UK - Sondex
Contents
1. SONDEX Instruction and Maintenance Manual Spiral Heat Exchanger 1 Content VSS CHUN AE T EE EEA EE AEE T A AE ONAE AE AE Section 2 IMEI CHM AEAEE TAR AE IOLAIR AREON AA ORAE EES A EEA TAR Section 3 Important safety PrecautiONSmaisnepanann a RREAN Section 4 EAT A E A NEN ER E E AEA A EA Section 5 Correct Installato iisseiinr iis a n a E iadaaa aaa EEE E Section 6 SATELY Alert NOCE Sangani anai a E R I A Section 7 Diosa IADE e 0 EA EEE EE A A A E EE E E A E E E Section 8 MastalatiO Menee ssdcesayatsoclocsasdesecn coevesseotscacsstheastseascoctssveaspsssettonseldsseds E A a a a EE Section 9 Maintenance Section10 2 Description This instruction book is meant as a guide in connection with installation operation and maintenance of Sondex spiral heat exchangers A spiral heat exchanger utilizes the spiral flow on both sides of the heat exchanger Spiral heat exchangers are typically used for liquids liquids ratio gas into liquids or condensing of steam into liquids 3 Introduction The instruction book can be used for all spiral heat exchangers produced and delivered by Sondex Sondex cannot be held responsible for damages as a result of incorrect installation use and or maintenance of Sondex spiral heat exchanger in case the instructions in this instruction book have not been observed Please notice that our spiral heat exchangers are specially designed and built for operation conditions pressure tempe2. Build Year 123 Serial Number Marking Nom Capacity kW ize Flow l h 123 Heat Surface m2 123 Product Medium Max Working Pressure Bar 12 12 Max Differential pressure Bar 12 Vol Product side ty h2 Medium side it 12 Min Worki Max Working Temp C T 2 Temp C eo IMPORTANT 4 The starting of the phe must be done without shocks and against closed valves 2 Max working pressure snd tempersture may not be exceeded at any time SONDEX A S DK 6000 KOLDING DENMARK 6 Correct Operation This user manual provides information and instructions for correct and safe operation of the unit Many accidents are caused by incorrect use It is essential that you study the instructions carefully and above all ensure the availability to those who install maintain and operate the spiral heat exchanger on a daily basis This manual is of no value if it is not available at the time when your staff needs it If a problem occurs with your Sondex Spiral Heat Exchanger which is beyond the scope of this manual do not hesitate to contact us The installation should not be put into operation before all indistinctnesses have been solved To avoid injuries and damages follow the instructions and local applicable safety regulations Also take the necessary protective measures depending on the nature of your process or circumstances related to it at your plant We draw
3. construction with only one single channel makes fouling velocity slow but various kinds of deposit on the surfaces of the walls may occur The deposits consist of materials with a low thermal conductivity which will increase the total resistance of the wall In consequence of this a layer of deposits may reduce the total heat transfer velocity heavily and corrosion may appear in cracks below these deposits Sondex recommend all repairs to be undertaken by skilled manpower with a thorough knowledge of spiral heat exchangers 10 3 Cleaning In order to maintain the nominal performances the heat transfer surfaces must be kept clean Cleaning in place CIP without opening the spiral heat exchanger or manual cleaning after opening the spiral heat exchanger see below is possible 10 4 Cleaning In Place CIP The most effective procedure is to rinse the spiral heat exchanger frequently without opening the doors and to use of a suitable solvent acid or alkaline solution The pipes must be supplied with by pass valves enabling circulation of the detergents In order to obtain the best results the flow direction must be opposite the normal flow direction Backflush The detergents must be compatible with the installation and used according to instructions of Sondex Never use solutions with chlorides Make sure that the detergent is suitable for the gasket The flow velocity for the detergent solution must be equal to or larger than the nominal flow
4. velocity However flow velocities significantly lower than the nominal flow velocity can have an acceptable effect when compensating with a prolonged cleaning After cleaning the spiral heat exchanger must be thoroughly rinsed with water in order to remove any detergent surplus especially when acids have been applied Check pH and chloride content in the rinse water The spiral heat exchanger must be totally emptied unless it is set adrift again The type of solution and the cleaning frequency must be fixed in every single case Below follows general directives Type of Deposit Scale Cleaning Detergent Limitation Grease wax Hot water or steam petroleum Grease proteins Sodium hydrate Max 15 and 60 C Fouling of biological growth Sodium hydrate Sodium carbonate Max 15 and 60 C Max 15 and 60 C Calcium Carbonate Calcium Sulphate Silicates sulphide Nitric acid Sulphuric acid Max 15 and 60 C Max 3 and 20 C Metallic oxides Alumenium oxide Corrosives Phosphoric acid Sulfamic acid Citric acid All acids are only intended for stainless steel Complex agents EDTA Sodium polyphosphate Max 20 and 60 C Max 5 and 50 C Max 20 and 60 C Residual oil asphalt Hydrocarbon deposits Paraffin or naphta based solvents WARNING Only apply Inhibited hydrochloric acid on carbon steel All other acids are only suitable for stainless steel M
5. ational safety rules which must be observed To reveal leaks by means of gas or air it is sufficient to use a very low pressure overpressure 0 5 bar it is also possible to use a less volatile gas e g helium in stead of putting the whole system under pressure WARNING It is of utmost importance to fix the side to be tested by means of cross balks The Otherwise the hydraulic pressure may deform the body and thus result in permanent or irreparable damages Test by means of air or other compressed gases must be in accordance with any national security and regulations Sondex Head Office Jernet 9 DK 6000 Kolding Denmark Tel 45 76 306 100 Fax 1 45 75 538 968 Fax 2 45 75 505 019 info Sondex dk www Sondex dk SONDEX Copyright 11 2012 Sondex A S Sondex A S can accept no responsibility for possible errors in catalogues brochures and other printet materials Sondex A S reserves the right at any time to change the specifications without notice
6. ax 250 ppm chlorides in all acids demineralized water and rinsing water applied for stainless steel at max temperatures of 60 C Protect carbon steel parts when corroding chemicals are applied If CIP Cleaning In Place is not possible the cover are removed and the unit is cleaned mechanically or manually Remove loose depots of fixed substances manually A high speed water or steam jet is recommended for effective removal of fixed substances and deposits 10 5 Re Rinsing In case of clogging because of deposits of fixed substances at the inlet or in the first part of the channel re rinsing may be a good solution Re rinsing is turning the flow direction of the one or both liquids or rinsing with water in the opposite direction of the normal flow direction The flow direction should be bigger than the normal flow in a period of 15 30 minutes Specially designed with built in flushing connections Long life gasket solution Ay WARNING By inspection of a passage do not remove the spiral heat exchanger before the pressure is totally shut off on both sides of the installation If it is the intent to inspect the one side of the spiral heat exchanger with the other side still under pressure the removed cover must be replaced by a special device approved by Sondex in order to avoid damages on the spiral body Please refer to the concerned chapter in the instruction manual or contact Sondex for further informa
7. e supplied with valves All valves must be opened slowly in order to increase the flow velocity successively at start up The flow velocity is reduced successively during stop In order to secure a normal flow during maintenance bypass lines are recommended When using displacement pumps a decompression bypass line with a time controlled slowly working valve is recommended Furthermore take precautions by means of pressure controlled switches pressure relief gauges delivery pipes when using pumps with adjustable velocities and shut off pumps Large tolerances especially pressure drop increases beyond the nominal values stated must be considered when calculating associated products such as pumps and spiral heat exchangers These are results of possible variations of the liquid properties the flow velocities boiler scale or deposits on the heat transmission surfaces Assembling Lift the spiral heat exchanger by means of the lifting eyes only Install any drain pet valves ALWAYS Use the lifting eyes if fitted NEVER Lift using the connections WARNING Never lift the spiral heat exchanger by means of connections or studs 10 Maintenance 10 1 Preparation Repairs must be undertaken by skilled manpower employed by Sondex and with knowledge of spiral heat exchangers Inspection of the units must take place according to the regulations valid in the country where the unit is installed 10 2 Fouling and Clogging The
8. edium may start boiling depending on pressure and temperature pressure and media types and the spiral heat exchanger may be damaged Sudden pressure and temperature amendments should be avoided When a spiral heat exchanger filled with water or liquid compounds is not in operation and is subject to temperatures below 0 C a deformaty risk is present in case of icing In case of frost risk the spiral heat exchanger must be totally emptied Leak risks are always available Therefore we advise you to take this into account by installation and we recommend a drip tray under the spiral heat exchanger in order to avoid liquid on the floor and or damages on associated electronic equipment short circuit moisture damage If the spiral heat exchanger is used at temperatures above 60 C or with aggressive liquids it is recommended to shield the spiral heat exchanger so that the risk of contact is avoided In case of welding work near the spiral heat exchanger this must never be used as earth connection for the construction work Voltage may result in severe damages to the spiral heat exchanger Therefore demount the connection flanges and thereafter isolate the spiral heat exchanger from the system 8 Thermal Design Sondex spiral heat exchangers are designed and calculated according to the newest technology If performance test has to be carried out the spiral heat exchanger must be totally clean In the Sondex data sheet the nominal capacity and
9. he contact gaskets are intact and clean before reassembling By replacement of gaskets please contact Sondex The spiral heat exchanger is supplied with a specific number of hook bolts and the spiral heat exchanger may not be oprated with a less number or other dimentions of hook bolts The distance between the hook bolts has to be the same distance as between the hookbolts on the cover Tightening torque On reassembling the gasket and the head follower are re placed Tighten successively the hook bolts diagonally at the lowest tightening torque To secure that the unit is tight it is possible to increase the tightening torque without exceeding the maximum value stated in below table Hook Bolt Type Gasket Type Min Torque N M Max Torque N M NBR EPDM 150 450 10 9 Test Hydraulic test It is possible to use normal hydraulic test procedures after total reassembling of the spiral heat exchanger Air under water test Supply air at low pressure 0 2 0 5 bar overpressure in the closed channel Do not exceed 0 5 bar overpressure Air bubbles will reveal any leaks in the channel welding Repeat the procedure for the other channel welding if necessary A normal hydraulic test can be undertaken after a total reassembling of both covers The maximum test pressure is stated on the name plate A hydraulic test must always be made before test by means of air or other compressed gases and may involve special n
10. pressure losses are mentioned The pressure loss can deviate up to 15 from the data in the data sheet depending on plate thickness the plate material and the difference in the two working pressures 9 Installation Requirements to the installation area It is very important that enough space around the spiral heat exchanger is kept free for servicing of the unit Installing the pipe connections The type the Sondex spiral heat exchanger type will be provided with flanges connections threaded pipes etc WARNING When connecting the pipe system to the spiral heat exchanger make sure that no stress or strain is imposed by the pipe system onto the spiral heat exchanger We advise you of the following e Heavy pipe work needs to be supported This will prevent heavy forces on the spiral heat exchanger e Always install flexible connections on the spiral heat exchanger to prevent vibrations These flexible connections also prevent expansion of the pipe work caused by temperature influence onto the spiral heat exchanger The pipe work needs to be thoroughly cleaned and flushed before connecting to the spiral heat exchanger Always install vents on both sides of the spiral heat exchanger Valve direction and pumps Avoid that the nominal pressure of the equipment is exceeded and take necessary precautions in order to avoid pressure chocks water hammer To isolate the unit it is of big importance that the connection pipes ar
11. ratures capacities and liquid types provided by the customer Pressure peaks below normal working pressure or shock waves occurring by start stop of the system may result in severe damages and must be avoided Sondex cannot be held responsible for damages arisen as a result of any operation deviating from the original design conditions 4 Safety Alert Notices Following points MUST be observed when working with spiral heat exchangers e Observance of local valid safety precautions e Before work is started make sure that the outlet of the spiral heat exchanger is free emptied and cooled below 40 C e Always use gloves before handling the spiral heat exchanger in order to avoid hand injury from sharp edges The Law or other regulations may require acquisition of suitable protection measures in the company A YELLOW TRIANGLE Refers to applicable SAFETY ALERT notices in this instruction book This information is given where danger of bodily harm is present 5 Generally Identification of the Spiral plate heat exchanger All types of Sondex spiral heat exchangers are supplied with a name plate with following specifications e Type of spiral heat exchanger e Year of production e Manufacturing number e Nominal capacity in kW Effective heating surface in m e Max working pressure in bar e Test pressure in bar e Max working temperature in C e Max differential pressure Volume Flow SONDEX A S SHE Type hzi
12. tion J SONDEX 10 6 Opening of the Unit 1 Close the main valves of the in outlet side and let the spiral heat exchanger cool before opening Control that None of the sides of the spiral heat exchangers are under pressure Both sides of the spiral heat exchanger are emptied 2 Disconnect the pipes 3 Most of the spiral heat exchangers are equipped with flat or conical strengthened covers which are kept down by means of suitable tools The contact gaskets can stick to the surfaces of the covers or the surfaces of the body When the remaining gasket material is removed avoid damaging the surface of the covers the edges of the spiral heat exchanger body plate or the sealing ring 10 7 Maintenance Each channel can be examined visually from one of the sides of the spiral heat exchanger body If the spiral heat exchanger has a big channel width and or a small distance it may be necessary to use an endoscope The channels must be examined for e Corrosion often visible at the sealed weldings near the surface of the body and thus easy to find e Erosion often visible in the middle or peripheral inlet and near the distance plates e Fouling clogging In spiral heat exchangers deposits of fixed substances in the bottom part e Mechanical damage deformation In case of heavy corossion erosion or a mechanical damage contact Sondex for advice with regard to possible repair in place 10 8 Reassembling Make sure that t
13. your attention to the fact that our spiral heat exchangers are specially built and designed according to the requirements of the customers pressure temperature capacity liquid types Sudden abnormal pressure shock or working pressures at start up stop may result in severe damages and should be avoided Furthermore pressure shock from e g positive pumps result in damages on the spiral heat exchanger Sondex cannot be held responsible for damages arisen in consequence of wrong operation In case of amendments of the operation conditions please contact Sondex 7 Safety Alert Notices Bodily harm can be caused by Burning as a result of touching the spiral heat exchanger or other parts of the installation The uncontrolled release of pressurized media with which the danger of burning and other injuries is present Contact with chemicals Touching sharp edges of the installation Damage to equipment can be caused by External forces Corrosion e Chemical action e Erosion e Material fatique Water hammer e Thermal and or mechanical shock e Freezing Wrong transport lifting Be careful by stop of the plant as some parts may still be hot The spiral heat exchanger is only applicable with the media stated in the data list For the prevention of damages the cold and hot media must run through the spiral exchanger simultaneously In case the cold medium is not adrift simultaneously with the hot medium the cold m
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