PLATE HEAT EXCHANGER

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

Contents

Page

1. General Description and Terminology

1.1
1.2
1.3
1.4
1.5
1.6
1.7

2. Frame Assembly
2.1

Frame Assembly

3. Gasket Attachment to Plates

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4.1
4.2
4.3

11

Positioning of Plates
Installation of Plates Model T2 T8
Installation of Plates Model T13 Larger

5. Tightening of Plates
5.1

12

Manual Tightening

6. Hydrostatic Testing
6.1

12

Hydrostatic Testing

7. Installation and Operation

7.1

13

Installation and Operation

8. Starting Up

13
Start up

9. Maintenance
9.1
9.2
9.3
9.4
9.5

14

Chemical Cleaning / Clean In Place

Manual Cleaning
Replacing a Gasket
Replacing a Plate
Installing New Plates

10. Storage of Spare Parts

10.1
10.2
10.3

15

Plate Storage
Gasket Storage
Glue Storage

11. Additional Information

11.1
11.2
11.3
11.4

Glued Gasket System

Preparation for Gluing Gaskets
Gluing Gaskets
Ballplate - Glueless Gasket System
T-Tab - Glueless Gasket System
Clip Style - Glueless Gasket System
Plate Preparation for Gasketing
T-Tab 4-Corner Gaskets

4. Plate Installation

8.1

Frames
Terminology for Connections
Terminology for Intermediate Grids
Heat Exchanger Drawing
Plates and Gaskets
Gasket Orientation
Special Plates

16

Ordering Parts
Damaged Shipments
Returned Material
Contact Information
1

Section 1
General Description and Terminology
1.1 Frames
-

FIXED AND MOVABLE HEADS are made of thick, rigid, high quality stainless steel
plates. They are used to compress the plate pack.

- TOP RAIL is attached to the fixed head only, on bracket mounted (S) frames.
TOP RAIL is attached to the fixed head and end support on all free standing (S, E, and
EZ) frames. It is used to support and align the plate pack.
-

BOTTOM RAIL is used to support and align the bottom of the plate pack.

TIE BARS are evenly spaced around the periphery of the fixed and movable heads
and are used to compress the plate pack.

END SUPPORT is used to support the back end of the heat exchanger. Located on free
standing frames.

UNIVERSAL MOUNTING BRACKET is used to mount bracket mounted frames from the
top, side, or bottom of heat exchanger.

Figure 1: Typical free standing and bracket mounted style frames.

Note: Heat exchangers are top heavy. Center of gravity is towards the fixed head.
Use CAUTION when lifting.

1.2 Terminology for Connections on Fixed and Movable Heads

- Connection nozzles are designated by a letter and a number on both the fixed and
movable heads.
F is for fixed head
M is for movable head

FIXED HEAD

MOVABLE HEAD

Figure 2: Connection nozzle location.

1.3 Terminology for Connections on Intermediate Grids

- Letters designate which sections the grids are between i.e.; AB, BC,CD, etc.
- The number designates which corner the nozzle is located which also matches the fixed
head nozzle location.
- The last letter designates a horizontal H or vertical V positioned nozzle.

Figure 3: Intermediate connector grid connection nozzle location.

1.4 Heat Exchanger Drawing

On the last pages of this manual you will find the heat exchanger drawing. It provides useful
information such as the serial number, bill of materials, and thermal duty. The assembly
diagram which includes height, width, length, and tightening dimension (see Fig. 4). Also
included is the plate arrangement/ flow diagram (see Fig. 5) and an isometric view of the
heat exchanger (see Fig. 6) that helps illustrate connection location which can be difficult to
interpret from the flow diagram alone.

Figure 4: Assembly diagram.

Figure 5: Plate Arrangement/Flow Diagram .

Figure 6: Isometric View.

1.5 Plates and Gaskets

-

Plates are mounted with gaskets facing the fixed head.

Ends of each plate are labeled with N for north and S for south.

- The first plate is mounted with N at the top, second plate with S at the top, third plate
with N at the top, etc.
Diagonal Flow

Same Side (Vertical) Flow

Leak Detect Vents
to Atmosphere

Leak Detect Vents

to Atmosphere

Leak Detect Vents

to Atmosphere

Leak Detect Vents

to Atmosphere

Leak Detect Vents

to Atmosphere

Leak Detect Vents

to Atmosphere

Leak Detect Vents to

Atmosphere

Fluid Flow Is Vertical

Fluid Flow Is Diagonal

Figure 7: Fluid flow between plates.

1.6 Gasket Orientation

-

The first plate is equipped with a special 4 corner gasket which isolates the 4 port
openings and prevents fluid passage between the first plate and the fixed head.

All other plates are equipped with standard gaskets.

All gaskets are equipped with vents to prevent fluid intermixing if a leak occurs.

Multiple pass units are supplied with either flat port gaskets that are glued to the
movable head or O rings which seat into a groove on the movable head or
intermediate grid, depending on the size of your heat exchanger.

1.7 Blocked Plates

- Usually blocked plates are odd plates, with N at the top.
- A standard plate is a plate with 4 openings. All plates with ports that are blocked off
are called blocked plates in the nomenclature on the heat exchanger drawing. Each plate
has a four digit identifier. Open ports are numbered 1, 2, 3 and 4 starting at the top left
and continuing clockwise around the plate. Blocked ports are labeled 0.
- See Figure 8 for examples.

Figure 8: Different configurations of plates.

Section 2
Frame Assembly
2.1 Frames Assembly
- Assemble the fixed head, top rail, and bottom rail.
- Install the movable head (and intermediate grid if applicable).
- Install the end support if you have a free standing frame or the universal bracket if you
have a bracket mounted frame.
- Install the plates as per the plate arrangement drawing provided, ensuring that plates are
aligned properly and evenly. This is necessary for a uniform plate pack and a leak
free exchanger.
- When the heat exchanger has an opening on the movable head or intermediate grid,
either a flat port gaskets or O-ring (depending on exchanger model) must be in place in
order to prevent leakage between the last plate and the ports.
Note: Plate edges are sharp! Wear adequate hand protection when handling plates.
Use CAUTION when handling!

Section 3
Gasket Attachment to Plates
Thermaline Inc. plate heat exchangers, depending on model, are available with
either glued or glue-less gasketing system. Please check your plate arrangement
drawing for the gasketing system in your heat exchanger.
3.1 Glued Gasket System
- Original and spare plates are supplied with gaskets glued on. Gaskets can also
be supplied loose, in which case the user must glue them to the plates using the
following method.
3.2 Preparation for Gluing Gaskets
- Prior to gluing, it will be necessary to understand gasket terminology per section 1.2, i.e. 4
corner gaskets, and standard gaskets glued in odd or even positions. The gasket grooves
on the plates must be dry, undamaged, and clean of any foreign material.
- The side of the gasket to be glued should first be roughened using emery cloth or sand
paper. Do not roughen the side of the gasket which will not be glued.

3.3 Gluing Gaskets

- Glue should be applied with a small, round pure bristle brush. Use a minimum amount of
glue, applied evenly over the entire gasket groove.
- It is recommended to use 3M Glue EC 1099 or equivalent.
- Allow the glue to set for a few minutes, or as recommended by the manufacturers
instructions. When glue is tacky line up the gasket with the groove and press the gasket
into place. Do not force or stretch the gasket. It is necessary to ensure that no foreign
matter is left between the gasket and plate, as this will cause leakage. To ensure proper
gasket seating, the gasket can be lightly tapped into place with a soft-faced mallet.
- Glue must be completely dry before the plate pack is placed into service.
- Stack the plates horizontally on a support so that the plates are centered.
Ensure that the gaskets remain in the grooves. If a support is not available, the heat
exchanger frame, placed horizontally, may be used. Place a uniform weight on the top
plates and allow it to sit for at least 24 hours to ensure proper glue adhesion.
- Glue should be allowed to cure in warm (150F Maximum dry air.) Do not cure with
steam. Poor adhesion will result if the glue is cured below 60F.

Note: Consult glue manufacturer for material safety data sheet. Follow
manufacturers instructions when using glue.

3.4 Glue-less Gasket System (Ball Plate Gasket Replacement)

- Balls made of the same material as the plate are strategically positioned and welded
inside the gaskets groove, including port areas.
- Ballplate gaskets can also be used as glued gaskets but not vice versa.
- Ballplate gaskets are installed on the plate simply by pressing the gaskets into the gasket
groove, over the balls. To ensure proper gasket seating, the gasket can be lightly tapped
into place with a soft faced mallet (see Fig. 10).
- See section 3.7 for plate preparation details.

Figure 9: Ballplate Gasket Same Side and Diagonal Flow.

Figure 10: Detail of Ballplate Gasket.

3.5 Glue-less Gasket System (T-TAB Gasket Replacement)

-

T-Tab gaskets are installed on the plate by pressing the protruding T-tabs into the
notches provided around the plate periphery.

T-Tab gaskets are available only in Same Side Flow on all models T2 to T100.

- See section 3.7 for plate preparation details.

Figure 11: T-Tab Gasket Same Side and Diagonal Flow.

3.6 Glue-less Gasket System (Clip Style Gasket Replacement)

-

Clip style gaskets are installed on the plate by pressing the single tab on each clip
into the notches provided around the plate periphery.

Clip style gaskets are available in Same Side Flow on models T2 to T20 and
In Diagonal Flow on models T28 to T100.

- See section 3.7 for plate preparation details.

Figure 12: Clip Style Gasket Vertical Flow.

3.7 Plate Preparation for Gasketing

- Plates must be clean and free of debris, especially in the gasket groove, in order to
guarantee proper installation of the gasket.
- Plates must receive gaskets in unique position to ensure correct plate pack configuration.
Please consult the plate arrangement drawing provided.

3.8 4-Corner Gasket

- Corner gaskets are usually made from two standard gaskets. Special procedures are
followed when installing a 4-Corner gasket (see Fig. 12). (Note: T14, T-28 and T45 4Corner gaskets are constructed differently then a typical 4-Courner Gasket. Please contact
manufacturer for specific instructions regarding the T14, T-28 and T45 4-Corner gaskets.)

Figure 13: Making 4-Corner Gaskets.

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Section 4
Plate Mounting
4.1 Positioning of Plates
- Plates must be correctly installed for a uniform plate pack and proper gasket seating.
Fig. 13 shows a plate correctly positioned on the top rail.

4.2 Installation of Plates: Model T2 T8

- Models T2, T4 and T8 have round top and bottom rails. The plates are supported
by the top rail and guided by the bottom rail. Take care to support the plates by hand
while installing the plate pack until the movable head is in place and some tie bars are
installed.

4.3 Installation of Plates: Model T13 Larger

- Model T13 and T20 plates are suspended by the top rail.
- Plates must be installed one or two at a time using the grooved area provided on the top
rail (see Fig. 14).
Note: Follow Figure 16 instructions for T13 and T20 Heavy-Duty frame plate installation.
- T28, T45, TR5 and T100 plates may be installed on the top rail at any location along rail
in 3 steps (see Fig. 15).
1. Put plate in position 1 on top rail.
2. Rotate the plate following arrow 2 around the top rail.
3. Rotate plate following arrow 3.

Figure 14: Correct Plate Position.

Figure 15: Top Rail Groove.

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Figure 16: Plate Installation.

Section 5
Tightening of Plates
5.1 Manual Tightening
- The plate pack is mounted against the fixed head. Each plate is moved along the top rail
and pressed against the preceding plate.
- The movable head is pushed into contact with the plate pack. The plate pack is tightened
with the tie bars placed into the slots on the heads.
- By successively tightening the tie bars, the plate pack dimension indicated on the heat
exchanger drawing will be reached. Tie bars should be tightened in a diagonal pattern.
Each tie bar should not be tightened more than at a time so as to prevent uneven take
up of the moveable head. Uneven take up can cause damage to the movable head.
- It is recommended that new plate packs are tightened to the average dimension. At the
minimum dimension, the plates are in contact with each other. The remaining tie bars are
installed and tightened to ensure an even pressure around the perimeter of the plate pack.
Note: The unit should never be tightened to dimensions smaller than the minimum
indicated on the heat exchanger drawing to prevent the plates from being damaged.

Section 6
Hydrostatic Testing
6.1 Hydrostatic and Cross Contamination Testing
- After each disassembly, it is necessary to perform a hydrostatic test. New units are
hydrostatically tested to the pressure indicated on the nameplate.
- Hydrostatic tests are performed to detect gasket leaks. Leaks from gaskets would appear
either at the side of a plate pack or at the leak detector vents, near nozzles. Gaskets
leaks always drain to the outside of the unit. It is not possible for one fluid to enter the
opposite circuit due to gasket failure. To simplify repairs, the location of a leak should be
marked prior to disassembly of the plate pack.
- Cross contamination testing (CCT) enables detection of defective plates. A hole in a plate
would allow leakage between circuits. During a CCT test, pressurized plant air is used to
charge one side of the heat exchanger. The opposite side of the heat exchanger is left at
ambient pressure with the Thermaline CCT tester installed. If there is a defect in a plate,
air is pushed through the pressurized side into the ambient side and is detected by the
CCT tester. Dye checking of the plates will confirm whether the plate has a leak or not.
Contact Thermaline INC. for information on our CCT Testing Program.
Note: All tie bars must be in place and properly tightened before a hydrostatic
or CCT test can be performed.

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Section 7
Installation and Operation
7.1 Installation and Operation
- Heat exchangers are delivered pre-assembled and tested. Bracket mounted style heat
exchangers can be rigidly mounted to the wall or ceiling using the universal mounting
bracket. Free standing style heat exchangers are designed to sit on the floor. The
following steps should be taken for correct installation:
a. Ensure that the heat exchanger is installed level.
b. Locate the heat exchanger in an area not congested with piping or other equipment.
c. Approximately 2 or 3 feet of clearance around the exchanger is recommended for
easy maintenance.
d. Ensure flexibility in piping the system to provide for thermal expansion and
accessibility to the movable head for disassembly.
e. Process piping should be adequately supported to ensure no tension on the heat
exchanger ports.
f.

Shut-off valves for all connections, and process drain valves for inlet and outlet
piping are recommended.

g. Process supply pumps should be provided with throttling valves. When maximum
pump discharge pressure exceeds maximum working pressure of the heat
exchanger, a safety relief valve should be provided on the supply piping before
entering the heat exchanger.

Section 8
Starting Up
8.1 Start Up
- A heat exchanger should be brought on-line gradually with the least severe circuit being
opened first. I.e.; lower pressure or temperature.
- On steam supplied units, the steam should be turned on last and turned off first. Do not
leave steam turned on with the liquid side flow turned off.
- Sudden opening and closing of valves may deform plates to the point of being unserviceable. Valves must be set to open and close gradually. Start-ups and shut-downs
must be done gradually without shocks.

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Section 9
Maintenance
9.1 Chemical Cleaning / Cleaning In Place
This method is recommended especially where corrosive cleaning chemicals are used.
Ensure the cleaning chemical is compatible with plate and gasket material.
The following procedure for cleaning in place is recommended:
- Drain both sides of the heat exchanger. If this is not possible then flush the process
liquids out with water.
- Remove static mixer if equipped, prior to CIP.
- It is recommended that the cleaning solution be pumped at a velocity 1-1/2 times the flow
rate of the process liquids.
- It is not recommended to use temperatures higher than the maximum temperature
indicated on the nameplate. Consult your cleaning chemical salesperson for the correct
temperature to use with the cleaning chemicals.
- Flush cleaning solution out with clean water. Do not allow cleaning solutions to set in the
plate pack for long periods of time. i.e. Over night.
Note: Do not use Hydrochloric Acid for cleaning plates. Consult your cleaning
chemical salesperson for recommendations.

9.2 Manual Cleaning

- It is sometimes necessary to disassemble the exchanger for cleaning. Slide plates apart
so they hang separately to allow cleaning by brush or pressurized water.
- When using high pressure water lay the plates flat to avoid damage.
- Always use a fiber brush (do not use a steel brush or steel wool). Be careful not to
scratch gaskets surface. After brushing rinse with water and wipe dry.
- After cleaning inspect the exchanger components carefully and reassemble the unit.
Note: Plate edges are sharp! Wear adequate hand protection when handling plates.
Use CAUTION when handling!

14

9.3 Replacing a Gasket

- Remove the plate from the heat exchanger and remove the gasket.
- If removal of the gasket proves difficult use a hot air gun to heat the gasket groove from
the back. As the adhesive softens pull the gasket off with pliers. Alternatively, the plates
may be dipped in liquid nitrogen and then knocked. The gaskets should crumble off.
- Clean the plate completely. Any remaining traces of old adhesive should be removed
from the gasket grooves with a cloth. Use a solvent such as Toluene, Acetone, or MEK.
- If solid particles remain in the gasket groove, remove them carefully with an abrasive cloth.
- Install the new gasket as described in Section 3 Gasket Attachment to Plates
- Install the plate in its original position.

9.4 Replacing a Plate

- Before removing the plate confirm the plate designation (A or B) and the gasket position,
(see Section 3.4 or 3.6 depending on gasket style). A replacement plate should be the
same thickness, pattern, designation, and have the same gasket material and position as
the original.

9.5 Installing New Plates

- Additional plates or plates with different designations (to modify number of passes) can be
installed. Thermaline Inc. can provide new duty calculations and revised plate arrangement
drawings concerning location of new plates and performance.

Section 10
Storage of Spare Parts
10.1 Plate Storage
- Spare plates should be stored in their original container or hung up in a protected area.

10.2 Gasket Storage

- Gaskets should be stored in an area sheltered from light at a temperature between 32F
and 70F. If gaskets are stored below 32F they must be warmed above 32F prior to
handling.
- Gaskets should preferably be stored flat. If space is restricted gaskets may be stored
folded in half but care should be taken to avoid sharp bends which will cause cracks.
15

Wherever possible gaskets should be stored in their original container.

10.3 Glue Storage

- It is recommended to stock glue for emergency repairs. Glue should be stored as per
manufacturers instructions and shelf life (usually 6 months) should not be exceeded.
Generally glue is to be stored in a cool and dry place.
Note: Consult glue manufacturer for material safety data sheet. Follow
manufacturers instructions when using glue.

Section 11
Additional Information
11.1 Ordering Parts
- Refer to the parts list on the plate arrangement drawing provided with the heat exchanger.
- When ordering parts or requesting information always refer to the serial number, model
number, and drawing number as provided with the heat exchanger.

11.2 Damaged Shipments

- Our equipment is carefully packaged and is shipped in good condition. Shipments are
made at the consignees risk. On receipt of shipments carefully inspect packaging and
equipment for damage. All claims for loss/damage etc. shall be made with the carrier.

11.3 Returned Material

- Units or parts are not to be returned without first obtaining permission from Thermaline
Inc. Parts authorized for return must be properly packaged and received by Thermaline
Inc. in good condition. All credits will be subject to re-stocking and transportation charges.

11.4 Contact Information

- Information concerning the operation, maintenance or care of Thermaline Inc. Equipment
is available from our local representative or by contacting Thermaline Inc. at:

Thermaline Inc.
1531 14th ST
Auburn, WA 98001
Phone:
Fax:
E-mail:

800-767-6720
253-833-7168
info@thermaline.com

Web Site: www.thermaline.com

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