Exothermics Stainless Steel Heat Exchangers: 3/20/2015 Installation Guide 500
Exothermics Stainless Steel Heat Exchangers: 3/20/2015 Installation Guide 500
Exothermics Stainless Steel Heat Exchangers: 3/20/2015 Installation Guide 500
3/20/2015
This is the safety alert symbol. It is used to alert you to potential personal
injurt hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
2
Product Information - Startup Record
Model number
Serial number
Start-Up Date
Exhaust Volume Pressure Drop (” w.c.)
Exhaust Temperature (Inlet) (Outlet)
Supply Volume Pressure Drop (” w.c.)
Supply Temperature (Inlet) (Outlet)
3
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Table of Contents
Introduction............................................................................................................................... 5
Audience .............................................................................................................................. 5
Purpose................................................................................................................................ 5
Safety......................................................................................................................................... 6
Safety Warnings................................................................................................................... 6
Capabilities........................................................................................................................... 6
Operator Training ................................................................................................................. 6
Replacement Parts............................................................................................................... 6
Installation................................................................................................................................. 7
Stainless Steel ..................................................................................................................... 7
Airflow .................................................................................................................................. 7
Installation Sketches ............................................................................................................ 8
Equipment Operating Limits ................................................................................................ 8
Receiving the Exothermics Heat Exchanger ....................................................................... 9
Pre-Installation ..................................................................................................................... 9
Drainage Considerations ..................................................................................................... 9
Multiple Units ....................................................................................................................... 10
Filters ................................................................................................................................... 10
Insulation ............................................................................................................................. 10
Temperature Control............................................................................................................ 10
Installation............................................................................................................................ 10
Rigging the Heat Exchanger ................................................................................................ 11
Equipment Support Methods ............................................................................................... 11
Operation ............................................................................................................................. 12
Maintenance ........................................................................................................................ 12
Access Cover Removal Replacement ................................................................................. 13
Product Warranty ..................................................................................................................... 6
Material and Workmanship .................................................................................................. 7
Performance Warranty......................................................................................................... 7
Appendix ................................................................................................................................... i
Conversion Factors.............................................................................................................. i
4
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Introduction 1
Exothermics is an internationally known manufacturer of Audience
aluminum and stainless steel air to air heat exchangers.
The Exothermics heat exchanger is a static, plate type This manual has been written for people who are already
exchanger used to reclaim energy normally exhausted to familiar with all aspects of industrial heating equipment
atmosphere from waste air streams of buildings or design.
manufactured processes. The transfer of thermal energy
from one mass to the other occurs through the plate or These aspects are:
heat transfer media which separates the two air streams.
• Design/Selection
The Exothermics heat exchanger is principally used in a • Use
counter flow fashion to maximize the heat transfer or • Maintenance
effectiveness. The two air masses flow through the heat
exchanger in opposite directions. The exhaust airstream The audience is expected to have previous experience
enters the heat exchanger at the same end that the supply with this type of equipment.
air is discharged. Each airstream is separated into
distinct, totally isolated, alternating passages formed by Purpose
the fixed plates or membrane. The purpose of this manual is to make sure the installation
of a safe, effective, and trouble-free system is carried out.
In addition, each plate has a proprietary die formed
corrugation and wave pattern which increases the heat
transfer coefficient by causing a break-down of the
boundary layers. The increased turbulence achieved with
the Exothermics design yields a high heat transfer
coefficient and high efficiency for the heat exchanger.
5
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Safety 2
Important notices which help provide safe operation will
be found in this section. To avoid personal injury and
damage to the property or facility, the following warnings NOTICE
must be observed. All involved personnel should read this
entire manual carefully before attempting to start or ■ This manual provides information regarding the
operate this system. If any part of the information in this use of these heat exchangers for their specific
manual is not understood, contact Exothermics before design purpose. Do not deviate from any
continuing. instructions or application limits described herein
without written approval from Exothermics.
Safety Warnings
Operator Training
The best safety precaution is an alert and trained
WARNING operator. Train new operators thoroughly and have them
demonstrate an adequate understanding of the
■ The duct sections are likely to have HOT surfaces. equipment and its operation. A regular retraining schedule
Always wear the appropriate protective equipment should be administered to ensure operators maintain a
when approaching the heat exchanger. high degree of proficiency. Contact Exothermics for any
■ Exothermics products are designed to minimize needed site-specific training.
the use of materials that contain crystalline silica.
Examples of these chemicals are: respirable
crystalline silica from bricks, cement or other
masonry products and respirable refractory
ceramic fibers from insulating blankets, boards, or
gaskets. Despite these efforts, dust created by
sanding, sawing, grinding, cutting and other
construction activities could release crystalline
silica. Crystalline silica is known to cause cancer,
and health risks from the exposure to these
chemicals vary depending on the frequency and
length of exposure to these chemicals. To reduce
the risk, limit exposure to these chemicals, work in
a well-ventilated area and wear approved personal
protective safety equipment for these chemicals.
6
Installation 3
Stainless Steel
Bolted or Stainless Steel
Special Welded
The stainless steel heat exchanger (SP) is manufactured Supply Membrane Wide Plate
Spacing
3” Structural Covers
with a stainless steel membrane and stainless steel Angle Flanges (1/2”)
casing. The unit is fully welded in its construction with no
sealants used. The stainless unit is available for different Fully
Welded
temperature ranges up to 1200°F (649°C) and up to 27" Primary
w.c. (67.3 mbar) differential pressure. Various stainless Seal
alloys are available for different temperatures or
applications.
The stainless steel (SP-HT) model, designed for operation Figure 3.1.
up to 1000°F (538°C) and 27" w.c. (67.3 mbar) differential
pressure is manufactured using an all stainless steel, fully Airflow
welded membrane. The primary seal is fully welded to a
stainless steel 3" (76 mm) structural angle. The remaining Airflow Configuration: The Exothermics heat exchanger is
3" (76 mm) structural steel angles are of mild steel. designed for counter flow operation. The standard
configuration has the exhaust air on the straight through
The stainless steel (SP-VT) model, designed for operation passage with the supply air flowing through the “U”
up to 1200°F (649°C) and up to 27" w.c. (67.3 mbar) passage.
differential pressure is manufactured of all stainless steel
This includes the fully welded membrane, fully welded Where contaminated exhaust is involved, the straight
primary seal, casing and structural angles. through passage should be used for the exhaust air. On
very high temperature applications, the hot side should be
the straight through passage.
7
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Air Flow Schematics
IU UU LU LL
Standard Optional
Figure 3.2.
Materials of construction and all dimensions for optional flow arrangement connections are the same as shown on the
standard flow (IU) drawing.
Installation Sketches Equipment Operating Limits
Differential
CAUTION Unit Model Temp.
Pressure
SP-HT/ 1000°F 27” w.c.
■ The heat exchanger must be installed so that the
plates are vertical. 304 Stainless HP-HT (538°C) (67 mbar)
Steel SP-VT/ 1200°F 27” w.c.
HP-VT (649°C) (67 mbar)
NOTES:
1.Differential pressure is the maximum pressure
measured in the exhaust air stream as compared to the
Unit Horizontal Unit Horizontal maximum pressure measured in the supply air stream.
“U” Pass Down “U” Pass Up
Membrane Vertical Membrane Vertical Example: Exhaust Air Stream -6” w.c.
Recommended Acceptable (highest measurement) (-15 mbar)
Supply Air Stream -4” w.c.
(highest measurement) (-10 mbar)
Differential Pressure Equals 2” w.c.
(5 mbar)
Example: Exhaust Air Stream -6” w.c.
(highest measurement) (-15 mbar)
Supply Air Stream 4” w.c.
(highest measurement) (10 mbar)
Unit Vertical Unit Horizontal
“U” Pass On Side “U” Pass On Side Differential Pressure Equals 10” w.c.
Membrane Vertical Membrane Horizontal (25 mbar)
Acceptable NOT Acceptable
2.Protection is recommended to assure that maximum
differential pressure is not exceeded under any
Figure 3.3.
conditions.
NOTE: Provide drains in ductwork for condensation
drainage.
8
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Receiving the Exothermics Heat Exchanger options selected, and whether a wash system is included.
Exothermics recommends vertical installation when the
Immediately upon receiving shipment, equipment should airstream is heavily laden with contaminants. Under these
be inspected for evidence of any damage received in conditions, the air stream has a considerable amount of
transit. If shipping damage has occurred, a claim should liquids entrained which can condense when a wash
immediately be filed with the transportation company. system is used. Where the unit is installed in a horizontal
manner, it should be pitched to allow condensate drainage
Equipment received should also be inspected for to the exhaust discharge end and drainage provided in the
compliance with original order. ductwork connection.
Handling the Unit Upon Receipt NOTE: Where the Exothermics wash option is used, the
Exothermics typically ships heat exchangers attached to a heat exchanger must be installed in a vertical position.
wood pallet using metal straps or metal angles bolted
securely in place. Check to ensure the straps or metal
Ductwork and Transitions
angles are secure before handling with a forklift. When The efficiency of the heat exchanger can be adversely
lifting the unit with a forklift, make certain the forks are affected by poor airflow distribution, therefore,
aligned to the pallet so no damage occurs to the heat Exothermics recommends that proper consideration be
exchanger. If for some reason the heat exchanger must given to transitions and/or elbows to assure uniform
be handled without the wood pallet, lift the unit by inserting airflow entering and leaving the heat exchanger. Where
the forks in the space between the supply air inlet and the space limits transition design or where elbows are
outlet flanged openings (referred to as the “U airflow” attached to the heat exchanger, it is recommended that
passages). Good practice incorporates safety procedures turning vanes be used. It is important that ductwork
when handling large equipment. connections or elbows be in the same orientation as the
heat exchanger plates (membrane). Avoid airflow
arrangements that cause air to enter or discharge at right
CAUTION angles (perpendicular) to the plates.
Drainage Considerations
■ Use caution when handling or lifting the heat
exchanger to avoid causing any damage to the It is recommended that provisions be made in the
heat transfer membrane. installation to facilitate drainage if condensation can occur
from moist air streams and to allow drainage of wash
Uncrating the unit requires that the metal straps and/or system fluids. These provisions are to be provided in the
bolts, which attach the heat exchanger to the wood pallet, exhaust discharge ductwork connection.
be removed. This should be followed by the removal of the
plywood covers on the exhaust inlet and outlet flanges.
The plywood covers are held in place with metal clips.
Storage
If the unit is to be stored prior to its installation,
Exothermics suggests the plywood end covers be
reinstalled and the unit be refastened to its wood pallet.
Pre-Installation
As with any mechanical equipment or component, proper
consideration given to arrangement, installation and
0.75” pitch
application will maximize the benefits and results from its per 12” of
use. unit length
9
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Horizontal Installation 4.Exothermics recommends that the drain piping be
constructed using fittings for cleanout purposes. If
Exothermics recommends that the heat exchanger be freezing can occur in the drain system, it is
pitched 0.75” (19 mm) per 12” (305 mm) of unit length recommended that heat tracing and insulation that is
toward the exhaust exiting (cooler) end if the air stream compatible with surrounding environment be used.
contains a substantial volume of condensibles or is
Multiple Units
heavily laden with contaminants.
When installing multiple units, be sure that mixing boxes
Vertical Installation and plenum designs are sufficient to assure even
Exothermics recommends that where a substantial distribution of the air streams.
volume of condensibles or where the air stream is heavily
laden with contaminants that the exhaust entering Filters
connection to the heat exchanger be made at the top so The Exothermics heat exchanger is unique in its design in
air flows downward through the heat exchanger. that the combination of the wide plate spacing (up to 1/2”
(12.7 mm) and access to the exhaust and supply sides,
facilitates total cleanability. On exhaust air streams that
are extremely dirty with lint, dust or other particulate,
Exhaust
Entering
Exothermics recommends the installation of filters to
reduce cleaning frequency.
Insulation
Exothermics heat exchangers do not require insulation
unless they are in a high temperature application where
personal safety is a concern, or if it is desirable to keep
heat losses to a minimum.
Counter Flow
Supply / Temperature Control
Make Up Air
Connections Supply air temperature and exhaust air temperature can
be controlled with the use of various bypass ducts and
control damper assemblies. In some cases an auxiliary
heat source is used to elevate supply air stream
Exhaust temperature to required levels.
Exit
10
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
occur at these locations, a gasket material should be Equipment Support Methods
selected that is compatible with the temperature and
environmental concerns of the installation. 3/8” Diameter
Rod (minimum)
Rigging the Heat Exchanger Unit Width Plus
Horizontal Unit 8” (203 mm)
Slings
Spreader
Bar
6” (152 mm)
Channel
(Minimum)
Figure 3.6.
Figure 3.8. Vertical
11
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
NOTES: Maintenance
1.Installation should take the removable access covers
into consideration and facilitate their removal. The Exothermics heat exchanger is a high quality, static
device with no moving parts and requires little or no
2.Where a wash system is to be used, the heat electromechanical maintenance. Periodic inspection and
exchanger must be installed in the vertical position. cleaning of the heat transfer surface is made easy by
Exothermics’ unique access cover design. Once installed
Operation in accordance with Exothermics recommendations and
Startup good ventilation/ engineering practices, periodic
inspection and routine preventive maintenance will assure
long term satisfaction from the use of the heat exchanger.
CAUTION
Access Cover Removal Replacement
■ System fans must be started at the same time and
control dampers must be open to assure that
excessive pressure differential does not occur at
startup.
After the air handling system has been started up, the Figure 3.3.
following operation measurements should be made:
Exhaust: STAINLESS STEEL (HT & VT)
• Entering exhaust temperature and static pressure Stainless steel (HT & VT) heat exchangers have the
• Exiting exhaust temperature and static pressure access covers installed on a flanged mounting surface.
The flanged mounting surface is welded to the heat
• Exhaust air volume in CFM (Nm3/h).
exchanger casing and has threaded studs welded in place
Supply: to secure the access cover. The access cover assembly is
a sheet having flat bars welded in place and holes
• Entering supply temperature and static pressure
punched to align with the flanged mounting surface’s
• Exiting supply temperature and static pressure threaded studs. The seal between the flanged mounting
• Supply air volume in CFM (Nm3/h). surface and the access cover is a high temperature
gasket material. The access cover is secured in place with
These measurements should be recorded and referred to washers and nuts. Removal of these access covers
when initiating a preventative maintenance schedule. requires that the fasteners be disassembled and the cover
assembly be removed from the flanged mounting surface.
NOTE: When an in-place wash system is installed, the Prior to reassembling these access covers, the high
heat exchanger must be installed in the vertical position. temperature gasket should be inspected and replaced if
required. Assembly is the reverse of the above.
DETERGENTS
Detergents and cleaning solutions are selected at the If you require additional information or assistance, please
discretion of the user. Exothermics suggests that the contact your Exothermics representative or our home
cleaning fluid, be compatible with the materials of office at any time.
construction of the particular heat exchanger, associated
ductwork, and piping.
12
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Product Warranty 3
Material and Workmanship: Performance Warranty:
Manufacturer warrants that the equipment proposed Performance figures or requirements, if any, must be
herein of their manufacture shall be free of defects in addressed in the quotation. Performance warranty, if any,
workmanship or materials for a period of one year from must be specifically covered in the quotation. Where no
date of shipment. Should any failure or defect appear performance figures are specified or warranted the
within one year of date of shipment, manufacturer shall manufacturer assumes no responsibility for compliance or
upon written notification of said failure and substantiation noncompliance.
that the equipment has been stored, installed, erected,
maintained, and operated in accordance with good THE FOREGOING WARRANTIES ARE EXCLUSIVE
industry practice and in accordance with manufacturer's AND IN LIEU OF ALL OTHER WARRANTIES, EXCEPT
instructions, correct such non-conformity by repair or THAT OF TITLE, AND EXOTHERMICS-ECLIPSE
replacement, F.O.B. factory. This warranty does not cover HEREBY DISCLAIMS ALL OTHER WARRANTIES,
labor or transportation charges for the removal, exchange, WHETHER WRITTEN, ORAL OR IMPLIED, IN FACT OR
or reinstallation of the equipment. IN LAW (INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR
Manufacturer shall not be responsible, nor shall allowance PURPOSE).
be made, for work done, equipment furnished, or for
repairs or replacements made by the purchaser or others, LIMITATION OF LIABILITY: IN NO EVENT SHALL THE
either with or without purchaser's approval, unless prior MANUFACTURER BE HELD RESPONSIBLE OR
written approval is made to the purchaser by the LIABLE ON ANY CLAIM WHETHER IN CONTRACT,
manufacturer. Any unauthorized repairs or parts will void TORT, NEGLIGENCE, STRICT LIABILITY, WARRANTY
the warranty. OR OTHERWISE FOR ANY SPECIAL, INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES
Products or goods manufactured by others, supplied by RESULTING FROM THE PURCHASE OF SAID
Exothermics, Inc. as a part of a system, are not covered EQUIPMENT, INCLUDING BUT NOT LIMITED TO
by this warranty. Exothermics, Inc., however, will give their INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR
customer the benefit of any such adjustment as it finally LABOR, LOST PROFITS, LOST PRODUCTION, LOST
obtains from that respective manufacturer of that SALES, INJURY TO PERSON OR PROPERTY OR ANY
component or product. OTHER INCIDENTAL LOSS OR DAMAGE.
Freight damage is specifically excluded from this warranty THE REMEDIES OF THE PURCHASER SET FORTH
and is the responsibility of the purchaser and the carrier. HEREIN ARE EXCLUSIVE AND THE LIABILITY OF THE
MANUFACTURER WITH RESPECT TO ANY
Damage as a result of the effect of corrosion, erosion, CONTRACT, OR ANYTHING DONE IN CONNECTION
excessive heat, freezing, dirt, dust or foreign materials, THEREWITH, OR FROM THE MANUFACTURE, SALE,
and normal wear for that application are specifically DELIVERY, INSTALLATION OR USE OF SAID
excluded from this warranty. EQUIPMENT COVERED BY OR FURNISHED UNDER
THIS PROPOSAL AND CONTRACT WHETHER IN
CONTRACT, TORT, WARRANTY, STRICT LIABILITY,
OR OTHERWISE, SHALL NOT EXCEED THE
PURCHASE PRICE ACTUALLY RECEIVED BY THE
MANUFACTURER FOR THE EQUIPMENT IN
QUESTION.
13
Exothermics Stainless Steel Heat Exchangers, Installation Guide 500, 3/20/2015
Appendix
Conversion Factors
Metric to English
From To Multiply By
actual cubic meter/h (am³/h) actual cubic foot/h (acfh) 35.31
normal cubic meter/h (Nm³/h) standard cubic foot /h (scfh) 38.04
degrees Celsius (°C) degrees Fahrenheit (°F) (°C x 9/5) + 32
kilogram (kg) pound (lb) 2.205
kilowatt (kW) Btu/h 3415
meter (m) foot (ft) 3.281
millibar (mbar) inches water column ("w.c.) 0.402
millibar (mbar) pounds/sq in (psi) 14.5 x 10-3
millimeter (mm) inch (in) 3.94 x 10-2
MJ/Nm³ Btu/ft³ (standard) 26.86
Metric to Metric
From To Multiply By
kiloPascals (kPa) millibar (mbar) 10
meter (m) millimeter (mm) 1000
millibar (mbar) kiloPascals (kPa) 0.1
millimeter (mm) meter (m) 0.001
English to Metric
From To Multiply By
actual cubic foot/h (acfh) actual cubic meter/h (am³/h) 2.832 x 10-2
standard cubic foot /h (scfh) normal cubic meter/h (Nm³/h) 2.629 x 10-2
degrees Fahrenheit (°F) degrees Celsius (°C) (°F - 32) x 5/9
pound (lb) kilogram (kg) 0.454
Btu/h kilowatt (kW) 0.293 x 10-3
foot (ft) meter (m) 0.3048
inches water column ("w.c.) millibar (mbar) 2.489
pounds/sq in (psi) millibar (mbar) 68.95
inch (in) millimeter (mm) 25.4
Btu/ft³ (standard) MJ/Nm³ 37.2 x 10-3
i
Notes
ii