plate and frame heat exchanger iom

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.


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• 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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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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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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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:________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

18701_API_SBPHE.indd 27 9/3/08 10:36:36 AM

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

18701_API_SBPHE.indd 28 9/3/08 10:36:39 AM

plate and frame heat exchanger iom

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