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-
thermal.com/ in the Knowledge Center. You can be sure you have the latest version of
this document by logging onto the Knowledge Center with your log-in and password.
Be sure to request level 2 for access to this document. Write [email protected]
for more information. Level 2 access will assure you have the most up-to-date Manual
available.

your smart ENERGY investment™
Page 3 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.
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

your smart ENERGY investment™
Page 4 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.
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

your smart ENERGY investment™
Page 5 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.
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 [phone]. 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.

your smart ENERGY investment™
Page 6 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.
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.

your smart ENERGY investment™
Page 7 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.
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.

your smart ENERGY investment™
Page 8 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.
Figure 2 Body Serial Number
Figure 3: Model Number Location
Liquid
body
Steam
inlet
Note –Nameplate may look somewhat
different than picture shown above

your smart ENERGY investment™
Page 9 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.
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

your smart ENERGY investment™
Page 10 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.
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.