HIGH-K Heat Exchanger

Rigging and Installation Instructions

HIGH-K Heat Exchangers should be rigged and installed by contractors or end-users as outlined in this
bulletin. The procedures should be thoroughly reviewed prior to actual rigging to familiarize key
personnel with the methods to be employed and to ensure that all necessary equipment is available at
the jobsite.

STANDARD METHOD OF SHIPPING GENERAL DESCRIPTION

The HIGH-K Heat Exchanger is designed and manufactured
to meet shipping, handling, and rigging requirements. To
simplify rigging and installation all HIGH-K Heat Exchangers
ship completely fabricated and framed for immediate
installation by a contractor or end-user. The unique
compression seal is factory torgued and each unit is
pressure tested after fabrication. (Refer to the HIGH-K
Heat Exchanger Operating and Maintenance Manual, for
detailed torque requirements.)
The fluid connections are covered during shipment to
prevent debris from entering the unit. Debris in the HIGH-K
Heat Exchanger may hinder performance. DO NOT
REMOVE the connection covers until piping the unit
--------
CHECKING UNIT BEFORE RIGGING .
When the HIGH-K Heat Exchanger is delivered to the
jobsite, it should be vissually inspected to ensure it is free
of shipping damage prior to signing the Bill of Lading.
ANCHORING . Nominal Tube
The HIGH-K Heat Exchanger is designed for easy installation
on floors, walls, and ceilings. All units ship with mounting
holeslocated in the support frame for floor mounting. In
addition, ceiling-mounted units ship with optional brackets
located on the support frames for securing to the ceiling
structure. For units installed on walls or ceilings, additional
supports are recommended to prevent lateral movement
of the Heat Exchanger. Refer to the support detail on the
certified drawing for location of the mounting holes.
Anchor bolts for floor-mounted units and hanging rods for
ceiling-mounted units must be provided by others.
Review the lifting procedures outlined in this bulletin prior
to rigging the HIGH-K Heat Exchanger to ensure proper
handling during installation. Refer to the certified drawing
for the unit's weight before selecting the rigging
equipment. The recommended spreader bar lengths are
given in this manual based on the HIGH-K shell diameter,
unit length and circuiting arrangement. The nominal shell
diameter, nominal tube length, and circuiting arrangement
can be obtained from the HIGH-K Heat Exchanger model
number. Figure 1 defines each digit of the model number.
Nominal Shell Number of Modules
Diameter (inches) (In series per circuit)
HK8-10-2-3A
Shellside Baffle
Bundle Length Number of Arrangement
(Feet) Parallel Circuits
Figure 1
HIGH-K Heat Exchanger Model Number Nomenclature
For example, the HIGH-K Heat Exchanger with model
number HK8-10-2-3A has an 8-inch nominal shell
diameter. 10-foot nominal tube bundle length, two
shells in series per circuit, and three parallel circuits on a
common frame. The shellside baffles have an "A" type
arrangement. Figure 2 shows a schematic of an HK8-10-
2-3A.
 THREE CIRCUITS IN SHELLSIDE CROSS- TUBESIDE RETURN
TWO SHELLS IN SERIES
PARALLEL OVER PIPE WATERBOX

Figure 2 -- HK 8-10-2-3A HIGH-K Heat Exchanger

The HIGH-K Heat Exchanger is available in 6, 8, 10, and 14-inch nominal shell diameters. The nominal tube bundle lengths range between 9 and 18
feet depending on the diameter. It is possible to have from 1 to 4 shells in series per circuit and 1 and 7 circuits on a common frame. Table 1 outlines
the nominal tube lengths and pass arrangements available for each shell diameter.

Table 1. HIGH-K Heat Exchanger Size and Configuration Options

Nominal Shell Diameters Nominal Tube Bundle Number of Shells Per Number of Circuits Per
(Inches) Lengths (Feet) Circuit Frame

4 9,11,13 1 to 3 1 to 5
6 9,11,13 1 to 3 1 to 5
8 10,12,14,16,18 1 to 4 1 to 7
10 10,12,14,16,18 1 to 4 1 to 5
14 10,12,14,16,18 1 to 3 1 to 4

Place additional
Rigging Procedures spreader bar "c" here
for wider unit.
HIGH-K Heat Exchangers should be lifted using two (2) slings placed
beneath the bottom shells. Locate the slings inside the frame as close to
the vertical support members as possible. The frame should not be used for "B & C"
lifting purposes except for ceiling-mounted units which may be lifted
through the ceilingmounting brackets. (Note: Take necessary measures to "A"
protect the exterior finish of the unit when liftinf with chain slings). _____

For single-pass, single circuit units, one spreader bar of length "a" (as
shown in Figure 3) is needed to hold the slings at the correct locations. For
multiple-pass, single-circuit or multiple-circuit units (Figures 4 and 5
respectively), one spreader bar of length "b" or "c" must be placed inside
the slings used at each end of the Heat Exchanger. Depending on the type
of lifting equipment used, additional spreader bars of length "a" may be
required to hold the slings in the correct location while lifting. Table 2
contains the spreader bar lengths for single-pass, singlecircuit (a), multiple-
pass, single-circuit (a & b) and multiple-circuit (a & c) HIGH-K Heat
Exchangers. ________________________________________

Figure 3-Recommended
Lifting Procedures for a
Single-Pass, Single-Circuit
Unit

Figure 4 and 5--Recommended Lifting Procedures for

Multiple-Pass, Multiple-Circuit Units
 Table 2. Spreader Bar Lengths (Inches)

Single-Pass Multiple-Pass Multiple-Circuits

Single-Circuit Single-Cicuit "b" "c"
HIGH-K Heat Exchanger
"a"
Optional for other units 2 3 4 2 3 4 5 6 7

HK 4-9 64
HK 4-11 90 17 27 38 49
HK 4-13 116 18 5/8 30 5/8 42 5/8 NA NA
1/4 7/8 1/2 1/8

HK 6-9 64
HK 6-11 90 17 27 38 49
HK 6-13 18 5/8 30 5/8 42 5/8 NA NA
116 1/4 7/8 1/2 1/8

HK 8-10 71
HK 8-12 98 24 33 46 59 71 84
HK 8-14 124 24 5/8 40 5/8 56 5/8
5/8 7/8 1/2 1/8 3/4 3/8
HK8-16 146
HK 8-18 170
HK 10-10 70
HK 10-12 96 26 42 58 74
HK 10-14 122 30 3/4 50 3/4 70 3/4 NA NA
3/4 3/4 3/4 3/4
HK 10-16 144
HK 10-18 168
HK 14-10 64
HK 14-12 90
HK 10-14 116 34 54 NA 35 56 77 NA NA NA
HK 10-16 139
HK 10-18 163

Installation
Instructions
General Guidlines
The following guidlines for installation of HIGH-K Heat Exchanger by contractors or end-users are recommended to assure efficient
operation and ease of maintenance. Refer to the HIGH-K Heat Exchanger Operation and Maintenance Manual for detailed start-up
procedures.

A. Space should be provided for access to the unit for routine maintenance (e.g., removal of the tube bundle or mechanical
cleaning).
B. Foundations must be adequate so that the HIGH-K Heat Exchanger will not settle and cause the piping to transmit excessive
strains to the nozzles of the unit.
C. The HIGH-K Heat Exchanger is provided with oplong mounting holes for the foundation bolts. Foundation bolts should be
centered in the oblong mounting holes. Foundation bolts should be loosened at one end of the unit to allow for free thermal
expansion of the heat exchanger.
D. System piping should be free of debris prior to connection to the HIGH-K Heat Exchanger.
E. Certified print should be checked to insure proper connection of the system piping to the HIGH-K Heat Exchanger.
F. Gaskets between inlet and outlet connection flanges should be centered to allow unrestricted fluid flow.
G. System piping should be properly supported. UNIT CONNECTIONS SHOULD NOT BE USED TO SUPPORT PIPING. All piping should
be supported independently through the use of pipe hangers or supports. Vibration isolation should be used in accordance with
standard piping practices.
H. Pressure taps and thermometer wells should be installed in the piping entering and leaving the Heat Exhcnagre. To assure
accurate measurements, locate the pressure taps and thermometer wells close to the Heat Exchanger as possible. Pressure taps
should be at least ten pipe diameters from any fittings.
I. Vent valves should be located at the highest point in the system to allow proper filling, draining and venting.
J. Provide throttling valves and a surge drum to prevent damage caused by pulsating fluids in the system piping. The surge drum
should be located upstream from the Heat Exchanger.
K. CONTROL OF THE SYSTEM PRESSURE IS ESSENTIAL. Relief valves are necessary where the system pump pressure output exceeds
the design pressure in the Heat Exchanger. (Refer to the Mechanical Specification Sheet for the Heat Exchanger design pressure.)
Control valves should be installed in the system piping at the inlets of the Heat Exchanger.
L. To facilitate maintenance, install valves and bypasses to allow isolation between the tubeside and shellside of the Heat
Exchanger.
M. It is recommended that the HIGH-K Heat Exchanger be installed indoors. UNITS LOCATED OUTDOORS MUST HAVE PROPER
FREEZE PROTECTION TO INSURE DAMAGE-FREE OPERATION.
Storage Procedures
When a HIGH-K Heat Exchanger is to be placed in storage for an extended period of time, the procedures listed below
must be followed:

1) If the unit has been recently shipped from the factory and is unused, disregard statements 2 and 3; follow
instructions 4 and 5.
2) If the unit has been used and long term storage is required, it must be completely drained.
3) Disassemble the Heat Exchanger. Thoroughly clean the unit internally and externally. Dry the unit. (Blowing dry, hot
air at approximately 150 degrees F on all areas is an excellent method.) Reassemble the Heat Exchanger without
replacing gaskets and without torquing bolts. (Refer to the Operating and Maintenance Manual Bulletin M903/1-0
for detailed assembly instructions).
4) Install blind flanges with gaskets on all connections.
5) Store under cover in a heated area, if possible. The ideal storage environment for Heat Exchangers is indoors, above
grade, in a dry low-humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Avoid
wide temperature swings which may cause condensation and "sweating" of steel parts.

SAFETY PRECAUTIONS
Adequate precaustions should be taken to safeguard the equipment and the premises from
damage and the public from possible injury as appropiate for the installation and location of these
products.

Notice
Operation, maintenance and repair of this equipment should be undertaken only by personnel
qualified to do so. Proper care, procedures and tools must be used in handling, lifting, installing,
operating, maintaining and repairing this equipment to prevent personal injury and/or property
damage.

Warranties
Please refer to the Limitation of Warranties applicable to and in effect at the time of the
sale/purchase of these products.

Freeze Protection
These products must be proteced against damage and/or reduced effectiveness due to possible
freeze-up by mechanical and operational methods. Please refer to the Cold Weather Operation
guidlines (page 11) or contact the local HIGH-K Representative for recommended protection
alternatives.