GB - SPX FLOW
Contents
1. 1 4 Start up and Close down of the unit Hybrid heat exchangers are designed for long term static type operating conditions Fre quent shut downs and start ups of units are to be considered as an alternating load re quirement Guideline if the unit is to be shut down and start up more than a few times per week than this is a load alternation condition and has ramifications for the long term integrity of the unit refer to point 3 above Ramped Start up Pressure Requirements It is required that hybrid pressures are built up over a period of time from start up The na ture of the core pack is that it is flexible and can be damaged with particularly harsh start up pressure ramps For advice please refer to SPX specialist for your specific application 1 5 Emergency shut downs Emergency shut down need to be a controlled event with the maximum differential pres sures considered as part of the shut down cycle Bothe sides of the hybrids may need to be considered in the shut down but this is dependent on the operating design rating of the core pack 1 6 Emergency Pressure Relief Please refer to Section 4 1 1 7 Pressure Drops The customer will define a maximum allowable pressure drop across the unit based on their plant process capability e g pumps Deviation from the Customers stated specifica tions in either flow rate or fluid property may result in a higher pressure drop than calcu lated from the theoretical calcula2. 6 1 6 2 Preparations for commissioning the HYBRID heat exchanger General instructions and remarks for commissioning and operating the HYBRID heat exchanger 6 3 Operational interruptions 6 4 Wet Storage 6 5 Dry Storage 7 Monitoring during operation 8 Operational disturbances 9 Quality Assurance 9 1 Checks 9 2 Servicing 9 3 Cleaning the HYBRID plate heat exchanger 9 4 Safety instructions 10 General information Appendix 1 First principals of Hybrid heat exchanger design 0 Preface Associated Documents e Product Specification e Contract e Final product documentation pack supplied by SPX e Hazard Analysis e Design drawing package e Data Sheet Health amp Safety Warning The Customer is advised to thoroughly review this manual and all associated documents before commencing installation commissioning or operation of the heat exchanger as they contain essential Health and Safety information Operational Warning The end user of the equipment must follow the start up procedures for hybrid heat ex changers both for commissioning and normal operation as substantial damage can occur to the unit if incorrect procedures are adopted Acronyms Used PED European Pressure Equipment Directives ASME American Society of Mechanical Engineers QA Quality Assurance ISO International Standards Organisation H amp S Health amp Safety SQL Safety Quality Licence for Boilers and Pressure Vessels Chinese Standard
3. P amp ID Piping amp Installation Diagram OEM Original Equipment Manufacturer Specification Data Sheet The agreed thermal specification of the unit is detailed in the data sheet and must be read in conjunction with this Service and Operating Manual The Data Sheet is concerned with the principal mechanical design of the plate pack The pressure vessel housing is de tailed in the general specification Health and Safety H amp S Requirements A clear understanding of the requirements to ensure the safe installation commission ing and long term service of the equipment by the customer is considered essential by SPX This manual therefore details the safe practices required for the unit If the Customer organisation has any issues or concerns with H amp S related to the unit please contact SPX directly via the contact details on the front cover of this document before commencing with the installation commissioning or operation of the equipment In this manual all H amp S and critical operating requirements issues are identified with the following symbol Experience Knowledge of Hybrid units and their application This manual is based on the Customers engineering organisation having a working knowl edge of the first principal application of hybrid heat exchangers If there is any doubt that this knowledge exists then please contact SPX before commencing with the installation commissioning or operation of the equipment Any con
4. operation etc The stipulations and conditions applicable for operating the pressure vessels particularly the safety regulations Guidelines for pressure devices must be adhered to e g PED Guideline 97 23 EG and ASME Section VIII Div 1 newest edition In case of any doubts send your queries to the respective professional bodies or cooperative societies or contact SPX as detailed on the front cover of this manual Weld or replace pressure resistant parts of the apparatus only after consulting the suppliers and with the approval from the responsible expert at the control centre Check the compatibility of the initial product flows with the materials processed in the heat exchanger The manufacturer shall not be responsible for corrosive damages caused due to chemical reactions Check and analyse the product flows at regular intervals Use the heat economizer as a preventive measure against standstill corrosion during opera tional interruptions modifications and in the system designing phase as well The effectiveness of the conservation measures must be checked constantly The OEM SPX is not responsible for any operating and servicing errors The technical engi neering or service department which is applicable in the end user s organisation in service regarding operating or servicing the heat exchanger Please specify the SPX Manufacturing No refer to the fascia and the SPX drawing number in your queries refer to the
5. TS the two slabs must be mounted again be fore removing and cleaning the corrugated side CS It is necessary to loosen all the bolts in the Column also the Column bolts on for exam ple CS when removing TS slabs TS M20 threads For Schackle Only for lifting the slab M20 threads For Schackle Only for lifting the slab Slab TS 22 Gasket When a slab has been removed for example due to cleaning it is necessary to replace the gasket afterwards The type and size of the gasket can be seen on the as build draw ing The tightening torque of the bolts can be seen on the as build drawing When the bolts must be tightened it is important to cross tighten the bolts Do not tighten the bolts to full torque at first Tighten the bolts a little at a time 9 4 Safety instructions Apart from the applicable accident prevention measures and the existing safety instruc tions the instructions of the supplier must also be followed during inspection and repairs of components and accessories The installations systems and components must be cleared by the responsible operating personnel before starting the operation Repairs and servicing should be executed only by authorised personnel Only approved lifting points may be used for mounting and demounting of slabs flanges etc Hereby the risk of work under floating loads is to avoid In the context of mounting and demounting of connections cleaning and access
6. of the detachable square flange covers are torque to the correct setting before use Refer to starting torques given in the drawing before commissioning e Check all connected and joined tubes for appropriate connections as per the circuit and the function e Check for the completeness of the fittings and measurement points corresponding to the system circuit diagrams not a part of the SPX supply scope and proper and functional installation Instructions The aforementioned checks are necessary only during initial commissioning and after modifications or repairs Setup all level monitoring devices including signalling and possible switch off and switch over processes Execute functional tests for the devices if necessary e Setup the flow control units and if necessary execute functional tests e Setup the level indicator local remote and if necessary execute functional tests e Check the start up and operational ventilations refer to point 5 E e Setup the temperature and pressure measurement points local remote and if necessary execute functional tests e Set up the upstream and downstream system components e Fill the HYBRID heat exchanger The ventilations are opened for liquid media and closed only after the liquid air free is discharged e Change of gaskets on flanges according to rules of gasket suppliers and according to remarks in drawings and part lists SPX 6 2 General instructions and remarks for commission
7. operating temperatures Failure to control chemical levels in the mediums may result in premature corrosion of the plate pack and sub sequent failure of the heat exchanger Note Damage of the unit due to corrosion is excluded from the SPX warranty 3 3 Fluid Particle Considerations The particle size has a direct impact on the design selection of strainers and pressing depth of plates 3 4 H S Content For certain applications there is a special requirement to consider the content of H S Hydrogen Sulphide Often referred to as sour service The H S will impact the surface of the materials and cause a special type of corrosion It is important to specify the H S content as these directly impact material selection plates and pressure vessel Health amp Safety Warning For Oil and Gas related applications the H S content is to be considered H S is a strong poison For this reason it is essential to choose the right material to avoid dangerous leakages and the possible impact on health and safety of operators em ployees 4 Design Conditions To meet regulations on the safe design of the pressure vessel housing it is required to specify the worst case elevated operating conditions pressure amp temperature This will enable the design of the housing to be specified in compliance with the rules of the control ling regulations e g P E D or ASME etc Key Rules e Design pressure must be higher or min equal
8. specific requirements Please refer to the assembly drawing to get the applicable differential pressures for both sides of the Hybrid heat exchanger 1 2 Alternating Loads Generally hybrids are designed for a static operating condition pressure and tempera ture An alternating load defined as changing pressures and temperatures changing over a defined period of time If the application requires the unit to experience alternating loads these must be specified in the Customer specification as there is an impact on the design of the unit which have to be embodied into the mechanical of the unit Alternating loads are specified as any number of normal operating conditions and the time taken to transition between the defined operating conditions Note the start up condition is part of this requirement but is a special case of alternating loads See below Generally if there are different operating conditions regarding pressure and temperature in a defined time period alternating loads are required to be considered as part of the specification Please refer to SPX specialist for clarification of the end user requirements for inclusion into the design specification 1 3 Pressure Shocks These are defined as spiked transient loads caused by inappropriate start up of e g pumps or the closing of valves etc Spikes can also be caused through steam hammering due to improper start up operating for steam condensers 25
9. II Div 1 newest edition By agreement with the Customer ASME designed units can be manufactured and supplied e Manufacturer licence PRC pressure vessels Chinese quality standard e ISO 9001 2000 SPX works to recognised ISO 9001 2000 quality management system Cert No 1510031701 The Supplied Heat Exchanger The heat exchanger is supplied as a single unit to a defined amp manufactured to the cus tomer s specification SPX are not familiar with a Customers plant systems or production processes or over all fluid mechanical system and SPX will only warrant in its commercial contracts the performance of the unit against the specification supplied and not the perfor mance of the Customers plant or manufacturing process For the avoidance of doubt no warranty whether express or implied shall apply within this manual 1 Design and function description of the HYBRID plate heat exchanger The core of the HYBRID heat exchanger is a completely welded plate pack This plate pack consists of embossed shaped plates The material of the plate pack can be made of different stainless steel alloys and nickel alloys dependent upon application requirements A flow cross section is created on one side due to a special type of embossing on the plates the layout of the plates with respect to each other and the staking of the plates The flow cross section corresponds to the structure of a number of internal tubes A wave flow cross section is created on th
10. Kolding Denmark T 45 7027 8444 F 45 7027 8445 APV Hybrid Welded PLATE HEAT EXCHANGERS The information contained in this document including any specifications and other product details are subject to change without notice While we have taken care to ensure the information is accurate at the time of going to press we assume no responsibility for errors or omissions nor for any damages resulting from the use of the information contained herein ISSUED 2015 10 COPYRIGHT 2015 SPX FLOW Inc
11. SPXFLOW a APV Hybrid Welded Plate Heat Exchangers Standard Range HYBRID MANUAL EN READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT REVISION Hybrid_999 A GB gt APV Always observe the Safety Notes designated by a warning symbol listed throughout this manual As these units operate with potentially dangerous fluids gases and are capable in certain circumstances of releasing potentially dangerous mediums there are clearly H amp S issues that the Customers organisation must be aware of and take the necessary safety precautions for the safe operation of the unit Please refer to the Hazard Analysis supplied with the final documentation pack for further details Do not lower the apparatus on the connecting pieces flanges or other connections To ensure personal safety please be aware of the dimensions and weights before transportation e g from the dimensional drawing or parts lists gt gt Ensure force and moment free connections if the manufacturer has not calculated the maximum load on the connecting pieces separately Provide the feeding tubes with appropriate bellows and fixed points Ensure that the connections are not subjected to forces that could lead to damage Safety valves are not included in the standard scope of delivery Their installation and provision is the responsibility of the user The Customer is responsible for ensuring that no operating commissioning or testing
12. a year Rectify the faults in the measuring devices and control units immediately It is recommended to record and archive important operating data inlet and outlet tempera tures and pressures at least 1 mass flow periodically If a leakage is suspected switch off and examine the HYBRID heat exchanger so as to avoid secondary damages Rectify all possible leakages before restarting the heat ex changer to avoid consequential damage 6 3 Operational interruptions In case of operational interruptions exceeding 100 hours the two separate pressure spac es of the heat exchanger must be conserved against standstill corrosion refer to 6 4 and 6 5 The apparatus must be protected against standstill corrosion in the design phase as well as while modifying While modifying please ensure that dirt does not settle in the open connecting pieces Dirt particles may damage the fixed equipment The apparatus may stop to operate correctly due to chloride accumulations if it has come in contact with flow media containing chlorides Localised corrosion may also result de pending on the material of the heating surfaces It is essential that the end user ensure that chloride or other corrosion enduing chemicals are kept to within the specified param eters Should the unit fail due to corrosion the user must stop operational use of the unit until a qualified assessment can be made of the potential damage to the unit If the End User s organisation has no
13. astened over the body using belt conveyors if loops or support straps are not available Do not lower the apparatus on the connecting pieces flanges or other connections To ensure personal safety please be aware of the dimensions and weights before transportation e g from the dimensional drawing or parts lists Only approved lifting points may be used for lifting the unit ar l T Model 12 amp 24 10 3 2 Installation The place of installation must be selected after considering the following conditions e The heat exchanger must be accessible from all sides in case any checking or servicing Is required e Instrumentation for level indicators ventilation drainage etc must be possible without causing any damage e Other components should not conceal the local measurement points e All detachable inlet outlet covers fixed equipment or attached parts should be easily removable e Consider the dead and operating weight of the heat exchanger as well as its weight during the pressure test specified in the accompanying dimensional drawings and parts lists while selecting the substructure or the base 3 3 Tube connection Connect the connecting pieces on the heat exchanger as per the dimensional drawing Seal the unnecessary connecting pieces using a blank cover or a sealing cap Do not con nect the ventilation and the drainage pipes for the various pressure spaces via a manifold Ensure force and moment free con
14. changer is equipped with additional connecting pieces for ventilation and drainage The connecting pieces are attached to the highest point for ventilation and or at the lowest point for drainage of the unit The positions for the ventilation and the drainage connecting pieces are given in the dimensional drawing If the heat exchanger is not equipped with additional connecting pieces then these must be provided onsite in the feeding and discharge tubes also at the highest and lowest point General Ventilation Requirements e The vents are opened for filling and draining the medium A e Itis closed during normal operation e Open the ventilation from time to time when the exchanger is in operation to check whether the medium is 100 full e See section 6 2 for ventilation requirements during commissioning Refer to Warning on potentially hazardous medium release If the HYBRID heat exchanger is operated in a vacuum region then evacuation must be done before commissioning using the start up and the operational ventilations Ventilation during the operation is provided constantly and carefully using the operational ventilations The start up ventilations are closed after the outlet temperature of the medium is attained corresponding to the load 14 6 Commissioning operating and operating conditions Instructions for conservation during standstill Heavy Equipment Warning Hybrids are heavily constructed units weighing in most cases seve
15. chemical spillages must be followed It is the responsibility of the Custom ers H amp S Officer to ensure that procedures are in place for these potential events and must be considered in any risk analysis carried out for the unit in its final operating position Remark Any accumulation of air and gas must be removed Accumulation of air and gas in the heat exchanger leads to a disturbances in the thermal functioning unit efficiency b possibility of corrosion 19 8 Operational disturbances The design data was not adhered to Cause Air and gas accumulations on the corrugated and tube sides Measures e Thorough ventilation of the corrugated and tube sides e Check the valve openings in the ventilation pipes secure the valves against uninten tional closing during operational ventilation vacuum operation e Check the ventilation pipes e Check the flange joints e Check the heat exchanger and the connecting tubes for open connecting baffles ma nometer thermometer and reserve connections Remark If the heat exchanger is operating in the vacuum region a lot of air may penetrate into the flanges of the connecting pieces This air cannot be extracted completely using the exist ing ventilation cross sections The leakages must first be repaired in such a case If these measures are not successful then the openings of the operational ventilation valves must be enlarged Cause Covering the heat exchanger surface Measu
16. conditions will exceed the maximum permissible differential pressure If the maximum permissible differential pressures are exceeded this may cause damage to the plate package The maximum allowable operating and differential pressures are detailed in the final drawing package Bare surfaces gt 50 C involve combustion risk in the operating mode The operator must ensure suitable protective measures This is also applicable for heat exchangers with low operating temperatures lt 25 C Ventilation and drainage of the apparatus involve a risk of scalding in case of products with temperatures gt 50 C and burning in case of aggressive media Take appropriate safety and precautionary measures before ventilating and draining The vents are opened for filling and draining the medium It is closed during normal operation Open the ventilation from time to time when the exchanger is in operation to check whether the medium is 100 full See section 6 2 for ventilation requirements during commissioning Hybrids are heavily constructed units weighing in most cases several tonnes Please refer to the the Final Assembly draw ing for the actual weight of the unit supplied The Customer or agent is advised to seek specialist assistance for the lifting positioning and installation of the unit The nozzles must not be used to lift the unit as the housing can be damaged and this may cause leakage of the process fluids or major external failure of
17. documentation These documents may neither be copied nor given to a third party especially a rival company without our consent They must not be misused 24 Appendix l First Principals of Hybrids General Warning a Hybrid Design Hybrids as a welded unit offers exceptional efficiency as they have a large surface area in comparison with the size of the unit however hybrids have operating considerations that are unique to hybrid construction and differs from e g a corresponding shell and tube design Defined operating principals do exist for the efficient and proper use of a hybrid unit and these must be respected as detailed below b Defining Pressures within the Specification Normally the datasheets will indicate operating pressures in pressure units absolute and design pressure are detailed in pressure units gauge It is vital that the Customer speci fies the pressure and the relative scales absolute or gauge c Defining temperatures within the Specification This appendix is for generic Hybrid information factors specific to the Customer s applica tion must be agreed between SPX and the Customers engineering team 1 Pressure Considerations 1 1 Maximum Differential Pressure The differential pressures have to be observed carefully through out the range of operating conditions including especially test and commissioning conditions The maximum differen tial pressures are to be agreed as part of the Customer
18. e other side of the heat exchanger due to em bossing The wave flow Corrugated side of the plate pack has thermal hydraulic prop erties that resemble those of gasketed plate heat exchangers while the tube side of the plate pack has thermal hydraulic properties that resemble the tube side of a tube and shall heat exchanger Stackheight Variable at Plate length Variable Plate width Constant Corrugated side Fig 1 Plate pack of a HYBRID heat exchanger Corrugated side flow Fig 2 Sectional view of the plate pack cross flows The plate width is constant 360 mm The plate length can be variable from 441 mm up to 2592 mm A complex embossing tool is been used to press the plates The deformation height embossing depth varies from 2 8 to 3 7 mm A so called shaped plate is created when two embossed plates are laid on top of each other and welded together The tube flow cross section and the plate pack are formed due to piling and welding the shaped plates The tube side is separated from the corrugated side via a plate profile that is welded to the corners of the plate pack Fig 1 The completely welded plate pack can be build into a pressure resistant housing having a design suitable for the specific application Inlet and outlet are welded onto the housing The HYBRID heat exchanger can be operated and installed horizontally or vertically de pending on the application The wave or tube side volume flow can be guided
19. gher turbulences the increased flow rate causes a mechanical effect Better solu bility at the surface coating can also be attained by heating the cleaning agent The cleaning agent must be selected depending on the type and coating of the dirt to be removed Important Before selecting the cleaning agent check its compatibility with the materials that are used or consult the concerned company The cleaning liquid should be prepared using water that is free from chloride e g de ionised water and is less hard Rinse using adequate clean water after the cleaning pro cess is done Provide separate washing cleaning connections in the tubes if an apparatus having media that form a coating on the surface is used 21 High pressure cleaning If cleaning with chemicals is not sufficient the slabs need to be removed for high pressure cleaning Plate types TuplaFlow 37 and TuplaFlow 28 are fully cleanable on tube side En ergySave plate and corrugated side on TuplaFow 37 and 28 are only cleanable in both end of the plate pack By high pressure cleaning be careful not to damage the plates Before removing a slab e Mark the slabs To ensure the slabs are being mounting in the same way again e Check that none of the two circuits are under pressure e Ensure that the two circuits are drained of fluids media When cleaning the slabs must be removed in pairs That means for example remove the two slabs on Tube side TS After cleaning
20. ing and operating the HYBRID heat exchanger The different system circuit diagrams not a part of the SPX supply scope clearly indi cate the layouts and integration of the HYBRID heat exchanger into the various systems The time for commissioning the heat exchanger is ascertained as per the start up process of the entire system or it depends on the operational requirements Consider the instructions and specifications given in the applicable safety rules while com missioning and operating and also while starting the system Required Commissioning Procedure A e Ensure that the tube and corrugated wave circuits are connected correctly the right way around as this could easily damage the unit beyond repair e Ensure that vents are open to allow for air bleeding Refer to Section 5 for the full ventilation requirements Warning make sure that no hazardous vapours are released to the local atmosphere or to the ground this may cause injuries or damage to the environment Note if hazardous fluids are present in the heat exchanger the venting nozzles must be routed to a closed loop system As pressure impacts shocks may damage the apparatus the fittings valves must oper ate slowly at the time of filling As a result pressure on the corrugated and tube sides rises gradually Pressure shocks are to be avoided at all times as they can damage the plate pack Furthermore it must be ensured that the maximum permissible diffe
21. nections if the manufacturer has not calculated the maximum load on the connecting pieces separately Provide the feeding tubes with appropriate bellows and fixed points Ensure that the connections are not subjected to forces that could lead to damage Subsequent welding on any part of a certified pressure resistant housing pressure vessel is not permitted by PED or ASME regulations without specific approval from a qualified and certified organisation This action may cause the pressure vessel to fail in a dangerous condition Vibrations and oscillations due to upstream or downstream system components must not occur in the heat exchanger Additional fittings like level indicator safety valves temperature and pressure measure ment positions etc not a part of the standard supply scope must also be detachable so as to avoid any damage during transportation Tooling is done onsite 11 4 Equipment instructions Take proper operating measures so that the maximum operational parameters are not exceeded 4 1 Maintaining maximum operating pressure In order to ensure that the maximum permissible operating pressure design pressure is not exceeded for closed piping systems the corrugated and tube sides must be provided with one safety valve each Safety valves are not included in the standard scope of delivery Their installation and provision is the responsibility of the user If the apparatus has connections for these safety
22. nozzles flanges the risk of injuring by squeezing is to avoid Operating the fittings or opening of flanges involves risk of scalding and or burning due to the discharge of aggressive and poisonous media 23 10 General information The APV heat exchanger may be used only for the directed purpose Using in any other manner is explicitly forbidden The heat exchanger may be operated serviced and if necessary repaired only by technical personnel and by adhering to all legal stipulations The HYBRID heat exchanger must be loaded and unloaded regularly Do not exceed the maximum permissible operating parameters The heat exchanger can be damaged if the threshold values are exceeded Guarantee claims are confined to the basic design parameters for calculating the strength Please refer to Appendix l section 1 2 alternating loads Hand operated valves should be operated slowly and without using force Risk of scalding depends on the operating temperature The heat exchanger should have a thermal insulation unit or a contact safety device An appropriately dimensioned thermal insula tion unit reduces the loss of heat radiations and also acts as a contact safety device A tank heat exchanger that is exposed to excess pressure during operation is subject to legal stipulations and conditions The type and scope of the stipulations depend on for example size the media to be heated and cooled processed materials place of installation
23. pable of sustaining long term performance with the specified chemicals present in the fluid mediums e g especially chlorides at elevated operating temperatures Failure to control chemi cal levels in the mediums may result in premature corrosion of the plate pack and subsequent failure of the heat exchanger For Oil and Gas related applications the H S content is to be considered H S is a strong poison For this reason it is es sential to choose the right material to avoid dangerous leakages and the possible impact on health and safety of operators employees Under no circumstances must the unit be operated outside the specified design conditions stated on the name plate also detailed in the drawing package The heat exchanger must be specifically designed to operate in a vacuum condition if this is to be part of normal operating conditions P gt gt gt be PP PP PPP PP gt Issued 999 A GB Copyright 2011 SPX Corporation Contents Preface Design and function description of the HYBRID plate heat exchanger Design data Transportation installation tube connection Transportation Installation Tube connection Equipment instructions Maintaining maximum operating pressure Maintaining maximum operating temperatures Insulation Maintaining the liquid level in the tank Mounting a prefilter Ventilation and drainage Commissioning operating and operating conditions Instructions for conservation during standstill
24. ral tonnes Please refer to the the Final Assembly drawing for the actual weight of the unit supplied The Customer or agent is advised to seek specialist assistance for the lifting positioning and installation of the unit Warning Lifting Points The nozzles must not be used to lift the unit as the housing can be damaged and this may cause leakage of the process fluids or major external failure of the pres sure vessel itself wnen commissioning commences which will have serious H amp S issues associated with this type of failure The specific lifting lugs must be used to lift the unit at all times refer to final assembly drawing Also no other parts of the machine is to be used as a lifting points only the approved lifting lugs Warning External Physical Shock Impacts The unit is susceptible to damage if subjected to physical impacts These must be avoided at all times while being lifted or moved 6 1 Preparations for commissioning the HYBRID heat exchanger Read the entire operating and service manual and supporting documentation Check the supports for the unit e unit properly supported with a structure that is capable of supporting the weight of the unit and will be unaffected by the unit s operating temperatures complete range of temperatures e all securing bolts are correctly tightened e Check the bolts of the connecting rod screws threaded rods attached at the pres sure retaining plate and the flange screws
25. rential pressure for the operating conditions and the pressure test on both sides is not exceeded also refer to section 4 1 The start up ventilations must remain open till the corresponding space is air free Recommendation Suitable gauges should be installed in the fluid circuit near the heat exchanger so that operating pressures can be observed and managed The HYBRID heat exchanger should heat up cool down gradually at the operating tem perature Temperature shocks must be avoided Please ensure that the maximum permissible temperature transient of 5 C min is not o Poodu during the operating phase for avoiding non permissible thermal stress The operating pressure must always be higher than the saturated steam pressure in order to avoid evaporation Evaporations will damage the apparatus The maximum temperature difference of 125 C should not be exceeded in a normal HY BRID design The total operating pressure should be set only after attaining the operating temperature Please ensure that the liquid levels and control ranges are adhered to Exceeding or remaining below the levels or ranges may lead to functional disorders and possible dam ages Vibrations and oscillations are not permissible in upstream or downstream system compo nents The HYBRID heat exchanger including the measuring devices and control units must be checked during operation not later than 6 months after commissioning and from then on at least 1x
26. res Cleaning the plate pack refer to point 9 3 20 9 Quality Assurance 9 1 Checks Depending on local country law it may be required to periodically test the unit The Customer is advised to verify with local authorities on their particular requirements for periodic checking These periods are applicable as per the latest technological development without consid ering any special conditions prevailing at the place country of installation Please refer to section 4 1 regarding pressure control requirements maximum oper ating amp differential pressure requirements In case of longer standstills for which no official tests have been specified it is recom mended that at least a visual inspection of the components must be executed Only the manufacturer or the company appointed by the manufacturer can undertake works within the guarantee period 9 2 Servicing Check for leakages in the flange and gasket joints at regular intervals Leakage tests and pressure tests should be executed till the maximum operating pressure We recommend a pressure rise of maximum 1 bar min for a long service life pressure impacts must be avoided 9 3 Cleaning the HYBRID plate heat exchanger Cleaning agents are guided through the apparatus instead of the operating medium Dirt particles are removed due to the dissolving ability of the cleaning agent The flow is increased or its direction is reversed counterflow for better cleaning Due to hi
27. s it may be necessary to maintain a specific level of the liquid in the tank The normal level is mentioned in the dimensional drawings The device required for monitoring and controlling the level is not included in the supply scope The heat exchanger may fail to function if the normal level is not attained 12 Examples Application Condenser with a sub cooling zone Natural circulation evaporator Seal for gaseous or vaporous Malfunctions if the level is not attained Outlet temperature of the condensate rises as calculated subsequent expansion may cause evaporation The apparatus acts as a direct evaporator circulation is no longer guaranteed A two phase mixture can be admitted to media downstream pumps Cavitation possible The HYBRID heat exchanger can be equipped with a level controlling unit for maintaining the liquid level 4 5 Mounting a prefilter Install a pre filter with a mesh width of 3 4 mm in the feeding tube for avoiding coarse dirt in the plate pack This is not required for clean media There is a basic engineering rule for hybrid heat exchangers that mesh size must be one half of the plate gap 13 5 Ventilation and drainage Ventilation and drainage of the apparatus involve a risk of scalding in case of prod Ay ucts with temperatures gt 50 C and burning in case of aggressive media Take ap propriate safety and precautionary measures before ventilating and draining The heat ex
28. sultancy service provided by SPX shall be subject to agreement of associated commercial terms and shall not relieve the customer from its liability for implementing proper health and safety practices Appendix of this manual offers some basic first principal guidelines only and is not de signed to replace good engineering knowledge practice in the customer s organisation in certain circumstances of releasing potentially dangerous mediums there are clearly H amp S issues that the Customers organisation must be aware of and take the necessary safety precautions for the safe operation of the unit Please refer to the Hazard Analysis supplied with the final documentation pack for further details f As these units operate with potentially dangerous fluids gases and are capable Note the Hazard Analysis provides details on Project information Working parameters Used materials Danger potential 5 Design Rules 6 Assembly and Commissioning 7 Operating amp Maintenance manual link Ao The Customer is required to develop implement and maintain a comprehensive H amp S plan for the installation commissioning and in service life of the heat exchanger Design Standards SPX works as standard to the following design standards Any specific Customer require ments are agreed as part of the contract to supply e PED 97 23 EG This is the European Pressure Equipment directive Designed according to EN 13445 e ASME Section VI
29. t the necessary experience in evaluating corrosion related failures please contact SPX via the detail on the front cover of this manual Dry or wet conservation must be executed in case of predetermined risk To prevent damages during standstills due to freezing the tube as well as corrugated sides of the heat exchanger must be completely emptied The conservation procedure to be followed must be decided upon depending on the re spective local circumstances and possibilities as well as the climatic conditions and the operating mode p g 47 6 4 Wet Storage This type of conservation can be implemented only if there is no risk of freezing The con servation period for this process is unlimited The quality of the filling water should be maintained at the same level by analysing the conservation liquid at regular intervals circulating the liquid every week and replacing the used chemicals Nitrogen padding can be used to seal the conservation liquid from the atmosphere Please refer to your local authorities for the Conservation of power plant systems Ensure that any additives to the system or replacement top up chemicals are fit for pur pose and unlikely to cause damage to the pate pack or supporting systems 6 5 Dry Storage Conservation period for this process is unlimited This process is implemented in case of longer standstills The apparatus must be absolutely dry before nitrogen or dry air can act on it This for e
30. the pressure vessel itself when commissioning commences which will have serious H amp S issues associated with this type of failure The specific lifting lugs must be used to lift the unit at all times refer to final assembly drawing Also no other parts of the machine is to be used as a lifting points only the approved lifting lugs The unit is susceptible to damage if subjected to physical impacts These must be avoided at all times while being lifted or moved Ensure that the tube and corrugated wave circuits are connected correctly the right way around as this could easily dam age the unit beyond repair Ensure that vents are open to allow for air bleeding Refer to Section 5 for the full ventilation requirements Furthermore it must be ensured that the maximum permissible differential pressure for the operating conditions and the pres sure test on both sides is not exceeded also refer to section 4 1 The start up ventilations must remain open till the corresponding space is air free Please refer to section 4 1 regarding pressure control requirements maximum operating amp differential pressure requirements The APV heat exchanger may be used only for the directed purpose Using in any other manner is explicitly forbidden The heat _ exchanger may be operated serviced and if necessary repaired only by technical personnel and by adhering to all legal stipulations The Customer is required to nominate materials that are ca
31. through one or more channels depending on the variations in design The type of installation and the flow medium are given in the accompanying data sheet and the apparatus drawings Dimensions and other design related details including the position and total number of connecting pieces are specified in the accompanying dimensional drawing Materials used in the pressure resistant components are given in the parts list in the final documentation The pack is normally made of SS316L material and the housing pressure vessel is made of Carbon steel If materials prescribed by the customer operator are used exclusively then the customer operator is responsible for their chemical resistance 8 2 Design data Apart from significant information the design data maximum rating and dimensions are clearly given in the accompanying data sheet Annex 1 as well as in the accompanying drawing and the identification plate 3 Transportation installation tube connection 3 1 Transportation The apparatus can be transported horizontally or vertically depending on its size However please ensure that the belts ropes chains are not fastened over the welded connecting pieces The connecting pieces can be damaged due to the dead weight Mounting brackets with lifting points are bolted onto the heat exchanger These are re quired during transportation using suitable elevators refer to the accompanying dimen sional drawing The apparatus is however f
32. tion 2 Temperature Considerations 2 1 Maximum Operating Temperature A general Hybrid can be used for application up to 350 deg C In principal a hybrid can be applied to high temperature applications however key temperature factors that need to be controlled are e Temperature differences between fluids on both sides This is a maximum of 150 De grees Celsius e The initial start up phase 1 The start up conditions require the temperatures differences in the unit not to exceed 150 Degrees Celsius 2 Temperature gradients must not be exceeded refer to Section 6 2 2 2 High Temperature Applications For applications whose specification is required to exceed the above limits units are sup plied by SPX as customer specific applications 26 3 Fluid Considerations 3 1 Fluid Properties The Customer s application must state the fluid properties as they are important for the thermal design of the unit otherwise SPX cannot correctly predict the efficiency of the unit and the corresponding pressure drops 3 2 Material Choice The selection of the materials used for the unit is the Customers responsibility The cor rosive nature of the fluids and the abrasive nature of the fluids are both key factors in the choice of the materials The Customer is required to nominate materials that are capable of sustaining long term performance with the specified chemicals present in the fluid mediums e g especially chlorides at elevated
33. to the operating pressure common prac tice e Any requirements for a vacuum or partial vacuum must identified 27 e The design temperature must also be stated as this has an impact on the strength calculation for the housing Note for any material that is considered for the design there are maximum lim iting temperatures and there are also limiting minimum temperatures If no minimal was speci fied the design will assume 0 Degrees Celsius Pressure Limits Under no circumstances must the unit be operated outside the specified design conditions stated on the name plate also detailed in the drawing package 4 1 Vaccum Operation of the Unit The heat exchanger must be specifically designed to operate in a vacuum condition if this is to be part of normal operating conditions 4 2 Accidental Vacuums For normal designed units there are operating conditions where an accidental vacuums may be created e g through incorrect closure of valves and the units headers may be forced to collapse through the formation of a vacuum If necessary a vacuum valve should be installed by the customer after analysis of the P amp ID 28 29 SPXF COUS SPX Flow Technologly Inc 1200 W Ash St Goldsboro NC 27530 USA T 1 919 735 4570 F 1 919 581 1167 For more information about our worldwide locations approvals certifications and local representatives please visit www spxflow com SPX Flow Technology Danmark A S Platinvej 8 6000
34. valves they are to be installed there If the heat exchanger is not equipped with them the valves must be installed in the supply and discharge pipe before the first shut off device Maximum Differential Pressures The Customer is responsible for ensuring that no operating commissioning or testing conditions will exceed the maximum permissible differential pressure If the maximum permissible differential pressures are exceeded this may cause damage to the plate package The maximum allowable operating and differential pressures are detailed in the final drawing package 4 2 Maintaining maximum operating temperatures Protection against exceeding the maximum operating temperatures must be ensured in accordance with the control technology by using temperature limiters pump or blower con trol systems control dampers or valves or via bypasses 4 3 Insulation The heat exchanger should be provided with a thermal insulation unit or a contact safety device not a part of the SPX standard supply scope An appropriately dimensioned ther mal insulation unit reduces the loss of heat radiations and also acts as a contact safety device Bare surfaces gt 50 C involve combustion risk in the operating mode The operator must ensure suitable protective measures This is also applicable for heat exchang ers with low operating temperatures lt 25 C 4 4 Maintaining the liquid level in the tank Depending on the application scope of the apparatu
35. xample can be done by blowing hot air into the apparatus after emptying it completely The drying process is complete when the relative moisture of the air blown in matches that of the discharged air The conservation air to be blown in must be free from oil dirt and aggressive components It can be generated in large quantities in a relatively easy manner using a regenerative adsorption dryer The discharged conservation air should have relative air moisture lt 30 at 20 C The wall temperature of the heat exchanger should be more than the dew point of the air so that formation of condensation water can be avoided Also a vacuum drying and filling with dry nitrogen afterwards can be carried out The dew point of the nitrogen after filling is to specify in advance Conservation measures should be verified at regular intervals 18 7 Monitoring during operation Check Supports of the apparatus Check Tightness of connections flanges Check Tightness of Gaskets Check Tube side corrugated side connections flanges and gaskets Check Pressure of the medium on the tube corrugated side Check Inlet and outlet temperatures of the media Thermal function Check Mass flow on both sides Check Operational ventilations Check Safety and monitoring devices Check No physical leakages from the main unit flange connection Warning if there are physical leakages containment actions in accordance with local H amp S laws regarding
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