TRC-PD-TP-IM-EN-1308-Rev2.

doc

| Installation Manual
RETORT TYPE: A-144-T

SERIAL NUMBERS: 582-583-584

CUSTOMER: TETRA RECART AB

YEAR BUILT: 2013

Surdry S.L. Pol. Ind. Trañapadura - 39700 - Abadiano - Vizcaya - Spain T +34 946814171 F +34 946813452
surdry@surdry.com www.surdry.com
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Content

Transport .............................................................................................................................3
Unloading.............................................................................................................................3
Transportation inside the plant premises .............................................................................5
Installation............................................................................................................................6
Leveling and fixation on the floor .........................................................................................7
Assembly of Heat Exchanger and Air Inlet valve .................................................................8
Supply of utilities ................................................................................................................11
Steam ............................................................................................................................11
Water (Process Fill) .......................................................................................................11
Water (Cooling water supply to the heat exchanger) .....................................................12
Compressed Air .............................................................................................................12
Electrical Power .............................................................................................................12
Steam-air exhaust and water drain ................................................................................13
Utilities ..............................................................................................................................14
Recommended properties of the retort process water .......................................................15
Recommended steam quality ............................................................................................16
Recommended cooling water quality .................................................................................16

SURDRY, S.L. 2/16

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TRANSPORT

All standard retorts fit regular lorries for ground transportation or standard 20 or 40 ft containers for sea
transportation. Containers must be open top to enable lifting the retort from the top lugs.

Retorts are fixed on the truck or container bed by means of nails or bolts.

The retorts are usually supplied with electric cabinets mounted on the retort skid and wired to the compo-
nents. Likewise all field components including the pump and heat exchanger remain assembled during
transport.

A plastic film cover is provided to protect the retorts against truck or container leakage during transporta-
tion or warehousing at destination.

UNLOADING

Unloading operation must be carried out only under supervision of a person with qualification to handle
heavy and big size equipment. A bad operation may result in serious material damage or personal injury.

The retort insulation is cladded with thin stainless steel sheet and it will be easily damaged by a small
load. Climbing or leaning against the retort must be avoided to prevent damage.

Likewise the valve pipes and the heat exchanger must not be used to climb, as there is risk of causing
damage.

Check the retort weight in the shipping documentation (*) and make sure that the crane or other equip-
ment used to unload is suitable for the indicated weight.

Make sure that the floor between the unloading dock and the final placement spot has no steps, is
smooth enough and has the necessary resistance for the load.

Prior to start lifting the retort, take off all bolts or nails used to fix the retort to the lorry or container bed.

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The retort must be lifted with an overhead crane with chain or straps tied to the top lugs. It is strictly for-
bidden to lift the retort from any other point.

Only Open-top containers and lorries must be used to enable overhead lifting.

(*) Check the packing list for the weight of retort plus possible accessories loaded inside.

SURDRY, S.L. 4/16

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TRANSPORTATION INSIDE THE PLANT PREMISES

If the retort cannot be placed at its final destination in the retort room by a crane, hydraulic jacks and cas-
ters for big loads (*). Casters will be fixed under the retort saddles.

Fixed casters are used under the rear saddle and turning casters on the front saddle.

(*) Check the packing list for the weight of the retort plus possible accesories loaded inside.

! !

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Forklift equipment not fixed to the saddle may slide and cause the retort to fall.

INSTALLATION

The retort must be installed in accordance to an installation project supervised by qualified and authorized
personnel of the customer or their contractor, in observance of the local or regional regulations on pressure
vessel installations.

An installation drawing is provided with this manual. Careful attention to both the instructions be-
low and in the installation drawing is strongly requested.

SURDRY, S.L. 6/16

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LEVELING AND FIXATION ON THE FLOOR

The standpoints where the retort is to be installed must be well leveled in both longitudinal and transver-
sal planes.

An unlevelled retort makes difficult the basket loading and unloading operation, harms closing and open-
ing the door and disables a right adjustment of the water level throughout the length and width of the retort.

Follow the instructions provided in the installation drawing for a correct leveling and foundation to the
ground.

The internal roller track must be aligned accurately with the roller track on the trolleys used to carry the
baskets both in height and roller alignment. With this purpose, a trolley guide is supplied with the retort (*)
which must be bolted down on the floor at the entrance of the retort. A correct leveling of this part is also im-
portant to enable easy loading and unloading of baskets.

It is recommended that the floor where the trolleys run on is flat and, if possible hardened, to enable
smooth carriage and good condition of trolley wheels and floor.

SURDRY, S.L. 7/16

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ASSEMBLY OF HEAT EXCHANGER AND AIR INLET VALVE

List of items in Packing list

o Retort.

o Heat exchanger´s Support.

o Heat exchanger (H/E).

o Assy of water valves with pipe to connect to H/E.

o Air inlet pipe.

o Bolts, nuts and washers for all components.

STEP 1: Retort as received

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STEP 2: Assembly of Heat Exchanger´s Support

STEP 3: Assembly of Heat Exchanger

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STEP 4: Assembly of water valves with pipe to H/E

STEP 5: Assembly of the air inlet pipe

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SUPPLY OF UTILITIES

Check the installation drawing and utility requirement documentation.

Steam boilers, vessels and pipeline of the installation must be sufficient to meet the supply requirements
in the installation drawing as well as to comply with the local regulations.

The installation of piping must be adequately secured so as to avoid vibrations and water hammer. In long
pipeline runs it is recommended to install flexible joints in order to avoid pipe deformation by thermal expan-
sion.

Steam

Components to be installed by the customer upstream the retort valve:

o 1 manual valve

o 1 steam filter

o 1 bleeder

o 1 pressure gauge (0 - 10 bar)

o 1 check valve

It is recommended to insulate the supply pipe of steam, especially in long runs from the boiler, so as to
minimize heat loss and condensates in the circuit.

Avoid a high concentration of steam condensate in the retort water that may cause corrosion on tinplate
containers.

In case a pressure reducer is required, it must not be installed near the steam connection to the retort.

(Follow the same component line recommendation for the optional steam preheat connection, except the
check valve).

Water (Process Fill)

Components to be installed by the customer upstream the retort valve:

o 1 manual valve

o 1 water filter

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o 1 pressure gauge (0 - 10 bar)

o 1 check valve

o The process water is used inside the retort.

Water in contact with the containers must be chlorinated. Water treatment is recommended to minimize
the chloride (*) contents and to prevent scale deposits over the containers and spray nozzles.

(*) Attention: Chlorine is the main cause of stress corrosion cracking of austenitic stainless
steels.

Water (Cooling water supply to the heat exchanger)

Components to be installed by the customer upstream the retort valve:

o 1 manual valve

o 1 water filter

o 1 pressure gauge (0 - 10 bar)

Check the utility requirements documentation for reclaim line design.

Compressed Air

Components to be installed by the customer upstream the retort valve:

o 1 manual valve

o 1 check valve

Supplied compressed air does not require special treatment on the customer side. The supply air line to
the valves and pneumatic components is filtered and lubricated through components supplied with the retort.
Class 3 ISO 8573-1:2001 quality guidelines are recommended.

Electrical Power

The electric installation must consider the machine requirements as well as local standards and ensure a
minimum supply fluctuation.

Actual power values must be within +/- 5% of the nominal value.

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Steam-air exhaust and water drain

All vent and draining pipework must be made of steel for temperatures up to 150 ºC (300 ªF) and 5 bar
(70 psig) pressure.

Pipework must be installed so that no counter pressure obstructs free venting or drain and must be over-
sized to minimize pressure drop.

Vent and drain lines must be ducted to places where they do not represent any hazard.

Local regulations must be permanently observed.

It is recommended to restrict access to the area next to the pipework, as there is risk of burning by con-
tact with hot pipes or in case of a leakage. Access should be limited to personnel with authorization for main-
tenance work.

SURDRY, S.L. 13/16

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UTILITIES
A-144
Metric English
STEAM
Valve size DN-65 2½”
101.5 – 116
Min and max supply pressure 7 – 8 bar
psig
Average consumption per cycle 440 Kg 969 lbs
Peak demand 1.760 Kg/h 3,881 lbs/h
CONDENSED STEAM DRAIN
Valve size DN-50 2”
Maximum exit temperature 140 ºC 284 ºF
Maximum exit pressure 4 bar 58 psig
Average drain volume per cycle 374 l 82 gal
RETORT PROCESS WATER INLET
Valve size DN-40 1½”
Min and max supply pressure 4 – 6 bar 58 – 87 psig
Volume 592 l 130 gal
Consumption per cycle 160 l 35 gal
RETORT PROCESS WATER DRAIN
Valve size DN-50 2”
Maximum exit temperature (approx.) 50 ºC 122 ºF
Normal exit pressure 0 bar 0 psig
COOLING WATER
Valve size DN-50 2”
Min and max supply pressure 4 – 6 bar 58 – 87 psig
3
Max flow through PHE 40 m /h 176 gpm
Pressure drop 0,3 bar 4.4 psig
Maximum temperature 25 ºC 77 ºF
6 Million
PHE power 1.755 Kw
BTY/h
COMPRESSED AIR
Valve size DN-25 1”
Min and max supply pressure 6 – 10 bar 87 – 145 psig
3
Average consumption per cycle 20 Nm 760 SCF
Peak demand 1.030 l/min 39.2 CFM
ELECTRICITY
400 V 50
Standard EU specification 400 V 50 Hz
Hz
Maximum installed power 9,5 Kw 13 HP

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RECOMMENDED PROPERTIES OF THE RETORT PROCESS

WATER

- pH 7 - 8,8

- Total hardness (ºD) 0,5 - 25

- M-alkalinity (ppm CaCO3) max. 350

- Chloride (ppm) max. 200

- Free chlorine (ppm) 0 – 1,5

- Iron (ppm) <1,5

- Manganese (ppm) <0,1

- Colony building (CBU/ml) <5.000

- Suspended solids minimal

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RECOMMENDED STEAM QUALITY

The utility requirement sheet indicates the quantity of steam that must be made available before the con-
trol valve of the retort. As the requirement calculation is made for dry saturated steam, any presence
of moisture, air or incondensable gases will result in loss of steam enthalpy and loss of heating power.

Therefore steam must be made available:

At the correct temperature and pressure

Free from air and incondensable gases

Clean

Dry

The use of steam bleeders, strainers and separators will help to provide good quality steam. Pipe design
and insulation are also important factors to supply dry steam and to prevent pipe hammer and subsequent
risk of component damage.

RECOMMENDED COOLING WATER QUALITY

The cooling water only passes through the plate heat exchanger affecting its components only.

Please check the heat exchanger instruction manual for water quality requirements or recommendations.

When the cooling water is recirculated through a cooling tower, the water quality specifications provided
in the manufacturer's instructions are usually more demanding than those for the heat exchanger special-
ly because of the biological hazards associated to cooling towers.

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