SPX Votator II Bedienungsanleitung

FPO

INSTRUCTION MANUAL

Votator®II

SCRAPED SURFACE HEAT EXCHANGER

FORM NO.: 95-03057 REVISION: 11/2012 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.

Information contained in this manual is subject to change

without notice and does not represent a commitment on the

part of SPX Corporation. No part of this manual may be

reproduced or transmitted in any form or by any means,

electronic or mechanical, including photocopying and

recording, for any purpose, without the express written per-

mission of SPX Corporation.

Revision Date: 11/2012

Publication: 95-03057

SPX Flow Technology

611 Sugar Creek Road

Delavan, WI 53115 USA

Tel: (800) 252-5200 or (262) 728-1900

Fax: (800) 252-5012 or (262) 728-4904

E-mail: [email protected]

Web site: www.spx.com

11/2012 95-03057 Page 1

Waukesha Cherry-Burrell Table of Contents

Warranty ......................................................................................................4

Shipping Damage or Loss ...........................................................................4

Warranty Claim ............................................................................................4

Safety ..........................................................................................................5

Care of Stainless Steel ..............................................................................6

Stainless Steel Corrosion ............................................................................6

Elastomer Seal Replacement Following Passivation ..................................6

Introduction ................................................................................................7

Models and Specifications ...........................................................................7

Cylinder Assembly .......................................................................................7

Product Side Pressure Rating .....................................................................7

Jacket Pressure Rating ...............................................................................7

Machine Serial Number ...............................................................................7

Votator II Media Configurations ...................................................................8

Special Considerations for Vertical Votator II ..............................................8

Installation ..................................................................................................9

Site Selection Considerations .....................................................................9

Foundation & Drainage ..............................................................................9

Clearances ..................................................................................................9

Leveling the Unit ..........................................................................................9

Electrical Power Connections ......................................................................9

Mutator Rotation Check ...............................................................................10

Mechanical Seals .......................................................................................10

Single Mechanical Seal .............................................................................10

Double Mechanical Seal ............................................................................10

2005 Mechanical Seal Design ...................................................................11

2012 Mechanical Seal Design ...................................................................11

Flush Fluid Requirements ..........................................................................12

Piping ..........................................................................................................12

Guidelines for Piping ..................................................................................12

Suggested Media Piping for Steam .............................................................12

Suggested Media Piping for Water or Liquid ...............................................13

Refrigeration Piping Installation ...................................................................14

Liquid Line Installation ...............................................................................14

Suction Line Installation .............................................................................14

Hot Gas Line (if required) ..........................................................................14

Pressure Relief Line ..................................................................................14

Refrigeration Valves ....................................................................................15

Liquid Feed Solenoid Valve .......................................................................15

Dual Pressure Regulating Valve ................................................................15

Sporlan Level Master Control (LMC) or Level Switch ................................15

Refrigerant Return Valve ...........................................................................15

Flow Control Valves ...................................................................................15

Hot Gas Pressure Regulating Valve ..........................................................16

Pressure Relief Valve ................................................................................16

Suggested Media Piping for Liquid Over Feed Refrigeration ......................16

Suggested Media Piping for Gravity Refrigeration ......................................17

Electrical Equipment ....................................................................................19

Refrigeration Wiring Schematics .................................................................20

Freeze Protection Components .................................................................20

Gravity Refrigeration with Level Master Control (LMC) .............................21

Gravity Refrigeration with Level Switch .....................................................22

Liquid Overfeed Refrigeration System .......................................................23

Media System Check ..................................................................................24

Page 2 95-03057 11/2012

Table of Contents Waukesha Cherry-Burrell

Special Considerations for Vertical Votator II ..............................................24

Minimum Height - Vertical Votator II ...........................................................24

Mounting Pole - Vertical Votator II ..............................................................24

Mounting Scrape Cylinders - Vertical Votator II ..........................................25

Hydraulic System - Vertical Votator II .........................................................25

Check and Adjust Hydraulic Cylinder ........................................................ 25

Fill Hydraulic Reservoir ............................................................................. 25

Check Balance and Pressure Settings ...................................................... 26

Gravity Refrigeration System - Vertical Votator II .......................................27

Typical Dimensional Data and Hydraulic Lift System ..................................28

Votator II General Assembly ..................................................................... 28

Horizontal Refrigeration Assembly ............................................................ 29

Vertical Refrigeration System .................................................................... 30

Horizontal Frame Options ......................................................................... 31

Vertical Mounting Pole/Hydraulics ............................................................ 32

Vertical Hydraulic Schematic .................................................................... 33

Operation .................................................................................................... 34

Pre-Startup Check .......................................................................................34

For Refrigeration Units Only ...................................................................... 34

Pre-production Run Setup ...........................................................................34

Startup Procedure .......................................................................................35

Heating/Liquid Cooling Applications .......................................................... 35

Refrigeration Applications - Pumped and Gravity Systems ...................... 35

Shutdown Procedure ...................................................................................36

Preventing Tube Scoring .............................................................................36

Maintenance ............................................................................................... 37

Routine Maintenance Checklist - Vertical Votator II ....................................37

Routine Maintenance Checklist - Horizontal Votator II ................................38

Scheduled Maintenance ..............................................................................40

Preventive Maintenance ..............................................................................41

Mutator Shaft Bearing .................................................................................41

Extra Heavy Duty Votator II Shaft Bearing ................................................ 41

Shafts ..........................................................................................................42

Gear Drive ...................................................................................................42

Blades .........................................................................................................42

Mechanical Seals ........................................................................................42

Tubes ..........................................................................................................42

Care of Heat Exchanger Tube ....................................................................43

Product Side ................................................................................................44

Inspection of Chrome Plated Nickel or Stainless Steel Tubes ....................44

Inspection of Stainless Steel Tubes ............................................................44

Jacket Side ..................................................................................................45

For Units Using Steam, Water, Or Liquid .................................................. 45

For Units Using Refrigerant ....................................................................... 45

Cleaning the Flanges ..................................................................................45

Leak Testing ................................................................................................45

Scraper Blade Maintenance ........................................................................45

Blade Inspection ........................................................................................ 45

Scraper Blade Removal & Replacement ................................................... 46

Scraper Blade Wear .................................................................................. 46

Blade Sharpening ...................................................................................... 46

Maintenance of Horizontal Votator II ...........................................................47

Shaft Removal - Horizontal Unit ................................................................ 47

Shaft Installation - Horizontal Unit ............................................................. 48

11/2012 95-03057 Page 3

Waukesha Cherry-Burrell Table of Contents

Heat Exchanger Tube Removal - Horizontal Unit ......................................50

Heat Exchanger Tube Installation - Horizontal Unit ...................................51

Maintenance of Vertical Votator II ...............................................................51

Shaft Removal - Vertical Unit .....................................................................51

Shaft Installation - Vertical Unit ..................................................................52

Heat Exchanger Tube Removal -Vertical Unit ...........................................53

Mechanical Seal Maintenance ....................................................................56

Single Mechanical Seal ...............................................................................56

Seal Head Insert Removal and Installation ................................................56

Seal Body Insert (Rotating Seal Face) Used Before 2012 ........................56

Single Mechanical Seal Installation ...........................................................57

One-Piece and Double Mechanical Seals ...................................................57

Primary/Secondary Seal Head Insert Removal and Installation ................57

2012 Primary/Secondary Seal Head Insert Removal and Installation .......58

One-Piece Primary Seal Body (Rotating Seal Face) .................................59

Removable Seal Body Insert (Rotating Seal Face) ...................................59

Assembly of Removable Primary Seal Body .............................................59

Assembly of 2012 Primary Seal Body .......................................................59

Assembly of Secondary Seal Body (For Double Mechanical Seal Only) ...60

Seal Assembly Installation on Shaft ..........................................................60

Servicing Mechanical Seals - Vertical Votator II ........................................61

Parts Lists ...................................................................................................63

Latch ............................................................................................................63

Product Heads .............................................................................................63

Cylinder Assembly .......................................................................................64

Cylinder Assembly - Shaft ...........................................................................66

Cylinder Assembly - Removable Tube ........................................................67

2012 Single and Double Mechanical Seal ...................................................69

One Piece Single & Double Mechanical Seal .............................................71

Single Mechanical Seal ...............................................................................73

Vertical Refrigeration Piping ........................................................................74

Vertical Frame/Hydraulics ...........................................................................76

Shaft Heater (Optional) ...............................................................................77

Votator II Blades ..........................................................................................78

Labels ..........................................................................................................78

Troubleshooting .........................................................................................79

Unthawing A Frozen System .......................................................................82

Water and Air in Refrigeration System ........................................................82

Warranty Waukesha Cherry-Burrell

Page 4 95-03057 11/2012

Warranty

Seller warrants its products to be free from defect in materials

and workmanship for a period of one (1) year from the date of

shipment. This warranty shall not apply to products which require

repair or replacement due to normal wear and tear or to products

which are subjected to accident, misuse or improper mainte-

nance. This warranty extends only to the original Buyer. Products

manufactured by others but furnished by Seller are exempted

from this warranty and are limited to the original manufacturer’s

warranty.

Seller’s sole obligation under this warranty shall be to repair or

replace any products that Seller determines, in its discretion, to

be defective. Seller reserves the right either to inspect the prod-

ucts in the field or to request their prepaid return to Seller. Seller

shall not be responsible for any transportation charges, duty,

taxes, freight, labor or other costs. The cost of removing and/or

installing products which have been repaired or replaced shall be

at Buyer’s expense.

Seller expressly disclaims all other warranties, express or

implied, including without limitation any warranty of merchantabil-

ity of fitness for a particular purpose. The foregoing sets forth

Seller’s entire and exclusive liability, and Buyer’s exclusive and

sole remedy, for any claim of damages in connection with the

sale of products. In no event shall Seller be liable for any special

consequential incidental or indirect damages (including without

limitation attorney’s fees and expenses), nor shall Seller be liable

for any loss of profit or material arising out of or relating to the

sale or operation of the products based on contract, tort (includ-

ing negligence), strict liability or otherwise.

Shipping Damage or Loss If equipment is damaged or lost in transit, file a claim at once with

the delivering carrier. The carrier has signed the Bill of Lading

acknowledging that the shipment has been received from the

seller in good condition. Seller is not responsible for the collection

of claims or replacement of materials due to transit shortages or

damages.

Warranty Claim Warranty claims must have a Returned Goods Authorization

(RGA) from the Seller before returns will be accepted.

Claims for shortages or other errors, exclusive of transit short-

ages or damages, must be made in writing to Seller within ten

(10) days after delivery. Failure to give such notice shall consti-

tute acceptance and waiver of all such claims by Buyer.

Waukesha Cherry-Burrell Safety

11/2012 95-03057 Page 5

Safety

READ AND UNDERSTAND THIS MANUAL

PRIOR TO INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT

SPX recommends users of our equipment and designs follow the latest Industrial Safety Standards. At a mini-

mum, these should include the industrial safety requirements established by:

1. Occupational Safety and Health Administration (OSHA), Title 29 of the CFR

Section 1910.212- General Requirements for all Machines

2. National Fire Protection Association, ANSI/NFPA 79

ANSI/NFPA 79- Electrical Standards for Industrial Machinery

3. National Electrical Code, ANSI/NFPA 70

ANSI/NFPA 70- National Electrical Code

ANSI/NFPA 70E- Electrical Safety Requirement for Employee Workplaces

4. American National Standards Institute, Section B11

Attention: Servicing energized industrial equipment can be hazardous. Severe injury or death can result from

electrical shock, burn, or unintended actuation of controlled equipment. Recommended practice is to discon-

nect and lockout industrial equipment from power sources, and release stored energy, if present. Refer to the

National Fire Protection Association Standard No. NFPA70E, Part II and (as applicable) OSHA rules for Con-

trol of Hazardous Energy Sources (Lockout-Tagout) and OSHA Electrical Safety Related Work Practices,

including procedural requirements for:

• Lockout-tagout

• Personnel qualifications and training requirements

• When it is not feasible to de-energize and lockout-tagout electrical circuits and equipment before working

on or near exposed circuit parts

Locking and Interlocking Devices: These devices should be checked for proper working condition and capa-

bility of performing their intended functions. Make replacements only with the original manufacturer’s renewal

parts or kits. Adjust or repair in accordance with the manufacturer’s instructions.

Periodic Inspection: Industrial equipment should be inspected periodically. Inspection intervals should be

based on environmental and operating conditions and adjusted as indicated by experience. At a minimum, an

initial inspection within 3 to 4 months after installation is recommended. Inspection of the electrical control sys-

tems should meet the recommendations as specified in the National Electrical Manufacturers Association

(NEMA) Standard No. ICS 1.3, Preventative Maintenance of Industrial Control and Systems Equipment, for the

general guidelines for setting-up a periodic maintenance program.

Replacement Equipment: Use only replacement parts and devices recommended by the manufacturer to

maintain the integrity of the equipment. Make sure the parts are properly matched to the equipment series,

model, serial number, and revision level of the equipment.

Warnings and cautions are provided in this manual to help avoid serious injury and/or possible damage to

equipment:

DANGER: marked with a stop sign.

Immediate hazards which WILL result in severe personal injury or death.

WARNING: marked with a warning triangle.

Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION: marked with a warning triangle.

Hazards or unsafe practices which COULD result in minor personal injury or product or property

damage.

Care of Stainless Steel Waukesha Cherry-Burrell

Page 6 95-03057 11/2012

Care of Stainless Steel

Stainless Steel Corrosion Corrosion resistance is greatest when a layer of oxide film is

formed on the surface of stainless steel. If film is disturbed or

destroyed, stainless steel becomes much less resistant to

corrosion and may rust, pit or crack.

Corrosion pitting, rusting and stress cracks may occur due to

chemical attack. Use only cleaning chemicals specified by a

reputable chemical manufacturer for use with 300 series stainless

steel. Do not use excessive concentrations, temperatures or

exposure times. Avoid contact with highly corrosive acids such as

hydrofluoric, hydrochloric or sulfuric. Also avoid prolonged

contact with chloride-containing chemicals, especially in

presence of acid. If chlorine-based sanitizers are used, such as

sodium hypochlorite (bleach), do not exceed concentrations of

150 ppm available chlorine, do not exceed contact time of 20

minutes, and do not exceed temperatures of 104°F (40°C).

Corrosion discoloration, deposits or pitting may occur under

product deposits or under gaskets. Keep surfaces clean,

including those under gaskets or in grooves or tight corners.

Clean immediately after use. Do not allow equipment to set idle,

exposed to air with accumulated foreign material on the surface.

Corrosion pitting may occur when stray electrical currents come

in contact with moist stainless steel. Ensure all electrical devices

connected to the equipment are correctly grounded.

Elastomer Seal

Replacement Following

Passivation

Passivation chemicals can damage product contact areas of

WCB equipment. Elastomers (rubber components) are most

likely to be affected. Always inspect all elastomer seals after

passivation is completed. Replace any seals showing signs of

chemical attack. Indications may include swelling, cracks, loss of

elasticity or any other noticeable changes when compared with

new components.

Waukesha Cherry-Burrell Introduction

11/2012 95-03057 Page 7

Introduction

Models and Specifications The Votator II can be furnished for horizontal or vertical

installation, available in the following models:

Model Heat Transfer Area Jacket Type

6 x 84 11 ft2(1.0 m2) Steam/Liquid Refrigeration

6 x 72 9 ft2(0.84 m2) Steam/Liquid Refrigeration

6 x 48 6 ft2(0.56 m2) Steam/Liquid Refrigeration

6 x 36 4.2 ft2(0.39 m2) Steam/Liquid Refrigeration

6 x 24 3.0 ft2(0.28 m2) Steam/Liquid Refrigeration

This manual covers the Horizontal and Vertical Votator II,

Concentric and Eccentric Designs, and the Extra Heavy Duty

Votator II. Every attempt has been made to note where special

considerations are needed for each model. These differences are

primarily in the installation and maintenance of the units.

Cylinder Assembly The cylinder assembly consists of a rotating shaft inside of two

tubes.The outer tube is called the jacket, and contains working

fluid to heat or cool the contents of the inner, product tube. The

product tube provides a heat exchange surface for the product.

Standard product tubes are one of the following:

• Pure nickel with a hard chrome plated interior surface.

• Stainless steel with a hard chrome plated interior surface.

• Stainless steel with no plating.

Product Side Pressure

Rating • 400 psi (28 bar) @ 400°F (204°C) - Oval Tube

• 600 psi (42 bar) @ 400°F (204°C) - Std. Votator II

• 800 psi (56 bar) @ 400°F (204°C) - U Stamp Votator II

Jacket Pressure Rating • 250 psi (17.5 bar) @ 400°F (204°C)

• 150 psi (10.5 bar) @ 400°F (204°C) (oval and high efficiency

tubes)

Check the data plate attached to the Votator cylinder for exact

specifications of the unit.

Machine Serial Number

Figure 1 - Machine Serial Number

Location

HE100-003a

SERIALNO.

MODEL

www.spx.com

Votator

The machine serial number is stamped on a serial number

nameplate located on the machine side as shown in Figure 1. On

vertical units (not shown), the nameplate is on the cylinder.

Include the machine model and serial number with each parts

order.

Introduction Waukesha Cherry-Burrell

Page 8 95-03057 11/2012

Votator II Media

Configurations The Votator II is available in the following configurations:

• BWS-BRINE/WATER/STEAM For liquid and steam heating

and cooling applications.

• LIQUID For water or glycol.

• VAPOR For steam or refrigeration.

Special Considerations for

Vertical Votator II The Vertical Votator II cylinder assembly is shipped for on-site

installation on the mounting pole. When receiving the shipment,

check for the following or multiples of (depending on the order)

shipped separately in their own crate or crates:

• Scraped Surface Heat Exchanger.

• Frame poles (including attached hydraulic cylinder) with

hydraulic pump & reservoir assembly(s).

• Accumulators, Refrigeration Valves and Piping, if furnished.

• Mount plates, nuts & bolts, and interconnecting product

piping.

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