AERCO Coil & Riser Replacement User Manual

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

TID-0004_0A

HE-109

Hardware Procedure:

Heaters

Applies to:

removal and replacement of Coil
Assemblies and Risers contained in

ry safety
precautions when working with high
temperature, pressurized steam and

Coil Assembly in Water Heater Heat Exchanger

TECHNICAL INSTRUCTIONS

Coil and Riser

Replacement

Procedures for All Styles

of A, B, C, and D

Indirect-Fired Water

Indirect-Fire Water Heaters.

Description of Document:
This Technical Instruction Document

provides the instructions necessary for

AERCO Indirect-Fired Heat Exchangers.
These instructions must be performed
by a skilled service technician capable
of exercising the necessa

water systems.

The original document was formatted as

HE-109, but has now been changed

To a Technical Instruction Document

(TID-0004), to better conform to the new

an Application Guide,

document definitions.

Revised: 06/20/2011

NOTE

Coil/Riser Replace Instructions for Helitherm Water Heaters

Technical instructions

Technical Support:

1-800-526-0288

www.aerco.com

HE-109

TID-0038_0A

(Mon–Fri, 8am-5pm EST)

Disclaimer

The information contained in this manual is subject to change without notice from AERCO International,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to
implied warranties of merchantability and fitness for a particular application. AERCO International is not
liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.

PR2: 04/01/11 Page 2 of 16

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Coil/Riser Replace Instructions for Helitherm Water Heaters

Technical instructions

HE-104

SW1B-Plus Heat Exchanger Installation, Operation & Maintenance Instructions.

HE-110

B-Plus II Water Wizard Heat Exchanger Installation, Operation & Maintenance

VA-109

For removal of CXT-S 1” thru 2” Control Valve prior to hydrostatically testing and

VA-110

For removal of CXT-S 2.5” thru 4” Control Valve prior to hydrostatically testing

VA-106

For removal of CXT-P Control Valve prior to hydrostatically testing and for

AC-103

For adjusting Barber-Coleman Temperature Controller for re-commissioning unit.

HE-109

TID-0038_0A

1. Introduction

This document provides the instructions necessary for removal and replacement of Coil Assemblies and
Risers contained in AERCO Indirect-Fired Heat Exchangers. These instructions must be performed by a
skilled service technician capable of exercising the necessary safety precautions when working with high
temperature, pressurized steam and water systems. It is imperative that the following Safety Warnings
and Precautions be observed at all times:

2. Overview of Procedure

Installation, maintenance and operating personnel must, at all times observe all safety regulations. The
following warnings are general and must be given the same attention as specific precautions included in
these instructions.

FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR DAMAGE

TO EQUIPMENT WHEN RELEASED

Shut off all incoming and outgoing steam and water stop valves and carefully decrease

all trapped pressures to zero before performing any maintenance.

WARNING!

Never search for leakage in a live steam line by sight alone or by “feel”. Use a

Always provide yourself with personal protective equipment, (PPE) such as

LIVE STEAM CAN CAUSE SEVERE BURNS

mirror or other suitable polished object.

gloves, eye protection, dust mask, hard hat, etc.

WARNING!

3. Reference Documents

Refer to the following AERCO documents when removing, replacing or adjusting the indicated
components and assemblies:

HE-107

SW1A-Plus Heat Exchanger Installation, Operation & Maintenance Instructions.

Instructions.

for re-commisioning unit.

and for re-commisioning unit.

re-commissioning unit.

PR2: 04/01/11 Page 3 of 16

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Coil/Riser Replace Instructions for Helitherm Water Heaters

Technical instructions

HE-109

TID-0038_0A

4. Tools and Equipment Required

The following common and special tools and equipment are required to perform the instructions contained
in this document:

Common Tools and Equipment

• Combination Wrenches: 7/16”, 5/8”,
13/16”, 1-1/16”, 1-1/8”

• Pipe Wrenches: 12” and 24”

• Chain Hoist

• Voltmeter:

• Brass Wire Brush

Special

Tools and Equipment

• Hydrostatic Pressure Pump: Range=
Up to 235 psig

• Torque Wrench, 75 ft.-lbs. With 1-1/4”,
1-5/16” & 1-1/2” Open-End Spanners
(1-1/4” Open-End Spanner required for
“A” Heater Only)

• Needle-Nose Pliers

• Gasket Removal Tool

• Carpenter’s Square

• Teflon Tape

• Orange Citric Cleaner

• Black Marker

• Coil Retaining Tool (Figure 1)

• Coil Spacing Tool (Figure 1)

• Short-Length Wrenches: 1-1 /4”, 1-

5/16”, 1-1/2”
(Overall wrench lengths should be
approx. 6 inches or less)

Figure 1: Tool Fabrication Details: Coil Spacing and Retaining Tools

Recommended Material: 1018 steel

PR2: 04/01/11 Page 4 of 16

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

Coil/Riser Replace Instructions for Helitherm Water Heaters

Technical instructions

procedures should be performed in the order specified to minimize repair time.

Section 5.1 Instructions

END

HE-109

TID-0038_0A

5. Heater Isolation and Disassembly

The procedures in the following paragraphs are arranged to isolate, disconnect and

disassemble the unit to the extent necessary to repair or replace defective items. These

NOTE

5.1 Isolating Heater

To isolate the Heater from all facility energy sources (steam, water, electrical, etc.), proceed as follows:

1) Disconnect and Lock-Out/Tag-Out external AC power supplied to the Control Box and any other
devices connected to the Heater.

2) Using a voltmeter, check to ensure that all incoming voltage readings are zero Before

3) If the Heater is equipped with a Pneumatic Steam Valve, close the valve supplying air inlet
pressure to the Pneumatic Controller.

4) Close all stop valves in the Steam Inlet and Condensate Outlet lines

5) On the water-side, close the stop valves in the following order

6) Carefully open the Relief Valve located on the Top Head to relieve pressure in the Heater Shell.

7) While holding the Relief Valve open to prevent creating a vacuum in the Shell, open the Drain

• Hot water outlet line

• Recirculation line

• Cold water inlet line

Water should stop flowing from the valve within one minute. If water continues to flow from the
Relief Valve, one of the water stop valves is not securely closed.

Valve in the Bottom Head on the Heater. Completely drain the potable water from the Heater.

Isolating the Heater

continuing.

:

PR2: 04/01/11 Page 5 of 16

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]