Operating Manual Version 1.0 AZ

O P E R AT I N G M A N U A L
Self-cleaning fluidized bed heat exchanger
info@klarenbv.com www.klarenbv.com
THIS MANUAL WILL BE PROVIDED
IN DUTCH LANGUAGE TO THE END CLIENT.
Installed at Cargill B.V.
Amsterdam, The Netherlands

Document No: KL/151001/OM/20/01
Operating Manual
Self-Cleaning Fluidized Bed Heat Exchanger
Equipment Number: SCHE-023
Ref. No.: 151001
0 17/06/2021 For Client AZA/MB MvB MvB
Revision Date Description Author Checked Approved
Page | 1 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

Contents
Important Information ....................................................................................................... 4

Safety Signs .......................................................................................................................... 5
Legal Notice .......................................................................................................................... 7
1. Introduction .................................................................................................................. 9
2. System Description ..................................................................................................... 11
2.1. Process Description ................................................................................................................... 11
2.2. Technical Specifications ............................................................................................................ 13
2.3. Component Description ............................................................................................................ 15
Heat Exchanger: Bottom Section (Oil-Oil HR Part) ............................................................ 15
Heat Exchanger: Top Section (Steam-Oil) ......................................................................... 16
Cleaning Particles .............................................................................................................. 18
Inlet Bonnet and Inlet Channel .......................................................................................... 19
Outlet Bonnet and throttle plate ....................................................................................... 21
Particle Separator and Downcomer .................................................................................. 22
Three Flange System ......................................................................................................... 23
Control Flow Arrangement ................................................................................................ 24
2.4. Differential pressure measurement .......................................................................................... 24
3. Installation .................................................................................................................. 27
3.1. Transport and Erection of Heat Exchanger Bundles ................................................................. 27
3.2. Weight of components, erection and operation ...................................................................... 27
3.3. Tightening Torque of Main Flanges .......................................................................................... 28
3.4. Thermal Expansion and Nozzle Loads ....................................................................................... 28
3.5. Three Flange System - Half-Opening......................................................................................... 29
3.6. Throttle Plate ............................................................................................................................ 31
3.7. Orifice located at the inlet of the Inlet Bonnet ......................................................................... 31
3.8. Position of plate with distribution nozzles ................................................................................ 31
3.9. Alignment between Inlet Tubes and Tubes in Heat Exchanger ................................................ 33
3.10. Assembly of Glasses in Sight Glass Body ................................................................................... 33
3.11. Earthing of equipment .............................................................................................................. 34
4. Operational Procedures ............................................................................................. 35

4.1. Pre-operational Checks ............................................................................................................. 35
4.2. Filling the System / Checking for leakages ................................................................................ 35
4.3. Filling Cleaning Particles............................................................................................................ 36
4.4. Start – Up .................................................................................................................................. 37
4.5. Checking correctness of pressure drop fluidized bed ............................................................... 38

4.6. Shutdown .................................................................................................................................. 39

4.7. Discharging/Draining the Process Liquid .................................................................................. 40
4.8. Removing Cleaning Particles from the System ......................................................................... 41
5. Monitoring Operation of the System ........................................................................ 42

5.1. Pressure Drop over the Tubes .................................................................................................. 42
5.2. Movement of Cleaning Particles in Downcomer ...................................................................... 42
6. What-If Scenarios ........................................................................................................ 43

6.1. Reduced Pressure-Drop over the Heat Exchanger Tubes ......................................................... 43
6.2. Pump Failure or Tripping .......................................................................................................... 44
7. Maintenance ............................................................................................................... 45
7.1. Maintenance Action in Case of Anomalies ............................................................................... 45
Checking the Correct Reading of the DPT .......................................................................... 45
Cleaning the Distribution Plate ......................................................................................... 45
Inspection nozzles ............................................................................................................. 46
7.2. Preventive Maintenance ........................................................................................................... 47
Inspection Scope................................................................................................................ 47
Inspection of wall thickness of the particle separator and the downcomer...................... 48
Checking Weight Reduction of the Particles ..................................................................... 48
List of Abbreviations ......................................................................................................... 49

Definition of Terminology ................................................................................................. 50
Appendices ......................................................................................................................... 51
Appendix A1: Calculation of Porosity in Heat Exchanger Tube ............................................................ 51

Important Information
• This manual should be read carefully before conducting any installation or
maintenance work and/or before use of the Self-cleaning Fluidized Bed Heat
Exchanger (SCHE).
• Self-cleaning fluidized bed heat exchangers have been designed for safe operation.
In order to avoid damage and unforeseen risks, the Safety Notices listed in this
manual must be followed.
• Personnel who install, commission and/or operate a self-cleaning fluidized bed heat
exchanger should be experienced in site work and trained on the importance of the
correct installation and operation of self-cleaning fluidized bed heat exchanger
units.
• If the user has any doubts, or if a more complete explanation of any feature is
required, please contact Klaren International B.V.

Safety Signs
Different combinations of words and warning signs are used in this operating manual.
They illustrate the gravity of possibile injuries if risks are ignored. Therefore, to avoid
injuries, operating instructions must be read carefully and followed properly. Here are
some of the factors to be understood carefully for safer operation:
• Hazards due to non-compliance with the safety instructions:
These are hazards occuring due to non-compliance with instructions given in the
manuals of the equipment for the safety of the operator as well as the safety of the
equipment. Thus, all the operating instructions must be thoroughly read and
followed.
• Working in a safety-conscious manner:
It is very important to work in a safe place following the instructions given by the
operating company and the standard instructions and regulations applicable in the
respective country. This minimises the accidents and harm to working personnel
and damage to equipment. Workers must be trained for making the work place safe
and working in a safe manner.
• Personal protective equipment:
The use of personal protective equipment, like helmets, hand gloves, safety shoes,
goggles or safety screens, etc. is vital in avoiding the harm to operator. The
instructions for the proper use of protective equipment.must be given to the
operators
• Qualification of personnel:
Qualification and appropriate training are vital for safe operation. Training an
operator on how to operate the equipment he is working on, minimises the errors
and accidents and risks involved. At the same time, if the operator is trained
properly, he can take proper corrective actions if anything happens.

The following safety symbols are used in this manual;
Danger
Stands for an immediate danger leading to severe physical injuries or death.

 Description for avoiding the danger
Warning!
Stands for a potentially dangerous situation leading to severe physical injuries

or death.
 Description for avoiding the dangerous situation
Caution!
Stands for a potentially dangerous situation which could lead to minor

physical injuries or damage to property
 Description for avoiding the dangerous situation
Notice
Stands for important information that must be observed for the intended use
and function of the equipment.
 Description of the required action for the intended function of the
equipment
Critical Operation
Stands for important information that must be observed for the proper
operation of the fluidized bed in the heat exchanger
 Description of the required action for the proper working of the
equipment

Legal Notice
These operating instructions are submitted as a part of the provided technical
documentation for safe and correct operation of the equipment. They contain
important instructions to ensure safe and proper start-up of the equipment and normal
operation maintenance of the self-cleaning fluidized bed heat exchanger (SCHE).
Observance of these instructions helps avoiding dangers, reducing repair costs and
down-times and thus helps increasing the reliability and life of the equipment.
These operating instructions are intended for the company owning and operating the
self-cleaning fluidized bed heat exchanger and personnel operating and maintaining
the equipment.
It is essential that the operating company and its operating and maintenance staff read
these operating instructions prior to start-up, use, maintenance, and dismantling of the
SCHE. This obligation to read also applies to personnel involved in activities during the
lifetime of the equipment.
The operating company must supplement these operating instructions with
instructions regarding health and safety at work and environmental protection on the
basis of respective national regulations for safety.
In addition to these operating instructions and the (local) regulations for safety at the
workplace, the recognised technical regulations for safe and professional work must be
observed.
The entire document comprises the operating instructions and instructions in case of
any trouble in the operation of the self-cleaning fluidized bed heat exchanger. For
operating or troubleshooting instructions of bought-out items like pumps, motors, etc.,
please refer to the operating manual provided by the respective supplier. Operating
manuals must be kept readily available where the equipment is installed. Refer to the
list of manuals of subsupplied components in this document (appendix B1), if
applicable.
Klaren reserves the right to make technical modifications during the course of further
development of the equipment covered by these operating instructions.

Illustrations and drawings in these operating instructions are simplified
representations. As a result of improvements and changes, it is possible that the figures
do not exactly match the equipment you are operating. The technical data and
dimensions are subject to change, thus no claims can be made on the basis of them.
Klaren cannot accept liability for damages:
- due to improper operating conditions,
- due to inadequate maintenance,
- due to improper operation,
- due to incorrect installation,
- due to incorrect or improper connections,
- resulting from or attributed to any improper modifications, failure to observe the
instructions,
- through the use of accessories or spare parts not supplied or recommended by
Klaren.
Technical documents submitted:
- Design Document for all the manufactured and bought out components of SCHE
system
- General Arrangement Drawings for all the components of SCHE system.
- P&ID

1. Introduction
Klaren International is a technology and engineering company based in the
Netherlands that develops self-cleaning fluidized bed heat exchangers for operation up
to zero-fouling.
This manual explains the operation of Klaren’s self-cleaning fluidized bed heat
exchanger (SCHE) used as a heater for sunflower oil in the refinery of Cargill in
Amsterdam. It also explains the necessary factors to be taken care of during installation
and erection, it describes what to if certain problems are detected, how to monitor the
system and it describes the required maintenance activities.
This manual is a complete guide to operate the self-cleaning fluidized bed heat
exchanger safely, efficiently and to its designed capacity. This manual can be used to
train the operators, supervisors and/or engineers operating this equipment and as a
guide for troubleshooting.
The self-cleaning fluidized bed heat exchanger is a heater for sunflower oil with
fluidized cleaning particles in the tubes. It is designed based on continuous cleaning
technology to avoid fouling on the tube walls in early stage of formation. The cleaning
is the result of the light scouring action of the cleaning particles on the tube wall keeping
the walls of the tubes clean thus resulting into an effective and efficient heat transfer
and increasing the equipment life.
As said, the self-cleaning fluidized bed heat exchanger in this application is intended to
heat sunflower oil before it enters the bleacher. The heat exchanger consists of a
bottom section (heat recovery section) where the sunflower is heated using heat from
the oil that returns from the deodorizer and a top section where in case the outlet
temperature from the heat recovery section is not high enough the temperature can
be further increased by condensing steam. The top section is also used during start-up
of the refinery where the sunflower oil in the feed tank needs to be preheated before
the process can start and the return oil stream is not available yet. In the start-up phase,
the heat input is only given by the condensing steam.

Installation Details
Location Name : Cargill B.V., Amsterdam, The Netherlands
Area : Non-hazardous
Overall Dimensions Length Width Height
Self-Cleaning Fluidized Bed : 14 m ___ m ___ m

Heat Exchanger unit

2. System Description
This chapter describes the overall heat transfer process in a self-cleaning fluidised bed
heat exchanger (SCFBHE) unit and also explains different components of the SCHE and
their functions in the process.
2.1. Process Description
Figure 2.1: Process and Instrumentation Diagram

The process liquid, which is sunflower oil, is pumped at a temperature of 60°C, from
the Bleach Feed Tank 964 to the Klaren heat exchanger 9041 by pump P-660. The pump
is a fixed rpm centrifugal pump. The flow through heat exchanger 9041 is controlled by
a flow control valve 660 FCV. The sunflower oil enters the self-cleaning fluidised bed
heat exchanger from the side of the bottom bonnet via an orifice and a downward bend
pipe.
The oil then flows into the inlet channel via distribution nozzles. In the inlet channel, the
cleaning particles from the downcomer are added to the main oil flow and are
distributed over all the tubes of the heat exchanger. The amount of cleaning particles
recirculating in the system is controlled by using the control flow line and control valve
9041 1 FCV. This is an automatically operated 60o V-port ball valve. The control flow is a
side-stream from the main feed line from the bleach tank to the heat exchanger that is
connected to the downcomer to push particles into the inlet channel.
By controlling the amount of cleaning particles, the required volume fraction of
particles in the tubes, also called porosity, can be maintained. The porosity is a key
factor to define the cleaning action in the tubes and can be determined by measuring
the pressure difference across the heat exchanger tubes with the help of a differential
pressure indicator/transmitter. The relation used for calculating the porosity as a
function of the pressure drop is given in Appendix A1.
As shown in figure 2.1 the SCFBHE 9041 consists of two main parts. The first is the
bottom section where the raw sunflower oil enters the tubes via the inlet channel and
exchanges heat with the high temperature oil flow at the shell side. In the shell of the
bottom section hot deodorized sunflower oil passes which enters at a temperature of
130°C. This part is called the heat recovery (HR) part of the SCFBHE.
The second part of the SCFBHE, is the top section of the SCFBHE where the heat input
is by condensing steam. The tubes contain the oil flow coming from the HR part or the
bottom section.
The oil flow in the tubes, after leaving the top section of the SCFBHE enters to the outlet
bonnet via a throttle plate.

A Particle Separator 9041 A is installed after the heat exchanger to separate the
cleaning particles from the oil. The separation is based on the gravity difference of
cleaning particles and process fluid. A downcomer is provided to recirculate the
cleaning particles from the particle separator back to the inlet channel.
After separation, the oil flow moves towards the bleacher 967 where this oil is
processed further. In the outline line from the SCFBHE 9041 there is also the possibility
to recirculate the heated oil back to the feed tank 964.
2.2. Technical Specifications
Design Conditions Top Section (Steam-Oil);
TUBE SHELL
MEDIUM SUNFLOWER OIL STEAM / CONDENSATE
MAX. PRESSURE bara 11.0 15.5
MIN. PRESSURE bara FV FV

o
MAX. TEMPERATURE C 200 200
o
MIN. TEMPERATURE C 0 0
Design Conditions Bottom Section (Oil-Oil);
TUBE SHELL
MEDIUM SUNFLOWER OIL SUNFLOWER OIL
MAX. PRESSURE bara 11.0 21.0
MIN. PRESSURE bara FV FV

o
MAX. TEMPERATURE C 200 200
o
MIN. TEMPERATURE C 0 0
Warning!
User is to ensure by basic system design or safety measures that the external
and internal design pressure cannot be exceeded.
User is also to ensure that by basic system design or safety measures the
design temperatures cannot be exceeded.
 Operating the double shell self-cleaning heat exchanger outside can give
a dangerous situation.

Process Conditions Bottom Section (Oil-Oil) @ 30,000 kg/h oil flow;
Tube Side Shell Side
Medium Sunflower oil Sunflower oil
Mass flow (*) 30000 kg/h 28242 kg/h
Temperature In/Out 60.9 oC 104.0 oC 142.3 oC 98.3 oC
Duty 826 kW
HTC 415 W/m2K
LMTD 34.4 oC
Heat Transfer Area 57.9 m2
(*) The mass flow can vary with -10% and + 20%, or between 27000 kg/h and 36000 kg/h.
Process Conditions Top Section (Steam-Oil) @ 30,000 kg/h oil flow;
In the following table the process conditions are given for the top heat exchanger
section under the assumption that the oil leaves the heat recovery section at 104 oC.
With this tube side inlet temperature, it is possible to increase the tube side oil
temperature to a maximum of 116 oC given the available heat transfer area;
Tube Side Shell Side
Medium Sunflower oil Steam
Mass flow (*) 30000 kg/h 400 kg/h
Temperature In/Out 104.0 oC 116.0 oC 150 oC 150 oC
Duty 237 kW
HTC 662 W/m2K
LMTD 38.1 oC
Heat Transfer Area 9.4 m2
(*) The mass flow can vary with -10% and + 20%, or between 27000 kg/h and 36000 kg/h.

2.3. Component Description
This section covers the main components of self-cleaning fluidised bed heat exchanger
involved in the operation.
Heat Exchanger: Bottom Section (Oil-Oil HR Part)
Figure 2.2: Bottom section SCFBHE 9041

In the bottom section of the SCFBHE heat is recovered from the deodorized oil at the
shell-side to heat the sunflower oil at the tubes side. The technical details of the Heat
Exchanger are as in Table 2.
Table 2.1: Technical Details Heat Exchanger Bottom Section
Technical Data
Type : Single-pass with fluidized bed self-cleaning
Tube Side : Sunflower Oil
Tubes : 61 tubes of 25.4 mm (OD), wall thickness = 1.65 mm
Total Tube Length 2 bundles of each 5983 mm
Shell Side : Sunflower (Deodorized) Oil
Shell : OD shell = 323.9 mm and wall thickness = 4.57 mm
Baffles 2 bundles with each 43 baffles, baffle distance = 130
mm
Heat Exchanger: Top Section (Steam-Oil)
In the top bottom section of the SCFBHE heat is supplied by condensing steam. As the
tube-side outlet temperature of the sunflower oil from heat exchanger 9041should be
maintained at a fixed temperature, the steam-oil part comes in function only when the
bottom HR part of the SCFBHE-9041 is not able to increase the oil temperature to the
desired point. Hence, the upper part is considered as a safety section and is required
primarily during start-up of the heat exchanger.
Table 2.2: Technical Details Heat Exchanger Top Section
Technical Data
Type : Single-pass with fluidized bed self-cleaning
Tube Side : Sunflower Oil
Tubes : 61 tubes of 25.4 mm (OD), wall thickness = 1.65 mm
Total Tube Length 1928 mm
Shell Side : Steam/Condensate
Shell : OD shell = 323.9 mm and wall thickness = 4.57 mm
Baffles 5 baffles at a baffle distance = 311 mm

Figure 2.3: Heat Exchanger-Upper Bundle

Cleaning Particles
Cleaning particles are mixed with the process fluid i.e. sunflower oil in the inlet channel.
They are specially designed and selected as per the feed-process fluid to be handled.
The size of the cleaning particles play an important role in the fluidisation in tubes. It is
the cleaning particles that cause scouring action inside the tube walls which leads to
removal of a developing fouling layer at the early stage of deposition.
Klaren suggests keeping 20% of the total required amount of cleaning particles spared
as an inventory. For advice on particles and/or spares requirement, contact Klaren
International in the Netherlands or an associate/dealer/supplier authorised by Klaren.
The technical details of the particles used in this system are given below:
Table 2.3: Technical details about cleaning particles
Technical Data
Material : SS 304
Diameter : 2.0 mm
Type : Cylindrical
Surface condition : G2 conditioned
Weight : 1450 kg in the system and 300 kg spare

Inlet Bonnet and Inlet Channel
This section describes the Inlet Channel which is mounted directly below the Heat
Exchanger and the Inlet Bonnet located below the inlet channel.
Inlet Bonnet
Inlet Channel Distribution nozzles inside the inlet

channel
Figure 2.3: Inlet bonnet and inlet channel

The inlet bonnet is the most bottom part of the heat exchanger. The incoming oil enters
this bonnet from the side whereafter by a downward facing bend the flow is directed
towards the bottom talking any particles that have dropped into the bonnet back
towards the inlet channel. At the bottom of the bonnet a drain nozzle N21 is provided
for liquid drainage. The drain has no welded sieve plate to prevent particle drain which
means that the drain can contain particles. The bonnet has a nozzle N15 where a
temperature transmitter is installed. This nozzle can be used for inspection by an
endoscope by removing the temperature transmitter. For an inspection, the heat
exchanger needs to be drained.
Above the inlet bonnet the inlet channel is located. The inlet channel is separated from
the inlet bonnet by the distribution plate. This distribution plate consists of 7
distribution nozzles required for a proper distribution of the flow into the inlet channel.
At the top, the inlet channel contains a distribution system that consists of inlet tubes
which are extensions of the actual heat exchanger tubes. These inlet tubes are required
for the desired uniform distribution of the cleaning particles over all the tubes. At the
side wall the inlet channel has a nozzle which is connected to the downcomer and
through which cleaning particles are entered from this same downcomer. The inlet
channel can be inspected by endoscope through nozzle N22.

Outlet Bonnet and throttle plate
Outlet bonnet Throttle plate inside the outlet

bonnet
Figure 2.4: Outlet bonnet and throttle plate
The Outlet Bonnet is also referred to as the Outlet Channel. The main flow with cleaning
particles exits the tubes at the top of the heat exchanger bundle. Just above the top
tube sheet, a throttle plate with specially designed throttle holes is mounted (see Fig.
2.4). As a part of the throttle plate configuration each tube is equipped with a tube insert
that together with the throttle plate gives the required throttle hole layout. The throttle
plate stabilises the oil-liquid flow and prevents particles falling back into the tubes.
During normal operation, a certain length of fluidised bed is built in the outlet channel.
The flow along with the cleaning particles leaves the heat exchanger through the outlet
nozzle (N7) at the side of the outlet bonnet as shown in Figure 2.4. The flow from this
outlet nozzle enters the particle separator. In the outlet bonnet a temperature
transmitter is mounted in nozzle N16 and at the top it has a vent nozzle, N11. Both
nozzles can be used for inspection by endoscope.

Particle Separator and Downcomer
Sight Glass
Figure 2.5: Particle Separator and Downcomer
The oil flow from the heat exchanger enters the particle separator to disengage the
cleaning particles from the main flow using gravity separation. Hereto, the particle
separator is equipped with an inclined downward facing inlet bend with an angle of 10o.

Inside the particle separator the separation is optimized by special provision of the inlet
bend and a special designed perforated plate at the outside of the vessel.
The particle separator can be inspected through the nozzle N14 (DN300). For filling the
particles, nozzle N10 is provided. As an alternative also nozzle N14 can be used.
The cleaning particles are recycled from the particle separator towards the inlet channel
through the downcomer. The separator also acts as a storage tank for cleaning particles
during a shutdown period. During normal operation and stand-still, the downcomer is
should be completely filled with cleaning particles.
To monitor particle transport in the downcomer, the downcomer is equipped with a
sight glass (SG) as shown in Figure 2.5. During normal operation, the cleaning particles
should move downwards with a velocity of ~8 cm/s.
Three Flange System
Figure 2.6: Location and positioning of half open flange
The downcomer is after the long radius bend connected to the inlet channel. At the
position of this connection a three-flange system is present. In this three-flange system,
the middle flange called ‘the half-open flange’ is partially closed, i.e. 30% of the area is
blinded whereas 70% of the opening is available for moving the cleaning particles. It is
very important that the opening of this semi-opened flange is at the bottom and the

closed part at the top. The arrangement can be easily understood as shown in the figure
2.6.
Control Flow Arrangement
Figure 2.7: Control flow arrangement
To regulate the transport of cleaning particles, a second flow is used. This flow is a side-
stream of the main flow and is called the control flow. The control flow arrangement is
shown in the figure above. To create enough control flow the main flow is throttled by
an orifice which is located directly before the inlet bonnet and if required by throttling
the ball valve in the main flow which is located in the downward pipe towards the inlet
bonnet. The orifice is designed to give a pressure drop of around 350 mbar. The
amount of control flow is further controlled by an automatic flow control valve, 9041 1
FCV. This valve is a DN25 60o V-port ball valve.
2.4. Differential pressure measurement
The measurement of the differential pressure (DPT) over the heat exchanger 9041 is
critical for monitoring the action of the fluidized bed. For this system use is made of a
measurement where the differential pressure is determined from 2 absolute pressure
measurements. In figure 2.8 a picture is given of a version of a DPT measurement using

2 absolute pressure measurements. The actual version as installed at Cargill is slightly
different because it has extended diaphragms.
Figure 2.8: Measurement of the differential pressure
The differential pressure measurement, indicated on the P&ID with 1PT 9041, is
connected to the inlet channel for the higher pressure side and to the particle separator
as its lower pressure side.
When using the device using 2 absolute pressure measurements, the measured
differential pressure includes the static height of the sunflower between the 2
measurement locations. For a correct representation of the pressure drop by the
fluidized bed, the measured value by 1PT 9041 therefore needs to be corrected as given
with the following relation;
𝑀𝑎𝑠𝑠 𝐹𝑙𝑜𝑤 𝑆𝑦𝑠𝑡𝑒𝑚 2

∆𝑝9041,𝐹𝐵 = 1𝑃𝑇 9041 − ∆𝑝𝑠𝑡𝑎𝑡 ℎ𝑒𝑎𝑑 − ( ) ∆𝑝ℎ𝑦𝑑
30,000
The value of ∆𝑝𝑠𝑡𝑎𝑡 ℎ𝑒𝑎𝑑 will be determined during commissioning. The last term, ∆𝑝ℎ𝑦𝑑 ,
represents the hydrodynamic flow losses by friction. Since these losses are dependent
on the system mass flow, the hydrodynamic loss at the normal operating flow (100%)
is corrected by the actual mass flow which is measured with flow transmitter 0FT 660.
The value of the term ∆𝑝ℎ𝑦𝑑,100% will be determined during commissioning.
Alternatively, it can be chosen to use the actual inlet density for the correction. The
relation would then become;

∆𝑝9041,𝐹𝐵 = 1𝑃𝑇 9041 − 𝜌𝑖𝑛𝑙𝑒𝑡 ∙ 𝑔 ∙ 𝐻𝑠𝑦𝑠𝑡 − ( ) ∆𝑝ℎ𝑦𝑑
33,000

The value of 𝐻𝑠𝑦𝑠𝑡 will be determined during commissioning. Whether the
measurement density at the inlet needs to be compensated for the reduction in density
when the sunflower is heated will need to be evaluated.

3. Installation
3.1. Transport and Erection of Heat Exchanger Bundles
During transport and erection of the heat exchanger bundles, the transport protection
around the bellows need to be in place to protect the bellows from bending. The
transport protection consists of 4 threads connected to the stiffening plate on either
side of the bellows as can be seen in figure 4.1. Please check if all nuts on either side of
the stiffening plates are tightened before erection starts.
Figure 3.1: Transport protection bellows in heat exchanger shell
The transport protection can be removed when the heat exchanger is in its final vertical
position.
For erection of the heat exchanger it is advised that prior to hoisting all bundles are
mounted together when being in a horizontal direction.
3.2. Weight of components, erection and operation
For the loading on the supporting structures the following weight need to be
considered;

Heat Exchanger side Particle Separator side
Weight Empty, kg 2200 480
Weight Filled*, kg 3250 2130
* Please note that the weight filled includes the weight of the sunflower oil in the
system as well as the cleaning particles.
3.3. Tightening Torque of Main Flanges
In the table the tightening torque is shown for the bolts in the main body flanges of the
heat exchanger and for the internally mounted plate with the inlet tubes and the
throttle plate.
3.4. Thermal Expansion and Nozzle Loads
In the design of the heat exchanger, it is chosen to support both the heat exchanger as
the particle separator on the top. This means that they expand from the same fixed
point. The expansion of the heat exchanger in downward direction measured from the
support till the inlet of nozzle N2 from ambient to operating temperature is 15 mm. The
connecting pipework should be mounted such that it creates minimal forces on the
heat exchanger nozzles.
The difference between the thermal expansion of tubes and shell is per shell
compensated by installed bellows.
To compensate for the difference between the thermal expansion of the heat
exchanger and the downcomer, the downcomer has a bellow installed with inner sleeve
for proper particle transport.

Component Bolt Size Torque
Heat Exchanger Flanges M20 240 Nm
Bottom Flange Inlet Channel M24 340 Nm
Downcomer Section M16 125 Nm
Plate with Inlet Tubes M8 30 Nm
Sight Glass Covers M6 3.5 Nm
3.5. Mounting of plate with inlet tubes and their proper alignment with the tubes in
the Heat Exchanger
The plate with the inlet tubes is mounted with 6 M10 bolts to the most bottom
tubesheet, see figure 3.2. The bolts prior to assembly need to be greased using HT1200
paste from Interflon. This paste is approved for food applications. The bolts need to be
tightened with a torque of 30 Nm.
Figure 3.2: Mounting of the plate with inlet tubes

Critical Operation
For a proper functioning of the distribution system, it is important that during erection
the inlet tubes are properly aligned with the configuration of tubes in heat exchanger.
After mounting of the plate with the inlet tubes, it is vital to verify the alignment with
the heat exchanger tubes.
3.6. Three Flange System - Half-Opening
Critical Operation
The three-flange system installed on the inlet channel plays a vital role in transport of
cleaning particles from the downcomer to the exchanger Heat Exchanger. To ensure
the proper transport of cleaning particles, the correct installation of the three-flange
system must be checked before operation. The middle flange of the system has 70% of
the area open for moving the cleaning particles. It is very important that the opening
of this semi-opened valve is at the bottom and the closed part at the top.
Figure 3.3: Correct positioning of half open flange

3.7. Throttle Plate
Critical Operation
Figure 3.4: Throttle Plate
The throttle plate consists of 2 parts being the tube inserts that are inserted per tube
and the throttle main plate which is mounted on top of the tube inserts as can be seen
in figure 4.2. During erection it must be assured that the throttle plate is mounted with
the hexagonal shapes faced upward, see figure 3.3.
The throttle plate is mounted with 6 M10 bolts. The bolts prior to assembly need to be
greased using HT1200 paste from Interflon. This paste is approved for food
applications. The bolts need to be tightened with a torque of 30 Nm.
3.8. Position of plate with distribution nozzles
Notice
To prevent backflow of particles into the inlet piping upon a sudden stop of the pump,
the orientation of the plate with distribution nozzles is important. In the below figure,
the correct orientation of the distribution plate is shown. In order to achieve the correct

orientation, a straight line could be imagined between nozzles N1 and N15. The correct
orientation is guaranteed if this line passes only one nozzle (the centre one) when going
from N1 to N15 along the distribution plate.
Figure 3.5: Top view of the distribution plate that shows the correct orientation of the
distribution plate/nozzles to the N1 and N15 nozzles.
3.9. Orifice located at the inlet of the Inlet Bonnet
Notice
An orifice is installed at the connection between the inlet piping and the fluid side inlet
of the inlet bonnet, nozzle N1, See also the below the schematic figure. The orifice has
a diameter of 40 mm.

Figure 3.6: Orifice at entrance of Inlet Bonnet.
3.10. Assembly of Glasses in Sight Glass Body
The sight glasses need to be assembled in the sight glass body with a gasket between
the glass and the body and a similar gasket between glass and the sight glass cover.
The covers are mounted with 8 M6 bolts that need to be tightened using the order as
shown in figure 4.7 and using a tightening moment of 3.5 Nm. Since the applied gaskets
have some relaxation after first tightening, the bolts need to be checked on the right
torque 3 hours minutes after the initial tightening.
Figure 3.7: Tightening moment and order of tightening for sight glass covers

To prevent personal injury in case of a breakage of the sight glasses and sunflower oil
being sprayed outwards, the sight glass is equipped with a Plexiglas cover to contain
the spray.
3.11. Earthing of equipment
To ensure that no electrical static potential can develop, the equipment must be
properly earthed on the supports of both the heat exchanger as well as the particle
separator.
Figure 3.8: Earthing of equipment

4. Operational Procedures
4.1. Pre-operational Checks
When the equipment is completely installed, the critical components of the system
which affect the operation of the system should be re-checked. In this paragraph, the
parts or components of the system are described that should be checked thoroughly
before starting the commissioning procedure.
4.2. Filling the System / Checking for leakages
At the first start-up or after a regular maintenance shutdown, the following steps must
be followed before the cleaning particles can be added to the system.
1. At the first start-up it can be considered to fill the unit with fresh water and to
pressurize it as a means to check for leakages. Using water has as an advantage that
when leakages would be found in welds, it is more easy to repair. Once filled with
sunflower oil, defects in welds will be more difficult to repair since oil will be present
in the porosities of the stainless steel metal.
2. Fill the unit with water or sunflower oil by using a fresh water connection or by
system pressure created by the main pump.
3. Before filling the main ball valve in the inlet line V019H (the one at the tie-inn
position) should be closed and the flow control valve 9041 FCV and the ball valve
V020H after the split of the control flow and before the inlet head should be opened.
4. It is required to gently fill the unit from the bottom side onwards. This to prevent
flow of particles from the inlet channel to the bottom bonnet. Filling is started by
gently and partly opening the ball valve V019H in the inlet line.
5. Kindly note that the vent valve on the top of the outlet bonnet and on the particle
separator must be kept open during filing. In all cases, after filling the vents need to
be opened to check is all air is removed.
6. Inspect the system for leakages.
7. In case water is used to fill the system, the water should be entered from the most
bottom drain in the line from the ball valve V021H after the split of the control flow
valve and the entrance into the inlet head.

8. In case water is used to test for leakages, and if no leaks are observed; after testing
water needs to be drained from the system.
9. In case sunflower oil is used; drain (to the extend possible) the sunflower oil back to
the feed tank by closing the outlet piping from the particle separator by the ball
valve V018H and opening the vent. The oil will then by the difference in height flow
back into the feed tank. For this all valves in between the tank and nozzle N1 of the
heat exchanger need to be open.
4.3. Filling Cleaning Particles
Caution!
While filling up the cleaning particles in the system, care must be taken not to spill the
cleaning particles out or on the floor. Because of the shape and size of the particles, the
floors may get slippery. This may lead to a fall of an operator with possible physical injuries.
Particle can be filled using nozzle N10. As an alternative also nozzle N14 can be used.
For filling it is required that the bottom side of the system till the height of the sight glass
contains sunflower oil.
1. With the system partly filled with sunflower oil such that the sight glass is fully
covered in sunflower oil, the system can be filled with cleaning particles.
2. Before opening nozzle N10 or N14 ensure that valves 9041 1 FCV, V019H and V020H
are closed.
3. Remove either the blind flange on nozzle N10 or open inspection nozzle N14 on the
particle separator.
4. To prevent spilling of particles it is recommended to use a funnel to enter the
particles.
5. Fill in the required amount of 1450 kg SS cleaning particles gradually and
periodically check if the particle level has reached the particle separator.
6. After the filling of particles, the level of particles in the system should have reached
a height of about xx mm below the perforated plate in the particle separator.

7. Close the particle separator by re-installing the blind flange with gasket. Now the
downcomer and separator are filled with cleaning particles.
8. Fill unit with sunflower oil as per the normal operating procedures till the system is
completely filled as explained in section 4.2.
4.4. Start – Up
The basic philosophy of starting the fluidized bed system is that first the correct flow
should be realized. Thereafter, particle transport can be started until the desired volume
fraction of particles in the tubes is achieved.
1. With the system completely filled with sunflower oil and all air removed from the
system by the vents, the system is ready for start-up.
2. Before the main pump 660 is started, it is important to verify that all flow from this
pump will pass through heat exchanger 9041 and that no flow will go through plate
heat exchangers 965 A and B. For this the ball valve (indicated red in figure 3.6)
should be closed and the V018H (indicated in green) needs to be open.
Figure 4.1: Valve position outlet heat exchangers 965 A and B.

3. Ensure that flow control valve 9041 FCV is fully closed and that ball valve V019H and
V020H in the inlet line to heat exchanger 9041 are open.
4. When all valves are in their correct position pump 660 can be started.
5. After starting the pump, ensure that the flow through heat exchanger 9041 as
measured by flow transmitter 0FT 660 is above [x] kg/h.
6. Once the flow is above the minimum required, particle transport can be started.
Particle transport is started by gradually opening valve 9041 1 FCV. When a rise in
the measured pressure drop over the tube bundle is seen, the valve should be kept
in position and after x minutes can be put on automatic. {The last part will need to be
finetuned during commissioning}.
7. The differential pressure drop across the heat exchanger tubes shall be around [x]
mbar which suggests that the porosity in the heat exchanger tubes is ~88% and the
system is running with stable fluidization in the tubes with SS cleaning particles.
8. Once a stable fluidized bed is achieved, the shell side flow (heating medium) can be
started. This can be either the flow at the shell side of the lower bundle (“deo-olie”)
or the steam flow in the upper bundle.
4.5. Checking correctness of pressure drop fluidized bed
The pressure drop by the fluidized bed is monitored by the differential pressure as
measured by transmitter 1 PT 9041 which is corrected for the static head between the
2 sensors and the hydrodynamic pressure loss in the system like earlier described;

∆𝑝9041,𝐹𝐵 = 1𝑃𝑇 9041 − 𝜌𝑖𝑛𝑙𝑒𝑡 ∙ 𝑔 ∙ 𝐻𝑠𝑦𝑠𝑡 − ( ) ∆𝑝ℎ𝑦𝑑,100%
33,000
An Important check as can be done by operation to verify the correctness of the reading
is to check that;
1) the value for ∆𝑝9041,𝐹𝐵 should be around 0 when the mass flow through the system is
nil. Deviations of +/- 30 mbar can be ignored and are the likely result of fluctuations in
the density.
2) the value for ∆𝑝9041,𝐹𝐵 should be around 0 when the mass flow through the system is
around the 100% or 33,000 kg/h and the fluidized bed has not been started. Deviations
of +/- 40 mbar can be ignored and are the likely result of fluctuations in the density or
changes in the normal pressure drop over the system.

4.6. Shutdown
In case of a planned stoppage, the system shall be shut down using the following
procedure:
1. Shut off the steam supply to the system by closing the steam temperature control
valve 0TCV 9041 and also closing the steam close-off valve 0CV 9041. This will the
energy input to the upper bundle.
2. Shut-off the energy input in the lower bundle by the hot incoming “Deo-Olie” by
opening the by-pass 9041 0FCV fully and subsequently closing the shut-off valve
9041 1 CV.
3. Maintain flow and the fluidized bed in the 9041 heat exchanger until the outlet
temperature as measured by 3TT 9041 is almost the same as the incoming oil
temperature measured by 0TT 9041.
Notice
Upon stopping the heat input to heat exchanger 9041, the particles are still
very hot. This means that to avoid any fouling in downcomer of heat exchanger
it is best to maintain the heat exchanger in circulation until it has cooled off.
4. When the unit has cooled down, particle circulation can be stopped by closing valve
9041 1FCV in the control flow line.
5. Keep the flow through the heat exchanger constant for 15 minutes. This allows the
majority of the particles to be collected in the particle separator vessel.
6. After 15 minutes the main oil flow through the unit can be stopped by gradually
throttling the main flow or by opening the flow to the original heat exchangers 978
A.

4.7. Discharging/Draining the Process Liquid
Caution!
The process liquid can be hot and is flammable. Thus, proper care must be taken while
discharging the process liquid to avoid harm to the operators or the environment.
This procedure should be followed in order to discharge or drain process fluid from the
system only after the shutdown procedure is completed.
The heat exchanger 9041 has a drain nozzle N20 located at the top side of the inlet
channel. This is the preferred nozzle to use for draining the process liquid and has the
least chance of taking cleaning particles with the drained liquid.
1. Before draining the unit, is should be checked that valve V018H (ball valve in outlet
line) is closed and valve V019H is closed (ball valve in inlet line)
2. Slowly partly open valve V027H.
3. After partly opening valve V027, gently open the vent valve V016H on top of the
particle separator.
4. Monitor if the flow out of nozzle N20 is steadily and not to strong. Then finally open
the drain nozzle in the bottom bonnet to drain remaining process liquid.
5. The speed of draining can be monitored by the pressure indicator which is mounted
near to the heat exchanger inlet, PI A007.
Caution!
Draining from the heat exchanger side will go faster than from the side of the downcomer.
This is because of the resistance of the packed bed of particles in the downcomer. Beware
that oil will drain from the downcomer for a longer period. Be patient. Do not open
inspection nozzles to soon!

4.8. Removing Cleaning Particles from the System
Caution!
While removing the cleaning particles from the system, care must be taken not to spill the
cleaning particles out or on the floor. Because of the finished surface and the size of the
particles, the floors may get slippery. This may lead to a fall of an operator resulting in an
accident involving physical injuries.
Before removing the cleaning particles, the discharging of process fluid must have been
completed.
Caution!
Before opening any flanges of the system care must be taken that the system is free of
process liquid and that is has no internal pressure.
Check always if the vents at the top side of the heat exchanger 9041 and the particle
separator 9041A are open and that the pressure indicator at the bottom side PI A007 shows
atmospheric pressure.
To remove cleaning particles, the downcomer is equipped with a particle discharge
nozzle at the bottom of the long radius bend in the downcomer.
1. As preparation a drum or plastic storage tray needs to be installed underneath the
particle discharge nozzle.
2. From the blind flange as mounted on the discharge nozzle, 2 bolts should be
completely removed.
3. After removing the first 2 bolts, the remaining 2 bolts van be alternately loosened
such that an equal gap appears.
4. If possible the gasket can be squeezed out of the gap by using a screw driver.
5. At some moment the particles will start flowing from the downcomer through the
spalt and will fall into the drum or tray.
6. The removal can be assisted by adding some fresh oil into the particle separator
using nozzle N10 or N14.

5. Monitoring Operation of the System
This chapter includes three major points which will help the operator to monitor the
operation of the self-cleaning fluidized bed heat exchanger.
5.1. Pressure Drop over the Tubes
The pressure-drop across the tubes or between the inlet channel and the outlet channel
can be monitored using ∆𝑝9041,𝐹𝐵 . This value is in the DCS derived from the measured
value of 1𝑃𝑇 9041 as is described in Chapter 3. This pressure drop gives an indication
of the amount of cleaning particles present in the tubes. This amount is defined as the
bed porosity which can be calculated as described in Appendix A1. For this system, the
pressure-drop over the tubes should be between 900-1000 mbar.
5.2. Movement of Cleaning Particles in Downcomer
The movement of cleaning particles through the downcomer can be monitored by
viewing the sight glass. On average, for a porosity of between 88% and 90%, the bed
should move down in the downcomer with a velocity of about 8 cm/s.

6. What-If Scenarios
In this chapter the main scenarios which indicate failure, or improper or unsafe working
of the system are listed. The possible reasons for these failures and the solutions to
correct the parameters to get the plant running in the normal safe and proper fashion
are explained.
6.1. Reduced Pressure-Drop over the Heat Exchanger Tubes
A reduced pressure drop normally indicates that fewer cleaning particles are present
in the heat exchanger tubes. In case this is observed, the following should be checked:
1. Check if the flow is at normal conditions by checking the measured value of 0FT 660.
The flow should be between 27 and 33 ton/h.
2. If the found flow on the flow meter is correct, please check if all valves are closed
that would allow a by-pass through the original heat exchangers 978 A and the
plate heat exchangers 965 A and B. One of theses valves is the valve indicated in
red in figure 4.1
3. If the flow is correct and there can be no by-pass flow then check the movement of
the packed bed of cleaning particles moving downwards in the downcomer
through the sight glass. If the movement is normal, then it most likely there is
something wrong with the measured value for the differential pressure by
1𝑃𝑇 9041. Please check the instrument.
4. A second alternative for checking the movement is to listen to the sound in the
downcomer. this (even with a hot downcomer) can be done by using a small
screwdriver and putting this with the sharp side on the downcomer and pushing
the other end to one’s ear.
5. If the movement of cleaning particles in the downcomer is indeed lower than
normal, the reduced pressure drop is caused by a reduced supply of cleaning
particles into the inlet of the heat exchanger. This can be due to the following
reasons:
a. The flow of the control flow has reduced. This can be checked by slightly closing
the ball valve in the downward line to the heat exchanger, valve V020H. This
will increase the pressure available to drive the control flow. If this work most

likely there has been increased resistance in the downcomer. Monitor how the
situation will develop and of after some time the valve can be fully opened
again.
b. The valve 9041 1FCV is an automatically controlled valve to keep the pressure
drop over the tubes constant. Please verify if the valve position in the last
period before the detected problem has been same as the normal value. Care
should be taken that this opening should not be more than 80-85%. If a more
than 80-85% opening is needed, it means that there is not enough flow through
the control flow line.
6. A test that can be done to test if the pressure drop over the tube reacts to a change
in control valve is by fully closing the automatic control flow valve to a valve position
of 0%. After closing the control flow valve the pressure drop over the tubes should
reduce and approach 0 mbar. If the pressure drop reacts like expected restart
particle transport by the normal procedure and see of the desired pressure drop
is reached with normal valve openings.
6.2. Pump Failure or Tripping
There are chances of pump failure due to various reasons like power cut, motor
tripping, or any other process or operation related factors. Upon a pump trip there are
chances of particles entering the inlet bonnet and in the worst cases of particles
entering into the inlet line between valve V020H and the inlet of the bonnet where the
orifice is installed.
Upon a restart please pay additional attention that the correct flow is realized before
particle transport is started. Also, check if valve 660 FCV has an opening that matches
the normal values. If this valve has an opening which is more than normal this could
indicate that particles are blocking the inlet line. This finding can be confirmed by the
pressure reading before the inlet of heat exchanger 9041, pressure gauge PI A007. This
value should be in normal conditions around [x] bara. Value to be confirmed during
commissioning.
In case some particles have entered the inlet pipe the system should be able to push
the particles back into the inlet channel of the heat exchanger.

7. Maintenance
In this chapter the maintenance actions are described in case of anomalies and the
actions required during a planned preventive outage. In this chapter it is assumed that
prior to the maintenance activity the unit has been drained. For the activities where it
is required to take out the particles from the system, this will be indicated. Both draining
the unit from process liquid as the removal of particles is described in Operational
Procedures Sections 6 and 0 respectively.
7.1. Maintenance Action in Case of Anomalies
If an anomaly requires inspection by opening any of the component follow the draining
procedure as described in Chapter 4.
Caution!
Before opening any flanges of the system care must be taken that the system is free of
process liquid and that is has no internal pressure.
Check always if the vents at the top side of the heat exchanger 9041 and the particle
separator 9041A are open and that the pressure indicator at the bottom side PI A007 shows
atmospheric pressure.
Checking the Correct Reading of the DPT
The instrument measuring the differential pressure over the tubes is important for a
proper monitoring of the system. In case of doubt about the reading, one easy checks
can be done. This check is reduce the flow in the heat exchanger to 0 ton/h. In that case
the direct reading of instrument 1𝑃𝑇 9041 should show the static head of the sunflower
oil between the bottom and the top reading which is about 1500 mbar. The in the DCS
shown value of ∆𝑝9041,𝐹𝐵 should show a value of around 0 mbar.
Cleaning the Distribution Plate
Normal procedure to clean the distribution plate is:
1. Move all or maximum possible cleaning particles in the heat exchanger to the
particle separator. This can be done by first stopping the control flow and

thereafter increasing the flow to around 120% of the normal value, so to a flow
of 36 ton/h.
2. Drain the process fluid from the heat exchanger using the standard draining
procedure provided in Chapter 3.
3. Before dismantling of the inlet bonnet with the distribution plate there is no
need to remove cleaning particles from the downcomer.
4. Disconnect the piping from the inlet bonnet.
5. Lower the distribution plate by using 3-4 long threads that replace the normal
bolts. After installing the long threads the other bolts in the 3-flange system at
the bottom of the inlet channel can be removed. By the treads the bottom inlet
with on top the distribution plate can be lowered for inspection and cleaning.
During the lowering of the distribution plate some particle that still are on top
will fall. So, use a plastic tray underneath the heat exchanger to collect the
particles that will fall.
6. After inspection and cleaning re-install the inlet bonnet with the distribution
plate. The particles that have fallen from the components should be collected
and recharged into the system.
Inspection nozzles
The heat exchanger assembly has the following nozzle intended for inspection
purposes in the case of anomalies;
Nozzle Inspection Purpose
N15 after dismantling the temperature transmitter, the flange opening can
be used to inspect the inlet bonnet by an endoscope
N14 nozzle N14 can be dismantled for a visual inspection of the particle
separator
N16 after dismantling the temperature transmitter, the flange opening can
be used to inspect the outlet bonnet by an endoscope
N22 this nozzle is solely intended for inspection purposes of the inlet channel
by an endoscope

7.2. Preventive Maintenance
It is recommended to plan a yearly outage to inspect the self-cleaning heat exchanger.
For an optimum result, it is advised to have an engineer of Klaren present during the
inspection. Prior to an inspection outage all the particles need to be removed.
Inspection Scope
The inspection scope should include the following components and their specific
attention points:
• inlet bonnet:
o downward bend
• inlet channel:
o distribution nozzles
o inlet tubes
o half open flange
• tube bundle / Heat Exchanger
o tubes
• outlet bonnet
o throttle plate
• particle separator
o inlet duct
o bottom conus
o perforated plate
• downcomer
o sight glass; gaskets should be exchanged upon dismantling

o inlet control flow into downcomer
All components should be inspected on overall condition, signs of wear/tear, fouling,
presence of cleaning particles or dirt or deposits.
Inspection of wall thickness of the particle separator and the downcomer
Every 2 years, it is recommended to monitor the wall thickness of the bottom conus of
the particle separator in the area underneath the downward facing bend. The minimum
allowed wall thickness is 4 mm.
Checking Weight Reduction of the Particles
It is recommended to check the weight of the particles during this yearly outage. To
check the weight, the following procedure should be followed:
• Take a sample of particles (hand-full) from one of the drums in which the
particles from the system are stored. It is important to mix the drum a bit before
the sample is taken, so that the sample is a representative one.
• Wash the sample using clean warm water with some soap, rinse the particles
and let it dry completely. Drying can be done in dry air or using an oven.
• Take a random sample of 100 particles and weigh them using a weighing scale
with an accuracy of +/- 0.01 g. Kindly repeat this 10 times and calculate the
average weight of the 10 samples. This value is the average weight of 100
particles and can be compared with the initial weight or with other recordings
of particle weight.

List of Abbreviations
SCFBHE : Self-Cleaning Fluidized Bed Heat Exchanger

DPG : Differential Pressure Gauge
DPT : Differential Pressure Transmitter
SCH : Schedule
DC : Downcomer
VLS : Vapour Liquid Separator
PS : Particle Separator
DPIT : Differential Pressure Indicator & Transmitter
PG : Pressure Gauge
PT : Pressure Transmitter
HR : Heat Recovery

Definition of Terminology
Process Liquid : The liquid feed to be heated in SCHE when SCHE is used as a heat
exchanger.
Control Flow : Control flow is a part of recirculation flow fed to downcomer to boost the
particle movement towards inlet channel.
Main Flow : Main flow is the flow of process fluid coming out from the SCHE.

Appendices
Appendix A1: Calculation of Porosity in Heat Exchanger Tube
The differential pressure over the heat exchanger tube is measured using the
differential pressure meter 1PT 9041. From this value in the DCS system the value for
∆𝑝9041,𝐹𝐵 is calculated. From this value, the porosity across the heat exchanger tube can
be determined as follows;
∆𝑝9041,𝐹𝐵 × 100
𝑃𝑜𝑟𝑜𝑠𝑖𝑡𝑦 = 1 −
(𝜌𝑝𝑎𝑟𝑡𝑖𝑐𝑙𝑒𝑠 − 𝜌𝑙𝑖𝑞𝑢𝑖𝑑 ) × 𝑔 × ℎ
Where,
∆𝑝9041,𝐹𝐵 = the differential pressure across the heat exchanger tube in mbar,
particles = density of the cleaning particles in kg/m³ = 7850 kg/m³
liquid = density of the sunflower medium in kg/m³ = 840 kg/m³
g = is the gravity = 9.81 m/s²,
h = the tube height which is 14 m.

Operating Manual Version 1.0 AZ

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operating Manual Version 1.0 AZ

Uploaded by

Copyright:

Available Formats

O P E R AT I N G M A N U A L

Self-cleaning fluidized bed heat exchanger

THIS MANUAL WILL BE PROVIDED

IN DUTCH LANGUAGE TO THE END CLIENT.

Installed at Cargill B.V.

Amsterdam, The Netherlands

Ref. No.: 151001

0 17/06/2021 For Client AZA/MB MvB MvB

Revision Date Description Author Checked Approved

Page | 1 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

Important Information ....................................................................................................... 4

4. Operational Procedures ............................................................................................. 35

Page | 2 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

4.6. Shutdown .................................................................................................................................. 39

5. Monitoring Operation of the System ........................................................................ 42

6. What-If Scenarios ........................................................................................................ 43

List of Abbreviations ......................................................................................................... 49

Page | 3 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

• This manual should be read carefully before conducting any installation or

manual must be followed.

correct installation and operation of self-cleaning fluidized bed heat exchanger

required, please contact Klaren International B.V.

Page | 4 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

some of the factors to be understood carefully for safer operation:

• Hazards due to non-compliance with the safety instructions:

• Working in a safety-conscious manner:

and working in a safe manner.

• Personal protective equipment:

instructions for the proper use of protective equipment.must be given to the

properly, he can take proper corrective actions if anything happens.

Page | 5 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

The following safety symbols are used in this manual;

Stands for an immediate danger leading to severe physical injuries or death.

Stands for a potentially dangerous situation leading to severe physical injuries

Stands for a potentially dangerous situation which could lead to minor

Page | 6 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

These operating instructions are submitted as a part of the provided technical

operation maintenance of the self-cleaning fluidized bed heat exchanger (SCHE).

lifetime of the equipment.

The operating company must supplement these operating instructions with

basis of respective national regulations for safety.

operating or troubleshooting instructions of bought-out items like pumps, motors, etc.,

list of manuals of subsupplied components in this document (appendix B1), if

development of the equipment covered by these operating instructions.

Page | 7 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

Illustrations and drawings in these operating instructions are simplified

representations. As a result of improvements and changes, it is possible that the figures

Klaren cannot accept liability for damages:

- due to improper operating conditions,

- due to inadequate maintenance,

- due to improper operation,

- due to incorrect installation,

- due to incorrect or improper connections,

- resulting from or attributed to any improper modifications, failure to observe the

- through the use of accessories or spare parts not supplied or recommended by

Technical documents submitted:

- General Arrangement Drawings for all the components of SCHE system.

Page | 8 Operating Manual for Self-cleaning Fluidized Bed Heat Exchanger

Klaren International is a technology and engineering company based in the

system and it describes the required maintenance activities.

guide for troubleshooting.

fluidized cleaning particles in the tubes. It is designed based on continuous cleaning

and increasing the equipment life.

Self-Cleaning Fluidized Bed : 14 m _ m _ m