Professional Documents
Culture Documents
KLIMA
PLATE HEAT EXCHANGER
Supplier information:
Homepage:
www.Klima.com
The Netherlands:
Klima Thermo-Tech B.V.
Rogier van de Weydenstraat 45
5642 JG Eindhoven
Postbus 300
5600 AH Eindhoven
Telephone:
+31 (0)40-2981818
Telephone service:
+31 (0)40-2981858
Telefax:
+31 (0)40-2981800
E-mail
info@klima.com
Supplier Belgium:
S.A. Klima Belgium N.V.
Leuvensesteenweg 49c
1932 Zaventem
Telephone:
Telefax:
E-mail
+32 (0)2-7206026
+32 (0)2-7203407
Klima.belgium@klima.com
Supplier Belgium:
Klima warmtetechniek N.V.
Buitenheide 4
3930 Hamont-Achel
Supplier France:
Klima S.A.R.L.
Chateau Rouge - 276
Avenue de la Marne
59708
Marcq-en-Baroeul
Telephone:
Telefax:
E-mail
+33 (0)320-65-91-65
+33 (0)320-65-91-60
Klima.france@klima.com
Publication: 16.12.2002
Table of Contents
1
2
3
General Information...........................................................................5
1.1
Product Information ...........................................................5
1.1.1
Design and Function..........................................................5
1.1.1.1 Plate Heat Exchangers ......................................................5
1.1.1.2 The Plate Stack - Medias...................................................6
1.1.1.3 Intermediate Frames..........................................................6
1.2
The Plates .........................................................................7
1.2.1
The Corner Holes of The Plates .......................................7
1.2.2
Code ..................................................................................7
1.2.3
Changing of Plates ............................................................7
1.3
Schematic Flow Diagram...................................................8
1.4
Placing of Connections ......................................................9
1.5
Installation Composition...................................................10
1.6
Prohibitions to (putting into) Operation ............................11
1.7
Guarantee........................................................................11
Safety ..............................................................................................12
2.1
General Safety.................................................................12
2.2
Protection: .......................................................................13
Transport, Storage and Installation Site. .........................................14
3.1
Instructions for Transport and Hoisting ............................14
3.2
Transport and Packaging.................................................15
3.3
Storage: ...........................................................................15
3.4
Installation Siting:.............................................................15
Installation .......................................................................................16
4.1
Safety Measures and Facilities on
the Heat Exchanger / Installation. ....................................16
4.2
Preparation for Installation...............................................17
4.3
Installation .......................................................................18
Start-up............................................................................................19
5.1
Inspection before putting the unit into operation ..............19
5.2
Filling and Venting. ..........................................................19
5.2.1
Filling a heat exchanger compartment with a liquid. ........19
5.2.2
Filling a heat exchanger compartment with a gas............19
5.2.3
Filling a heat exchanger compartment with steam...........20
5.3
Inspection after Start-up: .................................................20
5.4
Leakage during Start Up..................................................20
5.5
Shut Down of the Installation: ..........................................20
Maintenance and Inspection:...........................................................21
6.1
Inspection ........................................................................21
6.2
Cleaning of the Heat Exchanger. .....................................22
6.2.1
Disassembly of the Heat Exchanger................................22
6.2.2
Cleaning the Heat Exchanger..........................................24
6.2.2.1 Chemical Cleaning...........................................................24
6.2.2.2 Mechanical Cleaning .......................................................25
6.2.3
Control of Cleaning ..........................................................25
3
6.2.4
Assembly of the Heat Exchanger.....................................25
6.2.4.1 Gasket Construction ........................................................26
6.2.5
(Re)pressurizing of the Heat Exchanger..........................28
Malfunctions / Trouble-Shooting Guide ...........................................29
7.1
Identification and Correction of Malfunctions. .................29
7.1.1
A suspected leakage can be located in one
of the following ways:.......................................................31
7.2
Safety Measures / Facilities:............................................31
Customer Service:...........................................................................32
8.1
Ordering Spare Parts.......................................................32
8.1.1
rebuilt...............................................................................32
8.2
Complaints Procedure: ....................................................32
Accessories / Annexes: ...................................................................33
9.1
Instructions for Transporting and Hoisting. ......................33
9.2
General Information about Material and Mediums ...........33
9.3
Technical Specifications / Documentation .......................34
General Information
1.1
Product Information
Product
: Plate-Heat Exchanger
Type
: See Technical Specification Sheet or type plate
All the information that is present in this user manual concerns the plate-heat
exchanger that can be disassembled.
The information in this manual except the chapters referring to the
disassembly and assembly of the heat exchanger also concerns the brazed
plate-heat exchanger that cant be disassembled.
1.1.1
Each plate is supplied with a gasket, so that the plates form a closed system
of parallel flow channels, through which the medias flow alternately at every
second interval. (Fig. 8).
Fig. 1
1.2
The Plates
1.2.1
The Corner Holes of The Plates
Depending on the required liquid flow in the plate heat exchanger the 4
corner holes have to be opened. The corner holes named with numbers
starting left side on the top of the plate (to be seen from the gasket side) as
no. 1 after that continues no. 2, 3 and 4 clockwise. The corner holes are
opened as you see on the diagram drawings, describing the liguid flow in the
plate heat exchanger.
The opening of the corner holes are described in a code. For instance: 1234
means that all the corner holes are opened. Code 0204 means that hole 2
and hole 4 are open, and the holes 1 and 3 are closed.
1.2.2
Code
The plates are designed so they can be used both as right and as left plates.
The plates just have to be turned 180.
Right and left plates: On a right plate the flow runs from hole 2 to hole 3 or
reverse from hole 3 to hole 2. On a left plate the flow runs from hole 1 to hole
4 or reverse from hole 4 to hole 1. (Fig. 2.)
Fig. 2
1.2.3
Changing of Plates
Changing and mounting of new plates can be done after disconnection and
removal of the assembling bolts. Before mounting of spare plates check if
the plates are identical with the ones you want changed. Reduction of the
number of plates is possible, but it is a condition that the plates are removed
7
two by two so that the plate stack after reduction is still mounted by turns
right and left plates. The removed plates have to have all 4 corner holes
open. It is necessary to correct the minimum tightning measure after a
possible reduction.
Note! A reduction of the number of plates means that the transmission area
of the plate heat exchanger is reduced corresponding to the plates being
removed. A removal of plates will cause a rise of the pressure drop over the
plate heat exchanger.
1.3
The diagram shows the plate heat exchanger from the side, fig. 6. lt shows
the plate composition and the liquid flow in the plate stack. There are 4 lines
going horizontal, showing the 4 corner holes. The long vertical lines show left
plates. The short vertical lines show right plates.
On the diagram a left and a right plate are shown. On the left plate the f low
runs from hole 1 to hole 4 or from hole 4 to hole 1. On the right plate from
hole 2 to hole 3, or from hole 3 to hole 2.
The number codes over the vertical lines show the corner holes which are
open in the plates, to give the liquid flow wanted in the plate heat exchanger.
F = Head
B = Follower
M = Intermediate frames
H = Horizontal
V = Vertical
Example:
M
1
V
Vertical connection
Corner hole number
Intermediate frame from head
Intermediate frame
1.4
Placing of Connections
On the symmetrical drawing under the flow diagram, the placing of the
connections is shown. (Fig. 3).
The dot-and-dash intermediate frames are drawn up according to the
number of the intermediate frames in the plate heat exchanger.
The connections are marked with a letter and a numbercode.
Fig. 3
1.5
Installation Composition
Fig. 2
1.
2.
3.
4.
5.
6.
7.
8.
Lower pipe
Upper pipe
Plate Heat Exchanger
Compensator
Valve
Connecting flange
drain
Vent
10
1.6
1.7
Guarantee
11
2
2.1
Safety
General Safety
Physical injuries
Physical injuries can be caused by:
External forces.
Corrosion.
Chemical corrosion.
Erosion.
Fatigue.
Steam shock.
Impact load.
Freezing.
Transport
For transport See: Instructions for Transport and Hoisting
If handled incorrectly there is a risk for physical injury and/or
damage to the equipment.
Even after switching off the installation the heat exchanger
surface can still be hot.
The unit may only be fed with the mediums stated in the
technical specification sheet.
No fatigue analysis has been taken into account and therefore
the unit should only be used for static load.
A hot medium may NOT flow through the heat exchanger
without a cold medium also flowing through the heat
exchanger. This is to prevent damage to the heat exchanger.
12
2.2
Protection:
For the protection of others place the heat exchanger out of reach, in a
closed space, e.g. a boiler house, only accessible to authorized staff
acquainted with the safety requirements applying to the equipment stored
there.
If the heat exchanger is set up close to people, presenting a risk of burns,
insulation of the heat exchanger is mandatory.
The user must take care to provide adequate danger signs on exposed uninsulated parts of the installation, which present risk of burns or other injury
and/or damage.
13
3.1
Fig. 3
14
3.2
3.3
Storage:
3.4
Installation Siting:
The location where the equipment is placed must have enough space
for installation, maintenance and cleaning. See the relevant chapters.
Installation
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
installer.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.
4.1
Installation must be carried out in such a manner that all likely risks are
excluded.
To achieve this, the following points must at least be observed:
The necessary fittings must be attached so that filling and emptying the
equipment can take place safely.
There must be sufficient valves in the supply and return pipes, close to
the heat exchanger, so that the whole system does not have to be
drained if work needs to be carried out. .
For heat exchangers using steam as a medium one must ensure that
they are fitted with a correctly functioning system for condensate
drainage.
For the choice of a steam trap and other fittings it is advisable to seek
advice from the suppliers.
16
4.2
General:
The plate heat exchanger requires space enough for it to be opened for
inspection or repairs without problems, (fig. 6).
fig 6
It is necessary for the plates and the assembling bolts to have so much
space that they can be mounted and dismounted without problems.
The follower has to be pulled back to the column before opening for
service can be done without problems. (Fig. 7).
Fig. 7
17
4.3
Installation
The instructions for transport and hoisting must be observed when
placing or moving the equipment.
During assembly of the piping all pipes / flanges must be mounted
stress-free to the heat exchanger.
Pipes must be able to expand. If necessary compensators must be fitted
to the pipes.
Bolt-nut connections must be clean and lightly oiled.
Gasket used: reinforced graphite gasket 1,5 mm.
18
Start-up
The assembly and start-up must be carried by a suitably
qualified person appointed by the buyer or by a qualified
installer.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.
Pump start always has to be done with closed valves. After
that the manoeuvring of the valves must take place slowly in
the order to avoid liquid and pressure chocks.
5.1
5.2
5.2.1
Filling a heat exchanger compartment with a liquid.
Proceed as follows:
Open vent.
Ensure that all air has been allowed to escape from the unit.
Allow the circuit to pressurize and open the return valve so the medium
can flow through.
Check for leakages. In case of leakage see Chapter 7.
5.2.2
Filling a heat exchanger compartment with a gas.
Proceed as follows:
Allow the circuit to pressurize and open the return valve so the medium
can flow through.
5.2.3
Filling a heat exchanger compartment with steam.
Proceed as follows:
The cold medium must always circulate through the heat exchanger
first.
When the pressure in the heat exchanger rises too fast, the condensate
is forced through the tubes, possibly leading to water hammer. Heating
therefore needs to happen slowly, so the installation will heat up evenly.
Open the valves at the drainage points and let the steam enter the tube
very gradually, causing the pressure to slowly rise.
When the initial condensate has been drained and steam starts to
escape, then shut the valves again.
During the heating up phase, water hammer must not occur because it
can damage the installation.
5.3
After heating the heat exchanger for a certain period of time, all connections
must be inspected for leakage. In case of leakage they must be repaired.
See Chapter 7.
Check whether the settings of the measuring and control devices reflect the
expected values.
5.4
5.5
To shut down the heat exchanger the supply and return flows of the circuit
must be closed.
First close the supply of hot medium and then, only when the
heat exchanger has reached the temperature of the cold
medium, close the supply of the cold medium.
Danger of freezing.
When an idle heat exchanger (filled with water or a water
mixture not of an anti-freeze type) is exposed to temperatures
below zero, the pipes may burst and the covers may be
deformed. If there is a danger of freezing all the medium must
be drained from the heat exchanger.
20
6.1
Inspection
Leakage.
Pressure and temperature within the permissible limits.
Presence of air in a system where a liquid medium is being used.
If applicable, the presence of adequate condensate drainage.
Fouling of the heat exchanger (drop in capacity).
Vibrations / strange noises.
General condition of the installation.
Corrosion.
Functioning of the safety devices.
21
6.2
6.2.1
22
Fig. 8
1.
2.
3.
4.
5.
6.
7.
Head
Follower
Carrying bar
Guiding bar
Column
Plate pack
Clamping bolts
23
6.2.2
Cleaning the Heat Exchanger
As well the capacity as the corrosion resistance of the plate heat exchanger
are depending on the cleaning of the plate heat exchanger.
6.2.2.1
Chemical Cleaning
Nitric acid also has an effective build up effect on the passivation film of
stainless steel!
6.2.2.2
Mechanical Cleaning
The plate heat exchanger is separated and the plates are pulled from each
other. Use a soft brush and a qualified cleaning material for cleaning the
plates.
lf the cover is thick, from scale or organic material the plates are put in a vat
with a qualified cleaning material. Wire brush, sandpaper, metalscraper etc.
must not be used. Neither the plates nor the gaskets can bear heavy-handed
/ robust treatments.
A high-pressure-cleaner can be used but with absolute care, and never add
abrasives.
6.2.3
Control of Cleaning
Cleaning is an important part, influencing on the effectiveness of the plate
heat exchanger. Therefore the plate heat exchanger has to be separated for
inspection - and especially in the commissioning period. You will obtain
important experience concerning circulation times, temperatures, and
chemical concentrations.
Reasons for insufficient cleaning often have to be looked for among the
following:
- too low circulation quantity
- too short cleaning period
- too low chemical consumption compared to the scaling of the plates
- too long running intervals between the cleanings
6.2.4
The plates and the gaskets are checked carefully before mounting - the
plates have to be clean and the gaskets have to be without fatty substance
and other uncleanness. A grain or sand on the gasket can cause leak ness
during running and damage of gaskets. It is recommended to use new
gaskets.
The plates are being mounted according to the diagram - the gaskets always
have to be turned towards the head of the plate heat exchanger. lf the
gaskets have been changed or the plate heat exchanger has just been
delivered the plate heat exchanger is assembled according to the minimum
measure stated on the name plate and the enclosed drawings + 0.1 mm per
plate.
During the assembling the head and the follower have to be parallel. It is
therefore necessary to measure the assembling on the top and the bottom
on both sides. (Fig. 9).
25
Fig. 9
Make sure that all gasket faces are clean and undamaged.
Always use new gaskets.
Apply the gaskets.
26
Fig. 10
Glue Type
PLIOBOND 25 / SCOTCHGRIP 847 are nitrile rubber glues on soluble basis
(25% solid materials).
The glues are partly thermoplastic so that old gaskets can be unsticked by
boiling-water heating.
Detergent
For cleaning and degreasing new gaskets and gasket grooves
use,>ACETONE<. It is very important that every detergent is evaporated
before putting glue on.
Beware!
Solvents are dangerous to inhale!
Avoid contact of the solvent with the eyes and the skin!
Glueing.
After wiping gaskets and gasket grooves with a cloth moistened with
degreasing substance the glueing itself can begin. The glueing areas must
be quite clean - free from fingerprints etc. The gaskets are covered by a
brush with a thin coat of glue on the glueing area and are placed on a clean
and dry place in order to dry.
27
The gasket grooves, too, are supplied with a thin coat of glue, after which the
gaskets are pressed down equally all over in the groove. The glueing starts
in the plate ends and then continues along the straight edges.
The glueing process is done easiest on a solid table. After the gaskets have
been put into the plate gasket grooves the plates are stacked.
When the glueing is finished the plates are hung into the frames again and
the plate heat exchanger is clamped together. See description -Opening and
Assembling. The plate heat exchanger can be warmed up by hot water if the
glue is to dry quickly - but without pressure on the water
Drying time:
-Approximately 2hoursat80-100'C(194-212'F)
-Approximately 24 hours at 40-50'C (104'F)
-Approximately 48 hours at room temperature.
lf it is not possible to heat the plate heat exchanger it must be placed as
warmly as possible and in order to let off glue vapour from the plate heat
exchanger the connections are to be dismounted.
6.2.5
Proceed as follows:
28
7
7.1
Malfunction
Possible cause
Heat
exchanger
has
insufficient
capacity.
Possible cause
If the liquid is mixed it is
due to holes in one or
more plates.
Defective gasket.
External forces.
The operating conditions
deviate from those stated in
the technical specification
sheet.
29
Malfunction
Heat
exchanger is
leaking.
(External
leakage)
Possible cause
Gasket faces dirtied or
damaged.
Defective gasket.
Bolt tightened insufficiently.
External forces (expansion
of pipes) on the heat
exchanger.
Maybe the plate heat
exchanger is running with
a higher working pressure
than mentioned on the
name plate
plate heat exchanger is
pressureless
30
7.1.1
- Remove a pipe on one of the bottom pipe connections - then Put the
opposite side under pressure.
After the pressure is stabilized the liquid must not run off from the removed
pipe connection. lf the liquid continues to run off there is a leak on one or
more plates. The plate stack is demounted and every single plate is
examined carefully.
The plate heat exchanger is separated and all the plates are dryed, After
drying the plates are put into the plate heat exchanger and assembled. Now
the liquid is circulated with full capacity but only on one side (every second
plate interval). The other half of the plate interval is kept without pressure
and without liquid.
The circulation is stopped after a few minutes and the plate heat exchanger
is opened carefully so that no water is sprayed on the dry plate side.
The plates are examined carefully and thus it is possible to find the wet
areas on the dry plates. The areas have to be controlled with capillary liquid.
The plate heat exchanger is separated and all plates are controlled with the
capillary liquid.
7.2
Facilities must be provided (ladders, steps, cat ways etc.) to be able to safely
reach all places to make adjustments and to perform maintenance and
repair.
31
8
8.1
Customer Service:
Ordering Spare Parts
8.2
Complaints Procedure:
32
9
9.1
Accessories / Annexes:
Instructions for Transporting and Hoisting.
9.2
This data has been collected through years of experience and is merely
indicative and for information. The user of the unit remains responsible for
the mediums and materials he uses with regard to corrosion etc.
For your information
Materials:
Medium velocity:
Minimum
Maximum
1.0 m/s
3.0 m/s
1.0 m/s
1.5 m/s
1.0 m/s
3.0 m/s
1.0 m/s
2.0 m/s
1.0 m/s
3.0 m/s
Steel
Copper
Stainless Steel 316L
CuNi10
CuNi30
PH-value
Steel
0.00 oz/l
10 mg/l
>8
6-8
33
6-8
9.3
34
35
36