Bom Instruction Manual Plate Heat Exchangers N4 M7 N21 UT7 U3 U6 Part number 1644725-01Table of contents English DIVERSIFIED HEAT TRANSFER, INC. Table of contents a Description . ‘Main component Funetion ..... ‘Semi-welded PHE.... eas Installation Requirements Liting Raising ... Beow Operation ...... Start-up i Unit in operation .. Shut-down. Doan Maintenance no Cleaning-In-Place (CIP) Manual cleaning Pressure test after maintenance. Regasketing BSown Except for this Instruction Manual, the following documents are also included in this shipment: — Plate Heat Exchanger (PHE) drawing = Plate hanging list Parts list with exploded view drawing,English Environmental compliance AlfaLaval endeavours to perform its own op- erations as cleanly and efficiently as possi- ble, and to take environmental aspects into considerattion when developing, designing, manufacturing, servicing and marketing its products. Unpacking Packing material consists of wood, plastics, card- board boxes and in some cases metal saps + Wood and cardboard boxes can be reused, recycled or used for energy recovery. + Plastics should be recycled or burnt at a licensed waste incineration plant. + Metal straps should be sent for material recy- ling. Environmental compliance Maintenance + During maintenance machine are replaced. + All metal parts should be sent for material recy ling, + Worn out or defective electronic parts should be sent to a licensed handler for material recycling, Oil and all non metal wear parts must be taken. care of in agreement with local regulations. and wear parts in the Scrapping ‘At end of use, the equipment shall be recycled ac- ‘cording to relevant, local regulations. Beside the ‘equipmnet itself, any hazardous residues from the process liquid must be considered and dealt with in ‘proper manner. When i doubt, or in absence of lo- cal regulations, please contact the local AlfaLaval sales company Plate Heat ExchangerDescription English DIVERSIFIED HEAT TRANSFER, INC. Description a | Main components Carrying bar Bolt ‘Support Frame plate Gariesthechannelplates \, protection column and the pressure plate. Tightening bolts Press the channel plates together. , A Connections Holes through the frame plate, permitting the media to enter into the heat exchanger. ‘Threaded studs around the holes secure the pipes to the ap- paratus, Metallic or rubber-type linings may be used to protect the holes against corrosion, Guiding bar Keeps the channel plates inline at their lower end. Connections can also be pipes. {or welding or threaded. Pressure plate Moveable steel plate. in some cases pipes may be connected to the pres- Channel plates enae Heal is transferred from one ‘medium to the other through the thin channel plates. as Pipe connections ‘The number of plates deter- mines the total heat transfer surface. Protective sheets In the USA mandatory, in other countries optional. Plate Heat Exchanger -1English Function The plate heat exchanger consists of a pack of corrugated metal plates with portholes for the pas- sage of the two fluids between which heat transfer will take place. The plate pack is assembled between a frame plate and a pressure plate and compressed by N4, N7, N24, UT 7 N4, N7, N21, UTZ. A B The A-plate is a plate The A-plate is a plate hanging with the chevron hanging withthe chevron. pointing downwards. pointing upwards. Semi-welded PHE For certain plate sizes there are semi-welded plates (Cassettes) available. The function of the semi-welded PHE is the same as that of the con- ventional PHE. Chapters Installation and Opera- tion of this manual are applicable to full extent. Chapter Maintenance Is fully applicable when it The B-plate is a plate hanging with the chev- ron pointing upwards, Description ‘DIVERSIFIED HEAT TRANSFER, INC. tightening bolts. The plates are fitted with a gasket which seals the channel and directs the fluids into altermate channels. The plate corrugation pro- ‘motes fluid turbulence and supports the plates against differential pressure. U3, U6 A B The B-plate is a plate hanging withthe chevron pointing downwards, ‘comes to the parts Cleaning-in-Place and Pres- sure test after maintenance and partially applica- ble for the remaining part. To cover the specific requirements of the semi-ivelded PHE a separate additional manual has been made. G-2 Plate Heat ExchangerLifting Warning! Never lift by the connections or the studs around them. Straps should be used when lifting. Place straps Raising according to picture. Place two timber beams on the floor. oO Place straps around one bolt on each side. "SS Lift the neat exchanger off pallet using e.g @ ave Lift the heat exchanger off the timber beams, Place the heat exchanger on the timber \ beams, Lower the heat exchangaro horizontal m-4 Plate Heat ExchangerOperation English DIVERSIFIED HEAT TRANSFER, INC. Operation cose fs | Note! If there is a valve at the exit, make sure it If several pumps are included in the system, 8 is fully open. wee oe Open the vent and start the pump. Note! Adjustments of flowrates should be made slowly in order to avoid the risk of water hamme Water hammer is a shortlasting pressure peak that can appear during start-up or shut down of a system, causing liquids to travel along a pipe as a wave at the speed of ‘sound. This can cause considerable damage e Open the valve slowly. to the equipment. Open slowly Check that measurement A is correct. For ‘A, see enclosed PHE-drawing. pump and the unit controlling the system flowrate. e Check that the vaive is closed between the e Repeat steps 1~ 6 for the second media. Eu Plate Heat ExchangerEnglish Unit in operation Note! Adjustments of flowrates should be made slowly in order to protect the system against sudden and extreme variations of temperature and pressure. During operation, check that + av 7 7 media temperatures and pressures are within the limits stated on the PHE-draw- ing no leakages appear due to faulty tighten- ing of the plate pack or to defective or damaged gaskets support column, carrying bar and guiding bar are kept clean and greased the bolts are kept clean and greased. greased No leakage ‘Always consult your local Alfa Laval Representa- tive for advice on + new plate pack dimensions if you intend to change number of plates + selection of gasket material if operating temper- atures and pressures are permanently changed, or if another medium is to be proc- essed in the PHE. Operation Shut-down Note! {several pumps are included in the system, make sure you know which one should be stopped first. Slowly close the valve controlling the flow= 0 rate of the pump you are about to stop. e ‘When the valve is closed, stop the pump. e Repeat steps 1-2 for the other side, °e Ir the heat exchanger is shut down for sev- ‘eral days or longer, it should be drained. Draining should also be done if the proc- ‘ess is shut down and the ambient temper- ature is below freezing temperature of the media. Depending on the media proc- ‘essed, itis also recommended to rinse and ‘ry the heat exchanger plates and connec- tions. Plate Heat ExchangerMaintenance English ‘DIVERSIFIED HEAT TRANSFER, INC. Maintenance Cleaning-In-Place (CIP) ‘The Cleaning-In-Place (CIP) equipment permits CIP performs Cleaning of the plate heat exchanger without opening it + cleaning of fouling and descaling of lime deposits IfCIP cannot be done, cleaning must be performed + passivation of cleaned surfaces to reduce sus- manually, see section *Manual cleaning’. ceptibility to corrosion + neutralization of cleaning liquids before draining, Follow the instructions of the CIP equipment. CIP equipment Maximum number of plates CIP model ve | Me | Meat wo wH04H| TSE Cleaning liquids Cleaning liquid Description Caustic ‘Asstrong alkaline iquid, for removing paint, ft, oil and biological deposits. Phosphate ‘An acid cleaning liquid for removing metallic oxides, rust, lime and other inorganic scale. Passivate ‘An alkaline liquid for passivation (inhibition of corro- sion). Neutralizer A strong alkaline liquid for neutralization of AlfaCar- bon or AlfaPhos before drainage. Plate Heat Exchanger Eu -7English Manual cleaning Warning! AN Maintenance ‘DIVERSIFIED HEAT TRANSFER, INC. Opening To avoid hand injuries owing to sharp | edges, protective gloves should always be Warning! y wor when handing plates and protective ifthe heat exchanger is sheets hot, wait untilithas cooled 40°C by--104°F down to about 40 °C (104 °F). oO Drain the plate heat exchanger. Inspect the sliding surfaces of the carrying bar and wipe clean. Plate Heat ExchangerMaintenance English DIVERSIFIED HEAT TRANSFER, INC. ec a= See also point 5 under part 'Ciosing’. If plates are to be numbered, do this before removing the plates. Plates need not to be removed if cleaning is done using only water, ie. without clean- ing agent. atthe positions indicated below. Use these remaining 4 bolts to open the plate pack according to the following scheme. e Loosen and remove all bolts except the 4 ‘Step Bolt No. To dimension the plates 1,054, Opening Warning! Be careful so that the plate and pressure The plate pack may still contain a small re- plate are always in parallel, Skewing of the sidual amount of liquid after draining. De- pressure plate during opening must not ex- pending on the type of product and type of Coed 10 mm (2 turns per bolt) across the installation special arrangments, e.g. with and 25 mm (5 turns per bolt) vertically drainage box, may be necessary to avoid damages on personnel and equipment. Plate Heat Exchanger -9English Maintenance B Manual cleaning of opened units ‘DIVERSIFIED HEAT TRANSFER, ING. Caution! Note! Never use hydrochloric acid with Be careful not to damage the gasket dur- stainless steel plates. Water of more ing manual cleaning. than 330 ppm Cl may not be used for the preparation of cleaning solutions, Itis very important that carrying bars. and support columns in aluminium are protected against chemicals. Deposits removable with water and brush Plates need not to be removed from the plate heat exchanger during cleaning, hose. Remove deposits using a soft brush and Rinse with water using a high pressure Oz e Deposits not removable with water and brush Plates must be removed from the plate heat exchanger during cleaning, oO Brush with cleaning agent. Qe Rinse with water. EI- 10 Plate Heat ExchangerMaintenance English Cleaning agents — Incrustation, scaling Concentration max 4% Temperature max 60 °C (140 °F) Incrustation — Scaling Sediment Cleaning agent Calcium carbonate Corrosion products Nitric acid Calcium sulphate Metal oxides: Sulfamic acid Silicates silt Citric acid ‘Alumina Phosphoric acid Diatomic organisms and Complexing agents (EDTA, NTA) their exorement of various Sodium polyphosphates, colours Cleaning agents - Biological growth, slime Concentration max 4% ‘Temperature max 80 °C (176 °F) Biological growth — Slime Cleaning agent Bacteria ‘Sodium hydroxide Nematodes ‘Sodium carbonate Protozoa Cleaning effect can be considerably increased by the addition of ‘small quantities of hypochlorite or agents for the formation of com- plexes and surfactants. Cleaning agents - Oil residues, asphalt, fats Deposit Cleaning agent Oil residues. Paraffinic naphta-based solvent (e.g. kerosine) Asphalt Fats Note! Gaskets in EPDM rubber qualities swell in these media. Contact time should be limited to 30 minutes. Caution! The following solutions should not be used. + Ketones (e.g. Acetone, Methyletyike- tone, Methylisobutyiketone + Esters (e.g. Ethylacetate, Butylacetate) + Halogenated hydrocarbons (e.g. Ghioro-thene, Carbon tetrachloride, Freons) + Aromatics (e.g. Benzene, Toluene). Plate Heat Exchanger "1English B Closing Oo 8 8 Maintenance ‘DIVERSIFIED HEAT TRANSFER, INC. Check that all the sealing surfaces are Press the plate assembly together. Tight- clean, ening is done in two steps, see figures be- low. Be careful so that the frame plate and the pressure plate are always in parallel. Brush the threads of the bolts clean, using a steel wire brush. Lubricate the threads ‘step | BottNo. | Todimension with a thin layer of grease, e.g. Gleitmo 800 or equivalent. 1 [12 of 34 0A 2 1234 A Tighten the two diagonal pair of bolts alter- nately until the plate package measures 4,104, Attach gaskets tothe plates or check that ee all the gaskets are properly attached. a Note! : i If the gasket is wrongly positioned, it will 4 ca show by the fact that rises out of the gas- ket groove or that itis positioned outside: the groove. Insert the plates wih the herring bone pat After that bots are tightened alternately tem positioned in alternate directions and with the gaskets turned towards the frame, ane! dlegonslly;as shown i fhe.Agure, be plate. -12 Plate Heat ExchangerMaintenance English eee Pressure test after maintenance Finally the middle pair of bolts, and upper and lower bolts are tightened. Before start-up of production, whenever plates or gaskets have been removed, inserted or exchanged, itis strongly recommended to perform a pressure test to confirm the internal and external sealing func- tion of the PHE. At this test, one media side at the time must be tested with the other side open to the atmosphere. ‘The pressure testing shall be performed at a pres- sure equal to the operating pressure of the actual unit but never above the design pressure as stated on the nameplate. ‘The recommended test time is 10 minutes. Please note that PHE units for refrigeration applica- tions and units with media not mixable with water ‘must be dried after hydrostatic pressure testing, Note! Please consult the loca officelrepresentative of the ‘The actual measurement must never be ess Supplier for advice on the pressure testing proce- than the A-dimension. dure. edges form a “honeycomb” pattern, see e If the plates are correctly assembled, the picture below. Plate Heat Exchanger I-13English Maintenance Regasketing oO oo 8 Open the plate heat exchanger according to page 8, and remove the plate that is to have a new gasket. Remove the old gasket. Assure that all sealing surfaces are dry, clean and free of foreign matter. Attach the clip-on gasket to the plate. Slip the gasket prongs under the edge of the plate. Glued gaskets DIVERSIFIED HEAT TRANSFER, INC. Separate gluing instructions will be delivered togeth- er with the glue. il ° e Note! Make sure the two gasket prongs are in correct position. Proceed with the next plate to be regasket- ed until all plates in need of regasketing are done with, Close the plate heat exchanger according to page 12. LEN a Plate Heat Exchanger