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HomeMy WebLinkAboutParaflow Plate Heat Exchanger Instruction Manual 1990 Paraflow Plate Heat Exchanger Instruction Manual CONSTRUCTION General Type of closure tie bar frames spindle closed frames combination tie bar/spindle frames hydraulic closed frames Plates - general Connector grids PLATE ARRANGEMENT Plate arrangement drawing Schematic example PLATES Types - diagonal flow - vertical flow Standard angle and mixing angle plates Plate designation - diagonal flow - vertical flow INSTALLATION Space requirements Foundations Piping connections Hydraulic shock/pressure pulsation Pressure/temperature limits Plate pack covers ASSEMBLY Assembly of tie bar frames Installation of plates Installation of tie bars Tightening tie bar frames Assembly of spindle frames Installation of plates Tightening spindle frames 1.1 1.2 1.3 1.4 15 1.6 1.7 3.1 3.2 3.3 3.4 3.5 4.1 4.2 4.3 4.4 4.5 4.6 5.1 5.2 5.3 5.4 5.5 5.6 5.7 section page 3 con 10 11 12 START-UP & OPERATION Tightening Start-up Leakage during operation OPENING THE FRAME Cooling and pressure relief Opening tie bar frames Opening spindle frames Inspection and cleaning Reassembly CLEANING Manual cleaning CIP cleaning Care of T-316 s/s plates Care of T-304 s/s plates Care of titanium plates GASKET REPLACEMENT Removal of old gaskets Attachment of new gaskets (Paracril, Paratherm & Paratemp EPDM) Attachment of other gasket materials Clip-in type gaskets TROUBLE SHOOTING Decreasing capacity Visible leakage Non-visible leakage SPARE PARTS/ORDERING SPECIAL OPTIONS Pneumatic wrench Hydraulic opening/closing 6.1 6.2 6.3 7.1 7.2 7.3 74 7.5 8.1 8.2 8.3 8.4 8.5 9.1 9.2 9.3 9.4 10.1 10.2 10.3 11.0 12.1 12.2 section page 13 13 14 15 16 17 17 18 SECTION ONE CONSTRUCTION TOP PLATE CARRYING BAR FOLLOWER END SUPPORT HEAD BOTTOM PLATE GUIDE BAR KEY HOLE FIG. 1 a GENERAL 1.1 The APV Crepaco Paraflow plate heat exchanger consists of a head, end support, top carrying bar and bottom guide bar which are bolted together to form the exchanger frame (Fig. 1). A follower is suspended from the top carrying bar between the head and end support and is movable along the carrying bar. After plates are fitted with gaskets (Fig. 2), each plate is hung from the top carrying bar between the head and follower in accordance with the plate arrange- ment drawing. The plate pack then is compressed by means of tie bars inserted in holes or Key Hole slots along the edges of the head and follower or, in selected models, by tightening one or two spindles between the follower and end support (Fig. 3). Frames can be designed with connections on the fixed head, the movable follower, or both. Additional inlet and outlet connections can be provided by using intermediate connectors which divide the plate pack into sections. TYPES OF CLOSURES 1.2 TIE BAR FRAMES The great majority of Paraflow plate heat exchangers are fabricated with heads and followers that have tie bar holes or Key Hole slots along both sides. Tie bars inserted into FIG. 2 a, AE these openings are tightened (see Section 5) to compress the plate pack to the dimension required. These bars are made of high tensile carbon steel or stainless alloy steel in sizes of %” to 2” diameter. Tie bar length is determined by the number of plates within the frame or by anticipated future expansion of the plate pack to accommodate increased duties. WARNING: Replacement tie bars must be obtained from APV Crepaco to ensure proper strength and quality. Fifteen Paraflow models are available with tie bar frames. Junior SR2 R5 R6 TRO SR1 SR3 SR6 R10 SR14 HX R4 R8 SR9 SR23 1.3 SPINDLE CLOSED FRAMES Paraflow frames which are stainless steel clad and are designed for spindle or screw closing (Fig. 3) may be fur- nished with one or two spindles that extend from threaded bushings in the end support and compress the follower and plate pack against the fixed head. WARNING: If needed, replacement spindles must be obtained from APV Crepaco to ensure proper strength and LUBRICATE BOTH SOCKETS AND THREAD FIG.3 1.4 15 1.6 17 quality. In addition, the bolts that secure the head and fol- lower to the top and bottom bars are special, high strength fasteners. If damaged or lost, they must be obtained from APV Crepaco. Failure to do so can result in catastrophic failure of the unit. Six Paraflow models are available with spindle frames. SRI SR21 R51 HX SR31 SR61 COMBINATION TIE BAR/SPINDLE FRAME The Model R55 Paraflow utilizes both tie bars and two spindles. The spindles, however, can be used only for clos- ing and opening the plate pack. They are not designed to resist the operating pressures of the unit. For operation after the two spindles have been used to compress the plate pack to the proper tightness, the eight tie bars are inserted in the tie bar slots and tightened. The two spindle screws then must be backed off before the exchanger may be operated under pressure. CAUTION: Operation of Model R55 units with the tighten- ing spindles under tension can damage the unit and injure operating personnel. HYDRAULIC CLOSED FRAMES Paraflow frames which are stainless steel clad and are designed for hydraulic opening and closing have a self- contained hydraulic reservoir and motor. Three Paraflow models are available with hydraulic closure. CR3 CRS CR6 PLATES GENERAL When gasketed plates have been compressed within the heat exchanger, an effective seal between fluids and the atmosphere is formed. In addition, intermixing of fluids is prevented by a double gasket seal between the port and flow area, Fig. 4. This ensures that, in the unlikely event of a gasket failure, leakage is vented to the atmosphere to eliminate the possibility that the two fluids being processed will intermix. The plate pack forms a series of parallel flow channels in which the fluids move in counter-current paths, Figs. 5 and 6. CONNECTORS Some Paraflow models can be fitted with connector grids that permit simultaneous operation of more than one duty within a single frame. See Figures 7A and 7B. FIG. 4 Hem eth PRoouct HEATING OR COOLING FIG.5 uiauio FIG. 6 Single pass counter-current flow. SECTION TWO @ Thermal duty PLATE ARRANGEMENT © Model, work order number, and drawing number 6 List of plates and gasket materials 2.1 PLATE ARRANGEMENT © Physical capacity The Paraflow plate heat exchanger must be installed and ; | piped in strict compliance with the plate arrangement @ Dimensional data drawing that is prepared for each specific heat exchange A 7 duty. Listed at the right is the essential information o Special notes provided in the Figure 8 drawing. @ Assembly of plates [Scfemnaret tePT Ano ROOT. fom convemence on Ts Riso tas mates occu. THe ToTAL Momben OF EACH OMEN. LuSosxTES © - 1@ 188 COM WATER IN uneromtres © | & O50 GaN WATERS OUT PDLLOWERS HEAD WweomTe> © 4 MED SOCRN WATER UNBPoRTES @ - >@1880—M WATER OUT MODEL SR25~ HEAT EXCHANGER 2.2 SCHEMATIC EXAMPLE The plate arrangement drawing also shows the schematic plate configuration and fluid flow paths (Fig. 9). An isomet- ric representation of this configuration is shown in Fig. 10. CONNECTOR HEAD CONNECTOR GRID FOLLOWER FIG.9 Schematic representation FIG. 10 Isometric representation SECTION THREE PLATES TYPES OF PLATES Heat exchanger plates are pressed in two flow styles— diagonal flow and vertical flow. These are shown in Figs. 11A and 11B. 3.1 DIAGONAL FLOW PLATES Used in Models HX R5 R4 3.2 VERTICAL FLOW PLATES (same side flow) Used in Models Junior SR6 SR9 SR1 R6 TRI SR2 R10 SR14 SR3 R8 SR23 3.3 STANDARD ANGLE AND MIXING ANGLE PLATES Standard angle plates are available in all models while mixing plates may be had only for vertical flow Models SR2, SR3, SR6, R8, SRY, TRY, SR14 and SR23 standard and mixing angle plates. These are identified on the plate arrangement drawing and are shown in Figs. 12A and 12B. STANDARD MIXING PLATE PLATE CHEVRON STRAIGHT CORRUGATION CORRUGATIONS PLATE ON MIXING PLATE FIG. 12B CAN BE HUNG ONLY FROM ONE END RIGHT HAND PLATE ILLUSTRATED. PLATE OF THIS SERIES CAN NOT BE REVERSED TO BECOME A LEFT HAND PLATE. CAN BE HUNG FROM EITHER END RIGHT HAND PLATE ILLUSTRATED. PLATE OF THIS SERIES CAN BE REVERSED TO BECOME A RIGHT/LEFT HAND PLATE. 3.4 PLATE DESIGNATION—DIAGONAL FLOW FIG. 13A Plate designation chart (diagonal flow) oa oo Oo] [eo] [eo] [c-e| [c-e Li L21 L31 L41 L42 L13 L23 ma oy me a a eee ee| ee O-e| (ee) ee L33 L43 L14 L24 L34 L44 LEFT HAND FLOW PLATES Od) loge) ed ee ec ee O<Q} (O<Q| |O<@| O<@| @<Q|] |@<OQ | R11 R21 || R31 | R22 | R42 R13 R23 eee ae ee ee |e<C je<Q ee @-@ | | | || R33 || R43 R14 || R24 | R34 R44 | RIGHT HAND FLOW PLATES bw C0} (ed) [ee ee De ee eo ws 7 i — ws O<Q| (O<Q) {exo Q | Q ] ec) (O-e) p~e | KL11 KL21 KL31 KL41 KL12 | KL22 KL13 KL23 eS a od) [>e@} (Od) (Oe) (BS Cl a od) (oes Pa a =e 1) 71 oe eo ee pe eo ee KL33 KL43 KL24 KL 34 KL 44 J! la LEFT HAND END PLATES eo| &| ws i fi Sn fi As 1s Co os - KR11 KR 21 KR 42 KR13, KR23 od) (ed Ce) e&68 OSC) &O a Se eo e«o@ ea ee ee KR33 KR43 KR14 RIGHT HAND END PLATES KR 24 KR 34 KR 44 heel Vesta? ectoneell Ceseeees NY 1S NS 1. Y Diagrams show ty pes of blanking and blanking number. Plates viewed from gasket side. Blanking (hole) O/Unblanked (no hole) @ 3.5 PLATE DESIGNATION—VERTICAL FLOW OXxQ) {oxg O~<@ Ox<@) fexo) fexa LAA LAB LAC LBD LCA LCB OG) [O<@) [OO e-@) cc) los Te) ey) et Se e<0| (ee) (eo e<q| |e~e @~<e Lcc LCD LDA LDB LDC LDD D FLOW PLATES 0-0) |o<@) led WHT eo ec ee o-o) foro) (ore o=aq) (oa) {c O-e) (e0| (ea | || || RAA RBA RCA RDA li RBB | RDB RAC | RBC | | | xc C0) | > J ~@) |e 0) ee) Oro) DO jeep oe ee ero) eo) (ee ee | RCC RAD || RBD RCD ROD | | | | ~~ RIGHT HAND FLOW PLATES ee fo &e eQ ~=Q O=@| [e=0) (eo KLAA KLBA KLBB | KLBC KLBD KLCA KLCB | od oe e6) ><) low | teak Wf (i =f) A Ath) tod | (ee eo #0 eo | KLCC KLCD KLDA KLDB KLDC KLDD | SJ ] LEFT HAND END PLATES e~e| @| es mo es) eo &s exe fi O~@| [O-@ pxQ O~<@| (eq) (ea KRAA KRBA KRCA KRDA KR BB | KRCB KRDB KRAC KR BC od =<} bes e8 ed 88 bo te oa pa, ate aw iain gral aa, PE PR, ee Ps e eq ©-e| e-3« KRCC. | KR DC KRAD KRBD KRCD KRDD RIGHT HAND END PLATES Sd (os) led 08 eo ee FIG. 13B Plate designation chart (vertical flow) Diagrams show types of blankin, ig and blanking number, Plates viewed from gasket side. Blanking (hole) O/Un blanked (no hole) @ renee 1111 | 4.1 4.2 4.3 4.4 4.5 4.6 SECTION FOUR INSTALLATION SPACE REQUIREMENTS While the plate heat exchanger requires limited floor space, it should be located so that service and inspection can be performed. There must be sufficient space on both sides of the frame to remove and install plates and to oper- ate the tightening wrench (Fig. 14). FOUNDATIONS The foundation pad for the plate heat exchanger should be level and of sufficient size and strength to support the unit. PIPING CONNECTIONS The plate heat exchanger must be piped in accordance with the plate arrangement drawing. All pipe connections must be done in such a way as to minimize nozzle loadings and to allow the unit to be easily opened for inspection and maintenance. HYDRAULIC SHOCK/PRESSURE PULSATION Piston pumps, gear pumps, rotary type pumps and similar items must not be able to transfer pressure pulsations/ vibrations to the plate heat exchanger. Vibrations can cause fatigue fracture in the plates. Furthermore, as with all process equipment, damage can occur from hydraulic shock. This can happen during valve changeover, pump start up, etc. To avoid this situation, the use of throttling devices or automatic valves and slow start up on pumps is recommended. PRESSURE/TEMPERATURE LIMITS Limits on plate heat exchanger pressure and temperature are detailed on the plate arrangement drawing. Maximum working or operating pressure = the highest pressure to which the plate heat exchanger may be subjected during all phases of operation. Maximum working or operating temperature = the maximum temperature to which the plate heat exchanger may be subjected during all phases of operation. Maximum test pressure = the highest pressure at which the plate heat exchanger may be tested. This is a static, hydro test at ambient temperature. ‘Over-pressure’ protection must be included in the process or system design if it is likely to develop a higher pressure than the maximum operating pressure of the plate heat exchanger. PLATE PACK COVERS If the heat exchanger was purchased with top and side covers (Fig. 15), they must remain in place while the unit is operating or is under pressure. Top and side covers can be provided with all new heat exchanger models or can be field-fitted to existing units. (If desired, drawings can be furnished for local fabrication.) FIG. 15 5.1 SECTION FIVE ASSEMBLY ASSEMBLY OF TIE BAR FRAMES CAUTION: During all phases of assembly, components must be properly supported. When assembling a tie bar heat exchanger frame, start by erecting the head (H). Secure the bottom guide bar (B) to the head by bolts and block it up (1). Bolt the end support column (E) to the bottom guide bar (B). Bolt the top carrying bar (C) to the head and the end sup- port (2). Position the follower (F) in the frame and raise into place (3). Install roller and axle assembly (4). Hang follower (F) in place on the top carrying bar (C). Apply a petroleum- based grease to the top of the hanging strip (5) on the top carrying bar so that plates will slide freely. 5.2 INSTALLATION OF PLATES Before assembly, check to make certain that every plate and gasket is clean of all foreign matter. Even small debris such as sand, pipe scale or brush bristles can cause leakage and may damage the gaskets. Make certain that all gaskets are properly seated in their grooves. Use special care with Paraclip gaskets (gaskets not cemented) to avoid dislodg- ing them. With the follower (F) positioned next to the end support (E), install plates (P) on the top carrying bar in the sequence detailed on the plate arrangement drawing. NOTE: The plate arrangement drawing indicates if the gasketed side of the plate is to face the head or follower (6). This can vary with the heat exchanger model. Refer to the plate arrangement drawing. NOTE: During installation, always alternate left and right hand plates. For simplification only, whole blocks of identical left or right hand plates are shown on the plate arrangement drawing. The total number of each is given. 5.3 INSTALLATION OF TIE BARS 10 When all plates have been correctly installed, move the plates against the head (7) and roll the follower up to the end of the plate pack. Install the tie bars (T) into the frame holes or key hole slots. Clean the tie bar threads and liberally apply an anti-seize compound along the area which the nuts will travel during tightening. Also apply compound to both sides of the plain washer under the fixed tie bar nut. APV recommends: 1) For carbon steel tie bars—Never-Seez” Regular Grade lubricating grease. 2) For stainless alloy steel tie bars—Never-Seez Black Moly” lubricating grease. Do not use standard lubrication. CAUTION: Never-Seez Regular Grade is not suitable for stainless steel. 5.4 TIGHTENING TIE BAR FRAMES The intent of these instructions is to provide a method to evenly and safely tighten a Paraflow plate heat exchanger with tie bars. Proper tightening is essential to satisfactory unit operation and maximum gasket life. These instruc- tions should be followed closely for both initial assembly and whenever the exchanger is opened for service. WARNING: NEVER open a Paraflow until the unit has been cooled below 100°F. NEVER tighten or open a Paraflow which is under pressure from any source. NEVER tighten or open a Paraflow with piping connected to the follower or con- nector grids. 1) Wipe the top carrying strip clean and apply ordinary grease to allow the plates to slide freely. 2) Install all the plates of the type and quantity specified on the plate arrangement drawing, starting at the head end of the frame. Check to make sure that all plates are oriented properly, that gaskets are properly seated in their grooves, and that there is no debris anywhere on the plates or gaskets. Clean the sealing surfaces with a lint-free cloth. Push each plate firmly against the previous one. Use spe- cial care with plates having Paraclip gaskets (gaskets not cemented to the plate) to avoid dislodging them. 3) Clean the tie bar threads and apply a liberal amount of anti-seize compound along the distance the nuts will travel during tightening. Also apply compound to both sides of the plain washer under the fixed tie bar nut. Never-Seez Regular Grade is recommended for carbon steel tie bars and Never-Seez Black Moly Lubricant for stainless steel tie bars. Do not use common grease. CAUTION: Never-Seez Regular Grade is not suitable for stainless steel. 4) Move the follower (movable head) toward the fixed head as far as it can go. Install four tie bars as shown in Fig. 17. 5) Starting with the top pair and alternating with the bottom, tighten the tie bars evenly about 4" to 1" at a time until the platage (thickness of the plate pack) measured at the installed tie bars is equal and the follower parallel to the head. This measurement should be about 10% over the final platage dimension specified on the Paraflow plate arrangement drawing. 6) Install the rest of the tie bars between the ports (if appli- cable) and tighten them evenly until the platage dimension is the same at all installed tie bars. 7) Starting with the top pair of bars, continue tightening equally about 4” at a time until the platage measures about 5% above the final dimension. 8) Install the remaining tie bars (if applicable) above the top ports and below the bottom ports of the frame. Starting with the top pair and working down, tighten each pair 4%" at a time. After each tightening cycle of 4%" return to the top set of bars and repeat the procedure. NOTE: On large units using 2” diameter tie bars, it may only be possible to achieve '/16” movement during the final stages of tightening. 9) Tighten the exchanger to the platage dimension specified on the plate arrangement drawing. NOTE: Due to the O-ring type gasket seal, the minimum platage is determined by dimension, not tie bar torque. ° Oo 2 | iso] FIG. 17 | Some Paraflow Use these four bars ro & models are fitted for initial tighten- vith tie bets above ings as 5.4 (step 4). e top ports an a (° & below the bottom ports as 5.4 (step 8). 5 L o=={s lM FIG. 18 Be=s=a Measure platage <— DIM. —| dimension here Cc FIG. 19 Alternately tighten top and bottom tie bars. Install additional bars and tighten evenly. See 5.4, Steps 5 through 8 for full instructions. Manufacturing tolerances of the plates may result in the actual minimum platage dimension varying by as much as +.005 inches per plate from the specified dimension. 10) Pressure test the heat exchanger for leaks by using water at the desired pressure but do not exceed the pres- sure specified on the drawing. The test may be done on each side separately or on both sides at once. 11) If leaks occur, the heat exchanger may be further tightened by up toa maximum of .005 inch per plate. Follow Step 8. Exception: Titanium and nickel plates are softer than other alloys and should not be tightened more than .001 inch per plate below specified platage. This will avoid deforming the plates. 12) If the leaks continue, mark them carefully and open the exchanger in reverse order of Steps 4 through 8. Inspect the area of the leaks closely for damaged gaskets, plates, sealing surfaces or debris. Replace all suspect plates or gaskets, clean the sealing surfaces with a lint-free cloth, and repeat Steps 1 through 10. 11 5.5 ASSEMBLY OF SPINDLE FRAMES @ye »y d When assembling a spindle type frame, use the forks of a lift truck or other overhead device to support the head (H) in an upright position (1). Install the bottom guide bar (B), blocking up the free end (2). Install the top carrying bar (C & 3) and then bolt the end support (E) to both the top and bottom bars (C & B) (4). CAUTION: Make certain that the spindle bushing (S) is correctly positioned within the opening in the end support (E). The internal threaded end of the bushing faces the plate pack. The other end has external threads which accept a retaining nut. See Figure 20. Position the follower (F) in the frame and raise it into place (5). Install the roller and axle assembly (6) and hang the follower (F) on the top carrying bar (C). After greasing the top bar, install all plates in accordance with the plate arrangement drawing. Make certain that both sides of all plates are clean. 5.6 INSTALLATION OF PLATES Before assembly, check to make certain that every plate and gasket is clean of all foreign matter. Even small debris such as sand, pipe scale or brush bristles can cause leakage and may damage the gaskets. Make certain that all gaskets are properly seated in their grooves. Use special care with Paraclip gaskets (gaskets not cemented) to avoid dislodg- ing them. With the follower (F) positioned next to the end sup- port (E), install plates (P) on the top carrying bar in the sequence detailed on the plate arrangement drawing. NOTE: The plate arrangement drawing indicates if the gasketed side of the plate is to face the head or follower (6). This can vary with the heat exchanger model. Refer to the plate arrangement drawing. NOTE: During installation, always alternate left and right hand plates. For simplification only, whole blocks of identi- cal left or right hand plates are shown on the plate arrange- ment drawing. The total number of each is given. 5.7 TIGHTENING SPINDLE FRAMES Before tightening, make certain that the screw threads are fully lubricated with Rocol A.S.P. or Never-Seez Black Moly Lubricant. In addition, lubricate the end of the screw where it fits into the hinge bar (Fig. 20). Alternating between the upper and lower spindles (S), tighten both until they are under tension. (Some models will have only a single center spindle screw.) Tighten the spindles alternately by 4" to 34” increments until the plate pack dimension is about 20% over the final dimension as specified on the plate arrangement drawing. Continue tightening by 4” until the plate pack measures 10% beyond the final dimension and then finish tightening with 4%" movements until the final dimension has been achieved. Tolerance: Plate pack dimensions must be square within Vis" as measured top to bottom or left side to right side. SECTION SIX START-UP & OPERATION 6.1 TIGHTENING Before starting and operating the plate heat exchanger, make certain that the plate pack has been tightened to the proper dimension. See Section 5, Assembly. 6.2 START-UP Sudden pressure surges must be avoided to prevent leakage or possible damage to the heat exchanger frame, plates or 7A gaskets. Positive pumps should be started slowly. Centrif- 72 ugal pumps should be started against closed valves which can gradually be opened. It is recommended that control valves be located up stream of the plate heat exchanger if possible. This will reduce the chance of ‘deadheading’ pumps and reduce unnecessary pressure. 6.3 LEAKAGE DURING OPERATION To determine the cause and correction of plate heat exchanger leakage during start-up and operation, see paragraphs 10.2 and 10.3 of Section 10, Trouble Shooting. 7.3 TA 75 SECTION SEVEN OPENING THE FRAME To avoid possible injury to operating personnel and damage to the heat exchanger, it is essential that correct procedures be followed in opening the heat exchanger frame. COOLING AND PRESSURE RELIEF Before opening the plate heat exchanger, the unit must be cooled to below 100°F and all internal pressure removed. OPENING TIE BAR FRAMES Make certain that all fluids have been drained before open- ing the heat exchanger. It is important that the plate pack be opened as evenly as it was closed so that excessive stress is not applied to any one or pair of tie bar bolts. See part 5.4 of Section 5, Assembly. OPENING SPINDLE FRAMES After draining all fluids, open the unit by alternately loosen- ing the spindle screws—the reverse of tightening proce- dures given in part 5.6 of Section 5, Assembly. INSPECTION AND CLEANING Check every plate for cracks and punctures; gaskets for rips, flattening, lack of elasticity, brittleness, or displace- ment from gasket groove. Before reassembling plate pack, make certain that both sides of plates and all gaskets are clean. Remove all foreign matter since even small debris will cause leakage and may damage the gaskets. REASSEMBLY If the plates have been removed from the frame, they must be reassembled in the specific sequence as indicated on the plate arrangement drawing supplied with the heat exchanger. During installation, always alternate left and right hand plates. 13 8.1 SECTION EIGHT CLEANING APV Crepaco offers factory cleaning, testing and regasket- ing services for all Paraflow plates. Contact your local sales- man or the Tonawanda, New York, office at (716) 692-3000 for more information. To maintain the corrosion resistance of heat exchanger plates, it is essential that the plates are kept clean. Coat- ings, scale or other soil must be removed, either manually or by CIP (Clean In Place) procedures. To properly clean a plate heat exchanger, it may be neces- sary to use chemical solutions. Many of these commonly used chemicals are potentially harmful, especially when they come into contact with the eyes and skin or when fumes are inhaled. All personnel should wear suitable pro- tective gear and should be thoroughly trained in the safe handling, use and subsequent disposal of cleaning solu- tions in accordance with OSHA and Hazardous Material Safety Data Sheets. MANUAL CLEANING After a heat exchanger has been opened, individual plates can be removed for cleaning with a soft brush and a suit- able detergent. In the case of thick layers of scale or organic material, the plates can be placed in a tub or tray witha suitable cleaning fluid. Do not use a steel brush, metal scraper or similar tool which will damage the plate or gasket. A high pressure cleaner can be used with care. CAUTION: This type of high pressure cleaning system can loosen, damage or remove gaskets from the plates. However, never use with sand or similar abrasive added. 8.2 CIP CLEANING A wide range of Paraflow plate materials and gaskets is employed and care must be taken to ensure that cleaning fluids, although suitable for the removal of deposits formed within the Paraflows, also are compatible with the plate gaskets and materials themselves. It is not possible, therefore, to make firm recommenda- tions in a general document of this kind. Each user usually will be aware of the most suitable type of cleaning agents for the plate heat exchanger in question. 8.3 CARE OF T-316 S/S PLATES 14 Stainless steel is an excellent material for the processing of most food and many chemical products since it is readily cleaned and sanitized and has good resistance to natural acids. The metal, however, may be subject to attack if it is not properly cared for when used to handle potentially corrosive liquids. The life of Paraflow stainless steel sur- faces, therefore, is very much dependent upon the product being processed, the duty performed, and the care given to the metal. Since every operation is different, there can be no broad guarantee against corrosion of the heat exchanger surfaces. To provide maximum protection for heat exchanger stain- less steel surfaces, it is recommended that contact be made with a reputable manufacturer of chemical cleaning and sanitizing products who maintain a customer advisory service. Once they know operating details, they should be able to recommend cleaning and sanitizing procedures. In general, precautions should be taken against the follow- ing potential sources of attack on stainless steel surfaces: 1) Foods such as ketchup, table sauces, and starch paste with salt as well as other high acid products that may contain salt must be thoroughly cleaned from all stainless steel surfaces as soon as daily operations are completed. 2) When cleaning with alkali compounds such as caustic soda, carbonate of soda, sodium phosphate or sodium metasilicate, directions should be followed carefully. Con- centrations in excess of 3% by weight normally should not be necessary. Under no circumstances should temperatures exceed 200°F. 3) Many common cleaning and sanitizing agents contain halogen release agents (chlorine, etc.) which can attack stainless steel. Ideally, these should be avoided. If used, however, they must be employed under strictly controlled conditions. 4) Water scale may be removed by carefully using dilute nitric acid under 1% at 140°F or phosphoric acid under 5% at temperatures no higher than 185°F. These solutions must be free from salt and immediately after use, must be thor- oughly flushed from all stainless steel surfaces with water. 5) Sodium Hypochlorite. Precautions must be taken to minimize the possibility of corroding 304 and 316 stainless steel. The maximum concentration of available chloride should be less than 50 ppm at maximum 80°F. Whenever possible, maximum contact time should not exceed 15 minutes, and solutions must be thoroughly rinsed immediately after each use. 6) CAUTION: HYDROCHLORIC, MURIATIC, HYDROFLUORIC, SULFAMIC AND SULPHURIC ACID NEVER SHOULD BE USED WITH T-316 S/S. 8.4 CARE OF T-304 S/S PLATES In general, be aware of the following potential sources of attack on T-304 stainless steel surfaces: 1) Food products such as vinegar, ketchup, table sauces, starch paste with vinegar, liquids containing salt or brine, and liquids with high acid properties should not be processed in contact with T-304 stainless steel. 2) Water containing in excess of 50 ppm chloride ions. 3) Since chlorine can attack stainless steel, heavily chlori- nated water supplies (i.e., greater than 2 ppm) should not be used on stainless steel surfaces. 4) Sodium Hypochlorite. Precautions must be taken to mini- mize the possibility of corroding 304 and 316 stainless steel. The maximum concentration of available chloride should be less than 50 ppm at maximum 80°F. Whenever possible, maximum contact time should not exceed 15 minutes, and solutions must be thoroughly rinsed immediately after each use. 5) When cleaning with alkali compounds such as caustic soda, carbonate of soda, sodium phosphate or sodium metasilicate, directions should be followed carefully. Con- centrations in excess of 3% by weight normally should not be necessary. Under no circumstances should temperatures exceed 200°F. Some caustic cleaning compounds also con- tain chlorine release agents. These should be used with ex- treme caution and never at temperatures exceeding 150°F. Thorough rinsing and complete removal of the residues at the end of the cleaning cycle is essential. Acids never should be introduced into a heat exchanger or system which has been cleaned with these detergents until all traces have been removed. 6) Water scale may be removed by carefully using dilute nitric acid under 1% at a maximum of 140°F, or phosphoric acid under 5% at a maximum of 185°F. These solutions must be free from salt, and immediately after use, must be thoroughly flushed with water from all stainless steel surfaces. 7) HYDROCHLORIC, MURIATIC, SULPHURIC ACID, SULFAMIC OR HYDROFLUORIC ACIDS MUST NEVER BE USED WITH T-304 S/S. CARE OF TITANIUM PLATES Limit caustic and alkali compounds to a maximum of 5% by weight and temperatures up to 180°F. Acids such as nitric and phosphoric used to remove water scale should not exceed concentrations to 5% at 80°F. CAUTION: Make certain that piping and other compo- nents in any cleaning circuit are suitable for cleaning with caustic and acid concentrations. UNDER NO CIRCUMSTANCES SHOULD HYDRO- FLUORIC ACID BE USED. FACTORY REGASKETING SERVICE * AN 5 After being given an acid wash, dye penetrant tested and regasketed if found usable. 15 92 9.2 16 SECTION NINE GASKET REPLACEMENT Plate heat exchanger gaskets are fixed to individual plates by two methods: 1. Glue-in gaskets See 9.2 Paracril (nitrile rubber) Paratherm and Paratemp (EPDM) 2. Clip-in gaskets See 9.4 REMOVAL OF OLD GASKETS In removing worn gaskets, break the thermoplastic bond between the gasket and plate by using a propane torch to heat the plate (non-gasketed side) directly behind a gasket area around a port. As the adhesive softens, use pliers to pull the gasket from the groove. Continue this process until the entire gasket has been removed. CAUTION: Keep the flame moving to prevent scorching and discoloring the plate finish. To remove remaining traces of old adhesive, grease or dirt from gasket grooves, use a solvent such as Acetone or acommercial gasket removal solution. DO NOT USE ABRASIVES TO CLEAN GASKET GROOVES. ATTACHMENT OF NEW GASKETS Paracril, Paratherm & Paratemp (EPDM) 3M formula EC-1099 adhesive must be used to attach Paracril (medium nitrile rubber), Paratherm (resin cured), and Paratemp (EPDM) gaskets. To attach new replacement gaskets, apply a thin, even film of 3M formula EC-1099 cement to a clean gasket groove. Using a small ‘acid brush’ dipped in acetone, spread the adhesive smoothly and evenly along the bottom of the groove. Allow to dry until tacky and then press the gasket firmly into place with the bonding side against the cement. After all plates have been regasketed and placed in the heat exchanger frame, tighten the plate pack just enough to prevent leakage. Attach a low pressure (less than 15 psig) desuperheated steam line to the inlet ports and slowly raise the temperature of the plate pack toa minimum of 220°F or toa temperature 10°F higher than the highest expected operating temperature of the unit. MAINTAIN TEMPER- ATURE FOR AT LEAST THREE HOURS. If steam is unavailable, hot water may be used to heat the plate pack. Hold curing temperature for at least three hours at a minimum of 220°F or at 10°F above the highest expected operating temperature. If the plate pack must be tightened to prevent steam or hot water leakage, turn off steam or water before tightening. NEVER TIGHTEN THE UNIT WHILE UNDER PRESSURE. HEAT TREATMENT IS ABSOLUTELY NECESSARY TO ACHIEVE A GOOD ADHESIVE BOND. After the heat exchanger has been allowed to cool naturally to room temperature, refer to the tightening instructions and tighten the plate pack accordingly. 9.3 ATTACHMENT OF OTHER GASKET MATERIALS To attach gaskets of alternate materials—Paradur (Viton E60C), Paraflor (Viton VTR5927), Paracone (Silicon)—refer to the factory or to special instructions supplied with the heat exchanger. 9.4 CLIP-IN TYPE GASKETS Paraclip gaskets are available for heat exchanger models SR1, SR2, SR3, SRY, R5 and TRY. With the development of the Paraclip press-in gasket, a unique method is available for on-site gasketing of Para- flow heat exchanger plates without the need for cement- ing, heat treating, or special tools. This greatly simplifies service procedures and reduces downtime and expense when plate maintenance is required. Paraclip gaskets have a series of small sprues or projections molded as integral parts into the underside of the gasket. As the gasket is fitted to the plate gasket groove, these sprues are simply pressed into corresponding slots located around the periphery of the plate and the port areas. After the plate heat exchanger has been assembled and tightened, a complete and secure seal is assured. SPRUES 10.1 SECTION TEN TROUBLE SHOOTING DECREASING CAPACITY In the event of reduced heat transfer performance and/or increasing pressure drop, the plate heat exchanger should be cleaned in place or opened for manual cleaning. After the exchanger has been closed, the plate pack must be tightened to the dimensions stated on the plate arrange- ment drawing. 10.2 VISIBLE LEAKAGE If leakage of the process liquid or service media becomes apparent: 1) Check first to determine if the plate heat exchanger is being operated at a higher pressure than is permissible. If pressure is excessive, immediately reduce it to the correct working pressure. 2) Tighten the heat exchanger plate pack but do not exceed minimum tolerance dimensions. NEVER TIGHTEN THE PLATE PACK WHEN THE HEAT EXCHANGER IS UNDER PRESSURE. After tightening, check to make certain that the head and follower are parallel. 3) Open the heat exchanger to determine if individual plates are deformed or fouled. Also check that the gaskets are elastic and non-deformed, and that the sealing faces are clean. Before reassembling the plate pack, carefully clean all plates and gaskets to remove all small debris which may cause renewed leakage. 4) If the plate pack still is leaking after cleaning and tightening to the minimum dimension, it is recommended that plate gaskets be replaced. 5) Leakage at the ‘leak detect hole’ of the gasket may occur. This indicates that there is a break in either the port or bridge gasket. See Fig. 4, Construction. 10.3 NON-VISIBLE LEAKAGE Detection of the intermixing of the fluids being processed is a sign of ‘non-visible’ leakage which is caused by holes or corrosion of one or more plates. This condition can be corrected only by the replacement of the plate in question. Suspected leakage can be localized by one or all of the following procedures: 1) Pressurize one side of the heat exchanger and remove pipe work from the other side. By looking into the non- pressurized port, liquid leaking will be visible. The plate which is leaking may be determined by measuring to the leak inside the port. 2) Remove and subject all plates to dye-penetrant checking procedures. 3) If one fluid being processed has a unique color, opening the heat exchanger and examining the plates may reveal the point of leakage by the presence of that color. SECTION ELEVEN SPARE PARTS/ORDERING When ordering spare parts for a plate heat exchanger, always refer to the Model designation and the Work Order (W/O) number. When ordering gaskets and heat exchanger plates, always refer to the heat exchanger Model designation and to the gasket and plate materials required. Don’t overlook the need for port gaskets and adhesive. Since a special declaration is required to ship the 3M formula EC-1099 cement by air, orders must be placed early in the day to facilitate same day shipment. 17 SECTION TWELVE SPECIAL OPTIONS 12.1 PNEUMATIC WRENCH To facilitate the closing and tightening of large heat ex- changers or units containing numerous plates, a pneumatic wrench is available in duplex or single versions. Figs. 23-25. 12.2 HYDRAULIC OPENING/CLOSING Three Paraflow models (CR3, CR5 and CR6) are available with self-contained hydraulic systems to actuate the open- ing and closing of the tightening screws. Fig. 26. FIG. 24 FIG. 23 18 19 eX APV APV Crepaco Inc Executive and International Headquarters 8303 W. Higgins Rd., Chicago, IL 60631 (312) 693-4000 Telex 25-4537 Engineering and Manufacturing 395 Fillmore Ave., Tonawanda, NY 14150/(716) 692-3000 Regional Sales Offices: Los Angeles (Cerritos), CA/(213) 926-9700 * Chicago, IL/(312) 693-4000 « Metropolitan New York (Haworth, NJ)/(201) 387-9500 * Nashville, TN/(615) 255-0342 « Dallas (Irving), TX/(214) 257-3455 PLATE SYMBOLS: 29/00 00/807 29-bbd TSUN Sg ec ke eC A ww uv 10 10 a rapwracr SoD aD D DPPPDIIMmD 5 Sak RX Skot HOS oyoywgna COCLER PASSES 29/HKe St/we yee 25,7 ISO°E. Gu/eol = 1 oF 42 \S5‘ €. GLYCOL — | OF a2 BU WE me <A sil SEER RL A ll It a a eet Some tae ai? PLATES MUST BE ARRANGED ALTERNATELY LEFT AND RIGHT. FOR CONVENIENCE ON THIS DRAWING, WHERE BLOCKS OF R AND LAA PLATES OCCUR, THE TOTAL NUMBER OF EACH IS GIVEN. @ sone. inl © 190° aLyeo te ——> © 50% F GryYcol OT @187.09° HEAD <I @ 5BOd, & Grycoet int @ i5s° 50% &. GrYcol oUT@ 'si° PLATES “SHOWN. BELOW ILLUSTRATE pans m SR2 re STYLES -§R2/00 > oa7 30q7 RCB RDB we (3) % [22] pia. BOLT HOLES . i244 ® PLATAGE | 3-2" Ye" [at] (9¢5] MAX.0.A. FOLLOWER ~HEAD ee say TIE BAR SUPPORT [13] '2 | s"H (76) DIM. TOLERANCES — FRAME FOUNDATION § BO NOZZLE CENTERLINE & (2) % [19] pia. LIFTING HOLES t HOLE Locations: + Ya [6] ce: +78" [3] UiIrPoRTED F)LLOWER TT AAT 1. ALL PLATES VIEWED FROM GASKET SIDE. 2. END PLATES DENOTED BY LETTER K’PRECEDING SYMBOL . 3.@ THIS MODEL HEAT EXCHANGER IS DESIGNED TO _ BETWEEN PLATE SURFACES, ALL SUPPORT 1S FROM PLATE CROSS OVER POINTS AND NOT FROM GASKET SEAL. THEREFORE THIS MACHINE MUST ALWAYS BE TIGHTENED TO A DEAD HARD CONDITION BEFORE OPERATION. THE PLATAGE ~ DIM. SHOWN IS NOMINAL ONLY, QUE TO PLATE MFG TOLERANCES PLATAGE CAN VARY 40.005" > PER/PLATE, 4. INSTALL PLATES ALTERNATING LEFT AND RIGHT. © 5: THIS MODEL HEAT EXCHANGER IS TIGHTENED USING WRENCH ON HEX NUTS AT THE HEAD OR FOLLOWER END. y 6. CUSTOMER'S PIPING TO FOLLOWER OR CONNECTOR GRIQ NOZZLES MUST ALLOW FOR FREE MOVEMENT WHEN UNIT IS OPENED FOR SERVICE AND PRONDE FOR VARIATION OF THE TIGHTENED PLAIAGE DIM.® oF + 4” PER 100 PLATES. 7. ALLIDIMENSIONS ARE IN INCHES. DIMENSIONS IN BRACKETS [ J] ARE IN MILLIMETERS. BARS. CLEAN AD ICATE THREADS BEFORE COMPATIBLE — Soon STEEL: j -NEVER-seez REGULAR GRADE DO NOT USE COMMON GREASE. DATE REVISION OPERATE WITH METAL TO METAL CONTACT é |@ PLATAGE: 24 INCHES THIS UNIT 1s EQUIPPE WITH CARBON STEEL TIE | OPENING OR CLOSING. YOU MUST USE ALUBRICANT anna r nt ————=_aeor—om = Se eaeienen ao LIQUID RATE. | TEM Re |BO” BE. GLYCOL] 1BOo GEM \90°—— 13 SO*E. cyca|] Soaem ss \S709"| : - ber Y LIST OF PLATES: P- -SRz BieS:S, 7PARICRIL SeLle 4 SisKee se 25 LAA/45 ; 46 maa /ey 23 LAA/oo | ROS/S7 | LpAfeco eee | KRAB/ST | FRAME Sigers. MAX, OPERATNG PRESSUREIO® PSI. MODEL SR25M_ VOL, OF PROCUCT:S.2_ GALS. HEAT EXCHANGER oa WT. OF MACHINE DRY: SB as. ae WT.OF MACHINE FLOODED:3@ LBS. FITTINGS: 2/4 '-I1S0* cSTL, DEO PATTERN “ALBA Raye Moai ae a Peeve ee eee