USER MANUAL

KLIMA
ELEMENT
WITH REMOVABLE COVERS
Supplier information:

Homepage:
www.Klima.com

The Netherlands:
VDL Klima b.v.
Meerenakkerweg 30
5652 AV Eindhoven
P.O. Box 300
5600 AH Eindhoven
Telephone: +31 (0)40-2981818
Telephone service: +31 (0)40-2981858
Fax: +31 (0)40-2981800
E-mail info@klima.com

Supplier Belgium:
Klima Belgium n.v.
Leuvensesteenweg 49c
1932 Zaventem
Telephone: +32 (0)2-7206026
Fax: +32 (0)2-7203407
E-mail Klima.belgium@klima.com

Supplier Belgium:
Klima warmtetechniek n.v.
Buitenheide 4
3930 Hamont-Achel

Supplier France:
VDL Klima France s.a.r.l.
Chateau Rouge - 276
Avenue de la Marne
59708
Marcq-en-Baroeul
Telephone: +33 (0)320-65-91-65
Fax: +33 (0)320-65-91-60
E-mail Klima.france@klima.com

Publication: 27.03.2006

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Table of Contents

1 General Information........................................................................... 4
1.1 Product Information ................................................................ 4
1.2 Installation Composition ......................................................... 5
1.3 Prohibitions to (putting into) Operation ................................... 6
1.4 Guarantee .............................................................................. 6
2 Safety ................................................................................................ 7
2.1 General Safety ....................................................................... 7
2.2 Protection: .............................................................................. 8
3 Transport, Storage and Installation Site. ........................................... 9
3.1 Instructions for Transport and Hoisting................................... 9
3.2 Transport and Packaging ..................................................... 10
3.3 Storage:................................................................................ 10
3.4 Installation Siting: ................................................................. 11
4 Installation ....................................................................................... 12
4.1 Safety Measures and Facilities on the Heat Exchanger /
Installation. ...................................................................................... 12
4.2 Preparation for Installation ................................................... 13
4.3 Installation ............................................................................ 14
4.4 Tightening of the Bolts.......................................................... 14
5 Start-up............................................................................................ 15
5.1 Inspection before putting the unit into operation................... 15
5.2 Filling and Venting................................................................ 15
5.2.1 Filling a heat exchanger compartment with a liquid.............. 15
5.2.2 Filling a heat exchanger compartment with a gas. ............... 15
5.3 Re-tightening of the Bolts. .................................................... 16
5.4 Inspection after Start-up: ...................................................... 16
5.5 Shut Down of the Installation:............................................... 16
6 Maintenance and Inspection:........................................................... 17
6.1 Inspection ............................................................................. 17
6.2 Cleaning of the Heat Exchanger........................................... 18
6.2.1 Disassembly of the Heat Exchanger. ................................... 18
6.2.2 Cleaning the Heat Exchanger .............................................. 20
6.2.3 Assembly of the Heat Exchanger. ........................................ 20
6.2.4 (Re)pressurising of the Heat Exchanger. ............................. 21
7 Malfunctions / Trouble-Shooting Guide ........................................... 22
7.1 Identification and Correction of Malfunctions....................... 22
7.2 Safety Measures / Facilities: ................................................ 23
8 Customer Service: ........................................................................... 24
8.1 Ordering Spare Parts ........................................................... 24
8.2 Complaints Procedure:......................................................... 24
9 Accessories / Annexes: ................................................................... 25
9.1 Instructions for Transporting and Hoisting. ........................... 25
9.2 General Information about Material and Mediums................ 25
9.3 Technical Specifications / Documentation ............................ 27

3
1 General Information
Pictograms used in this manual

Dangerous situation with possibility of personal injury as well

as damage to the equipment.

Reference to tips, comments and supplements with regard to

using the equipment.

The general standards apply to symbols that are applied to the installation by
the owner.

This manual supplies information and instructions for the correct and safe
use of the device.
Many accidents are the result of incorrect use.
Instructions in this manual must therefore always be followed.
The safety instructions must also always be observed when work is done on
the equipment.
The complete manual must be carefully read.
If, after reading this manual, questions still exist, you must contact the
supplier / contractor for more information.

The installation may NOT be put into operation before all

unclear issues have been resolved.

1.1 Product Information

Product : Element with removable covers
Type : See Technical Specification Sheet or type plate

Elements with removable covers are primarily used in installations for

exchanging heat between a liquid and a gas, using a medium in the tubes
from which internal fouling is expected.
The removable cover makes it possible to clean the heat exchanger
mechanically.
These heat exchangers are often built into so-called air-water coolers in
order to eliminate the excess heat produced by the electromotor. The hot air
flows past the finned tubes that give off the heat to the cooling water running
through the tubes.

4
1.2 Installation Composition

Fig. 1

1. Medium supply (heating) / Medium return (cooling)

2. Medium supply (cooling) / Medium return (heating)
3. Element
4. Connecting flange
5. Valve
6. Compensator
7. Pipe
8. Vent and drain
9. Leak indicator

5
1.3 Prohibitions to (putting into) Operation

It is Prohibited to operate the Unit beyond Design Conditions

The equipment is designed according to the design parameters as

stated in the enclosed technical specification sheet. If these parameters
are exceeded then it is PROHIBITED to put the installation into operation
without prior consultation with the manufacturer.
Moreover all continued use in such a non-design situation is considered
contrary to the regulations. The manufacturer is not liable for any
material damage or personal injury that results from further use : this
risk is solely the responsibility of the owner / user.

Klima has advised in the choice of materials, the user remains responsible
for the media used with regard to corrosion. Some information on materials
and mediums that Klima has collected during many years of experience can
be found in Chapter 9.2. This is purely informative. The user remains
responsible for the mediums and materials that he uses.

1.4 Guarantee

Unless covered by a separate agreement, Klima guarantees the products

supplied by the company to be sound and in good working order, according
to the technical specifications, for a period of 6 months after being put into
operation, up to a maximum of 12 months after delivery.
The General Terms of Sale and Delivery can be requested from your
supplier.
Any damage and/or decrease in capacity due to non-observance of this user
manual are not covered by the guarantee.
The guarantee expires if any adaptations or changes are made to the heat
exchanger.
The equipment must always be inspected upon delivery for damage to the
equipment during transport.
The manufacturer must immediately be notified of any damage during
transport.

6
2 Safety

2.1 General Safety

Physical injuries
Physical injuries can be caused by:
• Burning, by touching the heat exchanger or other parts of
the installation.
• The accidental release of a medium under pressure,
which presents a risk for burns and other injuries
because of the high pressure.
• Contact with escaping chemicals.
• Contact with the fins or other sharp parts of the
installation.

Damage to the equipment

Damage to the equipment can be caused by:
• External forces.
• Corrosion.
• Chemical corrosion.
• Erosion.
• Fatigue.
• Steam shock.
• Pressure / temperature too high.
• Impact load.
• Freezing.
• Transport

For transport See: Instructions for Transport and Hoisting

If handled incorrectly there is a risk for physical injury and/or
damage to the equipment.

Even after switching off the installation the heat exchanger

surface can still be hot.

The unit may only be fed with the mediums stated in the
technical specification sheet.

No fatigue analysis has been taken into account and therefore

the unit should only be used for static load.

7
 If a cold medium is present in the heat exchanger but is not
flowing whilst a hot medium is flowing through the heat
exchanger, then the cold medium may start boiling and the
heat exchanger will be damaged.

Sudden changes in pressure and temperature must be

avoided.

The values stated in the technical specification sheet must not

be exceeded.

This manual describes other safety instructions than those

safety instructions related to the chapter in which they occur.
The complete manual must therefore be read to be aware of
all safety provisions and measures to be taken when using
this installation.

Danger of freezing. When an idle heat exchanger (filled with

water or a water mixture not of an anti-freeze type ) is
exposed to temperatures below zero, the pipes can burst and
the cover can be deformed. In cases where a danger of
freezing may exist all of the medium must be drained from the
heat exchanger.

2.2 Protection:
For the protection of others place the heat exchanger out of reach, in a
closed space, e.g. a boiler house, only accessible to authorised staff
acquainted with the safety requirements applying to the equipment stored
there.
If the heat exchanger is set up close to people, presenting a risk of burns,
insulation of the heat exchanger is mandatory.
The user must take care to provide adequate danger signs on exposed un-
insulated parts of the installation, which present risk of burns or other injury
and/or damage.

8
3 Transport, Storage and Installation Site.

3.1 Instructions for Transport and Hoisting

Fig. 2

9
3.2 Transport and Packaging

For transport see: Instructions for Transport and Hoisting

Always use the appropriate hoisting facilities and equipment.

Respect the prescribed safety norms and regulations.

If handled incorrectly, danger for physical injury and/or

damage to the equipment exists

Any packaging must be removed carefully and disposed of in

an environmentally friendly way.

3.3 Storage:
The device must be stored covered and dry.
Long-term storage from 2 to 24 months requires airtight sealing of the device
adding an absorbent material e.g. silica-gel, or filling with inert gas.
Storage longer than 6 months requires inspection of the seals and possible
replacement before the device is put into operation.

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3.4 Installation Siting:

Fig. 3
We certify that the heat exchanger with the CE-sign on the
type plate satisfies the EC-directives of the EC-pressure
equipment 97/23/EC. See Fig. 3

General conditions on installation siting / location should satisfy:

• Sufficiently firm and level ground or construction, adapted to the load
that is expected.
• Sound construction and vibration-free installation of the device.
• See the technical specification sheet for product-related information.
• Protect if necessary against possible damage by e.g. internal transport.
The fins especially need to be protected in such a manner that there is
no risk that they will be damaged.
• For safety in general see chapter 2.2 under “Safety”.
• The location where the equipment is placed must have enough space
for installation, maintenance and cleaning. See the relevant chapters.
• The unit is anti seismic to maximum earthquake intensity in accordance
with Eurocode 8.

11
4 Installation
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
installer.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.

4.1 Safety Measures and Facilities on the Heat

Exchanger / Installation.
Installation must be carried out in such a manner that all likely risks are
excluded.
To achieve this, the following points must at least be observed:
• The necessary fittings must be attached so that filling and emptying the
equipment can take place safely.
• The installation must be fitted with adequate drainage and venting
facilities.
• There must be sufficient valves in the supply and return pipes, close to
the heat exchanger, so that the whole system does not have to be
drained if work needs to be carried out. .
• A pressure-limiting device must be fitted, adjusted to the maximum
pressure allowed for in the design and registered on the type plate.
• A temperature-limiting device must be placed in the circuit to protect
against excessive temperatures.
• The fitting of inspection and checking facilities such as temperature and
pressure gauges.
• For heat exchangers using steam as a medium one must ensure that
they are fitted with a correctly functioning system for condensate
drainage.
• For the choice of a steam trap and other fittings it is advisable to seek
advice from the suppliers.

12
4.2 Preparation for Installation
General:
• For a heat exchanger with removable covers there must be sufficient
space available around the covers of the heat exchanger to facilitate
problem-free disassembly of these covers.
• For heat exchangers that have removable covers ensure that there is
enough space so that the brushes used for mechanical cleaning can be
employed without problem. (see fig. 4, distance X).

Fig. 4
• Remove the plastic caps from the connecting holes.
• Before the heat exchanger can be connected, the tubes must be clean
so that no pollutants can enter the unit.
• The gaskets used must be suitable for the medium, temperature and
pressure to be applied.
• The bedplate, construction and mounting must be of sufficient strength.
• Pressure impulses, pulsation’s and mechanical vibrations in the heat
exchanger should be avoided.

The design specifications, stated in the technical specification

sheet must always be respected. If the user deviates from
these values, the responsibility is his.

13
4.3 Installation
• The instructions for transport and hoisting must be observed when
placing or moving the equipment.
• During assembly of the piping all pipes / flanges must be mounted
stress-free to the heat exchanger.
• Pipes must be able to expand. If necessary compensators must be fitted
to the pipes.
• Bolt-nut connections must be clean and lightly oiled.
• Gasket used: reinforced graphite gasket 1,5 mm.

4.4 Tightening of the Bolts

The bolts of the removable covers must be tightened with a torque wrench
(for the torque and order of tightening see diagrams in Fig. 5).
Tightening of bolts must be done “diagonally” in at least four steps.

Bolt ø Torque Nm
Steel
Step 1 Step 2 Step 3 Step 4
M10 12 23 34 46
M12 20 40 60 79
M16 48 96 144 193

Bolt ø Torque Nm
Stainless Steel Step 1 Step 2 Step 3 Step 4
M10 10 20 30 40
M12 17 34 51 68
M16 42 85 127 170

Fig. 5

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5 Start-up
The assembly and start-up must be carried by a suitably
qualified person appointed by the buyer or by a qualified
installer.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.

5.1 Inspection before putting the unit into operation

As a rule the safety devices in the system to guard against excesses in
pressure and temperature must be properly adjusted and tested before start-
up. The entire circuit must also be inspected to check whether all
connections have been properly made.
All relevant safety regulations must be observed both before and during
start-up.

The unit has been tested by Klima in accordance with the test
pressure stated on the type plate

5.2 Filling and Venting.

5.2.1 Filling a heat exchanger compartment with a liquid.
Proceed as follows:
• Open vent.
• Slowly feed the medium.

If a cold medium is present in the heat exchanger but is not

flowing whilst a hot medium is flowing through the heat
exchanger, then the cold medium may start boiling and the
heat exchanger will be damaged.

• Ensure that all air has been allowed to escape from the unit.
• Allow the circuit to pressurise and open the return valve so the medium
can flow through.
• Check for leakage’s. In case of leakage see Chapter 7.

5.2.2 Filling a heat exchanger compartment with a gas.

Proceed as follows:
• Slowly feed the medium.
• Allow the circuit to pressurise and open the return valve so the medium
can flow through.
• Check for leakage’s. In case of leakage see Chapter 7.

15
5.3 Re-tightening of the Bolts.
The bolts on the connecting flanges must be re-tightened after the device
has cooled down for the first time.
See Chapter 4.4.

5.4 Inspection after Start-up:

After heating the heat exchanger for a certain period of time, all connections
must be inspected for leakage. In case of leakage they must be repaired.
See Chapter 7.
Check whether the settings of the measuring and control devices reflect the
expected values.

5.5 Shut Down of the Installation:

To shut down the heat exchanger the supply and return flows of the circuit
must be closed.

First close the supply of hot medium and then, only when the
heat exchanger has reached the temperature of the cold
medium, close the supply of the cold medium.

Danger of freezing.
When an idle heat exchanger (filled with water or a water
mixture not of an anti-freeze type) is exposed to temperatures
below zero, the pipes may burst and the covers may be
deformed. If there is a danger of freezing all the medium must
be drained from the heat exchanger.

Danger of corrosion.
When the heat exchanger (filled with a medium) is idle for
over 48 hours, all the medium must be drained from the heat
exchanger. Refer to chapter 3.3 for storage

16
6 Maintenance and Inspection:
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.

The owner must post warnings against environmental factors

that can pose a threat. Preferably using pictograms and/or
text.

The owner must enforce the wearing of protective clothing

and gloves by the personnel wherever necessary.

Maintenance, cleaning etc. must only take place on a shut-

down device.

Special measures apply for a shutdown device. See Chapter

5.5.

Depending upon operating conditions, maintenance should be carried out

every 1000 hours of operation or minimally 1x per year.

6.1 Inspection
To guarantee a high degree of operational reliability regular inspection of the
equipment by the maintenance and operating personnel is necessary for the
following:
• Fin surfaces damaged, dirtied or blocked.
• Leakage.
• Pressure and temperature within the permissible limits.
• Presence of air in a system where a liquid medium is being used.
• If applicable, the presence of adequate condensate drainage.
• Fouling of the heat exchanger (drop in capacity).
• Vibrations / strange noises.
• General condition of the installation.
• Corrosion.
• Functioning of the safety devices.
• Torque of the bolts.

17
6.2 Cleaning of the Heat Exchanger.

6.2.1 Disassembly of the Heat Exchanger.

(For Parts See Fig. 6.)

Proceed as follows:
• Close the supply and return flows of the circuit.
Firsts close the supply of hot medium and only when the heat
exchanger has cooled to the temperature of the cold medium
close the supply of the cold medium.

• Wait until the heat exchanger has cooled down!

• Drain the medium (vent open).
• Where necessary mark the position of the parts to be disassembled.
• Remove the supply and return pipes and disassemble the cover.

Beware! The covers must be supported during disassembly

due to the possible extreme weight of the covers.

Beware!
When disconnecting or disassembling the heat exchanger it is
possible that residual medium may seep from the heat
exchanger. To avoid damage to underlying parts or floor it is
necessary to catch the medium in, for example, a drip tray.

18
Fig. 6

1. Cover connecting side

2. Gasket connecting side
3. Tube bundle
4. Side wall
5. Fin package
6. Gasket return side
7. Cover return side
8. Bolt / nut
9. Leak indicator

19
6.2.2 Cleaning the Heat Exchanger

6.2.2.1 Chemical Cleaning

The heat exchanger can be cleaned by rinsing with a detergent or chemical
solvent. When using chemicals we advise you to contact a company that
specialises in chemical cleaning. Klima can if necessary advise you on this.
If chemicals are used the equipment (material) can be affected. Be
especially careful that the gaskets used are resistant to the chemicals used.

Beware! De leak indication space on double tube elements

may not be cleaned.

6.2.2.2 Mechanical Cleaning

Cleaning the Liquid Side of the Heat Exchanger.

Proceed as follows:

A heat exchanger with straight tubes can be cleaned internally with a special
brush. To do so the covers must be disassembled, See Point: “Disassembly
of the Heat Exchanger”. After cleaning, the tubes must be thoroughly rinsed
with a clean medium as noted in the technical specification sheet!

Cleaning the Gas Side of the Heat Exchanger.

Proceed as follows:

Blow the fins clean using compressed air in the opposite direction to the
normal airflow.
Take care that the fins do not deform.

6.2.3 Assembly of the Heat Exchanger.

• Make sure that all gasket faces are clean and undamaged.
• Always use new gaskets.
• Apply the gaskets.
• Assemble the cover (observe the marking!). See 4.4 for Torque
Specifications. For Start-Up See Chapter 5: “Start-up”.

20
6.2.4 (Re)pressurising of the Heat Exchanger.

Proceed as follows:
• Close the supply and return flows of the circuit.

First close the supply of hot medium and then, only when the
heat exchanger has cooled to the temperature of the cold
medium, close the supply of the cold medium.

• Drain the heat exchanger (vents open).

• Remove the supply and return pipes.
• Blind de cover flange with blind flanges.
• Fill the heat exchanger through a feeder with unheated, clean medium,
using the medium as specified in the technical specification sheet.
• Pressurise the system for 30 minutes (at room temperature) to the
design pressure as specified on the type plate.
• Inspect for leakage. See Chapter 7.
• Slowly de-pressurise the heat exchanger to atmospheric pressure.
• For assembly, See: “Assembly of the Heat Exchanger”.

21
7 Malfunctions / Trouble-Shooting Guide

7.1 Identification and Correction of Malfunctions.

Malfunction Possible cause Correction of the malfunction

Heat There is air in the Inspect the pipe work for

exchanger installation. possible air pockets.
has - Remove any air in the liquid.
insufficient - Then bleed the heat exchanger
capacity. thoroughly and if necessary fill
up the medium.
The operating conditions Adjust the operating conditions
deviate from those stated in to the specified / design
the technical specification conditions.
sheet.
The heat exchanger is Clean the heat exchanger (see
fouled. Chapter: Cleaning the Heat
Exchanger).
The connections have been Correct the connections.
interchanged.
The fins are dirtied or Clean and / or re-align the fins.
damaged.

22
Malfunction Possible cause Correction of the malfunction
Heat Gasket faces dirtied or Clean gasket faces. In case of
exchanger is damaged. damaged gasket faces, contact
leaking. your supplier.
Defective gasket. Replace gasket.
Bolt tightened insufficiently. Check the connection and
carefully re-tighten.
Defective tube. When a tube is defective it can
be blocked as an emergency
measure using conical plugs on
the inlet and outlet sides. This
may only be done after
consulting and obtaining
permission from Klima!
External forces. Assemble the installation to be
stress-free.
Defective tube – tube plate To replace a tube or to repair the
connection. heat exchanger: contact Klima’s
service department

7.2 Safety Measures / Facilities:

Facilities must be provided (ladders, steps, cat ways etc.) to be able to safely
reach all places to make adjustments and to perform maintenance and
repair.

23
8 Customer Service:

8.1 Ordering Spare Parts

When ordering spare parts it is important to provide the correct data.
One should at least state:
• Project and order number.
• Complete description of product / type (See Technical Specification /
type plate).
• Required part (for name see documentation).

8.2 Complaints Procedure:

For complaints, requirements, or imperfections of the device, please contact
Klima, or your supplier’s, service department.

24
9 Accessories / Annexes:

9.1 Instructions for Transporting and Hoisting.

See Chapter 3.1

9.2 General Information about Material and Mediums

This data has been collected through years of experience and is merely
indicative and for information. The user of the unit remains responsible for
the mediums and materials he uses with regard to corrosion etc.

For your information

Materials: Medium velocity:
Minimum Maximum
Steel 1.0 m/s 3.0 m/s
Copper 1.0 m/s 1.5 m/s
Stainless Steel 316L 1.0 m/s 3.0 m/s
CuNi10 1.0 m/s 2.0 m/s
CuNi30 1.0 m/s 3.0 m/s

Flue gas:
Combustion gasses must be free of pollutants, for example a sulphur level of < 10
mg/m³ and a chloride level of < 1 mg/l.

Chemical value for neutral water (fresh water).

pH –value : 7< pH.< 11
Chloride level 10 - 50 mg/l at 80ºC
< 250 mg/l at 40ºC
Ammonium level NH3 = 0
Hardness (calcium) maximum:
40 French degrees or 22 German degrees at 40ºC -Æ 400 ppm
1 French degree or 0.5 German degree at 80ºC (softened water) --Æ 10 ppm

Material values:
Stainless Steel:
AISI 304(L), 316(L), DIN17440 14306,14404
Danger from: -Stress corrosion by chlorides at temp. > 70ºC (maximum 10-50 mg/l
Chloride) and stress in the material.
-Biological corrosion from stagnant water.

Copper and copper alloys:

Sf-Cu, CuNi10, CuNi30, CuZn38SnAl
Danger from: - Ammonium compounds
- Low strength at high temperatures.
- Electroplated corrosion on carbon steel.

Steel: St.35.8, P265GH,

Danger from: -General corrosion
-Pitting corrosion by oxygen 02 and CO2
-Stress corrosion (lye pH < 8)

25
Maximum value
Steel Stainl.St.316L Copper alloys
Ammonium NH4 0.00 oz/l 10-50 mg/l 250 mg/1
Ammonium NH4 10 mg/l 0.00 oz/s
PH-value >8 6-8 6-8

26
9.3 Technical Specifications / Documentation
Technical specification sheet must be added here.

27