1. Flat Plate Heat Exchanger Installation
2. Heat Exchanger Design Manual
3. Side Arm Heat Exchanger Installation

Geothermal heat exchanger installation; and (4) integrated these findings into a document called. Engineering question determined by heat transfer issues and the construction equipment available for drilling the vertical borehole. The heating and cooling industry and regulators should. Loop field arrangement, drilling method, drilling. Heat exchanger cracks are worth finding but they aren’t the most dangerous issue for your customers in most cases. The reason I make this blasphemous statement is twofold. Many heat exchangers are at a negative pressure in reference to the air moving over the exchanger. Thermaxx Removable Heat Exchanger Insulation Jackets On the other hand, Thermaxx can have you up and running with highly effective heat exchanger jackets in virtually no time at all. Our heat exchanger insulation jackets frequently boast payback periods of less than a year, and share the following qualities.

March 1, 2012. The Project — ThermaXX entered into contract December 2011 with a Lowe’s Home Improvement Warehouse Located in Mooresville, NC to provide removable insulation for a plate and frame heat exchanger. In October, 2011, Lowe’s Maintenance and Engineering Teams visited the Thermaxx booth at the Carolina Industrial & Facility Maintenance Show in Charlotte, NC.

If you find that your furnace heat exchanger has trouble getting enough heat and power, then you may find that it has developed a crack or hole. Through this crack, combustion fumes can escape from the exchanger, and can build up in the room. This is dangerous, as one of the gases produced by the heat exchanger is carbon monoxide, a deadly poison which is virtually unnoticeable. In order to solve this problem, most people choose to replace the furnace heat exchanger, rather than run the risk of it developing more corrosion. Doing a repair such as this is a risk, as you could be exposing yourself to the dangers of carbon monoxide poisoning. However, if you need to perform a quick fix, it can be done.

Step 1 - Check the Furnace Heat Exchanger

Before you can do any repairs, you should make sure that you check over your furnace heat exchanger thoroughly. Remove it from the furnace, and examine it in the light. Look for signs that the metal has been overheated, or symptoms of long-term metal fatigue. Examine the crack itself. Look for evidence of rust, wiping down the surface with a cloth if necessary. Take steps to address the cause of the problem, as well as performing the repair. You should also look for signs of discoloration around the crack, as this suggests that a large amount of carbon monoxide has been pumped out into the atmosphere. If you find this, you need to call in a professional at this point.

Step 2 - Make the Repair

Once you are ready to begin the repair itself, put on your safety glasses and gloves. If you have a steel exchanger, then cut down a piece of sheet metal to cover the crack, plus 2 inches all the way around. Fire up a welder, and use the liquid metal to form a glue-like line around the edge of your sheet metal. Press this onto the furnace heat exchanger, and allow it to dry. Weld the sheet metal some more as it dries. If you have an iron heat exchanger, then you need to find an iron repair liquid, which uses chemical reactions to seal holes in iron. Pour a little bit of the chemical on the hole, and leave it to dry until it seals around the exchanger.

Step 3 - Aftercare

Now that you have fixed the heat exchanger, replace it in the furnace. Operate it for as long as you need to, but it is important to get the exchanger replaced as soon as you are able to. You should add a carbon monoxide alarm to the space above the furnace. This will give you a clear warning if fumes are leaking from your furnace, and protect you from possible poisons. Furnace heat exchangers are a vital part of your furnace, so altering them could also invalidate any warranty that you have on the furnace.

Unless otherwise specified, all plate heat exchanger installation shall be in accordance to approved shop drawings, manufacturer instructions and contract specifications.

Drawing plans, schematics, and diagrams indicate general location and arrangement of Heat Exchanger’s. Install Plate Heat Exchanger’s as indicated unless deviations to layout are approved on coordination drawings.

Plate Heat Exchanger shall be installed on the concrete foundations (by main civil contractor) as per approved foundation drawings, ensure adequate space is available for valves, piping and for future maintenance. It is important that enough space around the plate heat exchanger is kept free for servicing of the unit for renewal of plates, tightening of package.

Free space around the heat exchanger unit should be 1.5 to 2 times of the width. Examine areas and conditions with requirements for installation tolerances and other conditions affecting performance, operation and maintenance of Plate heat Exchanger.

Check the heat exchanger concrete foundation should be horizontal & smooth finishes from top. Check painting if required in civil detail. The plate heat exchanger should be mounted in an upright position (top on the nameplate is up) to avoid trapping air or other gases.

Shifting, Lifting and Placement of Plate Heat Exchanger

For transportation of heat exchanger to project site permission will be agreed in advance with main contractor and client.

Heat exchanger will be delivered at site by trailer. If plate heat exchangers are already available in the project store, shift plate heat exchanger from store to the area of installation as per manufacturer’s instruction.

Plate Heat exchanger should not be lift by connections or the stud around them. Strap should be used when lifting, place e strap according to the manufacturer’s instruction.

A level area will be cleared for the standing of the mobile crane and trailer. Existing underground services and ground conditions will be considered prior to the positioning of the mobile crane and trailer at the site.

Prior to standing and rigging of crane on the project site, the SHE Officer will be responsible for ensuring that Plant Check List is completed and that copies of all relevant documentation is attached to this lifting plan.

Where any non-conformance or defect is evident then the crane will be stood down, the lifting operation will be cancelled and immediately informed to the main contractor.

Lifting Plan will be briefed (toolbox talk) prior to the commencement of lifting operations to all operatives and third parties involved in the activity.

The lifting area will be designated “Authorized Personnel Only” and will be demarked and signage displayed to ensure that no unauthorized personnel can gain entry to the lifting area.

Plate Heat Exchanger Lifting Procedure with Mobile Crane

Outrigger mats, or suitable timbers, will be positioned under outriggers.

The hydraulic outriggers will be extended over mats and the crane leveled.

The cranes boom will be raised and telescoped to the required length.

The ASLI (Automatic Safe Load Indicator) will be checked for correct operation.

The above sequence of rigging will be in accordance with the manufacturer’s recommendations, which will be strictly adhered to all times.

Only one Heat exchanger to be lifted one at the time.

The slingers I banksman will attach chain sling from crane hook point, hook block.

The banks man will attached 2 no’s web sling with heat exchanger and chain sling hook.

Guide ropes/Tag lines will be attached by the helpers to prevent the swinging of the load.

Once it is confirmed by the Banksman I slinger that the load is level,the lift will commence to the required position under the strict guidance of the Banks man.

The Banksman is to be in direct line of sight with the crane operator at all times.

If the crane operator cannot see the Banksman then he is to stop the lift immediately.

One certified banks man I signaler will be appointed to control the crane movements and lifting operation and hand signals from other personnel will not be permitted and must be ignored.

Ensure that set down area is clear where the load is going to be offloaded.

Personnel remain clear of the load at all times until the load is at waist level. Tag lines are to be used to prevent swinging.

The slinger I signaler will stand in a secure position,where they are in view of both the load and the crane operative. Each signal will be distinct and clear.

Release lifting tackle, hoist clear and repeat until completion. On completion of lifting operations,all lifting equipment is to be removed and stored properly.

Heat Exchanger Lifting Procedure with fork lift truck

Safe access and egress for the route of the forklift will be determined. Access will be free of obstructions,and be properly maintained.

Heat exchanger column bar & tie rod bolts to be removed as per agreed & temporary change it with a shorter length to be able to accommodate the unit in the plant room.

The forklift utilized for the task should be safe working load capacity to lift off heat exchanger.

The lifting load will be suitably bound or lashed to ensure it is secure and on a pallet.

The forklift operator will only commence movement of the forklift to the pickup area under the guidance of the Banks man. Signals must be clear and precise and understood by all personnel involved in the work activity.

The forklift operator will only take instruction and direction from the assigned

Banksman. No other personnel are to provide guidance or instruction.

The banks man will stand in a secure position at all times, where they are in view of both the load and the forklift truck operative. Each signal will be distinct and clear.

The forks on the forklift truck will be adjusted to give maximum support to the load being lifted.

The forklift operator will insert the forks under the load with the guidance of the banksman.

The load will be lifted up until the forks take the load weight,whilst not lifting it off the ground, to ensure that the load is level.

Once it confirmed by the forklift operative that the load is level, the lift will commence to the required position under the strict guidance of the Banksman.

Forks will be tilted backwards during all load movements to ensure maximum stability of the load being moved.

The load will then be moved to the agreed location i.e. plant room/plinth under the strict guidance of the Banks man.

Cones will be set out, including barrier tape, to exclude unauthorized entry into the loading/work area.

The load will be lifted to the height of the plinth/location and slowly moved forward and get in position to the final placement with strict guidance of banks man.

Once the load placed in required position the forks will be released.

Flat Plate Heat Exchanger Installation

Reassembly of the column bar & tie rods of heat exchanger to restore its original dimensional details will take In place.

If supports/shock absorbers are required to be inserted under the heat exchanger, this must be done in advance to the load being offered to the final position.

Supervisors will coordinate with the banks man for the final positioning of the heat exchanger whilst the forklift in use.

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After putting down on the foundation the Plate Heat Exchanger should be leveled and aligned on the foundation.

After alignment put rubber pad between the foundation & Plate Heat Exchanger.

Upon satisfactory positioning of Heat Exchanger’s, it should be covered with polythene sheet to secure & protect it from moisture and dust ingress until such time as the units are available for commissioning.

Heat Exchanger Piping Connections

If the connection is rubber lined, the liner will act as the flange gasket.

Bolt the connecting flange directly to the end plate using the drilled and tapped holes provided.

Tighten the bolts evenly, do not over tighten as this could strip the threads cut into the frame plate.

If loose backing flanges are fitted to the heat exchanger a suitable gasket is required to seal the flange.

The heat exchanger is usually connected for counter-current flow.

The heat exchanger inter-connecting piping and piping supports should be designed such that loads and stresses on the exchanger connections are eliminated. Thermal expansion must be taken into consideration when designing the piping system.

Heat Exchanger Design Manual

By-pass piping and valves should be considered to allow isolation of each side of the heat exchanger for inspection, cleaning, repairs, and replacement.

Install flexible connections onto the follower to prevent vibrations onto the heat exchanger and also the expansion of the pipework, caused by temperature influence onto the Heat Exchanger.

Drain piping should be designed to assure complete draining. Download adobe flash player free download for windows 7. Avoid common drain manifolds.

The venting system design should take into account all applicable operator and environmental safety requirements.

Install relief valves on Heat exchanger heated fluid connection. Install shut off valves at Heat exchanger inlet and outlet connections. Remove all plugs, shipping covers, desiccant containers, and other protection immediately prior to connecting unit.

Avoid unnecessary exposure of internals to contaminants and moisture.

The pipe works /piping system shall be thoroughly cleaned and flushed before connecting into the heat exchanger. After completing system installation,including outlet fitting and devices, inspect exposed finish, remove burrs, dirt and construction debris and repair damaged finishes.

Plate Heat Exchanger Inspection and Testing

In process works shall be monitored for quality of workmanship and installation against approved construction drawing by the relevant Supervisor, Project Mechanical Engineer, Construction Manager and QA/QC Engineer.

Ensure that the installation of Plate Heat Exchanger complies with the specification requirements and notify the main contractor I consultant in advance at least 24 hours before installation inspection must be made.

Side Arm Heat Exchanger Installation

Ensure a factory authorized service representative to inspect, test and adjust field assembled components and equipment installation, including connections, and to assist in field testing of plate heat exchangers.