Rotarty Ash Cooler Manual

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O & M MANUAL
FOR
ROTARY BED ASH COOLER
CONTENT
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CONTENT
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CONTENT
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CONTENT
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CONTENT
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CONTENT
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CONTENT
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CONTENT
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CONTENT
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HEAT EXCHANGER
CONTENT
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DATA SHEET
FOR
HEAT EXCHANGER
CONTENT
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DATA SHEET FOR HEAT EXCHANGER

SL.NO
DESCRIPTION
UNITS
SHELL SIDE
TUBE SIDE
DM Water
Cooling Water
TPH
230
920
Fluid Name
Flow
Temperature In
Deg.C
95
32
Temperature Out
Deg.C
67
39.03
Velocity
m/s
0.69
2.78
Pressure drop
Kg/cm2
0.220
0.388
Fouling resistance
m2- hrc/kcal
0.0001
0.0004
Design Pressure
Kg/cm2
12
12
Design Temperature
Deg.C
250
250
10
No. of Passes
11
Shell Thickness
mm
10
12
Corrosion Allowance
mm
1.6
13
No. of Tubes
385
14
Tube OD
mm
20
15
Tube Thick
mm
1.25
16
Tube Length
mm
5750
17
Pitch
mm
26
18
Shell ID
mm
584
19
Baffle Type
mm
Double
Segmental
20
Surface area
m2
136.63
WEIGHT
21
Weight -Dry
Tons
22
Weight Flooded
Tons
4.7
MATERIAL
23
Shell, channel & dish ends
24
Tube
25
Baffles
SA 516 Gr.70
304 SS (18CR 8 NI)
SA 36
Page 659 of 699
NOZZLE SIZES
SL MARK NOZZLE
.N
O
QTY
NOZZLE NOZZ
SIZE (NB) SCH
FLANGE DETAILS
TYPE
REMARKS
FACE RATING FINISH
N1
Tube side
inlet
450
10
SO
RF
150#
SERR.
N2
Tube side
outlet
450
10
SO
RF
150#
SERR.
N3
Shell side
inlet
250
20
SO
RF
150#
SERR.
N4
Shell side
outlet
250
20
SO
RF
150#
SERR.
N5
Shell side
Drain
40
XX
STRG
SO
RF
150#
SERR.
WITH
BLIND
FLANGE
N6
N7
Tube side
Drain
40
160
SO
RF
150#
SERR.
WITH
BLIND
FLANGE
N8
M1
&M2
INST
CONN
15 NPT
300#
COUPLING
WIHT PLUG
10
M1
&M2
INST.
CONN
15 NPT
300#
COUPLING
WIHT PLUG
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GA DRAWING
FOR
HEAT EXCHANGER
CONTENT
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CONTENT
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O & M MANUAL
FOR
HEAT EXCHANGER
CONTENT
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INDREF Heat Exchanger
OPERATION
AND
MAINTENANCE MANUAL
AIRFRIGE INDUSTRIES
10/65, KIRTI NAGAR INDL. AREA
NEW DELHI-110015
PHONE NO.:
FAX:
e-mail:
website:
2592 7118, 2592 7219, 2593 1909, 2593 1972

011-2543 6781
airfrige@vsnl.com
www.airfrigeindustries.com
Page 664 of 699
HEAT EXCHANGER
Customers Order No.:
SHREE CEMENT LTD.,

A/c Cethar Vessels Limited
Shree Mega Power Project
Beawar,305901
RAJASTHAN
MBJ059/0341/S dated 10 January, 2011
Item Description:
Shell & Tube Type Heat Exchanger : 1 No.
Item Job No./Serial No.:
AFI-J011210A-01 APR 2011
Loose Items/Spares:
NIL
Orientation of HE.:
HORIZONTAL
Consignee:
OUTSIDE TUBES
INSIDE TUBES
Fluid:
DM Water
Cooling Water
No. of Passes:
ONE
ONE
Inter-changeability
of YES
YES.However, direction of
nozzles. Whether inlet can
cooling
and
DM water
be made outlet and vice
should be counter flow only.
versa?
Plugs:
Provided
Provided
Counter Flanges:
Provided
Provided
Bolts and Nuts for Cou nter Provided
Provided
Flanges:
Gasket
for Cou
nter Provided
Provided
Flanges:
Sequence for Start-Up:
Open
DM
Water
NEXT
Sequence of Shut Down:
Close
Inlet Open Cooling Water
Inlet
FIRST
DM
Water
FIRST
Inlet Close Cooling Water Inlet

NEXT
Copyright of these particulars shall remain our sole property. This instruction booklet may neither be copied
nor made available to a third party without our written consent.
This instruction booklet corresponds to th e item num ber given above. The production engineer as well as
the setter ought to be thoroughly familiar with its contents.
We shall be only too glad to furnish information on all technical problems and welcome all suggestions.
SERVICE DEPARTMENT- AIRFRIGE INDUSTRIES
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1. INSTALLATION OF HEAT EXCHANGERS

1.1 HEAT EXCHANGER SETTINGS
1.1.1
CLEARANCE FOR DISMANTLING

For straight tube Heat
Exchangers fitted with remo
vable bundles, provide
sufficient clearance at the stationar y head to p ermit removal of the bundle fro m
the shell and provide adequate space beyond the rear head to permit removal of
the shell cover and / or floating head cover.
For fixed tube sheet Heat Exchangers, provide sufficient clearance at one end to
permit withdrawal and replacement of the tubes and enoug h space be yond the
head at the opposite end, to permit removal of the bonnet or channel cover.
For U-tube Heat Exchangers, provide sufficient clearances at the stationary head
end to permit withdra wal of the t ube bundle, or at the o pposite end to permit
removal of the shell.
1.1.2
FOUNDATIONS
Foundations must be a dequate so that Heat Exchangers will no t settle and
impose excessive strains on the e xchanger. Foundation bolts should be set to
allow for setting inaccuracies. In concrete footings, pipe sleeves at least one size
larger than bolt diameter slipped ov er the bolt a nd cast in p lace are best for this
purpose, as they allow the bolt center to be adjusted after the foundation has set.
1.1.3
FOUNDATION BOLTS
Foundation bolts should be loosed at one end of unit to allow free exp ansion of
shells. Slotted holes in supports are provided for this purpose.
1.1.4
LEVELING
Heat Exchangers must be set level and square so that pipe connections may be
made without forcing.
Page 666 of 699
1.2 CLEANLINESS PROVISIONS

1.2.1
CONNECTION PROTECTORS
All Heat Exchanger openings should be inspected for foreign material. Protective
plugs and covers should not be removed until just prior to installation.
1.2.2
DIRT REMOVAL
The entire system should be clea n before st arting operation. Under some
conditions, the use of strainers in the piping may be required.
1.3 FITTINGS AND PIPING

1.3.1
BY-PASS VALVES
It may be desirable to provide valves and by-passes
in the piping system to
permit inspection and repairs.

1.3.2
TEST CONNECTIONS
When not integral with the Heat Exchanger no zzles, thermometer and pressure
gauge connections sho uld be insta lled close t o the excha nger in the inlet and
outlet piping.
1.3.3
VENTS
Vent valves should be provided so units can b e purged to prevent vapor or gas
binding.
1.3.4
DRAINS
Drains may discharge to atmosphere, if permissible, or in to a vessel at lower
pressure. They should not be piped to a common closed manifold.
1.3.5
PULSATION AND VIBRATION

In all installations, care should be taken to eliminate or minimize transmission of
fluid pulsation and mechanical vibrations to the Heat Exchangers.
Page 667 of 699
2. OPERATION OF HEAT EXCHANGERS

2.1 DESIGN AND OPERATION CONDITIONS
Equipment must not be operated at conditions that exceed those specified on the n ame
plate.
2.2 OPERATING PROCEDURES
Before placing any He at Exchanger in operation, referen ce should be made to the
exchanger drawings, specification sheet(s) and name plate(s)
for any sp ecific
instructions. Improper start-up or sh ut-down sequences, particularly of fixed tube sheet

units, may cause leaking of tube-to-tube sheet and / or bolted flanged joints.
2.2.1
START-UP OPERATION
Most Heat Exchangers with removable tube bundles may be placed in service by
first establishing circulation of cold medium, followed by the gradual intr oduction
of the hot medium. During start-up operation all vent valve s should be opened
and left open until all passages have been purged of air and completely filled with
fluid. For fixed tube sheet Heat Exchangers, hot and cold medium must be
introduced in a manner to minimize differential expansion between the shell and
tubes.
2.2.2
SHUT-DOWN OPERATION
For Heat Exchangers with remo vable tube bundles, the unit s may be s hut down
by first gradually stopping the flow of hot medium and then stopping the flow of
cold medium. If it necessary to stop the flow of cold medium, the circulation of hot
medium through the Heat Exchan ger should also be sto pped. When shutting
down the s ystem, all units should be drained completely when
there is the
possibility of corrosion damage. To reduce water retention after drainage, the

tube side of water-cooled Heat Exchangers should be blown out with air.
2.2.3
TEMPERATURE SHOCKS
Heat Exchangers normally should
not be su bjected to abrupt temperature
fluctuations. Hot fluid must not be suddenly introduced when the unit is cold, nor
cold fluid be suddenly introduced when the unit is hot.
Page 668 of 699
2.2.4
BOLTED JOINTS
Heat Exchangers are p ressure tested before A IRFRIGEs shop in accordance
with ASME Code requirements. However, normal relaxing o f the gasketed joints
may occur in the interval between testing in the AIRFRIGEs shop and installation
and, if necessary, after the Heat Exchanger has reached operating temperature.
Page 669 of 699
3. MAINTENANCE OF HEAT EXCHANGERS

3.1 INSPECTION OF UNIT
At regular intervals and as frequently as experience indicates, an examination should be
made of the interior and exterior condition of unit. Neglect in keeping all tubes clean may
result in co mplete stoppage of flow through
some tubes which could cause se
vere
thermal strains, leaking tube joints, or structural damage to other components. Sacrificial
anodes, when provided , should be inspected to determin
e whether t hey should be
cleaned or replaced.
3.1.1
INDICATIONS OF FOULING
Heat Exchangers subject to fouling or scaling should be cleaned periodically. A
light sludge or scale coating on the t ube greatly reduces it s efficiency. A marked
increase in pressure drop and/or reduction in performance usually indicate
cleaning is necessary. The unit should first be checked for air or vapor binding to
confirm that this is not the cause f or the reduction in perf ormance. Since the
difficulty of cleaning increases r apidly as the scale t
hickness or deposit
increases, the intervals between cleanings should not be excessive.

3.2 CLEANING OF TUBE BUNDLES
3.2.1
CLEANING METHODS
The heat transfer surfaces of Heat Exchangers should be kept reasonably clean
to assure satisfactory p erformance. Heat Exch angers may be cleaned by either
chemical or mechanical methods. The method selected must be the choice of the
operator of the plant and will depend on the type of deposit and the
available in the plant.
Following are several cleaning
facilities
procedures that be
considered:(1) Circulating hot wash oil or light distillate through tubes or shell at high velocity
may effectively remove sludge or similar soft deposits.
(2) Some salt deposits may be washed out by circulating hot fresh water.
(3) Commercial cleaning compounds are available for removing sludge or scale
provided hot wash oil o r water is n ot available or does not give satisfactory
results.
(4) High pressure water jet cleaning.
Page 670 of 699
(5) Scrapers, rotating wire brushes, and other mechanical means for removing
hard scale, coke, or other deposits.
(6) Employ services of a q ualified organization that provides cleaning services.
These organizations will check the
nature of the deposits to be removed,
furnish proper solvents and / or acid solut
ions containing inhibitor s, and
provide equipment and personnel for a complete cleaning job.

3.2.2
CLEANING PRECAUTIONS
(1) Tubes should not be cleaned by blowing steam through individual tubes since
this heats the tube and may result in severe expansion stra in, deformation of
tube, or loosening of tube-to-tube sheet joint.
(2) When mechanically cleaning a tu be bundle, care should be exercised to
avoid damaging the tubes.
(3) Cleaning compounds must be compatible with
the metallurgy of the Heat
Exchanger.
3.2.3
GASKET REPLACEMENT
Gaskets and gasket surfaces should be thoroughly cleaned and should be free of
scratches and other d efects. Gaskets shou ld be properly positione d before
attempting to retighten bolts. It is r ecommended that when a Heat Exc hanger is
dismantled for any caus e, it be reassembled with new gaskets. This will tend to
prevent future leaks an d/or damage to the gasket seating surfaces of the Heat
Exchanger. Composition gaskets become dried out and brittle so that they do not
always provide an effective seal wh en reused. Metal or metal jacketed gaskets,
when compressed initially, flow to match their contact surfaces. In so doing they
are work hardened and, if reused , may pro vide an imperfect seal o r result in
deformation and damage to the gasket contact surfaces of the exchanger.
Bolted joints and flanges are desig ned for use with the particular type of gasket
specified. Substitution of a g
asket of d ifferent construction or improper
dimensions may result in leakage and damage
to gasket surfaces. T herefore,
any gasket substitutions should be of compatible design.

Any leakage at a gasketed joint should be rectified and not permitte d to persist
as it may result in damage to the gasket surfaces.
Page 671 of 699
Metal jacketed type of gaskets when used with a tongue and groove joint without
a nubbin, t he gasket should be installed so that the t ongue bears on the
seamless side of the g asket jacket. When a n ubbin is use d, the nubbin should
bear on the seamless side.
3.2.4
SPARE PARTS
The procurement of spare or replacement parts from AIRFRI
GE shall be
facilitated if the correct name for th e part is given, together with type,
size and
serial number of the heat exchanger. Replacement parts should be p
urchased
from the original manufacturer only i.e. AIRFRIGE INDUSTRIES.
Page 672 of 699
OPERATION
AND
MAINTENANCE MANUAL
AIRFRIGE INDUSTRIES
NEW DELHI-110015
PHONE NO.:
FAX:
e-mail:
website:
2592 7118, 2592 7219, 2593 1909, 2593 1972

011-2543 6781
airfrige@vsnl.com
Page 673 of 699
HEAT EXCHANGER
SHREE CEMENT LTD.,

Beawar,305901
RAJASTHAN
Item Description:
AFI-J011210A-02 APR 2011
Loose Items/Spares:
NIL
Orientation of HE.:
HORIZONTAL
Consignee:
OUTSIDE TUBES
INSIDE TUBES
Fluid:
DM Water
Cooling Water
No. of Passes:
ONE
ONE
Inter-changeability
of YES
cooling
and
DM water
versa?
Plugs:
Provided
Provided
Counter Flanges:
Provided
Provided
Provided
Flanges:
Gasket
for Cou
nter Provided
Provided
Flanges:
Open
DM
Water
NEXT
Close
Inlet
FIRST
DM
Water
FIRST

NEXT
Page 674 of 699

1.1.1

1.1.2
FOUNDATIONS
1.1.3
FOUNDATION BOLTS
1.1.4
LEVELING
Page 675 of 699

1.2.1
1.2.2
DIRT REMOVAL

1.3.1
BY-PASS VALVES

1.3.2
TEST CONNECTIONS
outlet piping.
1.3.3
VENTS
binding.
1.3.4
DRAINS
1.3.5

Page 676 of 699

plate.
for any sp ecific

2.2.1
START-UP OPERATION
tubes.
2.2.2
SHUT-DOWN OPERATION
there is the

2.2.3
TEMPERATURE SHOCKS
Page 677 of 699
2.2.4
BOLTED JOINTS
Page 678 of 699

vere
3.1.1
hickness or deposit

3.2.1
CLEANING METHODS
facilities
procedures that be
results.
Page 679 of 699

3.2.2
Exchanger.
3.2.3
GASKET REPLACEMENT

Page 680 of 699
Metal jacketed type of gaskets when used with a tongue and groove joint without
a nubbin, t he gasket should be installed so that the t ongue bears on the
seamless side of the g asket jacket. When a n ubbin is use d, the nubbin should
bear on the seamless side.
3.2.4
SPARE PARTS
The procurement of spare or replacement parts from AIRFRI
GE shall be
facilitated if the correct name for th e part is given, together with type,
size and
serial number of the heat exchanger. Replacement parts should be p
urchased
from the original manufacturer only i.e. AIRFRIGE INDUSTRIES.
Page 681 of 699
OPERATION
AND
MAINTENANCE MANUAL
AIRFRIGE INDUSTRIES
NEW DELHI-110015
PHONE NO.:
FAX:
e-mail:
website:
2592 7118, 2592 7219, 2593 1909, 2593 1972

011-2543 6781
airfrige@vsnl.com
Page 682 of 699
HEAT EXCHANGER
SHREE CEMENT LTD.,

Beawar,305901
RAJASTHAN
Item Description:
AFI-J011210B-01 APR 2011
Loose Items/Spares:
NIL
Orientation of HE.:
HORIZONTAL
Consignee:
OUTSIDE TUBES
INSIDE TUBES
Fluid:
DM Water
Cooling Water
No. of Passes:
ONE
ONE
Inter-changeability
of YES
cooling
and
DM water
versa?
Plugs:
Provided
Provided
Counter Flanges:
Provided
Provided
Provided
Flanges:
Gasket
for Cou
nter Provided
Provided
Flanges:
Open
DM
Water
NEXT
Close
Inlet
FIRST
DM
Water
FIRST

NEXT
Page 683 of 699

1.1.1

1.1.2
FOUNDATIONS
1.1.3
FOUNDATION BOLTS
1.1.4
LEVELING
Page 684 of 699

1.2.1
1.2.2
DIRT REMOVAL

1.3.1
BY-PASS VALVES

1.3.2
TEST CONNECTIONS
outlet piping.
1.3.3
VENTS
binding.
1.3.4
DRAINS
1.3.5

Page 685 of 699

plate.
for any sp ecific

2.2.1
START-UP OPERATION
tubes.
2.2.2
SHUT-DOWN OPERATION
there is the

2.2.3
TEMPERATURE SHOCKS
Page 686 of 699
2.2.4
BOLTED JOINTS
Page 687 of 699

vere
3.1.1
hickness or deposit

3.2.1
CLEANING METHODS
facilities
procedures that be
results.
Page 688 of 699

3.2.2
Exchanger.
3.2.3
GASKET REPLACEMENT

Page 689 of 699

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DATA SHEET FOR HEAT EXCHANGER

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FACE RATING FINISH

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Page 661 of 699

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INDREF Heat Exchanger

2592 7118, 2592 7219, 2593 1909, 2593 1972

Page 664 of 699

Customers Order No.:

SHREE CEMENT LTD.,

Shell & Tube Type Heat Exchanger : 1 No.

Item Job No./Serial No.:

AFI-J011210A-01 APR 2011

nozzles. Whether inlet can

be made outlet and vice

should be counter flow only.

Bolts and Nuts for Cou nter Provided

Inlet Open Cooling Water

Inlet Close Cooling Water Inlet

SERVICE DEPARTMENT- AIRFRIGE INDUSTRIES

Page 665 of 699

1. INSTALLATION OF HEAT EXCHANGERS

CLEARANCE FOR DISMANTLING

Exchangers fitted with remo

vable bundles, provide

Page 666 of 699

1.2 CLEANLINESS PROVISIONS

1.3 FITTINGS AND PIPING

in the piping system to

permit inspection and repairs.

PULSATION AND VIBRATION

Page 667 of 699

2. OPERATION OF HEAT EXCHANGERS

for any sp ecific

instructions. Improper start-up or sh ut-down sequences, particularly of fixed tube sheet

possibility of corrosion damage. To reduce water retention after drainage, the

not be su bjected to abrupt temperature

Page 668 of 699

Page 669 of 699

3. MAINTENANCE OF HEAT EXCHANGERS

some tubes which could cause se

e whether t hey should be

increases, the intervals between cleanings should not be excessive.

Following are several cleaning

Page 670 of 699

nature of the deposits to be removed,

furnish proper solvents and / or acid solut