API Schmidt-Bretten Plate and Frame Heat Exchanger Installation and Maintenance Manual
API Schmidt-BrettenPlate and Frame Heat Exchanger
Installation and Maintenance Manual
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Table of Contents
1.0 Introduction .............................................................................3
2.0 Function & Components ........................................................3
2.1Frames...........................................................................3
2.2Plates.............................................................................3
2.3Gaskets..........................................................................5
2.4Flow&PlateArrangement.............................................5
3.0 Installation Procedures ..........................................................9
3.1Lifting.............................................................................9
3.2Installation......................................................................9
3.3Piping........................................................................... 11
3.4Storage........................................................................ 11
4.0 Operating Instructions .........................................................12
4.1General........................................................................12
4.2StartUp.........................................................................12
4.3ShutDown...................................................................13
5.0 Maintaining the Exchanger ..................................................13
5.1Opening.......................................................................13
5.2Closing.........................................................................15
5.3Gasketing.....................................................................17
6.0 Cleaning the Exchanger .......................................................20
6.1Fouling.........................................................................20
6.2FullyAssembled...........................................................21
6.3Disassembled..............................................................22
7.0 Problem Solving ...................................................................23
8.0 Replacement Parts ...............................................................25
9.0 Unit Specifications ...............................................................27
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1.0 Introduction
APISchmidt-Brettenplateheatexchangershavebeeninstalledworldwideprovidingawidevarietyofheattransfersolutionsusingdiversefluidsatdifferenttemperatures.
Thecoreoftheplateheatexchangeristhethinmetalcorrugatedthermalplatesthatbothenhanceandconductheattransferthroughthem.Thesethermalplateshaveanelastomergasket,confinedinaformedgroovearoundtheperimeteroftheplate,thatcontainsthefluidbetweentheplates.Theplateswithgasketsarethensequentiallyinstalledintoacompactpressureretainingframethatdistributesthefluidflow.
2.0 Function & Components
2.1 Frames
1.........FixedPressurePlate 2.........MovablePressurePlate 3.........UpperCarryingBar 4.........LowerCarryingBar 5.........SupportColumn 6.........RollerBearingAssembly 7.........PlatePackTieBars
Thefixedframeplate(1)andthemoveablepressureplate(2)aredensesteelplatesdesignedforwithstandinghighpressuresandcontainingthefluidconnections.
Thethermalplatesarearrangedintheframebyhangingfromtheuppercarryingbar(3)andkeptinalignmentbythelowerguidebar(4).Thebarsaresupportedbytheframeplateinfrontandinthebackbyasupportcolumn(5)whennecessary.Arollerbearingassembly(6)isusedonlargerunitsforeasiermaintenance.Thetighteningbolts(7)bringthethermalplatestometaliccontactwhilecompressingtheelastomergasketsufficientlytoseal.
2.2 Plates
Dependingontheheattransfersolutionandthefluidsbeingapplied,theplatecorrugationorsurfacepatternanditsthicknesswillvary.Asthethermalplate’scorrugationdepthlessenssocanit’splatethickness.
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APISchmidt-Brettenoffersthefollowingsurfacepatternsinavarietyofthickness:
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2.3 Gaskets
Thegasketthatgoesbetweeneachplatetoseparateandsealthetwofluidsiseithergluedinplaceorisaffixedtotheplateusingmechanicaloragluefreedesign.
Thecircularringportionofthegasketpreventsthefluidfromgoingacrossthethermalplateandsendsitontothenextopenplateorchannel.Theremainingfieldportionofthegasketchannelstheopposingfluidacrosstheplate/heattransfersurface.
Asdemonstratedabovethetwofluidsareisolatedbythegasket.Topreventpossibleintermixingofthefluidsbetweentheringandfieldportionsofthethermalplatespecialventsareprovidedinthisunpressurizedarea.
Anyfluidsescapingfromeithersidewillexittheheatexchangerthroughthesevents.Theseopeningsmustnotbepluggedascrosscontaminationoffluidscouldoccur.
Withthisdesignanygasketfailurewillonlyresultindetectionontheoutsideoftheheatexchangerandnointermixingofthetwofluids.
2.4 Flow & Plate Arrangement
Theplatesarearrangedinanalternatingpatternof“L”style(lefthandflow)or“R”style(righthandflow)toalternatethetwoopposingfluidsintheheatexchanger.Theassemblyofthethermalplatesbetweenthefixedframeplateandthemoveablepressureplateiscalledthe“platepack.”
WARNING! Forproperassemblyandsealingofthethermalplatesintheplatepack,theplatesmustbealternatedbetweenLandRstyle.Consequently,thechevronpatternontheplatesmustalternatebetweenpointingupanddown!!
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2.4 Flow & Plate Arrangement (continued)
Thefirstorendplateinaplatepackdoesnothavefluidflowingacrossit.Insteadithasfourringgasketstosealagainsttheinsideoftheconnectionsonthefixedframeplate.Inthismanner,thefluidsaredivertedtoopenchannelsintheplatepackanddonotgobetweentheendplateandthefixedframeplate.
Thefollowingaresometypicalflowarrangementsfoundinplateheatexchangers:
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Theconnectionlocationsmayvaryforagivenplateheatexchangerdesign.SinceallofAPISchmidt-Brettenplateheatexchangersareparallelorsamesideflow,allconnectionsforonefluidwillonlybeontherightsideandfortheopposingfluidontheleftside.Theconnectionlocationsaredefinedasfollows:
EveryAPISchmidt-Brettenplateheatexchangerisprovidedwithaplatearrangementdrawingshowingthepropersequencingandalignmentofthethermalplatesintheplatepack.Thefollowingaresomestandardrulesthatmustbefollowedwhenperformingmaintenanceworkontheplateheatexchanger:
• Allplatesarestampedwithan“L”atoneendandan“R”attheothertoassistinproperorientationoftheplates.
2.4 Flow & Plate Arrangement (continued)
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2.4 Flow & Plate Arrangement (continued)
• Thechevronpatternmustalwaysberotated180degreesfromplatetoplate.Forexample,ifplates1,3,5arepointingup,thenplates2,4,6shouldbepointingdown.
• Thefirstplate(endplate)shallhave4ringgaskets,asshownonpage6.• BecauseheattransferplategasketsfacethefixedheadonmostSchmidt-Bretten
models,unitswithmorethanonepassrequirecircularringgasketstosealbetweenthemoveablepressureplateandthebacksideofthelastthermalplate.
• Speciallyholedplatesmaybeusedinaccordancewiththefollowingfigures:
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3.0 Installation Procedures
3.1 Lifting
1) Refertonameplateforoverallweightofunit.Besureliftingequipmentisoverratedfortheweight.
2) Location“A”isdesignedforaclevisorliftingstraps.Bothpointsaretobeused.3) Location“B”shouldhavealiftingstrapwrappedaroundthecarrybar,closesttothe
pressureplate.4) Unitswithhighplatequantitywillrequiretheuseofaspreaderbar.
WARNING! Donotliftusingportconnections,tierods,orpressureplate!!
3.2 Installation
Theplateheatexchangershouldbeinstalledwithapproximately3feetofopenspacearounditforfuturemaintenance.
Underspecialconsiderationsforspace,thesedimensionsmaybereducedbutservicingtheheatexchangermaybecompromised.
Theheatexchangermustbemountedonafoundationthatislevelandadequateenoughsothereisnosettlingwhichcouldcauseastrainontheunitandtheattachedpiping.
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3.2 Installation (continued)
Aliquidretainingtroughordriptraywithavolumecapacityequaltothatoftheheatexchangershouldbemountedundertheplatepackforcorrosiveservicesorapplicationswherethereiszerotoleranceforprocessfluidsbeingonthefloor.
Allconnectionstotheplateheatexchangershouldbeequippedwithshut-offvalvessotheunitmaybeshutdownandopenedupwithoutdisturbingtheentiresystem.Toavoidwaterhammer,quickactionvalvesshouldnotbeused.
Fordependableoperationavoidsuddenpressureand/ortemperaturesurgestotheheatexchanger.Providesafetyreliefvalveswherethemaximumpumpdischargepressuremayexceedthedesignpressureoftheunit.Pumpsshouldhavethrottlingvalvesandcontrolvalvesshouldbelocatedattheinletstotheheatexchanger.Vibrationdampersshallbeusedonpositivedisplacementpumpsandparticularlyreciprocatingpumps.
WARNING! Suddenfluctuationsinpressureortemperaturecancausedamagetotheunit.
Provideairventsinpipingnearthehighpointoftheheatexchangerforproperventingandatthelowpointinthepipingforproperdrainage.
Priortoinstallationinspectalltheportsoftheheatexchangerforforeigndebristhatcouldbecomelodgedduringoperation.
Thefollowingaretypicalconnectiontypesusedforinstallingplateheatexchangers:
Threadedstudssecuretheflangestothefixedframeplate.Alloyorrubberliningsareaddedasnecessarytopreventcorrosion.
ForsmallerconnectionsizesthreadedNPTtypeconnectionsareused.
WARNING! Wheninstallingunitswithalloynozzles,thenozzlesmustbeheldinplacebyawrenchtoavoiddamage.
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3.3 Piping
Pipingtotheplateheatexchangershallbedesignedsothatitsthermalexpansionandweightdonotputtoomuchforceonthenozzlescausingprematurefailure.
AnyforcesormomentsappliedtothenozzlesoftheplateheatexchangermustbeapprovedbyAPISchmidt-Bretten.
Whenaplateheatexchangerhasconnectionsonthemoveablepressureplate,therearespecialconsiderations:
• Sincethepressureplateisnotfixed,itsnozzlescanwithstandlessloadingthanthenozzlesontheframeplate.
• Theplatepackmaybesubjecttoretighteningduringservice;therefore,whenattachingpipingtothepressureplate,allowforthisdifference(approximatelyplusorminus1%ofthefinalplatepacktighteningdimension).
• Thepressureplatemustmovebackwardforservicing.Useelbowedspoolpiecesforeasyremoval.
3.4 Storage
Iftheplateheatexchangeristobestoredforanextensivetimeperiod(i.e.morethanonemonth)thefollowingprocedureshouldbeused:
• Storeat60-70degreesFinaclosedroom.• Tierodboltsandplatepackshouldbetotallyuntightened.• Heatexchangershouldbetotallycoveredinblackplastic.• Avoidheat,ultravioletandweldinglight.• Applyarustpreventativetoallcarbonsteelmachinedparts(i.e.bolts,flangedfaces).
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4.0 Operating Procedures
4.1 General
Theplatepacktighteningdimensionmustbeasspecifiedonthenameplateorassemblydrawingbeforeoperatingtheplateheatexchanger.Note:Ifplateshavebeenaddedorremovedtooriginalheatexchanger,consultAPISchmidt-Brettenforpropertighteningdimension.Iftighteningisrequired,turnto5.1Opening&5.2Closingforproperinstructions.
WARNING! Beforeputtingaplateheatexchangerinoperation,becertaintheentiresystemisfreeofsandorparticlesthatwillplugtheunitduringoperation.
Checkandbecertainthatthesystemissetupsoitdoesnotexceedthedesignpressureortemperatureoftheheatexchanger.
4.2 Start Up
Alwaysstartuptheplateheatexchangerwiththefluidcircuitthatisatthelowerpressureandtemperature:
1) Closethefeedvalvelocatedbetweenthepumpandtheheatexchanger.2) Openfullytheshutoffvalveattheoutlet.3) Opentheventvalve.4) Startthepump.5) Openthefeedvalveveryslowly.6) Whenalltheairisremovedclosetheventvalve.7) Repeatprocessfortheotherfluidcircuit.
Specialconsiderationsduringstartupshallbegivenwhencondensingsteaminonecircuit:
• Neverhavethesteamsideonwiththeliquidsideoff.• Thesteammustalwaysbeturnedonsecondandshutofffirst.• Steamvalvesmustbesettoopengraduallytoavoiddamagingplates.
Topreventshockingtheheatexchanger,thesteamsideshouldbeslowlybroughtuptodesignconditionsbycontrolledthrottlingofthecoldsidefluid.
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4.3 Shut Down
1) Startingwiththefluidcircuitathighertemperatureandpressure,slowlyclosethefeedvalve.
2) Turnoffthepump.3) Closeoutletvalve.4) Repeatprocedurefortheotherfluidcircuit.
Forlongtermstorageormaintenance,ventanddraintheheatexchanger.Priortostorageflushandorcleantheplatestoremoveanycorrosivesubstances.
Storageproceduresarerecommendedforanyheatexchangerthatwillbeoutofserviceforamonthorlonger.
5.0 Maintaining the Exchanger
5.1 Opening
Theplateheatexchangermustbecompletelyshutdownanddrainedinaccordancewiththeprevioussectionbeforeopening.
1) Iftheunithasconnectionsonthepressureplate,thepipingmustberemovedinordertoallowittomovefreelybackwardonthecarryingbar.
2) Thecarryingbarshouldbeinspectedandwipedclean.3) Useawirebrushtocleanthethreadsofthetighteningboltsandthenlubricatethem
withathinlayerofmolybdenumdisulphideorotherequivalentgrease.4) Carefullyremovethesafetyshieldfromtheunit.
5) Theplatescaneitherbesequentiallymarkedastheyareremovedfromtheunitoradiagonallinecanbedrawnacrossplatepacktorecordeachplate’sposition.
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5.1 Opening (continued)
6)Recorddimension“A”ateachtierod.
WARNING! Thetighteningdimension“A”iscriticalforpropersealingoftheheatexchanger.Becertaintorecorditaccurately!!
7) Iftheunitisprovidedwithalockwasherunderthenutatthepressureplate,alllooseningandtighteningcanbeaccomplishedfromthenutattheframeplate.
8) Theheatexchangercannowbeopenedbylooseningoppositediagonallytighteningboltpairs.Looseneachnutonlyin1/4"to1/2"incrementstokeeptheheadsparallelandavoiddamagingtheheattransferplates.
9) Whenallthetensionisremovedfromthem,thetighteningboltscanbetakenout,thepressureplateslidbackandthethermalplatesarenowaccessibleforinspectionorremoval.
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Thethermalplatesarethenremovedorinstalledasfollows:
• Movethelowerendofthethermalplatediagonallybackuntilitisclearoftheguidebar.
• Linetheuppercarryingslotintheplateupwiththeflattenedareainthecarryingbarcalledtheassemblyslot.
• Rotatethethermalplatetoananglethatmatchestheassemblyslot.• Eitherremoveoraddplatesinthismanner.
WARNING! Theouteredgesofthethermalplatescanbeverysharp.Weargloveswhenhandlingthemtopreventinjury!!
5.2 Closing
Additionalplatesorreplacementplatesshouldbeinstalledwiththegasketedsidefacingtheframeplateunlessotherwisespecified.
Beforeinstallingplatesalwaysconsulttheplatearrangementdrawingforpropersequencingoftheplates.
1) Installtheplatesoneatatimepushingthemforwarduntiltheystop.2) Beforemovingplatesforwardmakecertainthegasketisproperlysecuredandthat
itisclean(wipingofgasketsurfacemaybenecessary).3) Theslidingsurfacesonthecarrybarshouldbecleanedandlubricated.4) Iftheplatepackwasdiagonallymarked,verifytheplatesareintheproperorder
beforetightening.
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5.2 Closing (continued)
5) Iftheplatesareassembledinthecorrectsequence,theedgeswillformthefollowingpattern:
6) Placethetighteningboltsbackinposition,wirebrushthemcleanandapplyathinlayerofgrease.
7) Theplatepackshouldbetightenedalternatingbetweendiagonallyoppositeboltpairscontrarytotheopeningprocedure.Whenmovingthepressureplateinduringtightening,caremustbetakentokeeptheframeandpressureplateparalleltoeachotherby1/4"to1/2".
WARNING! Donottightenundertheminimumtighteningdimensionspecifiedfortheheatexchangerplatepackasseriousdamagetothethermalplatescanoccur.
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8) Alltighteningboltsmustbeundertension.9) Whenfullytightened,thedifferencebetweenthe“A”dimensionatadjacentbolts
shallnotexceed1/16".10)Iftheunitdoesnotinitiallyseal,itcanbetightenedincrementallytotheminimum
dimensionspecifiedonthenameplateorprovidedbyAPISchmidt-Brettenforadifferentnumberofthermalplates.SeeWarning!
11)Replacethesafetyshield.
Specialconsiderationsmustgivenwhenclosingunitsthathavehardcompressedfibergaskets.Whenclosingaunitthathashardgasketsitmaybenecessarytoheattheunitwithwarmwaterorproductinordertocompresstheplatepacktotheappropriatedimension.
5.3 Gasketing
APISchmidt-Brettenprovidesglueless gasket typesformostmodels.Thesegasketsarereplacedasfollows:
• Removetheoldgasketmakingcertainallpartsofitaretotallyremoved.• Cleanthegasketgroovewithaclothmakingsurenoforeignmaterialremainsthat
coulddisruptthesealingprocess.• Attachthenewgasketstotheplatesusingtheprongsonthegasketsandattaching
themtoeithertheslotsorholesprovidedinthethermalplates.
• Beforeclosingtheheatexchangermakesurethegasketandalltheprongsareintheproperposition.
• Whentheplateheatexchangerisclosedandtightened,thegasketsprovideatightseal.
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5.3 Gasketing (continued)
Manyplateheatexchangersutilizeaglued gasket type.Sometimesthesegasketsmaybedifficulttochange,andreturningthemtoaqualifiedservicecenterforreplacementmaybeawiserchoice.Fieldreplacementcanbeaccomplishedasfollows:
• Oldgasketsmustbecompletelyremoved.Ahotairgunoralowtorchflameappliedtothebackofthegasketgroovewillsoftenthegasketadhesiveallowingthegaskettobepulledoffwithpliers.
• Asanalternative,platescanbedippedin-196°CliquidNitrogenwhichwillcausegasketstocrumbleoff.
• Theremaininggasketandadhesiveinthegasketgrooveshouldberemovedusingastainlesssteelscraperorwithemery/abrasivepaper.
WARNING! Useabrasivepapercarefullytoavoidcreatingdeepscratchesinthegasketgroovethatcouldleadtoleaksunderneaththegasket.
• Afterwardsthegasketgroovesmustbedegreasedbywipingthemwithacleanclothimpregnatedwithasolvent(trilene,tetrachloroethylene,acetone).
• Fornormalgluing,3M’stype3MEC1099adhesiveorequalisrecommended.Usemanufacturer’sinstructionsforbestresults.
WARNING! Theadhesivemustbecompatiblewiththeplateandgasketmaterialandtheheatexchangerservice.Consultsupplierifnecessarytoconfirm.
Approximateadhesivequantityrequirements: Ounces/plate Models 0.50 S7-S37 1.00 SX49-S66 1.50 S108-8149
• Beforeapplyingtheadhesivevisuallyinspectthegasketgroovemakingcertainitiscleananddry.
• Usesandpaperoremeryclothtoroughentheflatsideoftheelastomergasketthatwillbeattachedtotheplate.
• Applyathinevenlayerofadhesivetothegasketgrooveusingashorthardbrush.• Whentheglueistacky,whichcouldtake5-10minutes,carefullylinethegasketup
withthegrooveandpressitin.• Anelastomergasket’stolerancemaychangeduringandafterforming.Shortgaskets
mustbestretchedbypullingbeforeinstallationandlonggasketsshouldhavetheshortendsinstalledfirstandthenpressthegasketsinmovingtowardthemiddleoftheplate.
• Stacktheplatesinapilewithaweightontopandallowtodrypertheadhesivemanufacturer’sguideline.
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Specialconsiderationmustbegiventotheendplate gasketsthatsealthefirstthermalplateagainstthefixedframeplateandincasesofmultipassunits,thelastthermalplateagainstthemoveablepressureplate.
Thegasketingonthefirstthermalplateismadebycuttingtwostandardgasketsandapplyingthemasshownbelow:
Certainplatemodels(S26,S27,S66,S76,S96,S106,S108,S114,S136,S138,S149,S156,S229,SX29,SX49)requireaspecialendplategasket,asshown.
Note:Theaboveplatemodelsalsorequireseparatebridgesandrings.
WARNING!Inthecaseofaunitwhereconnectionsarelocatedonthemoveablehead,specialringgasketsmustbeinstalledonthepressureplatethatwillsealagainstthebacksideofthelastheattransferplate.
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6.0 Cleaning the Exchanger
6.1 Fouling
Thefrequencyandtypeofcleaningrequiredbytheplateheatexchangerisdependentonthetypeoffoulingencounteredforthespecificapplication.
Foulingcanbeminimizedbyincreasingthevelocitythroughtheheatexchangeratregulartimeintervals.Thisreducesfoulingbycreatinglargerturbulencethatwillremoveloosescaledepositsfromtheheattransfersurfaces.
Whensolidsmaybepresentinthefluidsgoingthroughtheheatexchanger,itisrecommendedthatastrainerorfilterbeplacedinthepipelinebeforetheheatexchangertopreventthesesolidsfrombecomingpluggedinthenarrowpassagewaysbetweentheheattransferplates.
Scalingisacommonformoffoulinginplateheatexchangers.Itiscausedbyhighconcentrationsofcalcium,carbonate,calcium,sulphateandsilicatesinthecoolingwater.Scalingisremovedeitherbychemicallycleaninginplaceordismantlingandusingasoftbrushandrunningwater.Chemicalcleaningcanbedoneusingthefollowingwithamaximumconcentrationof4%inwaterandamaximumtemperatureof140degreesF:Nitricacid,Sulfamicacid,citricacid,phosphoricacid,complexingagentsEDTAandNTAandsodiumpolyphosphates.
WARNING! Consultandfollowmanufacturer’sinstructionswhenusingcertaincleaningfluids.Weareyeandskinprotectionorusearespiratorasrequired.
Biological foulingresultsfrombacteriaandotherorganismssuchasprotozoafoundinthecoolingwater.
Thisfoulingisremovedeitherbychemicallycleaninginplaceordismantlingandusingasoftbrushandrunningwater.Chemicalcleaningcanbedoneusingthefollowingwithamaximumconcentrationof4%inwaterandamaximumtemperatureof140degreesF:sodiumhydroxideandsodiumcarbonate.
Sedimentary foulingconsistsofmetaloxides,corrosionproducts,silt,aluminaanddiatomicorganisms.Removesedimentinthesamewayasscalingdetailedabove.
Residual foulingishydrocarbonbaseddepositsfromoils,asphaltandfats.Theseareremovedbydismantlingandcleaningtheplateswithasoftbrushandaparaffinicornapthabasedsolvent(i.e.kerosene)followedbyrinsingwithwater.Thesecleaningcompoundscancausedamagetoelastomergasketssoexposuretothemshouldbelimitedtoonehalfhourorless.
Gross foulingorpluggingoftheheatexchangercanbecausedbyfibres,assortedsolidsandseaweed.Thereisnothingattachedtotheplateandastrainerbeforetheheatexchangercanusuallypreventthistypeoffouling.Backflushingoftheunitmaybeeffectivebeforedismantlingoftheunitandcleaningtheplateswithasoftbrushisnecessary.
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WARNING! Ensurethatanycleaningfluidusediscompatiblewiththeplateandgasketmaterialsoftheheatexchanger.Contactyourlocalcleaningsolutionproviderforrecommendations.
Someadditionalprecautionsthatshouldbetakentoavoiddamagingtheplateheatexchangerduringcleaning:
• Donotusehydrochloricacidsforcleaningstainlesssteelplates.• Usingfluidswithchlorideconcentrationsgreaterthan300ppmcandamagetheplates.• Ketones,halogenatedhydrocarbons,aromaticsandestersshouldnotbeusedas
cleaningfluidsastheywilldestroythegaskets.
6.2 Fully Assembled Cleaning
Backflushingisgoodmethodforkeepingaheatexchangerinservicethatispronetocloggingfromsolidsand/orsediment:
• Makeprovisionsinthepipingtoflowtheproblemfluidintheoppositedirection(backflushing).
• Thebackflushingshouldbedonewithwaterat1.5timesthenormalflow.• Problemfluidsshouldnormallyenteratthebottomoftheexchangerandexitatthe
topsoparticulateistrappedatthelowerportionoftheunitanddoesnotmakeitswayinbetweentheheattransferplates.
• Analternativebackflushingmethodistohavetheabilitytoreversebothfluidsflowdirectionandtodothisperiodically.
Cleaning in Place (CIP)isrecommendedforhighfoulingapplicationswherefrequentcleaningisrequired.Itisespeciallybeneficialforprolongingplatelifeinhighlycorrosiveapplications.
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6.2 Fully Assembled Cleaning (continued)
TheprocedureforCleaningInPlacefollows:
1) ClosealloftheisolatingvalvesanddraintheexchangerthroughtheCIPsystem.2) Flushbothsidesoftheunitwithwarmwater(100-120DegF)untiltheeffluentwater
isclearandfreeofprocessfluids.3) CompletelydraintherinsewaterfromtheCIPsystem.4) RefilltheCIPsystemwithwaterandaddtheappropriatecleaningsolution.
WARNING! Choiceofcleaningsolution,timeandtemperatureofcleaningprocedureisbasedonthetypeoffouling.Forbestresultsconsultthecleaningfluidsupplier.
5) Circulatethecleaningsolutionat140-180DegFfor3-6hours.6) DrainthecleaningsolutionfromtheCIPsystemandflushtheunitagainwithwarm
waterfollowingstepstwoandthree.7) ClosethevalvestotheCIPsystemandreopenthemainisolatingvalvestotheheat
exchanger.8) “StartUp”theheatexchangerasprescribedinsection4.2.
6.3 Disassembled Cleaning
ManytimesCIPwillnotbeeffectiveandtheplateheatexchangermustbedismantledtobecleaned.Formanualcleaningproceedasfollows:
1) Opentheheatexchangerasindicatedinsection5.1.2) Slidetheplatesaparttoallowforpossiblecleaningbyasoftbrushorwaterrinsing
whiletheyremainintheframe.3) Whenusingawaterjettocleantheplates,theymustbeplacedonaflatsurface
andthejetspraydirectedawayfromthegasketstoavoiddamagingthem.4) Donotuseasteelbrushorsteelwoolforcleaningtheplatesasdamagetothem
canoccur.5) Becarefulnottoscratchthegasketsurfaces.6) Usetheappropriatecleaningsolutionforthetypeoffouling,see6.1andWarning!
noteabove.7) Applythecleaningsolutiontotheplatesandletstandasnecessary.Brushand
rinse.Ifnecessaryrepeattheprocess.8) Afterfinalbrushingrinsewellwithwaterandthenwipedry.9) Inspectallpartsbeforereassemblingpersection5.2.
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7.0 Problem Solving
Thefollowingisaguidetotroubleshootingtheplateheatexchanger.IfmoreassistanceisrequiredpleasecontactAPISchmidt-Brettenpersonnelat(716)684-6700.
Condition: Fluid leak between the thermal plates to the outside.
Cause:Alooseordamagedgasket.
Solution:Notewhichplateisleakingandopentheheatexchangerinaccordancewithsection5.1andexaminethegaskettoseeifithasbecomedislodgedfromitsgasketgrooveorsuffereddamage.Repositionorreplacethegasketasnecessary.
Cause:Theplateheatexchangerisnotfullytightened.
Solution:Verifythatthenumberofplatesintheheatexchangermatchesthedrawings.Notethemaximumandminimumtighteningdimensionoftheheatexchangerfromthenameplateorthedrawing.Tightentheheatexchangerinaccordancewithsection5.2untiltheleakstops.
Cause:Athermalplatehasbeendamagedduetoovertighteningorphysicalabuse.
Solution:Typicallyadamagedplatemustberemovedfromtheheatexchangerandeitherrepairedorreplaced.Notewhichplateisleakingandopentheheatexchangerinaccordancewithsection5.1.Removethedamagedplateandreplaceitwithanewone.
Ifareplacementplateisnotreadilyavailable,theunitmaybemadeoperableasfollows:
1) Removethedamagedplate.2) Iftheplateisastandardfourholeheattransferplate,removetheplateimmediately
precedingorfollowingthedamagedplate.3) Closetheheatexchangerinaccordancewithsection5.2.4) Theheatexchangermustbetightenedtoanewreducedtighteningdimensiondue
totheremovalofthetwoplates.Consultthefactoryfortheproperdimension.
Cause:Athermalplateismisallignedintheplatepack.
Solution:Removetheleakingplateandrepairtheplatehangingareasotheplatehangsandallignsproperlyintheplatepack.Iftheplatestilldoesnothangproperly,thenitmustbereplacedwithanewone.Closeheatexchangerinaccordancewithsection5.2.
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Page24
7.0 Problem Solving (continued)
Condition: Fluid leak between the thermal plate and the fixed frame plate or moveable pressure plate.
Cause:Thegasketmayhavebecomedislodged,foreignmaterialcouldbeunderthegasketorthegasketsealingsurfacecouldhavedeepscratchesorotherdamage.
Solution:Opentheplateheatexchangerinaccordancewithsection5.1.Checkthesealingsurfacesontheframeplateforanyirregularitiesorforeignmaterialsthatcouldcreategasketsealingproblems.Makethenecessarycorrectionsandmakecertainthegasketisintheproperlocationonthethermalplate.Closeandtightentheheatexchangerinaccordancewithsection5.2.
Condition: Fluid leaks on the outside of the frame where the external piping is joined to the frame.
Cause:Thesealinggasketbetweentheframeandthematingflangemayhavebecomedislocatedordamaged.
Insomecases,thealloynozzleliningorstubendmayhavesuffereddamagefromexcessivenozzleloadingorcorrosion.
Solution:Thepipingtotheheatexchangermustbedisconnectedandremoved.
Ifthesealinggasketappearstobeoutofplaceordamaged,simplyreplacethegasket,makingcertainnoforeigndebrisispresenttointerferewiththesealingprocess.Thenreconnectandtightenthepiping.
Withthepipingremoved,thealloynozzleliningorstubendshouldbevisiblyexaminedforanysignofcracksorotherdamagethatcouldindicatealeak.Ifdamageissuspected,theunitshouldbedisassembledinaccordancewithsection5.1.Theliningorstubendcannowbeexaminedbydyepenetranttestingforleaks.Damagedpartsshouldeitherberepairedorreplacedandthenclosetheunitinaccordancewithsection5.2.
Condition: The heat transfer capacity of the heat exchanger is declining. Cause:Thethermalplatesarebecomingfouledduringoperation.
Solution:Followsections6.2and6.3forproceduresforcleaningtheheatexchanger.
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Page25
Condition: Fluid from one side of the heat exchanger leaks in to the other side.
Cause:Ifthepipingisconnectedtotheheatexchangeratthewronglocations,immediatecrosscontaminationormixingofthefluidswilloccur.Themostprobablecauseisthepresenceofholesinthethermalplatesduetocorrosion.
Solution:Makecertainthepipingiscorrectlyconnectedtotheheatexchanger.
Disconnectthepipingononelowerconnectionoftheheatexchanger.Bypressurizingtheremainingconnectedside,acrosscontaminationleakwillbeindicatedbyfluidleakingintotheopenedlowerconnection/portarea.Ifthereisnoleak,thenthecontaminationisoccurringawayfromtheheatexchanger.Ifthereisaleak,recordwhichplateisleakingandopentheheatexchangerinaccordancewithsection5.1.
Removethethermalplatesandexaminetheonesclosesttotheleaktoseeifyoucanobserveanyperforationsintheplates.Itisalsoimportanttoobservetheleakdetectorgroovesinthegaskets;ifdepositshavegatheredinthesegroovesandclosedthemoff,itispossibleforafluidtomigratefromonesideoftheexchangertotheother.Foreasierdetectionofperforations,amagnifyingglass,dyepenetranttestingorabrightlightbehindtheplatesmaybeused.
Perforatedplatesarenotrepairableandmustbereplaced.
Ifnecessary,theheatexchangercanbeputbackinservicewithfewerplates,see“Fluidleakbetweenthethermalplatestotheoutside.”
Condition: The pressure drop across the heat exchanger is higher than predicted.Cause: Thethermalplatesmayhavebecomeblockedwithdebris/scalingortheplatesmaybeinstalledwrong.
Solution:Accuratelymeasurethepressuredropacrosstheheatexchanger.Examinetheouteredgeoftheplatepackandbecertaintheouteredgesoftheplatesformacheckeredpatternindicatingthatallplatesareinstalledintheproperdirection.
Ifpossible,attempttobackflushtheheatexchangeratahighvelocitytodislodgeanytrappeddebris.Ifthisisnotsuccessfuloravailable,theunitmustbecleanedinaccordancewithsection6.3disassembledcleaning.
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Page26
8.0 Replacement Parts
API Schmidt-Bretten Parts Order Form
To: APISchmidt-Bretten Date:______________________________
Fax: 716-684-2129 NumberPages:______________________
Attn:____________________________________________
PurchaseOrderNumber:____________________________
ForbestservicetelefaxthissparepartsorderformtoAPISchmidt-Brettenat716-684-2129.
Fortelephonequestionscall718-684-6700.
Whenorderingorrequestingreplacementparts,thefollowinginformationisrequired:
HeatExchangerModel: __________________SerialNumberorPartNumber: __________________CompletePlatePack: ____Yes____NoCompleteGasketSet: ____Yes____No
Ifindividualthermalplatesarerequiredandtheaboveinformationisunknown,thefollowinginformationmustbeprovidedforeachnewthermalplaterequired:
HeatExchangerModel: __________________PlateMaterial: __________________PlateThickness: __________________PlateStyle(Page4): __________________GasketMaterial: __________________GluelessGasket: ____Yes____NoPlatePunching(Page8): __________________Endplate: ____Yes____No
Theaboveinformationiscriticalinprovidingtheproperreplacementparts.
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API Schmidt-Breffen SB Series Brazed Plate
Heat Exchanger Installation Manual
Page27
9.0 Unit Specifications
ExchangerModel:_______________________________________________________
ExchangerSerialNumber:________________________________________________
ExchangerPartNumber:__________________________________________________
DesignPressureandTemperature:__________________________________________
BillofMaterial:__________________________________________________________
PlateMaterial/Thickness:___________________________________________
NumberofPlatesandStyle:_________________________________________
NumberofGasketsandMaterial:_____________________________________
Frame/PressurePlateMaterial:______________________________________
ConnectionMaterial,HotSide:_______________________________________
ConnectionMaterial,ColdSide: ______________________________________
ServiceofUnit:_________________________________________________________
______________________________________________________________________
______________________________________________________________________
Notes:________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
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Divisions:
API Airtech ISO-9001 Certified
Air Cooled Aluminum Heat Exchangers 91 North Street • P.O. Box 68
Arcade, New York 14009-0068
(585) 496-5755 • Fax: (585) 496-5776
API Basco ISO-9001 Certified
Basco®/Whitlock® Shell & Tube Heat Exchangers 2777 Walden Avenue
Buffalo, New York 14225
(716) 684-6700 • Fax: (716) 684-2129
API Schmidt-Bretten Americas
Plate Heat Exchangers and Thermal Systems 2777 Walden Avenue
Buffalo, New York 14225
(716) 684-6700 • Fax: (716) 684-2129
API Schmidt-Bretten GmbH & Co. KG ISO-9001 Certified
Plate Heat Exchangers and Thermal Systems Langenmorgen 4
D-75015 Bretten, Germany
(49)725253-0 • Fax: (49)725253-200
API Heat Transfer (Suzhou) Co., Ltd. Air Cooled Aluminum Heat Exchangers Shell & Tube Heat Exchangers Plate Heat Exchangers 156 Qingqiu Street, 3rd District
Suzhou Industrial Park
Suzhou, Jiangsu 215126 China
(86)512-88168000 • Fax: (86)512-88168003
API Heat Transfer Inc.2777 Walden AvenueBuffalo, New York 14225(716) 684-6700www.apiheattransfer.com
Contact your local API Sales Representative or API Heat Transfer directly toll-free: 1-877-API-HEAT e-mail: [email protected]
Form SBPHE 8/09 © 2004 API Heat Transfer Printed in USA
Other Products Available from API Heat Transfer
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