam Injection (DSI) .................................................. 5
1.4 How the K500 Works...............................................................................6
1.5 Model Number Designation, Dimensions and Capacities............................... 7
1.5.1 Explanation of Model Numbers ........................................................... 7
1.5.2 Location of Markings on Body ............................................................. 7
1.6 Application Criteria.................................................................................. 9
1.6.1 Industries and Products .....................................................................9
1.6.2 Sizing Considerations ...................................................................... 10
1.7 Process and Steam Pressure Requirements............................................... 11
1.7.1 Maximum Process Pressure (Heater Discharge) ................................... 11
1.7.2 Minimum Process Pressure............................................................... 12
1.7.3 Superheated Steam ......................................................................... 12
1.7.4 Model Capacities and Heater Sizes.................................................... 13
2.0 Safety Precautions.................................................................................... 14
2.1 General Safety ...................................................................................... 14
2.2 Specific Safety...................................................................................... 15
3.0 Installation .............................................................................................. 16
3.1 General Installation ............................................................................... 16
3.2 Hardware Requirements ......................................................................... 17
3.2.1 Support and mounting ..................................................................... 17
3.3 Recommended Installation ..................................................................... 17
3.3.1 Steam Line Requirements ................................................................ 20
3.3.2 Strainer Sizing Table ....................................................................... 21
3.3.3 Condensate and Blow Down.............................................................. 21
3.3.4 Discharge Line Requirements ........................................................... 22
3.3.5 Insulation....................................................................................... 23
3.3.6 Utilities and Environmental Requirements.......................................... 23
3.4 Instrumentation and Control ................................................................... 24
3.4.1 General overview ............................................................................. 24
3.4.2 Components and Functions .............................................................. 24
3.4.3 Typical Control Logic ....................................................................... 26
3.4.4 K500 Control Characteristics............................................................ 26
3.4.5 Over Temperature Protection ............................................................ 27
4.0 Operation ................................................................................................ 28
4.1 Pre-Start .............................................................................................. 28
4.2 Initial Startup ....................................................................................... 29
4.3 Shutdown sequence (clean processes or short term with dirty fluids ............ 30
4.4 Shut Down sequence (long term with dirty fluids)...................................... 30
4.5 Applications with intermittent heat requirement ........................................ 31
5.0 Troubleshooting........................................................................................ 31
5.1 Insufficient Heating Capacity.................................................................. 31
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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U.S. and Canadian patents.
5.2 Rough Operation ................................................................................... 32
5.3 Excessive Temperature Variation ............................................................. 33
6.0 Maintenance ............................................................................................ 33
6.1 General Practices .................................................................................. 33
6.2 Recommended Maintenance................................................................... 34
6.2.1 Signs of Wear ................................................................................. 34
6.2.2 Anti-Seize Compounds..................................................................... 37
6.3 Inventory and Spare Parts Recommendations............................................ 38
7.0 Disassembly and Assembly ........................................................................ 41
7.1 Head-Actuator Removal.......................................................................... 41
7.2 Complete Disassembly ........................................................................... 42
7.3 Assembly.............................................................................................. 47
7.4 Torque Requirement .............................................................................. 58
7.5 Installing a Manual Combining Tube Adjustment (CTA).............................. 58
7.5.1 Zeroing Procedure ........................................................................ 59
7.6 How to Reverse Mount a New Style CTA................................................... 60
7.7 Rotating the Actuator............................................................................. 61
8.0 Illustrated Parts List ................................................................................. 63
8.1 Exploded View –K500........................................................................... 63
8.2 Exploded View –CTA Assembly ............................................................... 66
9.0 Bench Setting of K500 Hydroheater Actuator & Positioner ............................ 69
9.1 Actuator “Bench Set” Procedure (Pre-Installation of Positioner).................. 69
9.2 Positioners ........................................................................................... 72
9.3 Calibrating a Fisher DVC 6010 Positioner................................................. 72
9.4 Installing and Calibrating a DVC 2000 Positioner ...................................... 75
9.4.1 Mounting Magnet Array for DVC 2000 ............................................... 75
9.4.2 Calibrating a DVC 2000 ................................................................... 75
9.5 Installing and Calibrating a DVC 6200 Positioner ...................................... 78
9.5.1 Mounting Magnet Array for DVC 6200 ............................................... 78
9.5.2 Calibrating a DVC 6200 ................................................................... 78
10.0 Limited Warranty .................................................................................... 81
Appendix ....................................................................................................... 82
Appendix A: Steam Table ............................................................................. 82
Appendix B: Saturation Table ....................................................................... 84
Appendix C: Table of Figures ........................................................................ 85
Appendix D: Table of Tables ......................................................................... 86
Contact information: .................................................................................... 87
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K500 Auto Hydroheater –3.5 Rev: 8-2016
© Hydro-Thermal Corp., 2014. All rights reserved
Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
1.0 K500 Automatic Hydroheater –General Information
1.1 your smart ENERGY investment™
Your smart energy investment in the Hydro-Thermal® K500 Hydroheater® will bring
you years of service for your heating needs. It is a highly engineered patented steam
heating valve designed specifically for your process and operating conditions.
Hydro-Thermal direct steam injection heaters offer advantages no other heater can.
We are confident you will be pleased with the performance of your heater and the
increased efficiency it will bring to your operation. In fact, we guarantee the
Hydroheater will work properly for your specific application and under the operating
conditions you specified. Thank you for choosing a Hydro-Thermal heating solution.
1.2 Purpose of the Manual
Hydro-Thermal direct steam injection heaters are highly engineered products with
patented complex and precisely manufactured internal components. Regular
maintenance is essential to keep the heater in peak operating condition and continue
the performance warranty. Please read the maintenance section of this manual
carefully and follow the recommended schedule.
This manual contains information regarding installation, operation, troubleshooting,
maintenance, assembly/disassembly, and spare parts for all models of the K500
Series Hydroheater. It is provided as a guide for proper and safe operation of the unit.
CAUTION –It is essential to understand the material in this manual for proper
operation of the K500. Failure to follow these recommendations can result in
equipment failure, bodily harm, or void the warranty.
NOTICE –material may be subject to change: Hydro-Thermal maintains a
policy of continual product improvement. All information shown is correct
when published, but subject to change without notice.
To assist you, Hydro-Thermal offers a variety of comprehensive support programs that
include certification training, advance replacement, on-site maintenance, and total
maintenance and repair/refurbishment packages. Please call toll-free 1-800-952-
0121 or +1 (262) 548-8900. You may also visit www.hydro-thermal.com for more
information.
1.3 Principles of Direct Steam Injection (DSI)
The K500 is a direct steam injection heater that heats fluids or slurries by mixing
steam directly with the product. This method provides rapid steam condensation to
transfer heat to the product safely, quickly and accurately.
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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U.S. and Canadian patents.
Direct steam injection is capable of transferring 100% of the steam’s heat energy,
and may be more efficient and economical than indirect heating methods such as
heat exchangers or tank spargers.
In a heat exchanger, the fluid and the steam conduct heat through a steel barrier
layer that reduces heat transfer by as much as 15-30%. Additionally, scale and
minerals build up over time producing an insulating effect that further decreases a
heat exchanger’s effectiveness. A heat exchanger also requires more maintenance
and significantly more floor space.
Direct steam injection introduces steam directly into the product, resulting in a nearly
instantaneous change in temperature. All of the sensible and latent heat energy of
the steam is absorbed into the product, reducing actual steam usage. This efficient
use of energy, along with precise temperature control, allows for maximum
performance and reduced operating costs. Actual energy savings could be up to 30%
over heater exchangers or sparging.
Direct steam injection does not require a complicated condensate return system, and
since the K500 is internally modulated, there is no requirement for an external steam
control valve. For these two reasons, and the simple system requirements detailed in
Section 3.0, the K500 is easy to implement and provides an enhanced cost benefit.
1.4 How the K500 Works
Please reference figure 1 below. The K500 is an internally modulated steam injector
with a 90 degree fluid flow design favorable for slurries that require high shear
heating, applications with high changes in temperature, turbulent mixing, and self
cleaning for products that cause burn-on. A liquid or slurry enters into the combining
tube (CT) where steam is introduced into the fluid. Steam is modulated by a
stem/plug, through a nozzle and discharged into the liquid or slurry. The nozzle
discharges steam at very high, often sonic velocity. The turbulent nature of this high
velocity discharge enables steam to instantaneously penetrate, disperse, efficiently
mix and condense with the liquid or slurry to produce uniform heating. Temperature
is measured downstream and feedback is sent to a controller. The controller
modulates steam flow by sending a signal to an actuator directly linked to the
stem/plug. The actuator opens and closes accordingly to achieve a target
temperature.
The unit is designed such that steam pressure and steam velocity remain constant
throughout the range of operation, regardless of the amount of steam being added.
The high velocity of the steam discharge prevents burn on while creating a turbulent
interface between the product and steam. This interface causes atomized steam to
mix with the product and quickly condense, thereby transferring the heat rapidly and
in a controlled manner.
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
Figure 1: How the K500 Hydroheater Works
1.5 Model Number Designation, Dimensions and Capacities
1.5.1 Explanation of Model Numbers
The last two digits of the model number indicate the size of the Hydroheater.
Table 1: Explanation of Model Numbers
Model
Connection in inches [mm]
Discharge in inches [mm]
K510
2.5 inches [64 mm]
2.0 inches [51 mm]
K511
3.0 inches [76 mm]
2.0 inches [51 mm]
K512
3.0 inches [76 mm]
2.5 inches [64 mm]
K513
4.0 inches [102 mm]
4.0 inches [102 mm]
K514
6.0 inches [152 mm]
6.0 inches [152 mm]
K515
8.0 inches [203 mm]
8.0 inches [203 mm]
K516
10.0 inches [254 mm]
10.0 inches [254 mm]
1.5.2 Location of Markings on Body
Figure 2 shows the location on the body of the serial number and Figure 3 shows the
model number. The serial number is stamped on the steam inlet. The serial number
and model are also stamped on the nameplate.
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
Figure 2 Body Serial Number
Figure 3: Model Number Location
Liquid
body
Steam
inlet
Note –Nameplate may look somewhat
different than picture shown above
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
The serial number (a 5 or 6 digit number) is unique to each Hydroheater unit
manufactured. The code (i.e. 123456) is listed on the unit, the purchase order, as
well as on supporting documentation from Hydro-Thermal Corporation.
This serial
number is crucial for ordering additional units, spare parts, and accessories.
Please
refer to this serial number whenever contacting Hydro-Thermal Corporation.
1.6 Application Criteria
1.6.1 Industries and Products
The K500 Hydroheater is a versatile direct steam heater that can be used to replace
heat exchangers and/or spargers in many situations. These heaters fit into industrial
sustainability initiatives by using less water, all of the steam’s energy and they heat
precisely using up to 30% less energy than other traditional fluid heating devices.
Below is a partial list of applications for the K500 Hydroheater.
Table 2: Application Examples for the K500 Hydroheater
Industry
Product or Process
Ethanol
Process starch
Ethanol
Industrial mash
Ethanol
Slurry starch
Pulp & Paper
Size press starch dilution
Pulp & Paper
Size press (dry end) starch cooking
Pulp & Paper
Industrial coating starch cooking
Pulp & Paper
Industrial cationic (wet-end) starch cooking
Pulp & Paper
Process slurry PVOH
Pulp & Paper
Process pulp stock
Pulp & Paper
Brine dilution
Pulp & Paper
Black or other heavy liquor heating
Pulp & Paper
Green liquor heating
Pulp & Paper
Whitewater heating
Chemical/Pharmaceutical
Process chemical slurry
Chemical/Pharmaceutical
Jacketed kettle heating
Chemical/Pharmaceutical
Bio-kill
Food & Beverage
Fermentation, culture growing
Food & Beverage
MSG - mono-sodium glutamate
Food & Beverage
Cooking in-line soy products
Food & Beverage
Cooking in-line sauces, BBQ, tomato, ketchup, mayonnaise, etc
Food & Beverage
Cooking in-line dog food
Food & Beverage
Cooking in-line cheese
Food & Beverage
Cooking in-line baby food
Food & Beverage
Cooking in-line juice
Food & Beverage
Food related (thickening), Malt dextrin, Fructose, confectionary
Food & Beverage
Tapioca processing
Food & Beverage
Dairy
Multiple
Grain processing
Multiple
Water heating
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
1.6.2 Sizing Considerations
Note - For accurate sizing contact a Hydro-Thermal Representative
There are many factors to consider when choosing the specific size of a heater body
and the internal components. Please note that a given body has a wide range of
possible internals.
First, product flow rates, both now and in the future, should be considered to
optimize performance. However, it is important to select internals for the current
conditions. If higher flows are required in the future, they may be achievable by
replacing the internals. Over sizing the components today, for possible increased
future capacity, may result in poor temperature control. Please see section 5.0 –
troubleshooting for more details.
Second, heating capacity needs should be clearly defined for the full range of
expected process conditions—both process flow and temperature rise requirements.
The range of flow (steam or liquid) is called the system turndown, defined as the ratio
of the maximum and minimum flow rates.
Sizing Example 1: A system with a maximum liquid flow of 600 GPM [136 m3/h] and
a minimum flow of 200 GPM [45 m3/h] will have a liquid turndown of 600/200 =
3:1.
Steam turndown is a function of both liquid turndown and a variance in discharge
temperature.
Sizing Example 2: The system in Example 1 uses a K500 Hydroheater® to raise the
temperature of river water to 120° F [49°C]. In the winter, the river water is 40°F
[4.4°C], so the K500 heats the water 80°F [27°C]. However, in the summer the river
water is now 80°F [27°C], so the K500 only heats the water 40°F [4.4°C]. The
resulting steam turndown at any given flow rate is 2:1. Further, because the system
flow rate also has a turndown ratio of 3:1, the total steam turndown for the system is
6:1.
Continuous systems with steam and liquid turndown ratios less than 2:1 typically
require only simple control schemes. As the turndown ratios increase, systems need
more sophisticated instrumentation and control schemes.
The heater internals are typically sized to operate between 20-80% valve position. In
general 20% minimum opening is necessary for accurate temperature control and for
robust product reliability. Sizing to 80% capacity allows for variations in process
conditions and some additional capacity.
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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U.S. and Canadian patents.
1.7 Process and Steam Pressure Requirements
For stable operation, a correct relationship between steam and process pressure is
needed.
Please note that the pressures stated are those immediately at the heater during
operation. For example, steam pressure should be measured near the inlet flange of
the heater, because extended lengths of piping, elbows or valves would result in lower
steam pressure at the heater inlet. Process pressure should be measured near the
heater discharge for the same reasons.
1.7.1 Maximum Process Pressure (Heater Discharge)
In order to maintain stable flow conditions, the absolute pressure ratio of water to
steam should not exceed 0.6. Table 3 shows a number of common steam pressures
and each respective maximum allowable water pressure.
Table 3: Maximum Water Pressure
Table 3 follows a linear relationship and may be interpolated or extrapolated to
approximate your specific flow conditions. For more tailored, accurate and complete
or (262) 548-8900
Steam Pressure
(psig)
Max Water Pressure
(psig)
20
6
30
12
40
18
50
24
60
30
70
36
80
42
90
48
100
54
110
60
120
66
130
72
140
78
150
84
Steam Pressure
Bar (g)
Max Water Pressure
Bar (g)
1.5
0.5
2.0
0.8
2.5
1.1
3.0
1.4
4.0
2.0
5.0
2.6
6.0
3.2
7.0
3.8
8.0
4.4
9.0
5.0
10.0
5.6
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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U.S. and Canadian patents.
1.7.2 Minimum Process Pressure
For a given discharge temperature, the water discharge pressure should be
maintained at 5 psi [0.3 Bar] above the saturation pressure. Table 4 shows the
minimum allowable discharge pressure for a range of temperatures. For a more
complete table and curve, please see Appendixes A and B. As a general guideline,
for high temperature applications, over 250°F [121°C] or high temperature
differential, over 100°F [38°C], please contact Hydro-Thermal at (262) 548-8900 to
discuss this with one of our Applications Engineers.
Table 4: Min Water Discharge Pressure
Water Temperature
(°F)
Min Water Pressure
(psig)
210
5
212
5
220
7
230
11
240
15
250
20
260
26
270
32
280
39
290
48
300
57
310
68
320
80
330
93
Example: Heating to 250˚F [121°C]
Steam Pressure: 110 psig [7.6 Barg]
Result: Maximum water discharge pressure: 60.1 psig [4.15 Barg]
Saturation pressure at 250˚F [121°C]:15.1 psig [1.0 Barg]
Minimum water discharge pressure: 20.1 psig [1.4 Barg]
1.7.3 Superheated Steam
Superheated steam should be a maximum of 50°F [28°C] above saturation
temperature to assure smooth condensation. For superheat temperatures in excess of
50°F [28°C], please contact Hydro-Thermal for more detailed analysis.
Water Temperature
(°C)
Min Water Pressure
Bar (g)
100
0.34
105
0.54
110
0.76
115
1.02
120
1.32
125
1.65
130
2.03
135
2.46
140
2.94
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Figure 4: Dimensions of K500 Hydroheater
1.7.4 Model Capacities and Heater Sizes
Table 5: K500 Dimensions
Model
A
B
C
D
E,F
G
H
J
K
in(cm)
in(cm)
in(cm)
in(cm)
in(cm)
in(cm)
in(cm)
in(cm)
in(cm)
K510
13.19
17.31
5.00
5.00
2.50
2.00
16.00
45.00
4.00
(33.50)
(43.97)
(12.70)
(12.70)
(6.35)
(5.08)
(40.64)
(114.30)
(10.16)
K511
16.00
21.13
6.00
6.00
3.00
2.00
16.00
55.75
4.00
(40.64)
(53.67)
(15.24)
(15.24)
(7.62)
(5.08)
(40.64)
(141.61)
(10.16)
K512
16.00
21.13
6.00
6.00
3.00
2.50
16.00
55.75
6.00
(40.64)
(53.67)
(15.24)
(15.24)
(7.62)
(6.35)
(40.64)
(141.61)
(15.24)
K513
15.38
22.38
7.56
7.56
4.00
4.00
18.63
58.38
6.00
(39.07
(56.85)
(19.20)
(19.20)
(10.16)
(10.16)
(47.32)
(148.29)
(15.24)
K514
19.50
29.50
8.88
8.88
6.00
6.00
21.13
73.13
8.00
(49.53)
(74.93)
(22.56)
(22.56)
(15.24)
(15.24)
(53.67)
(185.75)
(20.32)
K515
25.00
37.00
10.75
10.75
8.00
8.00
21.13
82.13
8.00
(63.50)
(93.98)
(27.31)
(27.31)
(20.32)
(20.32)
(53.67)
(208.61)
(20.32)
K516
38.13
52.13
12.56
10.69
10.00
10.00
21.13
102.00
9.00
(96.85)
(132.41)
(31.90)
(27.15)
25.40
25.40
(53.67)
(259.08)
(22.86)
Note –Dimensions shown are for K500 Hydroheaters with 150# ANSI flanges
and should be used for reference only. For construction purposes, contact
Hydro-Thermal directly.
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Table 6: Approximate weight and general flow rate capacities
Model
Approx. Weight
Flow Rate
lbs(kg)
gpm(m3/h)
K510
160
28-174
(73)
(6.5-40)
K511
297
40-402
(135)
(9-91)
K512
305
40-402
(138)
(9-91)
K513
447
120-750
(203)
(27-170)
K514
704
300-1800
(319)
(68-409)
K515
934
400-2500
(424)
(91-568)
K516
1350
625-3900
(612)
(142-886)
Note - For accurate sizing contact a Hydro-Thermal Representative.
Internals are specifically sized for the process conditions provided
at the time of sale. Guidelines vary for different fluids & process conditions.
2.0 Safety Precautions
2.1 General Safety
It is the owners’ and installers’ responsibility that the installation conforms to all
applicable local, state, regional and federal codes and standards. Accommodation
should be made for compliance with further regulations relating to specific industries.
Complete systems incorporating a K500 should be designed to meet or exceed the
temperature, pressure and flow ratings as specified under the DESIGN CONDITIONS
on the EQUIPMENT SPECIFICATIONS sheet provided with the original quotation.
Installation of single or double action Back Flow Preventer and/or Vacuum Breakers
when connected to a potable water supply may be necessary.
The K500 is not designed to provide tight shutoff of steam flow. If the heater or its
associated piping is to be disassembled in any way, the steam supply should be
isolated from the K500 by closing a steam shutoff valve located on the steam line
upstream of the K500.
If the process requirements exceed this limit, contact Hydro-Thermal technical
service at 1-800-952-0121 or +1 (262) 548-8900.
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The following symbols will be used throughout this manual. The basic definitions are
listed below:
WARNING - This warning symbol means danger. You are in a situation that
could cause bodily injury. Before you work on any equipment, be aware of the
hazards involved with electrical circuitry and be familiar with standard
practices for preventing accidents.
CAUTION - This caution symbol means reader be careful. You are capable of
doing something that might result in equipment damage or bodily injury.
2.2 Specific Safety
WARNING - If the K500 or its associated piping is to be disassembled, the
steam supply should be isolated from the unit by closing a steam shutoff valve
located on the steam line upstream of the unit. Follow Lockout/Tagout
procedures.
WARNING - The K500 is capable of heating water to very high temperatures.
Access to extreme water temperatures and flash steam is a possibility. To avoid
serious injury, use extreme care and wear protective gloves, garments
and safety glasses at all times.
WARNING - Do not use the K500 with steam that exceeds the temperature and
pressure rating of the unit.
WARNING - Use of copied or modified parts could result in deviation of the
pressure vessel resulting in code violation and personal injury. Do not
substitute any component parts of the assembly. Use only factory produced
Hydro-Thermal genuine parts. Order through your Hydro-Thermal
CAUTION - To ensure stable operation of the K500, steam will be injected at
full pressure. For correct operation of the K500, refer to Section 1.7.
CAUTION - Read and understand all instructions before operating the K500.
The K500 must only be operated by persons trained in its installation,
operation, and maintenance. Hydro-Thermal offers maintenance and
operations training for your plant personnel. Inquire to
CAUTION - Always keep hands and fingers clear of moving parts and pinch
points as the Actuator operates. Always wear protective clothing, gloves, and
eyewear when working with steam.
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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U.S. and Canadian patents.
CAUTION - Only use K500 for the intended purpose of heating appropriate
liquids and slurries.
CAUTION - If you require assistance, or if your K500 cannot be installed in
accordance with these recommendations, please contact Hydro-Thermal
Technical Service, toll-free at 1-800-952-0121 or +1 (262) 548-8900 or
CAUTION - In high temperature applications (above 212°F [100°C]), the back
pressure required to prevent flashing should be at least 5 psi [0.3 bar] higher
than the saturation pressure given in the Steam Tables in Appendix A. Both
the steam and the water supply pressures must be constant for the heating
systems to operate with a uniform discharge temperature.
3.0 Installation
3.1 General Installation
Installation of the K500 requires American Society of Mechanical Engineers (ASME)
or equivalent applicable codes for piping systems. The K500 can be mounted in any
position. However for best operation, it is recommended that the heater be mounted
with the steam line horizontal, or entering from above, leading directly into the heater
as depicted in Figure 5. This preferred orientation will minimize backfilling (“dead-
legs”) in the steam line simplifying purging of condensate at start-up. If the K500
must be mounted vertically, the discharge should be orientated downward.
CAUTION - If the K500 is mounted with the actuator below the heater, leakage
from the assembly may cause the steel actuator to corrode and fail
unexpectedly.
To provide sturdiness, pipes should have a minimum wall thickness according to
ASTM standard A53 grade B schedule 40, or equivalent, for at least 10 pipe
diameters to the inlet and 40 pipe diameters at the discharge.
CAUTION - If your K500 cannot be installed in accordance with these
recommendations, please contact Hydro-Thermal Technical service for
assistance.
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
3.2 Hardware Requirements
3.2.1 Support and mounting
Piping surrounding the K500 should be adequately mounted, yet allow for thermal
expansion. A possible rigid mounting configuration is shown in Figure 5 below.
CAUTION - The K500, like any fluid heating device, must be properly secured
with rigid support for process instability conditions.
WARNING - The customer is responsible for adequately supporting the K500/
piping system in accordance with ASME B31.1 (Power Piping Code) and
ASME B31.3 (Process Piping Code) while minimizing external loading to
K500 flange connections.
Figure 5: Support Diagram
3.3 Recommended Installation
See Figures 6 and 7
Installation Notes:
1. Recommended straight lengths of pipe without directional or size change:
Inlet- 3 pipe diameters minimum
Discharge- 10 pipe diameters minimum
2. Temperature sensor should be located 20-40 pipe diameters from the heater
discharge (process parameters may influence exact locations).
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
3. For units 8" and above (K515 and larger) a steam warm-up valve (as shown on
figure 7) may be recommended. Contact Hydro-Thermal Customer Service for
further information.
4. Control system should verify process flow before permitting Auto On/Off Steam
Valve to open, either through Flow Switch shown or another method.
5. Abrupt flow variations can cause temperature swings. The control system
designer should allow for transient conditions and tune the temperature loop
accordingly. If water flow is shut off quickly the heater should be closed and
Auto On/Off steam valve should be disabled.
6. See sizing sheet for maximum discharge pressure. Pressure gauges should be
installed for verification.
7. Steam check valve should be located 3-5 pipe diameters upstream from the
heater.
8. Hydroheater can be oriented in any position, however, the preferred orientation
is with steam entering horizontally or if not, then from above. Steam lines
entering from below the unit could result in condensate slugging and possible
damage. For larger units (typically 4" and above) the Hydroheater is best
supported horizontally.
9. Steam line between the Auto On/Off steam valve and the heater should slope
downward towards the heater.
10. Check valve at process inlet may not be required for all fluids or system
configurations.
11. Isolation valves should be provided on each side of the Hydroheater for
maintenance purposes.
12. Steam strainer to have maximum screen size noted in section 3.3.2.
13. All piping, including downstream components, should be rated for the full
supply steam pressure or have an adequate safety relief.
14. For further details call Hydro-Thermal Customer Service at 800-952-0121 or
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
SOL-158
Figure 6: Piping Configuration
Figure 7: Process Diagram
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K500 Auto Hydroheater –3.5 Rev: 8-2016
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Hydroheater, Solaris, Jetcooker, EZ Heater and K5 Autopilot are trademarks of Hydro-Thermal Corp, and are protected under
U.S. and Canadian patents.
3.3.1 Steam Line Requirements
Typically, the steam branch line is constructed of carbon steel, but can be
substituted with stainless steel based on the application. The flange rating of the
steam should be based on the pressure of the system and ASME, or other
international code governing bodies, as well as local codes.
The steam branch line should be sized for allowable pressure drop and velocities.
This is generally the same size, or a pipe size larger, than the heater steam inlet
flange. The steam line should be sized to provide the pressure and capacity required
at the heater during operation. The steam line should be engineered to minimize the
number of bends and flow interruptions leading to the steam heater.
Steam branch connections should connect to the top of the steam main, rather than
the side or bottom to avoid condensate and debris which will adversely affect
equipment performance. (See Figure 8).
The shutoff valves or warm-up valve should be opened slowly to allow any existing
condensate to flow through the drain traps before high velocity steam is introduced.
This is especially important at a cold start-up.
The steam line must also include a check valve immediately upstream of the heater
to prevent backflow. The shutoff valve should be automated to close when flow is not
sensed.
CAUTION - It is necessary to install a properly rated shutoff valve on the steam
inlet piping to the K500. The heater does not meet class IV shutoff guidelines.
A pressure gauge should be installed downstream of the check valve. It is necessary
to read this pressure in order to properly adjust the heating system.
Figure 8: Line Connections
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