Page 1
Instruction
No.
AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA
SG-101
Installation, Operation
& Maintenance Instructions
PACKAGED
STEAM
GENERATOR
MODEL
SS1B PLUS
Printed in U.S.A. MAY, 2003
Page 2
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
Telephone Support
Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through Friday)
(800) 526-0288
Printing May, 2003
The information contained in this operation and
maintenance manual is subject to change
without notice from AERCO International, Inc.
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
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.
© Aerco International, Inc., 2003
Page 3
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
TABLE OF CONTENTS
Section Page
SAFETY PRECAUTIONS SG-101-1
GENERAL INFORMATION SG-101-3
INSTALLATION SG-101-5
PRINCIPLES OF OPERATION SG-101-7
OPERATING PROCEDURES SG-101-8
ROUTINE MAINTENANCE SG-101-10
TROUBLESHOOTING SG-101-11
CORRECTIVE MAINTENANCE SG-101-12
DESCALING BY THERMAL SHOCK SG-101-13
DISASSEMBLY SG-101-14
REASSEMBLY SG-101-16
RECOMMENDED SPARE PARTS SG-101-19
SAFETY PRECAUTIONS
Installing or 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 the instructions
FLUIDS UNDER PRESSURE MAY CAUSE INJURY TO PERSONNEL OR
SHUT OFF ALL INCOMING AND OUTGOING STEAM AND WATER STOP
VALVES AND CAREFULLY
(see Step OP8, Shutdown, in OPERATING PROCEDURES Section) BEFORE
PERFORMING ANY MAINTENANCE.
DAMAGE TO EQUIPMENT WHEN RELEASED
WARNING!
LIVE STEAM CAN CAUSE SEVERE BURNS
NEVER ATTEMPT TO SEARCH FOR LEAKAGE IN A LIVE STEAM SYSTEM BY
“FEEL”. USE A MIRROR OR OTHER SUITABLE POLISHED OBJECT.
WARNING!
DECREASE ALL TRAPPED PRESSURES TO ZERO
SG-101-1
Page 4
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
THIS PAGE INTENTIONALLY BLANK
SG-101-2
Page 5
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
GENERAL INFORMATION
INTRODUCTION
This instruction covers a HELITHERM Series A
or Series B Steam to Water Heat Exchanger.
Steam is the primary
Converted to steam is the secondary
side fluid.
The number of coils included in a particular
Heater is denoted by the last two digits in the
Heat Exchanger Model No. That is: 01 = 1 coi1,
03 = 3 coils, 10 = 10 coils, 15 = 15 coils, etc.
The Style designation for a Heat Exchanger
denotes materials of construction for the various
components. If this information is required for a
specific heat exchanger, or contact the nearest
AERCO Sales Representative.
or tube side fluid. Water
or shell
ACCESSORIES
Accessories included in the AERCO B-Plus
Steam Generator Package Assembly are (see
Figures SG-101-1, SG-101-8, and SG-101-10):
• Over-Pressure Limit System, including the
fo1lowing:
• Steam Pressure Controller - Installed in the
Control Box
• Liquid Level Controller - mounted on the side
of the Generator
• Water Solenoid Valve -- installed at the cold
water inlet
• Inlet and Outlet Steam Pressure Gages -- -mounted" below the Control Box
• Over-Pressure Limit System, including the
following:
• Pressure Switch - installed in the Control
Box
• Air Solenoid Valve -- installed in the
Control Box
• Indicator Lights -- "Power On" and "Over
Pressure" -- installed in the Control Box
• Pressure & Temperature Relief Valve – size
furnished as required in accordance with the
design Btu output of the Generator -- located
in the Generator top head
• Inverted Bucket Steam Trap -- located in the
Condensate Outlet (see Figure SG-101-1)
All other items, such as: stop valves, check
valves, strainers, unions or flanges and other
piping and fittings as shown in Figure SG-101-2
are to be furnished by the installer or user.
NOTE
The AERCO Steam Generator carries the
standard AERCO warranty against defective
material and workmanship. HOWEVER,
AERCO cannot honor its warranty if the
installer or user deviates in any way from the
instructions and precautions included herein
or makes any alteration of the equipment
from that as originally furnished without the
written approval of AERCO.
NOTE
THIS INSTRUCTION COVERS ONLY THE STEAM GENERATOR PORTION OF THE MODEL B-PLUS PACKAGED ASSEMBLY.
SEPARATE INSTRUCTIONS ARE INCLUDED IN THIS PACKAGE COVERING THE PRIMARY STEAM CONTROL VALVE
STEAM PRESSURE CONTROLLER LIQUID LEVEL CONTROLLER OVER-PRESSURE LIMIT SYSTEM AND ITS COMPONENTS
AND OTHER ACCESSORIES INCLUDED IN THE GENERATOR PACKAGE.
SG-101-3
,
Page 6
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
TABLE 1
GENERATOR
MODEL
SS1B+02 2
SS1B+03 3
SS1B+04 4
SS1B+05 5
SS1B+06 6
SS1B+07 7
SS1B+08 8
SS1B+09 9
SS1B+10 10
SS1B+11 11
SS1B+12 12
SS1B+13 13
SS1B+14 14
NOTE:
120V/60 Hz ELECTRICAL
POWER SUPPLY
AND
25 PSIG AIR SUPPLY
REQUIRED
STEAM FLOW CONTROL
VALVE WITH PNEUMATIC
OPERATOR - SEE TABLE 2
SS1B+15 15
NO. OF
COILS
HEATING
SURFACE
2
FT
(M2) A
15
(1.39)
20
(1.86)
25
(2.32)
30
(2.79)
35
(3.25)
40
(3.72)
45
(4.18)
50
(4.65)
55
(5.11)
60
(5.57)
65
(6.04)
70
(6.50)
75
(6.97)
INCHES
DIMENSIONS
INCHES (CM)
B
40.75
55.00
(103.5)
(139.70)
45.75
60.00
(116.20)
(152.40)
49.75
64.00
(126.37)
(162.56)
54.75
69.00
(139.07)
(175.26)
58.75
73.00
(149.23)
(185.42)
63.75
78.00
(161.93)
(198.12)
67.75
82.00
(172.09)
(208.28)
72.75
87.00
(184.79)
(220.98)
76.75
91.00
(194.95)
(281.14)
81.75
96.00
(207.65)
(243.84)
85.75
100.00
(217.81)
(254.00)
90.75
105.00
(230.51)
(266.70)
94.75
109.00
(240.67)
(276.86)
TABLE 2
VALVE
PRIMARY ST EAM
SIZE
INLET SIZE, NPT
INCHES
1.00 1.00
1.25 1.25
1.50 1.50
2.00 2.00 5.08
C
21.00
(53.34)
26.00
(66.04)
30.00
(76.20)
35.00
(88.90)
40.00
(101.60)
45.00
(114.30)
50.00
(127.00)
55.00
(139.70)
60.00
(152.40)
65.00
(165.10)
70.00
(177.80)
75.00
(190.50)
80.00
(203.20)
CM
2.54
3.18
3.81
APPROX. WT.
LBS. (KG)
DRY
WET
520
660
(237)
(300)
570
720
(259)
(327)
610
770
(277)
(350)
640
830
(291)
(377)
670
880
(304)
(400)
710
930
(322)
(422)
740
980
(336)
(445)
770
1030
(350)
(468)
800
1080
(363)
(490)
840
1130
(381)
(513)
870
1180
(395)
(536)
900
1230
(409)
(558)
930
1280
(422)
(581)
DIMENSIONS ARE SHOWN IN
INCHES (CENTIMETERS)
ASME CODE
CERTIFICATION STAMP
TABLE 3
HEAT EXCHANGER DESIGN PARAMETERS
SHELL
SIDE
TUBE
SIDE
MAX. WORKING
PRESSURE
PSIG (kPa)
50
(345)
250
(1723)
MAX.
TEMP.
DEG. F (DEG. C)
(204)
(204)
400
400
TEST
PRESSURE
PSIG (kPa)
75
(517)
375
(2584)
U-7
Figure SG-101-1. Dimensions for AERCO Packaged Steam Generator, Model SS1B-PLUS
SG-101-4
Page 7
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
INSTALLATION
1. Dimensions for an AERCO Steam
Generator Model SS1B-PLUS are shown in
Figure SG-101-1.
2. Uncrate the Generator carefully. Set it
upright by using a block and tackle or hoist
attached to the lifting lugs on the top head of
the Generator (the eye bolts shown in Figure
SG-101-9). Always use the lifting lugs
and/or move the Generator.
3. If possible, for easy in-place maintenance,
locate the Generator where there is at least
2 feet clearance all around the unit and
where the head room clearance is equal to
or more than dimension C in Figure SG-1011 for the size Generator furnished.
4. It is suggested that the Generator be
secured to the floor. However, any other
means for securing the Generator may be
used. If piping is used to secure the
Generator, the piping must
provision for expansion.
5. Make all piping connections as instructed in
Step 6 below and in accordance with Figure
SG-101-2 or with any specific piping
diagram which may have been furnished by
AERCO for this installation.
6. For best Generator performance, observe
the following very carefully in making the
piping installation:
include ample
to lift
d. Include all of the stop valves, check
valves, steam traps and other elements
in the piping as shown in Figure SG101-2 or as separately specified by
AERCO. Note that the steam trap and
Generator drain valve are included in
the Generator assembly.
e. Be sure to include a vacuum breaker in
the steam outlet line ahead of the stop
valve. This assures no vacuum buildup
during operation.
f. The condensate return piping should be
arranged to permit condensate to drain
freely by gravity from the Generator
bottom head. Failure to do so may result
in Generator improper operation and/or
in damage to the primary
steam/condensate system.
g. All drain discharges -- relief valve in the
top head of the Generator and drain
valve in the bottom head -- should be
piped directly to a convenient floor drain.
7. Before making final piping connections to
and from the Generator, blow out all piping
thoroughly.
8. Make the necessary air-operated Control
Valve supply air connection to the connector
through the side of the control box. THE
SUPPLY AIR PRESSURE MUST BE
MAINTAINED AT 25 PSIG.
a. Do not use cement or red lead in
making up pipe joints.
b. For Generator connection types, sizes,
and locations, see Figure SG-101-1.
c. All piping to the Generator top head
should be provided with unions or
flanges which are located beyond the
outside diameter of the Generator head
to permit removal of the head and
she!1for in-place maintenance.
SG-101-5
9. Connect 110V 60 Hz power supply wiring
through the side of the control box to the
electrical junction box.
Page 8
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
SECONDARY STEAM OUT
STEAM HEADER
CONTROL BOX
LEVEL CONTROLLER
P
PRIMARY
STEAM IN
CONDENSATE OUT
COLD WATER
SUPPLY IN
DRAIN
LEGEND
PRESSURE
STOP VALVE
RELIEF VALVE
CONTROL VALVE
STRAINER
RELIEF VALVE
STEAM TRAP
Figure SG-101-2. Piping Connections for AERCO Steam Generator
P
GAGE
PIPE UNION
OR FLANGES
VACUUM
BREAKER
SG-101-6
Page 9
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
PRINCIPLE OF OPERATION
The AERCO Helitherm Heat Exchanger
(Generator) SS1B-P1us consists of four
principal parts (see Figure SG-101-3):
1. Shell with Top and Bottom Heads
2. Coils assembled to Primary Steam Riser
and Condensate Return
3. Pressure Control Unit
4. Water Level Control Unit
Cold Water enters the Generator through the
inlet connection and dispenser (dispersion
tube) in the bottom head. The Cold Water in
the shell, then, flows upward among the coils
(heating surfaces) and, heated, is converted to
Secondary Steam which is discharged through
the Secondary Steam outlet connection in the
top head.
Primary Steam enters through the Primary
Steam Control Valve and its inlet connection in
the bottom head and is fed through the
Primary Steam riser to the inlet of each coil
unit. The Primary Steam then flows through
each coil unit simultaneously in parallel,
leaves through each coil outlet as
Condensate, enters the condensate return,
and leaves the Generator through the
condensate outlet connection in the bottom
head of the Generator.
The Pressure Controller senses the pressure
of the Secondary Steam at any given moment
and signals the Primary Steam Control Valve
to modulate between full open or closed as
necessary to maintain the required Secondary
Steam outlet pressure.
The Water Level Controller senses the level of
water in the Generator at any given moment
and signals the Water Solenoid Valve to open
or dose as necessary to maintain the desired
water level in the Generator.
Figure SG-101-3. AERCO Steam Generator
Schematic
SG-101-7
Page 10
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
OPERATING PROCEDURES
OP1. With the installation entirely completed,
including:
• All piping connections have been
made,
• All connecting piping has been
cleaned and blown out,
• All connections per steps 8 and 9
under INSTALLATION have been
made,
turn ON the electrical power supply and
open any stop valve(s) in the Cold
Water inlet line Hold the relief valve in
the Generator top head open to allow air
to escape (otherwise an air pocket will
be built up and the Generator will not fill
properly). The Level Controller will hold
the Water Solenoid Valve open to allow
water to flow into the Generator shell
until the desired water level is reached,
at which time the Level Controller will
close the Water Solenoid Valve. Then
close the relief valve.
OP6. Follow the instructions furnished with
the air-operated Pressure Controller and
Control Valve and:
a. Introduce Primary Steam to the
Generator.
b. Adjust the Pressure Controller until
the Secondary Steam outlet
pressure is being held steady at the
desired pressure. If the Secondary
Steam outlet pressure is erratic, see
step OP7 below.
c. Close the process steam outlet
valve which was opened in step
OP4}.
OP7. If the Secondary Steam outlet pressure
is erratic, especially during load
changes:
a. Put a load on the Generator by
opening a steam outlet or outlets in
the process as quickly as possible.
OP2. Temporarily set the Pressure Switch
(58) in the Control Box to its high
pressure limit. See Figure SG-101-8,
(Item 58) and the wiring diagram in
Figure SG-101-4.
OP3. Set the Pressure Controller (53) in the
Control Box at the pressure desired to
be held at the Secondary Steam outlet.
OP4. Open any stop valve(s) in the
Secondary Steam outlet line. Open a
steam outlet valve in the process to
insure a flow of steam from the
Generator. For best results in adjusting
the pressure control, a steam flow of
10% to 23% of Generator rating is
desirable.
OP5. Slowly open all stop valves in the
Primary Steam inlet and Condensate
outlet lines.
b. Adjust the Pressure Controller to
provide best response on load
changes. See the instruction
furnished with the Controller.
OP8. Adjust the Over-Pressure Limit System
Pressure Switch (58) in the Control Box
to its desired setting -- usually 5 to 7
psig higher than the desired Secondary
Steam pressure.
OP9. The Generator is now set for operation.
No further operation procedure is
necessary unless, or until, further
pressure control adjustments may be
required. If so, repeat steps OP4, OP5,
OP6, OP8, and, if necessary, step OP7.
SG-101-8
Page 11
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
OP10. To SHUT DOWN the system:
a. Close all stop valves in the Primary
Steam inlet and Condensate outlet
lines.
b. In this order,
close any stop valves
in:
(1) the Secondary Steam outlet line,
(2) the Cold Water inlet line.
OP11. For DRAINING THE GENERATOR, see
the instructions included under
ROUTINE MAINTENANCE.
OP12. To START UP again, with the shell filled
per step OP1 above, open the stop
valves in the following order:
a. stop valve in the Cold Water inlet
line,
b. stop valve in the Secondary Steam
outlet 1ine, and
c. stop valves in the Primary Steam
inlet and Condensate outlet lines.
OP13. After each startup, check the pressure
control, If necessary, make adjustments
per steps OP4 through OP8 above.
Figure SG-101-4. Over-Pressure Limit System Wiring Diagram
SG-101-9
Page 12
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
ROUTINE MAINTENANCE
The constant flexure of the coils under varying
load conditions automatically provides a
descaling action and prevents a buildup of brittle
scale. A periodic blow-down (draining) is
required lo remove accumulated solids.
After the first 3 months of initial operation, drain
the Generator as outlined below. Examine the
water being drained:
Check the pressure control at least once every 3
months. Make any necessary adjustments per
steps OP4 through OP8 of the OPERATING
PROCEDURES Section.
DRAIN THE HEATER as follows:
RM1. Close all stop valves in the Primary
Steam inlet and Condensate outlet lines.
a. If the amount of solids appears to be
heavy, set a schedule to drain the
Generator every 3 months.
b. If the amount of solids appears to be
light, set a schedule to drain the
Generator every 6 months.
c. Even if the amount of solids appears
to be very light, drain the Generator
at least once each year.
d. Also, see the TROUBLESHOOTING
and CORRECTIVE MAINTENANCE
which follow. If descaling by
thermal shock is required, schedule
that procedure in ROUTINE
MAINTENANCE
RM2. RM2. In this order, close the stop valves
in:
a. the Cold Water inlet line
b. the Secondary Steam outlet line,
RM3. Carefully open the relief valve in the
Generator top head to relieve pressure
in the Generator shell.
RM4. With the relief valve being held open (to
prevent creating a vacuum), open the
drain valve and drain the Generator
completely.
RM5. To refill the Generator and place it back
into service, close the drain valve and
follow steps OP1, OP12 and OP13 in
the OPERATING PROCEDURES
Section.
SG-101-10
Page 13
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
p
TROUBLESHOOTING
SYMPTOM
PROBABLE CAUSE & REMEDY
“CORRECTIVE MAINTENANCE” ITEM NO.
A. Generator does not maintain required pressure at
rated capacity.
B. Secondary Steam pressure is too high.
C. Secondary Steam outlet pressure fluctuates
widely.
D. Insufficient Water to the Generator.
E. Excess or insufficient Condensate being returned
from the Generator.
F. Steam being discharged into Condensate drain,
G. Relief Valve pops.
H. Generator shuts down below, at, or too near
above required Secondary Steam outlet
ressure.
I. Loud banging in Generator or in Primary Steam or
Condensate piping (not to be confused with a
normal clicking noise).
CM1, CM2, CM5, CM8, CM9, CM11, CM12, CM13
CM1, CM5, CM7, CM9
CM2, CM5, CM7, CM8, CM9, CM11, CM13
CM3, CM4
CM5, CM11
CM12, CM13
CM7, CM9, CM10
CM10
CM5, CM6
SG-101-11
Page 14
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
CORRECTIVE MAINTENANCE
Refer to the previous TROUBLESHOOTING
Table. The following are probable causes and
remedies for improper action of the Generator.
CM1. The Primary or Secondary Pressure
Gage may read wrong. Check each
with a gage that is known to be correct.
CM2. Primary Steam pressure is too low.
Check the Primary Steam pressure
gage below the Control Box. If the
reading is low, adjust the steam
pressure to that which is required. If
there is a restriction in the Primary
Steam supply line, the gage reading will
drop excessively when the Generator
calls for full steam even though the
pressure appears to be normal when the
load is light. If the Primary Steam
supply pressure is correct, its pressure
gage reading should reach design
pressure for steam in the coils as the
Generator Secondary Steam outlet
pressure drops. If it does not, check the
operation of the Primary Steam Control
Valve.
CM3. Water level is low or water supply fails.
Check the operation of the Level
Controller and Water Solenoid at the
Cold Water inlet.
CM4. Cold Water pressure is low. Check and
correct, if necessary, the Water
pressure to the Generator.
CM5. Condensate return piping has not been
installed so that the Condensate drains
freely by gravity and/or the Condensate
check valve leaks or has failed. If
necessary, rearrange the Condensate
return piping per step 6f in the
INSTALLATION Section. Inspect the
check valve and replace it if it is leaking
or has failed. Also, check to make sure
that there is no restriction in the
Condensate drain line.
CM6. Primary Steam supply line is not
properly trapped. Install a trap as
indicated in Figure SG-101-2.
CM7. The Primary Steam Control Valve does
not close. Check the instructions
covering the Valve.
CM8. The Primary Steam Control Valve does
not open. Check the instructions
covering the Valve.
CM9. The Secondary Steam pressure control
system is not operating properly. Check
the instructions covering the Pressure
Controller in the Control Box.
CM10. The Over-Pressure Limit System is out
of adjustment or some component of the
system has failed. Check out the
system setting per step OP8 under
OPERATING PROCEDURES above.
Inspect and repair or replace the
pressure switch and solenoid valve.
CM11. There is a leak in the Generator coil(s),
steam riser, or Condensate return,
causing water from the shell to leak into
the heating coil system, or steam or
condensate from the coil system into the
shell. To verify such a leak, shut off the
Primary Steam supply and break a
connection in the Condensate line – BE
CAREFULL TO AVOID SEVERE
BURNS --.Condensate will drain from
the coil system initially, but the flow
should stop after a minute or two. If the
flow continues, water is leaking from the
pressurized shell side to the tube side of
the Generator. Disassemble, inspect,
repair (if possible), replace, and
reassemble the Generator as outlined in
the DISASSEMBLY and REASSEMBLY
Sections.
CM12. The Generator coils are scaled up.
Descale the Generator by thermal shock
in the manner outlined under
DESCALING BY THERMAL SHOCK.
CM13. The Generator is being utilized at a rate
higher than its design capacity. Contact
the nearest AERCO Representative for
advice in remedying this problem.
SG-101-12
Page 15
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
DESCALING BY THERMAL SHOCK METHOD
Where, under certain conditions of continuous
steady usage, the cold water is so hard or
alkaline that normal flexure of the coils (see
ROUTINE MAINTENANCE) and routine blowdown (draining the Generator shell) will not
remove scale build-up on the coils, the heating
surfaces (coils) may be thermally shocked,
without damage to any part of the Generator, to
dislodge scale solids.
Proceed as follows:
TS5. Inject a flow of cold water through the
relief valve connection for about 2
minutes. Then shut off the water flow
and open the Condensate drain line
stop vaIve to drain off all Condensate.
TS6. Repeat steps TS4 and TS5 several
times until the water coming from the
Generator drain appears to be relatively
free of solids.
TS1. Drain the Heater per steps RM1 through
RM4 in the ROUTINE MAINTENANCE
Section. However, instead of holding
the relief valve open in step RM4,
remove the relief valve from the
Generator top head.
TS2. Open the Generator drain valve. Leave
the drain valve open until step TS8 in
the following procedure.
TS3. Connect a source of cold water (for
example, a hose) to the open relief
valve connection.
TS4. Open all stop valve(s) in the Primary
Steam inlet line and the Condensate
outlet line to allow steam to the
Generator. After about 30 seconds, or
until steam is blowing out of the
condensate drain line, close the stop
valve in the Condensate outlet line.
Leave the Primary Steam inlet line open
for about 2 minutes longer, then close
all Primary Steam inlet stop valves.
TS7. Remove the cold water source from the
relief valve connection. Open the stop
valve in the main Cold Water inlet line
and allow a complete flushing of the
Generator shell.
TS8. After
TS9. If Cold Water conditions are so severe
the Generator shell has been
completely drained, close the Generator
drain valve, replace the relief valve, and
place the Generator back into operation
per steps OP1, OP12, and OP 13 in the
OPERATING PROCEDURES section.
that thermal shocking does not remove
scale deposits, contact the nearest
AERCO Representative for advice.
SG-101-13
Page 16
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
DISASSEMBLY
Reference illustrations:
SG-101-4 Over-Pressure Limit System
Wiring Diagram
SG-101-8 Generator Control Box
Assembly
SG-101-9 Generator Assembly
SG-101-10 Generator Package Assembly
Special Tools Required;
(1) Torque wrench for 5/8" nuts.
(2) A block and tackle or ratchet or winch hoist
is recommended for lifting off the Generator top
head and shell, or for lifting and moving the
Generator.
NOTE that all part item numbers given in
parentheses ( ) in the instructions below refer to
those shown in Figure SG-101-8, SG-101-9, or
SG-101-10.
D1. Shut down and drain the Generator in
accordance with steps RM1 through
RM4 under ROUTINE MAINTENANCE
above.
D2. Disconnect ALL external piping from the
Generator top head, including that to the
Relief Valve (24). Disconnect the
Secondary Steam outlet piping at the
union or flanges located beyond the
outside diameter of the Generator top
head.
D3. Disconnect Union (29) located above
the Level Controller (34).
D4. Disconnect the power supply wiring to
the Control Box and the wiring between
the Control Box and the Level
Controller,
D5. Disconnect the air supply and control air
piping from the Control Box.
D6. Close the Shutoff Cock (38) in the
Primary Steam Pressure Gage line and
disconnect the Compression Fitting (25).
D7. Mark the edge of the Generator bottom
head flanges in order to indicate their
correct relative positions upon
reassembly.
D8. Remove Nuts (l4) and Studs (12) from
the Generator bottom head flanges.
D9. Using a hoist or block and tackle
attached to the Lifting Lugs (2) on the
Generator top head, CAREFULLY lift
the top head and shell STRAIGHT
off the Generator riser and coil,
assembly., DO NOT SCRAPE
lining against the coil tubing.
D10. Clean and inspect the inside of the shell
and the Steam Riser/Condensate
Return/Coils assembly for obvious
damage.
D11. With the Condensate Return stop valves
closed, open the stop valve(s) in the
Primary Steam inlet line to allow Primary
Steam to the Generator coils. Any leak
in the coils. Steam riser, or Condensate
return will become visible quickly. Note
where the leaks are and shut off the
Primary Steam.
D12. If a coil must be replaced,
open end wrench to disconnect the
unions holding the coils to the Steam
riser and Condensate return. Be careful
not to damage the spud threads (see
Figure SG-101-6).
D13. If either the Steam riser or Condensate
return must be replaced, it is
recommended that the Generator be
reassembled and returned to the
AERCO factory for replacement.
(AERCO has the proper factory setup,
pressure testing equipment, ready
access to any needed additional parts,
and the expertise necessary to provide
a guaranteed replacement.) Contact the
nearest AERCO Representative for
instruction for making the return.
use a 1-5/16"
UP
the shell
SG-101-14
Page 17
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
If, however, returning the Generator to
the AERCO factory is impractical, field
replacement may be made but cannot
be guaranteed by AERCO. If this
decision is made, proceed as follows:
a. Remove all coils per step D12
above. Examine each coil carefully
to make sure that replacement at
this time is not an advisable action.
b. Remove the damaged Steam riser
or Condensate return.
D14. If the shell copper liner has been
damaged, reassemble the Generator
and return it to the AERCO factory for
replacement of the 1iner. Contact the
nearest AERCO Representative for
instruction for making the return.
D15. If it is necessary for any reason to
remove the Generator top Head (1) from
the Shell (11):
a. Disconnect the Compression
Fittings (25) from their connections
at the top Head and pull the Tubing
(23) aside.
b. Remove the Nuts (14), Studs (3)
and (12), and Lifting Lugs (Eye
Bolts) (2), and lift the Head off the
Shell.
SG-101-15
Page 18
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
REASSEMBLY
Reference illustrations:
Same as DISASSEMBLY, plus:
SG-101-5 Alignment of Steam Riser and
Condensate Return
SG-101-6 Assembly of Coil to Steam
Riser or Condensate Return
SG-101-7 Coil Spacing Tool
Special Tools Required;
DISASSEMBLY, plus a coil spacing tool as
shown in Figure SG-101-7.
Same as for
Figure SG-101-5. Alignment of Steam Riser
and Condensate Return
NOTE
All part item numbers shown in parentheses
( ) in the following instructions refer to those
shown in Figures SG-101-8, SG-101-9, or
SG-101-10.
R1. If either the steam riser (7) or
Condensate Return (8) must be
replaced:
a. Use pipe joint compound or Teflon
tape on the threads and screw the
replacement Steam Riser and/or
Condensate Return into the
Generator lower head.
b. Tighten the Riser or Return taking
care to line up the spud centers with
the raised indicators on the bosses
in the head casting as shown in
Figure SG-101-5.
R2. If a coil must be replaced:
a. See Figure SG-101-6. A conical Coil
Gasket (10) is required for each Coil
union in the Generator. It is recommended that Coil Gaskets (10) be
replaced whenever a coil is
reassembled to a Riser or Return,
even though the Coil itself is not
being replaced. Snap the gasket
into the Riser or Return spud.
Figure SG-101-6. Assembly of Coil to Steam
Riser or Condensate Return
b. Before
c. Assemble the Coil union to the
attempting to assemble the
Coils to the Riser or Return spuds,
wrap each spud with Teflon tape
and apply a lubricant (grease) to the
back of the union nuts and
shoulders on the Coil tail pieces
(see Figure SG-101-6). Rotate the
nuts to spread the lubricant.
Condensate Return (8) first. Do not
tighten. Assemble the other Coil
union to the Steam Riser (7).
SG-101-16
Page 19
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
d. Using a torque wrench, tighten both
unions to approximately 75 ft-lb
while holding the coil so that the
turns of the coil remain perfectly
horizontal, where they are brazed to
the tail pieces, after tightening.
NOTE: Never
wrench to tighten a union nut.
Deformation and subsequent
leaking may result.
e. Space the Coil tubes evenly
throughout the Generator, with each
tube space at least 1/2" wide. It is
especially important that no tubes
rest on any Coil unions. A spacing
tool may be made up similar to that
shown in Figure SG-101-7 (available from AERCO, Part No. 12523).
Insert the tool flat between the Coil
tubes and twist the tool until the
desired spacing is obtained.
f. Test for leaks per step D11 of the
DISASSEMBLY Section. Make any
corrections necessary.
use a hammer on a
d. Realign the Tubing (23) and
reconnect the Compression Fittings
(25) to their connections at the top
Head.
R5. Place the Gasket (13) on the Generator
bottom Head flange.
R6. Using a hoist or block and tackle
attached to the Lifting Lugs (2) on the
Generator top Head (1), CAREFULLY
lower the top Head and Shell
STRAIGHT DOWN over the Coil and
Riser assembly. DO NOT SCRAPE the
Shell lining against the Coil tubing.
R7. Before resting the Shell flange onto the
bottom Head flange, make sure that the
Shell is positioned properly by lining up
the marking put on the edges of the
flanges in step D7 of the DISASSEMBLY Section. For further assurance,
check to see that the raised indicators
on the outside diameters of each of the
top and bottom Head flanges line up
with each other. This is very important.
R3. Clean all gaskets and gasket surfaces
thoroughly. AERCO recommends that
new
gaskets (13) be used whenever
reassembling either the top or bottom
head to the shell.
R4. If the Generator Top Head (1) has been
removed from the Shell (11):
a. Clean the Gasket surfaces
thoroughly and place a Gasket (13)
Gasket is recommended) on
(a new
the Shell top flange.
b. Replace the Generator top Head
onto the top of the Shell, lining up
the stud holes.
c. Reassemble the Studs (3) and (12),
the Lifting Lugs (Eye Bolts) (2), and
Nuts (14) into the Head and Shell
flanges. Cross-tighten the Nuts to
approximately 75 ft-lb torque to
obtain uniform seating. Then,
progressively tighten the Nuts to
approximately 150 ft-lb torque for a
tight seal.
R8. Assemble the Studs (12) and Nuts (l4)
into the bottom Head and Shell flanges.
Tighten the Nuts in the same manner as
in step R4c above.
R9. Reconnect the Compression Fitting (25)
in the Primary Steam Pressure Gage
line and open the Shutoff Cock (38).
R10. Reconnect Union (29) located above the
Level Controller (34).
R11. Reconnect the air supply and control air
piping to the Control Box.
R12. Reconnect the power supply wiring to
the Control Box and all wiring between
the Control Box and the Level Controller
(34).
R13. Reconnect all external piping to the
Generator Top Head, including that to
the Relief Valve (24).
R14. Refill and place the Generator back into
operation in accordance with steps OP1,
OP12 and OP13 in the OPERATING
PROCEDURES Section.
SG-101-17
Page 20
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
Figure SG-101-7. Coil Spacing Tool
SG-101-18
Page 21
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
RECOMMENDED SPARE PARTS
Quantity
Per Generator
* 9 Coil Assembly SG-101-9
** 10 Conical Coil Gasket SG-101-9
4 13 Head Gasket SG-101-9
1 24 Relief Valve SG-101-10
1 42 Water Solenoid Valve SG-101-10
1 53 Pressure Controller SG-101-8
1 58 Pressure Switch SG-101-8
1 62 Air Solenoid Valve SG-101-8
1 65 Compound Pressure Gage SG-101-8
1 75 Green Indicator Light SG-101-8
1 78 Red Indicator Light SG-101-8
* Minimum of 2 to a maximum of the number in your largest Generator
Item No.
** 2 per Spare Coil Assembly, Item 9 plus 2
Part Name
Shown in
Figure No.
SG-101-19
Page 22
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
TABLE 1
GENERATOR
MODEL
SS1B+02 2
SS1B+03 3
SS1B+04 4
SS1B+05 5
SS1B+06 6
SS1B+07 7
SS1B+08 8
SS1B+09 9
SS1B+10 10
SS1B+11 11
SS1B+12 12
SS1B+13 13
SS1B+14 14
NOTE:
120V/60 Hz ELECTRICAL
POWER SUPPLY
AND
25 PSIG AIR SUPPLY
REQUIRED
STEAM FLOW CONTROL
VALVE WITH PNEUMATIC
OPERATOR - SEE TABLE 2
SS1B+15 15
NO. OF
COILS
HEATING
SURFACE
2
FT
(M2) A
15
(1.39)
20
(1.86)
25
(2.32)
30
(2.79)
35
(3.25)
40
(3.72)
45
(4.18)
50
(4.65)
55
(5.11)
60
(5.57)
65
(6.04)
70
(6.50)
75
(6.97)
DIMENSIONS
INCHES (CM)
B
40.75
55.00
(103.5)
(139.70)
45.75
60.00
(116.20)
(152.40)
49.75
64.00
(126.37)
(162.56)
54.75
69.00
(139.07)
(175.26)
58.75
73.00
(149.23)
(185.42)
63.75
78.00
(161.93)
(198.12)
67.75
82.00
(172.09)
(208.28)
72.75
87.00
(184.79)
(220.98)
76.75
91.00
(194.95)
(281.14)
81.75
96.00
(207.65)
(243.84)
85.75
100.00
(217.81)
(254.00)
90.75
105.00
(230.51)
(266.70)
94.75
109.00
(240.67)
(276.86)
TABLE 2
VALVE
INCHES
PRIMARY ST EAM
SIZE
INLET SIZE, NPT
INCHES
1.00 1.00
1.25 1.25
1.50 1.50
2.00 2.00 5.08
C
21.00
(53.34)
26.00
(66.04)
30.00
(76.20)
35.00
(88.90)
40.00
(101.60)
45.00
(114.30)
50.00
(127.00)
55.00
(139.70)
60.00
(152.40)
65.00
(165.10)
70.00
(177.80)
75.00
(190.50)
80.00
(203.20)
CM
2.54
3.18
3.81
APPROX. WT.
LBS. (KG)
DRY
WET
520
660
(237)
(300)
570
720
(259)
(327)
610
770
(277)
(350)
640
830
(291)
(377)
670
880
(304)
(400)
710
930
(322)
(422)
740
980
(336)
(445)
770
1030
(350)
(468)
800
1080
(363)
(490)
840
1130
(381)
(513)
870
1180
(395)
(536)
900
1230
(409)
(558)
930
1280
(422)
(581)
DIMENSIONS ARE SHOWN IN
INCHES (CENTIMETERS)
ASME CODE
CERTIFICATION STAMP
TABLE 3
HEAT EXCHANGER DESIGN PARAMETERS
SHELL
SIDE
TUBE
SIDE
MAX. WORKING
PRESSURE
PSIG (kPa)
50
(345)
250
(1723)
MAX.
TEMP.
DEG. F (DEG. C)
400
(204)
400
(204)
TEST
PRESSURE
PSIG (kPa)
75
(517)
375
(2584)
U-7
Figure 1. Dimensions for SS1B-PLUS
SG-101-20
Page 23
INSTRUCTIONS – AERCO HELITHERM STEAM GENERATOR MODEL SS1B-PLUS
ITEM
QTY
NO.
REQ. DESCRIPTION
1 1 TOP HEAD 20886
2 2 5/8" EYE BOLT 12865
3 2 5/8"-llx4"L6STUD 6-248
4 2 1/4"-20 SOC. HEAD CAP SCREW 6816
5 1 RISER SUPPORT P IN 6690
6 | RISER SUPPORT BRACKET 6641
7 1 STEAM INLET RISER ASSY 18888
8 1 CONDENSATE RETURN ASSY 8676
9 TABLE
COIL ASSEMBLY 844-A
PART NO
10 TABLE
11 1 SHELL ASSEMBLY TABLE A
12 28 5/8"-11x3-l/2" LG STUD 6-173
13 2 HEAD GASKET BG
14 62 5/8"-11 NUTS 6-178
15 1
16 1 BOTTOM HEAD & SKID ASSY 18890
USED ONLY WITH MODELS SS1B+07 THRU SS1B+15
CONICAL GASKET 8079
WATER INLET DISPERSION TUBE
122480
TABLE A
MODEL
SS1B+02 2 4 B20
SS1B+03 3 6 B24
SS1B+04 4 8 B29
SS1B+05 5 10 B33
SS1B+06 6 12 B38
SS1B+07 7 14 B42
SS1B+08 8 16 B47
SS1B+09 9 18 B51
SS1B+10 10 20 B56
SS1B+11 11 22 B60
SS1B+12 12 24 B65
SS1B+13 13 26 B69
SS1B+14 14 28 B74
SS1B+15 15 30 B78
QUANTITY REQ.
ITEM 9 ITEM 10
ITEM 11
PART NO
Figure SG-101-9. AERCO Steam Generator Model SS1B-PLUS Assembly and Parts List
SG-101-21
Page 24
INSTRUCTIONS - AERCO HELITHERM STEAM GENERATOR - MODEL SS1B-PLUS
)
)
ITEM
QTY
NO.
REQ
21 1 1"xl/4"NPT REDUCING BUSHING 9-493
22 4 3/8"x1/2"HUB 90° CONDUIT 122104
23 A/R 3/8"OD TYPE L COPPER TUBING RM6041
24 1 PRESS. RELIEF VALVE (NOTE A)122500
25 3 3/8"OD TUBE x 1/4" NPT COMR 8-6
26 3 1" NPT STREET ELL 9-328
27 1 1" NPT 90° ELL 9-222
28 1 2''x1” REDUCING BUSHING 9-365
29 3 1"NPT UNION 9-291
30 1 CONTROL BOX ASSEMBLY (SEE ASSY
31 A/R 3/8" TYPE LT CONDUIT RM2000
32 A/R 14 GA. BLACK STRANDED WIRE RM4524
33 A/R 14 GA. WHITE STRANDED WIRE RM4525
34 1 LIQUID LEVEL CONTROLLER 122501
35 A/R 1/4"IMPOLENE TUBING RM3041
36 1 1/4"xl/8" NPT 90° IMPOLENE COMP. 8-4
37 1 AIR OP CONTROL VALVE (NOTE C)20774
38 1 1/4" FEMALE/MALE SHUTOFF COCK 121975
39 1 INSULATION (NOTE B) 18777
40 A/R 1" BLACK IRON PIPE RM358
41 1 HEATER ASSEMBLY (NOTE B
42 1 1/2" WATER SOLENOID 5134
43 1 1" NPT BALL VALVE 12820-7
44 1 2" NPT BALL VALVE 1282045 1 STEAM INLET ASSEMBLY 18762
46 1 VALVE SPOOL PIECE (NOTE C
47 1 INVERTED BUCKET STEAM TRAP 122502
DESCRIPTION
PART
NO.
20887
A/R - LENGTH OR QUANTITY AS REQUIRED
NOTE A - WHEN ORDERING STATE SIZE
NOTE B - WHEN ORDERING STATE NUMBER OF
COILS IN HEATER
NOTE C - WHEN ORDERING STATE CONTROL
VALVE SIZE
Figure SG-101-10. AERCO Packaged Steam Generator Model SS1B-PLUS Assembly and Parts List
SG-101-22
Page 25
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