INSTRUCTION MANUAL

OIL HEATER(U−TUBE TYPE)

1575−6, SONG JEONG DONG, GANGSEO−GU, BUSAN, KOREA

TEL : + 82 51 970−1114 FAX : + 82 51 970 − 1131

Web Site : www.dh.co.kr

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 2 OF 14
OPERATION & MAINTENANCE

CONTENTS

PAGE NO

1. DESCRIPTION ---------------------------------------------- 3

2. INSTALLATION --------------------------------------------- 6

3. OPERATION ----------------------------------------------- 7

4. MAINTENANCE AND CLEANING --------------------- 9

5. REGULAR INSPECTION ------------------------------------ 11

6. CAUSES FOR TROUBLE AND INSPECTION ----- 13

7. A/S NETWORK ------------------------------------------------ 14

1. DESCRIPTION

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 3 OF 14
OPERATION & MAINTENANCE

Our shell & tube type (U-tube) oil heater is primarily installed for the purpose of
heating fuel oil, lubricant oil and diesel oil.

Our heater is mainly designed with various sizes of surface areas ranging from
0.6[M2] to 36.32[M2] as our standard, and other capacities of oil heater would be also
designed depending on customer's request.

Our heater types are approved by so many classification societies and every
heater is delivered with a classification certificate and factory certificate.

STEAM INLET OIL OUTLET

STEAM OUTLET OIL INTLET

(i) Construction and different components

Our standardized heater is of very compact design. The heater body mainly
consists of fabricated carbon steel shell unit, tube bundle, tube sheet and fabricated
carbon steel cover unit.

Carbon steel is generally used as tube material, and carbon steel plate is generally
used as tube sheet material in most of the vessels.

For detailed description, please refer to below Fig.1.

Different components of heater are as follows:

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 4 OF 14
OPERATION & MAINTENANCE

(a) Shell unit

Shell unit is mainly composed of shell body(shell, shell flange, shell end plate,
saddle, lifting lug) and additive accessories such as thermometer, press gauge, air vent &
drain valve.

(b) Bundle unit(U-tube bundle with baffle plate)

U-type tubes are arranged and combined with required numbers of baffle plates to
ensure firm support and optimal heat efficiency.

(c) Cover unit

Cover unit is composed of cover bonnet, cover flange and cover end plate.

(d) Insulation
Shell & cover is insulated by glass wool with galvanized steel sheet, except for
cover flange-tube sheet-shell flange to reserve flange bolting space.

NOTICE:
DO NOT GIVE AN IMPACT TO INSULATION

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 5 OF 14
OPERATION & MAINTENANCE

FIG 1. SCHEMATIC DIAGRAM OF OIL HEATER

(ii) Flow of steam & oil

Steam generally flows into tube inside and oil flows outside of tubes. Thus, above
two fluids basically exchange their heat with each other at internal & external surfaces of
tubes and rate of heat exchange is more improved by regulating velocity of each fluid.

When velocity is more, heat transfer coefficient is also increased, by which

pressure drop will also be increased. Thus, the better performance of oil heater can be
acheived by regulating the fluid velocities within allowable pressure drop.

In addition to this, for designing compact & optimum size of oil heater with
excellent performance, various technical thermal factors are taken into consideration by
using sophisticated specialized HTRI (Heat Transfer Research Institute) programme.
The design skill is much more developed by our vast experience and technical skills.

Please refer to below FIG. 2 for the flow of each fluid in case of oil heater.

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 6 OF 14
OPERATION & MAINTENANCE

FIG 2. FLUID FLOW OF OIL HEATER

2. INSTALLATION

(i) Space selection for installation and foundation

Installation place should be carefully taken into consideration to reserve removal
space for U-tube bundle and cover unit and foundation must have high rigidity to
withstand loading condition and external forces.

(ii) Installation of oil heater

a. Foundation seats must always be placed in horizontal positions.

b. Insert adjustment piece between heater saddle and foundation seat, in case there
is appearance of any gap.
c. When lifting up the heater, make sure that lifting lugs are always used for
directly lifting up the item.
d. When connecting each nozzle, the gap between flange faces and it's inclination
should not be compensated with gaskets.
e. While carrying out the connecting works, proper care should be taken not to
give external forces.

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 7 OF 14
OPERATION & MAINTENANCE

f. Steam control valve, which is supplied by shipyard, must always be placed in

horizontal position.
g. Ball float type steam trap, which is supplied by shipyard, should always be
installed close to condensate water outlet valve as much as possible and should
also be placed in horizontal direction.
h. Oil line must be provided with oil inlet and outlet valve.
i. During the operation, proper attention should be paid so that no air pocket
exists
in the oil line and heater.
j. Before connecting heater, remove all plugs and blind flanges, and make sure
that no impurities and foreign materials are present inside connections and
heater.

3. OPERATION

(i) General
(a) Before startup, make sure that all connections are securely tightened in exact
locations.
(b) Safety(relief) valve must be adjusted to maximum design pressure or below.
(c) Oil in & outlet valves should be opened.
(d) Operate oil pump : After confirming the proper pump discharge pressure,
open
oil pump discharge valve should be gradually opened.
(e) Open air vent valve for a while, and then close the valve.
(f) Check steam control valve, oil viscosity controller, oil filter and purifier.

(ii) Start-up
(a) Start oil pump.
(b) Check pressure pulsation and vibration of oil side.
(c) Check oil leakage during startup.
(d) Open air vent & drain valve, thus ventilate air and drain condensates of oil
side.
(e) Gradually open steam inlet valve in slowly manner.
(f) Check pressure and temperature of oil side.
(g) Perform leakage check of steam side.

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 8 OF 14
OPERATION & MAINTENANCE

NOTICE:
Strong attention should be paid to the below steps for
start-up operation.

(a) At first, cold fluid should be supplied into heat exchanger before supplying
the hot fluid.
(b) Supplied steam must be in dry saturated condition and it's pressure should be
same as like design condition.
(c) Performance of oil heater could be affected by condition of steam trap. So,
proper size and type of steam trap must be applied (disc type trap is not
recommended).
(d) Proper attention should be paid to condensate steam line layout to avoid any
kind of negative effect of counter pressure.
(e) Operate the oil heater for a while, then stop and re-tighten all screws properly.

(iii) Shutdown
(a) Close steam valve.
(b) Recirculate oil for about 30minutes after shutdown.
(c) Shutdown of oil pump.
(d) Open air vent & drain valve.

NOTICE:
Strong attention should be paid to the below steps for shut
down operation.

(a) Heated oil is to be flowed for about 30minutes after shutdown of steam in
order to cool down the oil heater completely.
(b) Corrosion occurs if any non-distilled or alkaline condensate remains in the
heat exchanger. Even though it's fully emptied, corrosion would be occurred
by the presence of condensates, water residues and any other foreign materials.
Hence, proper attention should be paid to protect heater against any kinds of
corrosion after shutdown.

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 9 OF 14
OPERATION & MAINTENANCE

4. MAINTENANCE AND CLEANING

Maintenance check should be carried out deliberately as belows;

(i) If the specified required temperature can not be obtained, then the heater should be
checked properly and necessary cleanings should be performed in case of necessity.

(ii) In case of suspension for failure of any tubes, it is necessary to check for leakages of
water by the follwing mentioned procedure as below.

(a) Make inside of oil heater completely empty (both shell & cover side).
(b) Remove channel cover.
(c) Fill the inside of shell with fresh water and apply air pressure or water pressure
of 1Kg/cm2 or 14.2psi. through upper part of the shell.
(d) Dry out tube sheet so as to check fresh water leakage easily.
(e) In case any water leagages are found, block the tubes with tube plugs.
(f) If excessive tubes are plugged, it causes loss of heat transfer efficiency, which
subsequently results in decrease of heater's performance. In such cases, tube
bundle should be fully replaced with new one.

(iii) Cleaning of Tube Bundle

In case of any contamination, the performance of heater will be gradually

deteriorated. In such situations, tube bundle should be removed carefully from heater
body and cleaned by chemical method (mechanical method is also available).

(a) Chemical cleaning

For chemical cleaning purposes, chemical agents such as citric acid and methylene
chloride are used. However, we have not much experience about the kind and quality of
chemical agents. We don’t have any special skills about chemical or detergent agent. So,
it's difficult for us to recommend you most suitable brand and maker, as each maker have
its own special characteristics.
For this reason, we recommend you to contact specialist chemical agent maker if
required.
There are two types of chemical methods, which are mentioned as below.

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 10 OF 14
OPERATION & MAINTENANCE

- Method 1 –

The procedure for this method has been mentioned in below steps.

1. Turn off heater.

2. Close steam in/out valves and oil in/out valves.
3. Open drain valve to make inside of shell completely empty.
4. Remove cover and pull out tube bundle from the shell using chain block.
5. Clean in & outside of tube bundle (mainly outside) with chemical agent by
using a sharp liquid jet.
6. Replace shell & cover flange gaskets with new ones and check out for presence
of any foreign material inside of heater.
7. Finish off all the above steps, check condition of the bundle and resume running
of the oil heater.

- Method 2 –
The procedure for this method has been mentioned in below steps.

1. Turn off heater.

2. Close steam in/out valves and oil in/out valves.
3. Open drain valve to make inside of shell completely empty.
4. Remove cover and pull out tube bundle from the shell using chain block.
5. Prepare a plastic or steel vessel of bigger size than tube bundle at a dry place,
into which the detergent agent is poured.
6. Submerge the bundle into detergent agent for about 1 hour and keep it
upside down a bit later (holding time is different according to kinds of agents
and manufacturers)
7. Insert air into the vessel and make bubbles for more effective cleaning.
8. If the bundle is not clean, then the above procedure should be repeated.
9. Take out the bundle, flush with fresh water and dry with fresh air.
10. Replace shell & cover flange gaskets with new ones and check out presence of
any foreign material inside of heater.
11. Finish off all the above steps, check condition of the bundle and resume
running of the oil heater.

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 11 OF 14
OPERATION & MAINTENANCE

5. REGULAR INSPECTION

In this kind of heater, it is very important to pay proper attention for the
following items with regard to maintenance and inspection of each part during operation.

(i) Maintenance during operation

ITEM INSPECTION PROCEDURE

Check steam inlet pressure regularly and pay attention to oil
Temperature or press
temperature.
Of heating steam

Inspect the proper tightening of all flange bolts.

Leakage

Take condensate water as a sample and check it's quality & pH

Condensate water
value. Inspect all the time for checking if oil is mixed into
Quality and oil
condensate water or not. However, alkaline condensate water will
invasion into steam
be appeared due to invasion of boiler water.

Open air vent valve a little bit and check for presence of any air
Air venting of shell still remaining in the shell.

Temperature control Throttle the steam line and check the temperature control
valve valve for proper operation.

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 12 OF 14
OPERATION & MAINTENANCE

2) Regular inspection
In order to prevent any unexpected accident, the following regular inspection are
required.

INSPECTION
ITEM INSPECTION PROCEDURE
PERIOD
Tube outside Check the quantity of the scale adhering to tube
Every 6months
outside.
a) Open channel cover.
Leakage b) Fill shell inside with water or air and apply
from Every 1 month air pressure of 1kg/cm2 to the top
heating tube c) By drying tube sheet sufficiently, leaking
position(s) can be found.
Cleaning of
Every 6months or 1year For details, refer to "Tube bundle cleaning"
tube inside
Chemical
Every 1year For details, refer to "Tube bundle cleaning"
cleaning

DongHwa Entec REV. : 0

 DATA :
INSTRUCTION
FOR
REV.NO. : 0
PAGE : 13 OF 14
OPERATION & MAINTENANCE

6. CAUSES FOR TROUBLE AND INSPECTION

Oil heater shows satisfactory performance if handling and maintenance work has
been performed properly. In case of any trouble, prompt countermeasure should be taken
out for its remedy, which has been mentioned in the below table.
TROUBE POSSIBLE CAUSES CHECK POINTS
a) Proper performance of the heater
1) Scale adhesion or contamination b) Inlet/outlet oil temperature
of heating tube and tube bundle. c) Opening condition of air vent
2) Insufficient steam pressure valve on the top of the shell
3) Excessive oil flow rate d) Inlet steam condition(It must be dry
4) Accumulated air at upper side saturated one with design pressure)
of oil side e) Operating pressure of oil supply
Low oil
5) Low temperature of inlet oil pump
temperature
6) Insufficient discharge f) Check type and size of steam
of condensate water trap(disc type is not recommended
7) Insufficient size of steam control and size should be same as the
valve and steam trap connection of oil heater)
8) Wrong setting and insufficiency g) Proper differential pressure(ΔP)
of viscosity controller between oil in/outlet connection
h) Pollution of tubes
a) Condition of tube sheet and tube
1) Excessive oil flow rate
after overhauling of cover
2) Invasion of foreign materials and
b) Remove the presence of
adhesion of microorganisms
contamination and microorganisms
Damaged 3) Change of oil flow rate
c) Fill the shell with water and
tube 4) Excessive vibration of tube
check for leakage
bundle
d) Deterioration of oil and boiler
5) No oil flow
feed water in quality
6) Air pocket
e) Air pocket in the shell

DongHwa Entec REV. : 0

 A / S NETWORK

Netherland
France

Greece
Korea
China Japa America
n
India

Singapore
Indonesia

South Africa Brazil

Australi

CHINA DONGHWA ENTEC SHANGHAI BRANCH OFFICE JAPAN SEIKA COPORATION HIROSHIMA BRANCH
Chenhui Rd Shanghai Zhangjiang Hi-Tech Park (Hiroshima) 4-25, Fukuro-machi, Naka-ku, Hiroshima-shi
Tel : +86-21-5027-1828 Tel : +81-082-248-5831

GREECE FRANMAN LIMITED INDONESIA PT. ESPRIT ENGINEERING

220,Syngrou Avenue,Athens,176 72 KM7 TanJung Uncang Batam Indonesia
T. +30 210 953 2350 T. +62 (778) 392 811

BRAZIL DANTHERM SOUTH BALTIMORE AIRCOIL COMPANY LTD.

Av. Atalaia, Jardim Cumbica, Guarulhos, Sao AFRICA Philippi 7781, P.O.B. 88, Philippi 7785, Cape
Paolo, T. +55 116 412 8188 Town, T. +27 114 533 146

SINGAPOR SINGAPORE OFFICE FRANCE BARRIQUAND ECHANGUERS

E BLK 4No 58Pandanloop Singapore 128273 9-13 Rue Saint-Claude, F-42334 Roanne Cedex
Tel : 776-3344(5Lines) Tel : +33-477-442-220