Chapter 4 Kaori BPHE User Manual
Contents
1. Kaori BPHE can be used in Heat pumps Industrial chiller plastic machines welding machines hydraulic presses oil and compressor oil cooling Air conditioning Refrigeration Air dryer Water cooler drinking water or process water for various industries Temperature holding for storage tanks Heat recovery including heat recycling from hot steam Indoor heating including floor heating Refrigerant applications BPHE function as Evaporators Condensers Super heaters for gas Desuper heaters for gas Subcoolers for condensate Economizers Intercoolers Oil coolers 3 Advantages Kaori BPHE provides many advantages such as Highly thermal efficiency Compact in size and light weight High allowable working pressure High thermal resistances and high operating temperature Lower cost for the same performances Lower pressure drop and high corrosion resistance No gaskets required therefore no leakages Easy installation easy replacement with less maintenance Durability 4 3 4 Specification amp BPHE Dimension Type L1 L2 W1 W2 Weight Thickness Area Volume NO mm mm mm mm Kg mm 2 Liter Channel of plate K025F 205 172 73 42 0 81 0 04 1 8 2 27 N 1 0 012 0 025 60 K025F A 206 2 172 74 2 40 0 3 0 044 2 11 2 25 2 0 012 0 025 60 K025F B 206 2 172 742. 2 42 0 3 0 044 N 2 11 2 25 2 0 012 0 025 60 K030 194 154 80 40 0 8 0 05N 10 2 25 0 0117 0 025 60 K030E 194 5 154 80 5 40 0 3 0 045N 7 2 25N 0 0117 0 025 60 K030S 194 154 80 40 1 2 0 05N 12 2 25N 0 0117 0 025 60 K040 311 278 73 40 0 84 0 07N 10 2 3N 0 01946 0 040 60 KO40E 311 278 73 40 0 68 0 07N 942 3N 0 01946 0 040 60 K040S 311 278 73 40 1 3 0 07 12 2 3 0 01946 0 040 60 K050 306 250 106 50 1 5 0 135N 10 2 4N 0 0255 0 055 100 K050S 306 250 106 50 2 2 0 15 1242 4N 0 0255 0 055 100 K070 304 250 124 70 1 6 0 15N 10 2 4N 0 03 0 065 100 0705 304 250 124 70 2 5 0 17N 12 2 4 0 03 0 065 120 K095 522 466 106 50 3 1 0 22 10 2 4N 0 0475 0 095 100 K095S 522 466 106 50 5 0 0 24N 13 2 4 0 0475 0 095 100 K105 504 444 124 64 3 5 0 24N 10 2 4N 0 0533 0 107 120 K105S 504 444 124 64 6 240 27N 13 2 4 0 0533 0 107 120 K200H 613 519 186 92 7 12 0 41N 1442 4N 0 09446 0 206 160 K200L 613 519 186 92 7 12 0 41N 1442 4N 0 09446 0 206 160 K200M 613 519 186 92 7 12 0 41N 1442 4N 0 09446 0 206 160 K200S 613 519 186 92 11 88 0 47N 17 2 4N 0 09446 0 206 160 K200E 613 519 186 92 1 84 0 4 11 5 2 4 0 09446 0 206 160 K205 528 456 246 174 7 2 0 52N 11 542 4N 0 1099 0 232 200 K205S 528 456 246 174 12 9 0 59N 14 54 2 4N 0 1099 0 232 190 K210 527 430 245 148 8 5 0 490N 11 2 85 0
3. condenser from top right In the case of condenser heat is transferred from refrigerant to water and both fluids are in counter flow direction Mounting suggestions There are four different ways to mount the BPHE a Bottom support b Sheet metal bracket c Crossbar amp bolts d Stud All items should be supported independently Do not apply excessive forces to the fittings Except for small sized K030 model our BPHE cannot be fastened directly to the fittings piping Using flexible hoses or vibration dampers to reduce pulsation shock or vibrations that are caused by the operating system 4 8 8 Anti Freezing Protection Methods formation of freezing icing will damage and the refrigeration system The following methods will prevent BPHE from freezing Use brine e g glycol when evaporation temperature is close to the freezing point Low working pressure will cause low evaporation temperature If the evaporation temperature is below 0 it will cause water to freeze Since the bottom portion has the lowest temperature it is the most likely spot for the BPHE to crack To start the refrigeration system always start the water pump for a few minutes and then start the compressor To stop the system always stop the compressor first and then stop the water pump 1 Low Pressure Cut off Switch LP A low pressure cut off switch should be installed with properly set va
4. to protect the hand and wrist against the sharp metal edges If the rubber strip is not a required part of your order be careful of the sharp metal edge When moving the BPHE always wear gloves and pay attention to the sharp edges around the bottom of BPHE Our BPHE can come without the rubber protective strip at your request 12 Warranty Terms Free replacement of the defective unit if the defect is found to be caused by manufacturing material or manufacturing workmanship Warranty period is standard 12 months after delivery date or according to the period listed on the official proforma invoice Exceptions are 1 The failure or malfunction of BPHE is caused by improper or negligent usage of BPHE 2 Malfunctions from freezing or icing flood fire any natural disaster or accident 3 Damages caused by improper or faulty installation or product exposed to corrosive elements harmful to the structure 13 Label and Marking The following nameplate is an example of KAORI BPHE K205 type Kaori brazed plate heat exchanger 3 ype Max working temperature 200 C Max working pressure 30 bar Test pressure 43 bar Made in C 0343 Model name K205 26 26D S9 will be shown on the label attached For tracking purposes a serial no 09052121019 26 26D S9 will be carved on the front cover plate and below the two upper connectors of the BPHE 4 12
5. 1036 0 289 200 K215 529 449 247 167 7 2 0 52 13 2 4 0 11 0 22 200 K215D 529 449 247 167 7 240 52N 13 2 4 0 11 0 22 200 2155 529 449 247 167 13 1 0 52N 16 2 4N 0 11 0 22 200 K040C 314 275 76 40 1 98 0 137N 13 2 0 0 01925 0 0295 60 K040C gt xA 314 275 76 40 2 02 0 124N 13 2 0 0 01925 0 0295 60 K040C gt 8 314 275 76 40 2 06 0 124N 13 2 0 0 01925 0 0295 60 K095C 524 466 108 50 5 0 0 37N 13 242 16N 0 0475 0 071 120 095 524 466 108 50 5 1 0 32 13 242 16N 0 0475 0 071 120 K095C 8 524 466 108 50 5 240 32N 13 242 16N 0 0475 0 071 120 5 Design Condition for Brazed Type Max working Test Pressure Max working Pressure Temperature KO25FxA K025FxB 10 Bar 15 Bar 160 200 C K030E K040E K200E K210 16 Bar 23 Bar 160 200 C K025F K030 K040 K050 K070 K095 K105 K200H K200L 30 Bar 43 Bar 160 200 C K200M K205 K215 K215D K215S 30 Bar 43 Bar 160 200 C 0305 0405 0505 0705 0955 1055 45 65 160 200 C 2005 2055 working Test Pressure Side 1 Sid
6. Chapter4 User Manual KAORI lt 77 81g LX ARIF 78 KAORI HEAT TREATMENT CO LTD BRAZED PLATE HEAT EXCHANGER User Manual pe 5 Working Principle Application Advantage Specification amp BPHE Dimension Design Condition for Copper Brazed PHE Standardized Connections Installation Guide Anti Freezing Protection Methods for BPHE Soldering Instruction 10 Cleaning 11 Warning 12 Warranty Terms Sener Sent 4 1 1 Working Principle Kaori s Brazed Plate Heat Exchanger BPHE consists of chevron plates of acid resistant stainless steel Every other plate is reversed so the ridges of the herringbone pattern intersect one another on adjacent plates forming a lattice on contact points When these points are vacuum brazed together two separate systems of channels for two media flow in counter current are formed The lattice structure causes vigorous turbulence thus ensuring maximum heat transfer The BPHE is a highly efficient corrosion resistant and pressure resistant heat exchanger The standard BPHE is designed to meet 30 bar 200 C with the largest model capable of handling a maximum flow capacity of 900 liter min 4 2 2 Application can be used for various mediums such as All type of refrigerants Nickel brazed models used for Ammonia solvents Water Oil Various brine solutions glycol mixtures CaCle alcohols etc
7. e 2 Side 1 Side 2 K040C K095C 140 Bar 30 Bar 200 Bar 43 160 200 C 040 095 70 Bar 30 Bar 100 Bar 43 Bar 160 200 095 095 100 Bar 30 143 Bar 43 160 200 C 4 5 6 Standardized Connections Connections for fluid applications are threaded connectors Connections for refrigerant units are soldered sweat connectors Threaded Connections PT NPT GB Male PT NPT G Female N Soldered Connections i 5 8 3 4 7 8 1 1 1 8 1 3 8 1 y 16 15 y 19 25 y 22 36 25 60 28 80 35 25 X K 2 2 Ke KK X lt K gt 2 2 2 KK gt lt Threaded Connections Soldered Connections 4 6 7 Installation Guide Illustration of 10 General purpose of BPHE 2 Types of fluid applied 3 Arrangements of fluids directions Application Fluid 1 Fluid 2 Fluid 3 Evaporator single refrigerant Refrigerant A22 A1 Chiller water B1 B2 Evaporator dual refrigerant Refrigerant 1 A22 A1 Chiller wate
8. lues When the actual evaporation pressure is lower than the setting value the compressor will be cut off automatically 2 Low Temperature Thermostat LT The function of the thermostat is to prevent evaporation temperature going under 0 C If evaporation temperature is always above 0 C then water has no chance to freeze and expand 3 Water Temperature Sensor Installation of an anti freezing temperature sensor near the water outlet is another method to prevent the water from freezing The setting temperature is suggested at 4 C for buffering purposes 4 Water Flow Switch Installation of a water flow switch in the water circuit can prevent possible BPHE freezing up due to low water flow rate Usually low water flow rate may be caused by malfunction of water pump leaking pipes pipe blockage due to pipe contamination or dirty filter 4 9 9 Soldering Instruction Cleaning and degreasing the surface of copper pipes and connectors before soldering is important To avoid the inside of copper pipes and BPHE from oxidation protect the inside with Place the BPHE on a flat surface and wrap a wet rag around the connectors to protect the BPHE from excessive heating Use a 40 45 silver alloy soldering rod to weld the copper pipe into the connector at a maximum temperature of 800 C After soldering clean and dry the connection and BPHE 10 Cleaning Cleaning of fouled plate heat exchangers by back flushing will remove
9. most of the soft debris that is blocked the inside The solution used for back flushing shall be weak acids with concentration less than 5 one example the citric acid If the acidity is too high the copper and stainless steel inside the PHE may be etched or corroded Before restarting the system flush the plate heat exchanger with large amounts of fresh water to purge any remaining acid solution 11 Warning Fluid that is explosive extremely flammable highly toxic highly corrosive hazardous in nature cannot be used with the BPHE Examples are nitric acid sulfuric acid ammonia for copper models etc When unknown quality of water is applied to BPHE filter and strainer should be placed at the water inlet of BPHE to filter out the dirt or large particles Mesh size of around 20 is suitable for most cases Blockage of evaporator due to dirt or large particles will reduce the flow rate of water which might cause freezing effect and consequently damage the integrity of the BPHE Chlorinated water seawater etc are not suitable for BPHE due to their corrosive nature on regular stainless steel and copper For example swimming pool water 4 10 Solution which applied to shall have PH values ranging between 6 8 Ground water with high sulfuric compound sulfuric acid low PH value may cause gradual copper corrosion and damage the BPHE in a few years Rubber strips always cover the bottom edge of the BPHE in order
10. r B1 B2 Refrigerant 2 C22 C1 Condenser Refrigerant A1 2 Cooling water B25 Heating Cooling Cold water A22 A1 Hot water B1 B2 Oil cooler Air Dryer Refrigerant Cooling water A22 A1 Refrigerant A22 A1 Cil B1 B2 D22 1 B1 B2 Air gt Separator C1 C2 Air Cil cooling Air compressor Cil A22 A1 Cooling water 2 D1 2 B1 2 B2 Air C12 C2 Always install your BPHE vertically especially for a refrigerant system This is done to secure the BPHE and keep minimum amount of water below the connector In order to achieve high thermal efficiency and high heat transfer rates BPHE has to be installed in a counter flow direction 4 7 When BPHE works as Evaporator the two phased liquid an gas refrigerant enters the evaporator at the bottom left connector and the single phased gas refrigerant leaves the evaporator from the top left connector after the heat transfer process The water enters at the top right connector and leaves from the bottom right In the case of evaporator heat is transferred from water to refrigerant and both fluids are in counter flow direction When BPHE works as a condenser the single phased gas refrigerant enters the condenser at top left connector and the single phased liquid refrigerant leaves the condenser from the bottom left connector The water enters the condenser at bottom right and leaves the
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