SEC Heat Exchangers phe-service-manual-r1
Contents
1. can maximise energy transfer efficiently from the unique combination of high turbulence and thin plate technology for any given unit size Maintenance costs are also reduced due to it s compact size Variety of Options The has been developed to allow many types of plates and gaskets for a large number of applications Changing the number of plates or configuration of the plate pack allows for a change in duty requirements in the shortest possible time Maintenance is also greatly simplified should Re gasketing or the cleaning of the plate surfaces be required Excellent versatility The PHE can carry out many kinds of processes from ice making cooling heating and condensing or evaporation etc with one set of suitable plates High quality IS09001 Certified The highest standards of manufacture are employed and combined with extensive technological know how gained from over 20 years of experience the performance of your is assured All design and construction operations are performed by computerised systems Performance calculations are optimised for your particular duty requirements 1 3 APPLICATIONS CHEMICAL INDUSTRY Cooling of Soda Pigments Fertilisers Refined Oils Oil and Fat Medicines Acids Kerosene Soft Water Brine Hexane Polymerisation Process and Heating of Glycerine and Condensing of Ethanol STEEL INDUSTRY r Dd 52 PRS Cooling of Mould Furnace Coking Plant Castin2. 2546 Iona Road Belfast Prince Edward Island Canada COA 1A0 Tel 902 659 2424 Toll Free 800 335 6650 Fax 902 659 2800 Email quotes secheatexchangers com SERVICES AVAILABLE HEAT EXCHANGERS ENGINEERING SERVICES Brazed Plate Program Design Maintenance Heat Transfer Design Plate amp Gasket Supply Waste Water Solutions
3. Ask your heat exchanger supplier for more details on applicable duties 5 Removing Calcium Deposition Ask your heat exchanger supplier for details 5 1 Submerge the plate in phosphoric or nitric acid nitric acid of specific gravity 1 4 1 litre water 10 litres for 5 10 minutes at normal temp and rinse wash with water 5 2 After acid cleaning passivate the plate with a neutraliser such as caustic and again rinse clean with water 3 3 Cleaning in Place CIP Ask your heat exchanger supplier for details An alternative cleaning method is CIP cleaning which does not require the disassembling of the plate pack see Cleaning Brine the brine should be expelled completely and then run the system with pure water at normal flow rates until the unit is clean Cleaning brine with hot water follow the sequence above and loosen the retaining bolts for gasket s expansion 100 plates 5mm The flow rate of the cleaning water should be higher than the duty flow rate for maximum affect In chemical cleaning the temperature and density of caustic are not that critical but for nitric or phosphoric acids higher temperatures accelerate the acids activity Nitric acid should not be used on any material except stainless steel If the PH of the acid falls below 5 adjust to over 7 for improved performance 3 4 Cleaning of Edible Oil Heat exchangers on food duties should be cleaned every day suggested method 15 Discha
4. BAR STAINLESS NOZZLE GUIDE BAR STAINLESS DETERMINED BY UNIT TYPE AND DESIGN 2 3 TYPICAL FLUID FLOW Moveable Pressure Plate Carry Bar Heat Transfer Plate Fixed Frame Tightening Bolt Support Column Guide Bar 2 4 CONSTRUCTION OF THE GASKET The gaskets are designed as duplicate structure to prevent mixing the fluids Should the ring gasket fail the liquid vents to the atmosphere part and is prevented from mixing with the opposing liquid by the diagonal gasket In similar manner if the diagonal gasket fails the ring gaskets acts as secondary seal AT PART GASKET W PEATE N Fig 3 GASKET DUPLICATE STRUCTURE OF THE GASKET 2 5 CONSTRUCTION AND APPLICATION OF THE FRAME The construction of the frames is dependent on the application pressure requirements and the type of the plates held in the frame The frames are protected from the liquids due to the welding or pressing of liners into the appropriate connection In general terms the construction and operation of the frames is the same for all PHE S 2 6 FLUID FLOW ARRANGEMENT to CONFIGURATION Forming of the plate pack channels is accomplished by hanging the plates gasketed plates should be faced to the frame in alternative A then fashion can be seen in Fig 6 the plate which has the ring and diagonal gasket on the right hand side and chevron pattern pointing down the pla
5. i ki 1 tj 1 d 3 i i i 1 z 4 1 11 TE in H a I u F nu a a 1 T 1 1 j b 1 a i L a il i i L i a f i is y d J FEE T L a a SINGLE amp MULTI MULTI PASS ARRANGEMENT 2 7 2 SEPARATOR CONNECTION PLATE Should more than one heat transfer duty be required in the same unit separator or connection plate can be incorporated The separator allows two or more individual heat exchanger duties to be performed and is especially suited to UHT pasteurisation duties SEPARATOR OR CONNECTION PLATES HEAT EXCHANGER WITH TWO CONNECTIONS 3 0 DISASSEMBLING A UNIT Remove frame 1 Remove any foreign material and apply grease to all bolts 2 Loosen the intermediate bolts and remove from the frame 3 Loosen the diagonals in sequence to maintain the pressure plate parallel to the frame plate Caution Never allow the pressure plate to be at an angle to the plate pack as the plates maybe distorted due to excessive loading To Disassemble the plates 1 Remove any foreign material and apply grease to the top guide bar for easier movement of the plates 2 Remove each plate one at a time in the direction of the arrows as shown ensuring that the gasket is not held onto the plate in front of it 3 1 RE ASSEMBLING THE UNIT The f
6. ICE SIDE DESIGN PRESS __ PSI pesiGNtemp __ TEST PRESS PSI EMPTY WEIGHT 22 Ibs CHANNEL ARRANGEMENT X PASS NO ORIGINAL TIGHTENING DISTANCE mm SEC Plate and Frame Heat Exchangers 2546 lona Road Belfast Prince Edward Island Canada 1 0 Tel 902 659 2424 Toll Free 800 335 6650 Fax 902 659 2800 Email info secheatexchangers com CUSTOMER NAME Basic Unit Information See enclosure for full unit details UNIT SERIAL HOT COLD TYPE NUMBER SIDE SIDE ADDITIONAL UNITS UNIT SERIAL HOT COLD TYPE NUMBER SIDE SIDE JU 1 0 PRINCIPLE OF THE PLATE HEAT EXCHANGER PHE 1 1 PRINCIPLE The PHE is composed of corrugated thin alloy plates which are hung between top and bottom guide bars The plates are compressed by bolts in between fixed and movable frames until metal to metal contact is reached and channel is formed The manner in which the gaskets are fitted enables alternative flow channels to be created and heat transfer to pass from one side of the plate to the other The alternative channels maximises the heat transfer surface in compact manner Therefore it can produce the most effective performance from the compact size 1 2 FEATURES OF PHE High performance total heat transfer co efficient of the is 2 000 6 000 Kcal m2 hrC The value is 3 to 10 times higher than the traditional shell and tube heat exchanger High economic tendency The
7. SEC HEAT EXCHANGERS Plate and Frame Service Manual rev 1 Table of Contents Name Plate Insert Basic Unit Information Insert Principles of the Plate Heat Exchanger Features of PHE 5 10 LI 12 7 1 3 Applications 2 0 ConstructionofthePHE 2 1 Plate Characteristics 22 22_ Components 2 3 Typical Fluid Flow O 2 4 Construction of the 2 5 Construction and Application of the Frame 0 2 6 Fluid Flow Arrangement to B Configuration 0 30 31 32 _ 3 3 CleaninginPlace CIP LL O 3 4 Cleaning of Edible Oil 40 50 60 Tightening Devices Transportation and installation of the PHE Installation and Minimum Clearance Piping and Fitting on Multi Pass Units p General Operating Instructions 1100 Re Gasketing 0 1101 General Instructions for Glued Gaskets 0 261102 LongTermStorage O 1110 Spare Parts Numbering System 0 ___27 111 GasketCodeSystem 1112 with Gasket Code System 0 1113 FrameComponentCode System 28 120 PipeLoadng 1 1 O BO Assistance and Field Service 0 Steam 2 7 T o 14 7 Service History Log Service History Loc 34 151 ServiceHistoryLog O NAME PLATE To assist in rapid reply to any questions please quote your serial number PROCESS SIDE SERV
8. accumulators whenever possible Negative pressure vacuum on standard design plate heat exchanger may also result in gasket leakage problems plate heat exchanger must never bes ubjected to vacuum unless designed for vacuum application during normal operations or during start up and shut down procedures 14 6 FLUID INCOMPATIBILITY This is evidenced by swelling of gaskets upon unit opening tacky or liquid surface to gaskets and gaskets failing off plates Advice should be obtained from factory pe rsonnel whenever these conditions are encountered Quite often minute quantities of contaminants in the fluid can have large effect upon some elastomers Fluid sample testing and gasket coupon testing of various elastomers in the customer s process fluid can determine the proper compound to use In extremely difficult cases dual gasketing system using two different gasket materials on the fluids may solve the problem 14 7 LEAK DETECTION AND ELIMINATION Because of vented areas between portholes and plate faces barring corrosion completely through plates fluids cannot cross within the unit If any leakage does occur it will be to the outside of the unit and observed as slow leak If a unit starts leaking check operating temperatures pressures and the dimension When pressures and or temperatures are in excess of design conditions take measures to correct them and restart the unit If the a
9. bove are within design conditions allow the unit to cool to ambient temperature and relieve the pressure on all fluid circuits within the unit At this time begin tightening the compression bolts in the prescribed manner but do not go below the Q dimension by more than 1 If the unit still continues to leak it may contain damaged or worn out gaskets Open the unit and individually examine gaskets for particulates glue failure or damage and wear Remove those gaskets which appear to be have reached their life span and replace with new gaskets If there appears to be a problem with fluid crossing that is internal leakage this indicates a condition that has been favorable for corrosion causing pinholes through the plates The damaged plate or plates may be located by two methods for single pass units Shut the unit down and relieve all pressure within the unit The piping on one side of the unit is now removed to allow viewing of the portholes for the length of the plate pack At this time pressure 16 again turned to the piped side and leakage may be observed by shining a flashlight into the porthole to view and locate the leak With multiple pass units the above procedure will only allow partial viewing of the plate pack because of the non punched portholes in some locations In this case the unit is opened and all plates are either wiped dry or allowed to air dry The compression bolts are then replaced and the unit
10. de during flow interruption 14 3 EXCESSIVE PRESSURE AND SPIKES The normal maximum operating pressure for a plate heat exchanger is generally 16 bar for ASME code units ASME un its require ASME relief devices per UG 125 of ASME Code Section VIII Div 1 Preventing Excessive Pressure However plate heat exchangers which can operate at pressures up to 25 bar are available 14 4 DESIGN PRESSURE Operating plate heat exchanger above its design pressure will result in gasket sealing problems These problems vary depending on the type of plate being used but are most often indicated by protruding gaskets which will extrude between plates and be visible on the perimeter of the plate pack Leakage may or may not be present but in either case steps must be taken to correct the situation Excessive pressure must be reduced to limit s within the design pressure of the unit All regulating and throttling valves are to be placed on the inlet sides of the exchanger Excessive lengths of piping being stopped by valves on nozzle outlets can cause tremendous pressure on gaskets and this 16 to be avoided at all times 14 5 PRESSURE SPIKES Pressure spikes can also cause extremely high pressures Some of the causes are totally closed systems without allowances for expansion booster pump start up and rapid acting control valves When these conditions exist they should be handled with vented closed systems slow acting control valves and
11. first running a unit the pipes should be flushed out and all foreign material removed e g sand welding slag etc Failure to do so may void the warranty and affect heat transfer rates 9 0 GENERAL OPERATING INSTRUCTIONS Check the sealing of the plates Check the outlet valve 15 opened Open the inlet valve of the PHE Run the pump Open the pump outlet valve slowly watching the PHE s inlet pressure meter if fitted Control the amount of liquid according to the temperature gradient Start the cold side of the unit first and then the hot side In the case of steam pass the medium liquid first then steam slowly 10 0 RE GASKETING For units fitted with clip on gaskets clean the gasket groove and fit the gaskets with all tags facing out For glued gaskets it is recommended that you contact your heat exchanger supplier for detailed instructions 10 1 General Instructions for Glued Gaskets After plate cleaning Paint contact adhesive glue should not contain chlorides on the grooved area in which the gasket will be attached with strong brush tip Naturally dry the glue for 3 5 minutes and press the gasket onto the exact grooved area Press the stacked plates for at least 10 hours the longer the better Remove excessive adhesive with solvent Do not use excessive amounts of glue as distortion of the plate may occur on reinstallation 10 2 Long Term Storage When the PHE has not been in o
12. g Facilities Ammonia Water Electrolysis Gilt Compressor Oil Press Oil and Recovering of Waste Heats MECHANICAL INDUSTRY Cooling of Mechanical Apparatus Emulsion Press Oil Grinding Liquid Furnace Engines and Waste Heat Recovery FOOD INDUSTRY Cooling Heating Heat Recovery Concentration and Sterilisation of Juice Milk Soy and Sesame Oil Sugar Liquid and Alcoholic Liquids J uice Preheating Before Evaporation TEXTILE INDUSTRY Cooling of Cleaning Water for Spinning and Weaving NaOH Liquid and Dyeing Water Recovering of Waste Heats Luci k Preparation of Dyeing Liquid SHIP BUILDING INDUSTRY Central Cooling Lube Oil Jacket Piston Water Heavy Oil Transmission Oil Heating Oil Central Cooling Cooling of Lube Oil Jacket Piston Water Heavy Oil and Transmission Oil and preheating of Heating Oil BUILDING FACILITY Local Heating Supplying Water Heating Air Conditioning Systems Heating and Cooling of Circulating Water AUTOMOTIVE INDUSTRY Spray Booth Cooling of Heat Treatment Liquids Cutting Liquids Coating and Spray Booth Paint and Heating of Pre treatment Liquid PULP amp PAPER INDUSTRY Cooling of Black process water Heating of incoming Supply water and Waste Heat Recovery VARIOUS OTHER APPLICATIONS Heat Transfer and Waste Heat Recovery of Electric Electronic Semiconductor Factories Power Stations Sea water Heating or cooling of building
13. irst plate is the plate followed by a plate until all plates are hanging in the frame Re assemble the unit in the opposite sequence of disassembling see bolt tightening sequence below 12 balts 10 bats Kull bolts 5 T wile ole E Iz d ZI EE ve Get aie ae Ses 1 FEE 5 Vra ze A tel fe G 4 ee am 1 JE a cr re em ul kr Ef 1 d dena dl tue Ai I ho Ti eMe esse r EPLE es LI LI LI Maca eS ae gt rar EN x im f cds 3 2 CLEANING Follow the next sequence to clean the plates after disassemble 1 Clean the plates one by one with high pressure water or chemical clean in an appropriate acid or caustic 2 Remove clip on gaskets and ensure the gasket groove is clean before reattaching the gasket Any foreign material left will cause the gasket to leak on resealing of the unit 3 Cleaning the gasket Do not use a steel brush or the gasket will be marked and a leak will occur on re tightening of the unit Mild soap or water should be used with a cloth 4 Should your unit have a corrosive duty ensure that any opening of the unit is keep to a minimum This will prevent excessive swelling of the gasket
14. is re tightened to the minimum dimension One side only is now pressurized for approximately 15 minutes Pressure is then relieved and the unitis now reopened Carefully separate the plates one at a time going from movable frame to fixed frame It will be noticed that every other flow channel is wet with a dry channel in between When you find two adjacent wet channels you have located the affected plate It will be one of the two plates in the centre Once the suspected leaking plate 1s located you may confirm with visual inspection or dye penetrant techniques If the plate at fault is punched 1 2 3 4 the unit may be rapidly put back on line by removing an adjacent plate with the same punching Heat transfer will be reduced only to a minor extent If this punching arrangement is other than above you will have to remove and replace the faulty plate s before restart Always reduce the Q dimension when removing plates by the thickness of the gasketed plates The amount of reduction in the Q dimension necessary for each plate removed may be obtained by using the multiplier shown on the data plate 15 0 SERVICE HISTORY LOG DATE SERVICED COMMENTS SERVICED UNIT NUMBER e gt gt un m C gt z 5 un ea Q m 24 ea Un lt am un Z ea gt gt Q fo ea Q gt gt un 24 gt Z SEC Plate and Frame Heat Exchangers
15. ive hot side fluid or steam temperatures Unit being operated under conditions for which it was not designed Superheated steam Cold fluid stoppage on units operating at upper gasket temperature limits Corrective measures should include checking for excessive operating temperatures and lowering where needed or replacing with higher temperature gaskets If the unit is being used for services other than those for which it was designed the necessary adjustments or gasket replacement should be done to ensure gasket compatibility with the operating temperature 14 2 STEAM Quite often high pressure steam is put through a reducing station without going through a desuperheater The steam is now at a lower pressure while still retaining much of its previous high pressure temperature This of course has a very detrimental effect upon gaskets and greatly reduces the overall performance of the heat exchanger be cause of the decreased availability of latent heat while steam is in the superheated state Plates and gaskets will generally be at a temperature between the hot and cold fluids Intermittent cold flow conditions can cause problems in units operating at borderline temperature conditions As the cold flow is interrupted the unit will begin to come up to the temperature of the hot fluid and damage gaskets if upper temperatures are exceeded This can be alleviated by ensuring a constant cold side flow or by throttling down the hot si
16. n If there is gap between pressure plate and fixed nut turn the nut by hand Repeat this sequence to arrive at the required Q distance MANUAL UNIT AUTOMATIC UNIT 5 0 TRANSPORTATION amp INSTALLATION OF THE P The most desirable way to transport is either by the use of lifting lugs if supplied or connection below the top two tightening bolts Never lift on the connections or guide bars Note On arrival of your unit check that the bolts do not require re tightening as they may have loosened during transport LIFTING HOOK a fr Ree 6 0 INSTALLATION and MINIMUM CLEARANCE On arrival at the installation site keep the unit horizontal and fix it with anchors or setting bolts The required minimum clearance on either side of a unit is 0 6m to allow for removal of the plate pack TYPICAL P H E MINIMUM DISTANCE FROM OBSTRUCTION 600mm 7 0 PIPING amp FITTING ON MULTI PASS UNITS Pipe work may be connected directly to the nozzles However an alternative is offered and this will make maintenance faster and cleaning easier Support the nozzle as shown below do not place excessive weight on the pipe work at this point Insert a flexible pipe section to make it possible to enlarge the amount of plates if required Flexible Connection gr i er 4 Pipe Connection UI EOS 1 rc gt 2 Plan View 8 0 FLUSHING Before
17. ng must be supported and preferably connected to the unit with flexible connections While itis always considered good engineerin g practice to support all piping the clad and lined ports can take considerably more load as the frame takes the support rather than a nozzle In all port configurations pumps should be mounted a minimum of six pipe diameters from nozzle flanges 13 0 Assistance and Field Service An in house group of highly specialized engineering and service personnel to deal with questions and problems related to our plate heat exchangers together with many other manufacturers These groups at your disposal at all times to help with and answer questions pertaining to Design Engineering Systems Applications Gasket Compatibility Plate Compatibility Installation Operation Maintenance Field Service In House Servicing Regasketing 14 0 TROUBLE SHOOTING 14 1 EXCESSIVE TEMPERATURES The normal maximum operating temperature for a plate heat exchanger is approximately 120 degrees Celsius Higher temperatures may be reached with special gasket and adhesive materials Operating any plate heat exchanger at temperatures above the design temperature of the gasket material will result in gasket and adhesive failure An excessive temperature gasket failureis indicated by a hard shiny surfaced gasket face Quite often these gaskets are so brittle they can be crumbled with the fingers Points to look for are Excess
18. peration for an extensive period of time make the following arrangements Disassemble and clean the plates and loosen the bolts 100 plates 500mm If the is not easily disassembled clean the with water or chemical solvent and loosen the bolts to release the liquid Do not keep any unit in an unclean condition for an excessive period of time as corrosion of the plate surface may occur 11 0 Spare Parts Numbering System All parts are created by the application of either an alpha numeric or numeric code system A part number can be created for any gasket plate with gasket or frame component by applying the appropriate code Ask your plate heat exchanger representative for detailed part numbers for your particular units 11 1 GASKET CODE SYSTEM 0000 00 0 UNIT GASKET GASKET Type Material Material 11 2 PLATES WITH GASKET CODE SYSTEM 000 00 00 0 0000 0 Unit Plate Gasket Plate Hole Plate Type Material Material Material Location Orientation 11 3 FRAME COMPONENT CODE SYSTEM 0000 00 00 UNIT COMPONENT LENGHT OR TYPE TYPE THICKNESS 12 0 Pipe Loading The plate heat exchanger offers variet of port arrangements to suit customer requirements The alloy clad studded port is offered as standard with elastomeric liners and ANSI lap joint loose flange connections offered as alternates The loose flange connection cannot withstand external loading and all pipi
19. rge the fluid with water and monitor the situation through the glass tube Pass pure water through the heat exchanger for 5 10 minutes Circulate 70 litres water for 20 30 minutes Circulate 60 70 litres 0 7 nitric acid for 30 minutes Circulate pure water to flush out any material Neutralise the plates with 60 70 litres 0 7 1 caustic for 30 60 minutes Circulate pure water again Caution Take care that the temperature and density of the nitric acid does not exceed the limitations above The cleaning sequence nitric treatment and caustic cleaning can be changed but there must not be any residual acid left in the unit Nitric acid should not come in contact anything except stainless steel Food duty heat exchangers must be sterilised after cleaning The most common way 15 to sterilise with hot water or steam If you are using chlorine based disinfectant Titanium plates are required 4 0 Tightening device Hydro Torque Wrench Automatic Type Pre assemble the heat exchanger and after placing the tightening units on the diagonal nuts apply oil pressure The piston will travel forward and rotate the pitch wheel to tighten the nut For disassembling a unit reverse the unit and apply oil pressure Manual Type Pre assemble the heat exchanger and after placing the tightening units on the diagonal nuts apply oil pressure The piston will travel forward and the pressure plate will travel in the same directio
20. s HVAC Waste Heat Recovery 2 CONSTRUCTION OF THE PLATE HEAT EXCHANGER GUIDE BAR CONNECTION PART OF THE GUIDE BAR FLUID CHANNEL GASKET HEAT TRANSFER AREA amr dna RING GASKET Fig 1 PLATE MAIN FEATURES OF A HEAT TRANSFER PLATE 2 1 PLATE CHARACTERISTICS Plate thickness is normally in the range 0 6 1 0mm Stainless steel Titanium Hastelloy Copper Nickel and Al brass are available The plates are pressed to form corrugations which increase the surface area and strength of the plates The plate has up to four connection holes for fluid transfer with gaskets fitted to confine the liquids Gaskets are made from composed rubber and are chosen in accordance with the types of fluids to be used in the PHE The corrugated shape on the plates maximises the heat transfer efficiency by creating high turbulence in the channels Centrally located cut outs on the top and bottom ends of each plate is designed to make the plate hang correctly either side to the top and bottom guide bars au Ra LS S Ar v ta ta b es LJ LJ Me t LJ t OUN TT HERRINGBONE TYPE 2 2 FRAME COMPONENTS CONNECTION UPPER GUIDE BAR TIGHTENING BOLTS NAME PLATE PRESSURE PLATE SUPPORT FRAME PLATE COLUMN DRAIN VALVE LOWER GUIDE BAR PLATE STAINLESS PLATE PLATE STAINLESS BOLT COLUMN STAINLESS GUIDE
21. te is called the A plate and when rotated becomes the plate One fluid flows on the surface of each of the A plates while the alternative fluid flows over the B plate pir a P Du vr MC et ee SS M m nus ES dh gt HII lt a Mic P 1 gt i NS EU a 4 A A id LE LE A Wes p B PLATE FIG 6 The flow directions are normally counter current to each other The hot fluid flows with two parallel lines top to botton and bottom to top and the cold fluid with 4 parallel lines flows bottom to top The plate arrangement can be written as 2x2 1 4x 1 where I represents the end plate which does not perform any heat transfer The four holes in the plate are distinguished as 1 2 3 and 4 from their positions and means no hole There are 16 hole combinations possible depending on the application and temperature approach 2 7 TYPICAL PLATE ARRANGEMENTS EXAMPLE OF PLATE ARRANGEMENT AND FLOW NO 1 H W IN C W OUT HW CUT C W IN 1234 A1034 B1034 A1234 B1234 A1234 25 Aa Lid E r Id SINGLE AND MULTI PASS ARRANGEMENT 2 7 1 ADDITIONAL PLATE ARRANGEMENTS HE MULTI PASS ARRANGEMENT T 7 EN E E Li h E E t g 1 1 Emi
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