INSTRUCTION MANUAL
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
Models BCF, HCF & SSCF
Fixed Tube Sheet Heat Exchangers
Table of Contents
Introduction and Safety………………………….……………………………………………2
Introduction...…………………………………………………………………..……………….2
Safety………………………………………………………………………….………………..2
Safety terminology and symbols……………………………………………..……………...2
User Safety ………………………………………………………………….……………….3
General safety rules ……………………………………………………… ………………..3
Safety equipment …………………………………..……………………… ……………….4
Product Warranty ……….………………………………………………….………………...4
Product Description…………………………………………………………………….……..5
General description………...……………………………………………………….………...5
Installation…………………………………………………………………………….………...6
Installation ………………..………….……………………………………...........................6
Operation……………………………………………………………………………………….6
Startup ………………………………… .……………………………….............................6
Maintenance…………………………………………………………………........................ 7
Maintenance and cleaning Procedures………………………………………………..…..7
Storage
Storage ……………………………………………………………………………………... 9
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual
1
Introduction and Safety
INTRODUCTION
Th
e purpose of this manual is to provide necessary information for:
-Installation
-Operation
-Maintenance
CAUTION:
Read this manual carefully before installing and using the product.
Improper use of the product can cause personal injury and damages to
property and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the
location of the unit.
SAFETY
WARNING:
-The operator must be aware of safety precautions to prevent physical injury.
-Operating, installing, or maintaining the unit in any way that is not covered in
this manual could cause death, serious injury, or damage to the equipment.
This includes any modification to the equipment or use of parts not provided
by Xylem. If there is a question regarding the intended use of the equipment,
please contact a Xylem representative before proceeding.
-Do not change the service application without the approval of an authorized
Xylem representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so
could result in physical injury, damage, or delays.
Terminology and symbols
It is extremely important that you read, understand, and follow the safety
messages and regulations carefully before handling the product. They are
published to help prevent these hazards:
-Personal accidents and health problems
-Damage to the product
-Product malfunction
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual
2
Hazard levels
Hazard categories
DANGER:
A
hazardous situation which, if not, avoided, will result in death or serious injury
WARNING:
A hazardous situation which, if not, avoided, could result in death or serious injury
CAUTION:
A hazardous situation which, if not, avoided, could result in minor or moderate
injury
NOTICE:
-A potential situation which, if not avoided, could result in undesirable conditions
-A practice not related to personal injury
Hazard categories can either fall under hazard levels or let specific symbols
replace the ordinary hazard level symbols.
These are examples of other categories that can occur. They fall under the
ordinary hazard levels and may use complementing symbols:
-Crush hazard
-Cutting hazard
-Arc flash hazard
USER SAFETY
General safety rules
Applicable general safety rules:
-Always keep the work area clean.
-Pay attention to the risks presented by gas and vapors in work area.
-Avoid all electrical dangers and pay attention to the risks of electric shock or arc
flash hazards.
-Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual
3
Safety equipment
Use safety equipment according to the company regulations. Use this safety
equipment within the work area:
-Hard hat
-Safety goggles, preferably with side shields
-Protective shoes
-Protective gloves
-Gas mask
-Hearing protection
-First-aid kit
-Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific
information about safety devices in other chapters of this manual.
PRODUCT WARRANTY
Coverage
Xylem undertakes to remedy defects in products from Xylem under these
conditions:
-The faults are due to defects in design, materials, or workmanship.
-The faults are reported to a local sales and service representative within the
warranty period.
-The product is used only under the conditions that are described in this manual.
-All service and repair work that is done by Xylem authorized personnel.
-Genuine Xylem parts are used.
Limitations
Warranty does not cover defects caused by:
-Deficient maintenance
-Improper installation
-Modifications or changes to the product and installation that are made without
consulting a Xylem authorized representative
-Incorrectly executed repair work
-Normal wear and tear
Xylem assumes no liability for the following situations:
-Bodily injury
-Material damages
-Economic losses
Warranty claim
Xylem products are high quality products with expected reliable operation and long
life. However, should the need for a warranty claim arise, contact your local sales
representative or the manufacturer.
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual
4
Product Description
GENERAL DESCRIPTION
BCF, HCF & SSCF heat exchangers are fixed tube heat exchangers using 1/4", 3/8"
and 5/8" diameter tubes. BCF units use copper tubes, brass shells and CI bonnets.
SSCF units are made of all 316 S/S materials. Material options exist for both
products. Tubes are roller expanded into the tube shells.
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual
5
INSTALLATION
1. Before installing this equipment, environment and service
conditions should be checked for compatibility with materials of
construction. Contact your nearest Xylem Representative if you
are not sure what the actual materials of construction are.
2. Provide valves and by-passes in the piping system so that both
the shell and tube sides may be by-passed to permit inspection
or repair.
3. Provide thermometer well and pressure gauge connections in all
piping to and from the unit and locate as near the unit as
possible.
4. Provide convenient means for frequently cleaning the unit as
suggested under “Maintenance.”
5. Provide necessary air vent cocks for units so they can be
purged to prevent or relieve vapor or gas binding of either the
tube or the shell sides.
6. Foundations must be adequate so that exchangers will not settle
and cause piping strains. Foundation bolts should be set to
allow for setting inaccuracies. In concrete footings, pipe sleeves
at least one size larger than bolt diameter slipped over the bolt
and cast in place are best for this purpose, as they allow the bolt
center to be adjusted after the foundation has set.
7. Loosen foundation bolts at one end of unit to allow free
expansion of shells. Oval holes in foundation brackets are
provided for this purpose.
8. Set exchangers level and square so that pipe connections may
be made without forcing.
9. Inspect all openings in exchanger for foreign material. Remove
all thread protectors and shipping pads just before installing. Do
not expose units to the elements with pads or other covers
removed from openings since rain water may enter the unit and
cause severe damage due to freezing.
10.Be sure the entire system is clean before starting operation to
prevent plugging of tubes with sand or refuse. The use of
strainers in settling tanks in pipe lines leading to the unit is
recommended.
11.Drain connections should not be piped to a common closed
manifold.
12.Location of the operating fluids in the heat exchanger can be a
function of the application. A few tips for the location of the
operating fluids are:
a. As a cooler, the preferred arrangement is with the hot
medium through the shell and the cooling medium through
the tubes. When the hot fluid is dirty or fouling, it is better to
put it through the tubes because they are easier to clean.
With single pass units be sure the shell inlet is on the same
end as the tube side outlet. In two pass units, the shell inlet
should be at the inlet-outlet bonnet end. It is customary for
the cooling medium to enter the lower bonnet connection,
although this can be reversed if necessary.
b. As a heater, the hot medium, usually steam or hot water,
must be in the shell. If it is steam, either of the shell
connections, or both, can be used, dependent on the actual
entering velocities.
c. For the above applications and for temperatures above
150°F, the higher temperature fluid should be circulated
through the shell side of the exchanger and precaution
should be taken to avoid shock from abrupt changes in fluid
circulation temperatures.
13.Steam hammer can cause serious damage to the tubes of any
heat exchanger. A careful consideration of the following points
before an installation is made can prevent costly repairs which
may be caused by steam hammer.
a. A vacuum breaker and/or vent, should be used in accordance
with the type of steam system installed.
b. The proper trap for the steam system installed should be
used.
c. The trap and the condensate return line to the trap should be
properly sized for the total capacity of the convertor.
d. The trap should be sized for the pressure at the trap, not the
inlet pressure to the steam controller.
e. The trap must drain into an unpressurized condensate return
system. Condensate return lines must not be run at an
elevation above the bottom of the heat exchanger. To do so
may result in a buildup of the condensate level in the heat
exchanger, which could cause water hammer and damaged
tubes.
CAUTION: During times of shutdown, volumetric expansion
can occur. We recommend the installation of a properly sized relief
valve on both sides of the heat exchanger.
OPERATION
1. When placing a unit in operation, open the vent connections and
start to circulate the cold medium only. Be sure that the
passages in the exchanger are entirely filled with the cold fluid
before closing the vents. The hot medium should then be
introduced gradually until all passages are filled with liquid,
close vents and slowly bring the unit up to temperature.
2. Start operation gradually. Do not admit hot fluid to the unit
suddenly when empty or cold. Do not shock unit with cold fluid
when unit is hot.
CAUTION: Fluids must be gradually introduced to the unit.
Failure to do so can cause damage to the heat exchanger.
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 6
3. In shutting down, flow of hot medium should be shut off
f
irst. If it is necessary to stop circulation of cooling medium
the circulation of hot medium should also be stopped by
by-passing or otherwise.
4. Do not operate equipment under conditions in excess of
those specified on nameplate.
5. Do not blow out heat exchangers with air when operating
f
luids are of a flammable or otherwise hazardous nature.
WARNING: P
clothing, equipment, etc.) to protect personnel from injury
due to escaping fluids.
roper precautions must be taken (special
WARNING: F
within the design pressure and temperature on the
nameplate may result in damage to the heat exchanger and
potential injury to adjacent personnel.
5. Drain all fluids when shutting down to eliminate possibility
of freezing and corrosion. To guard against water
hammer, condensate should be drained from steam
heaters and similar apparatus both when starting up and
when shutting down.
6. In all installations there should be no pulsation of fluids
since this causes vibration and strain with resulting leaks.
7. All gasketed joints should be checked after starting for
leaks and tightened if necessary.
WARNING: T
suit able for use as heaters using steam as the heating
medium. These exchangers are, however, fixed tubesheet
units and, therefore, not designed to absorb thermal shock
inherent in the intermittent service of on and off heating with
frequent short intervals of demand. Their recommended use
is where service is continuous or steady, with relatively long
periods between shutdown and start-up. Heat exchanger
failure due to thermal shock may result in potential personal
injury.
ailure to operate the heat exchanger
he BCF, HCF & SSCF exchangers are
MAINTENANCE
1
. Do not open heads until all pressure is off equipment and
the unit is drained.
f. Provide convenient means for frequently cleaning heat
exchangers as suggested below:
a. Circulating hot wash oil or light distillate through tubes
or shell at good velocity will effectually remove sludge or
other similar soft deposits.
b. Soft salt deposits may be washed out by circulating hot
fresh water.
c. Some cleaning compounds on the market, such as
“Oakite” may be used to advantage for removing sludge
or coke, provided hot wash oil or water, as described
above, does not give satisfactory results.
d. If none of the above described methods are effective for
the removal of hard scale or coke a mechanical means
may be used. The interior of the tubes may be rodded.
e. The exterior or shell side of the tubes of a fixed sheet
heat exchanger can only be cleaned chemically by
using a chemical dissolved in water solution. We
suggest that the user contact the manufacturer of the
cleaning chemical for instructions.
WARNING: P
clothing, equipment, etc.) to protect personnel from injury
due to escaping fluids.
roper precautions must be taken (special
2. Remove the bonnets. Inspect all tubes carefully for
p
ossible erosion, corrosion, or foreign material.
3. Inspect all anodes to be sure they are neither excessively
corroded nor insulated with scale. Scrape to a bright
surface.
4. Inspect filters in the system to prevent foreign matter from
entering the exchanger.
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 7
7. When replacing heads, use a torque wrench.* Tighten 1/4“
d
iameter bolts (2” diameter units) to 6 ft-lbs., 5/16“
diameter bolts (3" & 4" diameter units) to 16 ft-lbs., and 3/8“
diameter bolts (5", 6", & 8" diameter units) to 24 ft-lbs. If the
gasket joint still leaks, tighten in 2 ft-lb. increments until
leak stops.
*The above torque values apply to well lubricated nut
bearing surfaces.
8. All bolted joints should be tightened uniformly and in a
diametrically staggered pattern as illustrated below:
START
1
1
6
9
14
4
7
12
15
6
11
8
3
13
10
5
2
9. Frequently and at regular intervals, observe interior and
exterior condition should be according to scale build-up.
CAUTION: N
eglect in keeping all tubes clean may result
in complete stoppage of flow through some tubes with
consequent overheating of these tubes, resulting in severe
expansion strains, leaking tube joints, and damage to the heat
exchanger.
F
RONT HEAD GASKET
FRONT HEAD
(BUNDLE & SHELL ASSEMBLY)
10.Exchangers subject to fouling or scaling should be cleaned
periodically. A light sludge or scale coating on the tube
greatly reduces its effectiveness. Therefore, low-fouling
fluids should be used in the shell side of all heat
exchangers with non-removable tube bundles. A marked
increase in pressure drop and/or reduction in performance
usually indicates cleaning is necessary, especially if the
unit has been checked for air or vapor binding and this has
been found not to be the cause. Since the difficulty of
cleaning increases rapidly as the scale thickens or deposits
increase, the interval between cleanings should not be
excessive. interior and exterior condition should be
according to scale build-up.
ANODES
1. Some exchangers may be equipped with renewable
anodes. The purpose of the anodes is to inhibit electrolytic
corrosion. In order to remain active the anodes must be
kept free of scale or other surfaces coatings.
2. On some applications where electrolytic corrosion is not a
problem, pipe plugs may be substituted for the anode. The
pipe plug material selected should be softer than the base
part to avoid pipe thread damage.
CORE
REAR HEAD
RENEWABLE ANODES
(ZINC)
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 8
REAR HEAD GASKET
MOUNTING LEGS
Xylem
www.xylem.com/standardxchange
Standard Xchange is a trademark of Xylem Inc. or one
of its subsidiaries.
© 2018 Xylem Inc. BCF HCF SSCF September 2018
Loading...