EN Instruction Manual Brazed plate heat exchangers AC, AXP, CB, CD, DOC 3450021401-EN 2017-06 Original manual
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Table of contents Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Name plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface Preface This manual provides information needed to install, operate and carry out the maintenance of the plate heat exchanger. Intended use The plate heat exchanger has been designed to meet the requirement for a wide range of heat transfer applications such as refrigeration, comfort heating, industrial heating and cooling, and the process industry. Safety considerations The plate heat exchanger must be used and maintained in accordance with the instructions in this manual.
Preface Definitions of expressions Warning! Type of hazard WARNING indicates a potentially hazardous situation that, if not avoided, may result in death or serious injury. EN Caution! Type of hazard CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. Note! NOTE indicates a potentially hazardous situation that, if not avoided, may result in property damage.
Preface Environmental compliance Alfa Laval endeavours to perform its own operations as cleanly and efficiently as possible. Environmental aspects are taken into consideration when developing, designing, manufacturing, servicing and marketing the company’s products. Brazed Plate Heat Exchangers (BHE) consist of stainless steel channel plates and frame elements and bonded stainless steel or carbon steel connections.
Description Description Function Plate heat exchangers consist of a pack of corrugated metal plates with ports for the passage of the two fluids between which the heat transfer will take place. EN The media in the heat transfer are led into the plate pack through portholes at the corners and are distributed into the passages between the corrugated plates. 1 4 3 2 Figure 1. Function: Cover plate (1), corrugated plates (2), seal (3) and ports (4). Warning! The heat exchanger must not be opened.
Installation Installation Unpacking Carefully open the package containing the plate heat exchanger. Check that all items are included according to the specifications and that all parts are undamaged. Before installing the plate heat exchanger, remove the plastic plugs or caps in the connections. Lifting Warning! Never lift only by the connections or anyb of the studs. Use straps when lifting and place them according to the figure below. Figure 2. Examples of lifting.
Installation Warning! Plate heat exchangers with large plate packs may be difficult to lift without lifting lugs because the center of gravity may cause the plate heat exchanger lean too much. If in doubt, use lifting lugs. EN Requirements Warning! The plate heat exchanger must be installed and operated so that no risk of injury to personnel or damage to property. Caution! Protective gloves should always be worn when handling the plate heat exchanger to avoid hand injuries caused by sharp edges.
Installation Connection loads at installation Mb Fs Mt Ft Figure 3. Connection loads. With reference to definitions in figure, the loads during installation should not exceed the limits specified in table below. Maximum recommended connection loads during installation D Figure 4. Outer diameter of the connection (D). Outer diameter mm (inch) 15 -28 (0.6 - 1.1”) 29 - 35 (1.1 - 1.4”) 36 - 45 (1.4 - 1.8”) 46 - 55 (1.8 - 2.2”) 56 - 76 (2.2 - 3.0”) 77 - 99 (3.0 - 3.9”) 100 (3.
Installation Mounting It is recommended to mount the plate heat exchanger on the floor, on feet or on the wall. EN Larger heat exchangers should be secured with support mountings (ordered as accessory) intended for a specific heat exchanger, or be secured with straps or by means of mounting bolts. Note! Regardless of the mounting method minimize the pipe loads at installation. Maximum tightening torques for the mounting bolts according to table below.
Installation Installation in general Warning! Safety valves must be installed according to pressure vessel regulations. Note! Before connecting any piping, make sure all foreign objects have been flushed out of the system. The installation must be installed with equipment that protects it against pressures and temperatures outside the approved minimum and maximum values shown on the name plate.
Installation Welded connections – To minimize the heat impact of the heat exchanger it is recommended to use TIG or MIG welding methods. Preparation for welding: Grind inside and outside of the pipe and, if bevelled, also the bevelled edge at least 25 mm from the pipe edge and inward. This should be done to avoid contamination of copper in the welded area, which might cause the weld to crack.
Installation Heat exchanger with a refrigerant distribution system should be mounted with the distributor at the bottom. Typical installation of single circuit: 2 S4 S1 1 3 A 4 S4 S1 B S3 S2 1 4 2 S3 S2 3 Figure 5. Single circuit: A evaporator; B condensor. 1.Refrigerant inlet 2.Refrigerant outlet 3.Water/Brine inlet 4.Water/Brine outlet For an evaporator, the pipe should be straight (at least 150 mm / 5.9 inch length) between the expansion valve and refrigerant inlet.
Operation Operation Start-up Note! If several pumps are included in the system, make sure you know which one should be activated first. EN Note! Adjustments of flow rates should be made slowly in order to avoid the risk of water hammer. Water hammer is a short-lasting pressure peak that can appear during start-up or shut-down of a system, which causing liquids to travel along a pipe as a wave at the speed of sound. This can cause considerable damage to the equipment.
Operation Step 5 When all air is expelled, close the vent valve (5). Step 6 Repeat steps 1–5 for the second media. Unit in operation Note! Adjustments of flow rates should be made slowly in order to protect the system against sudden and extreme variations of temperature and pressure. During operation, check that: • • media temperatures and pressures are within the limits stated on the name plate no leakages appear due to faulty tightening of the connections.
Operation Protection against thermal or/and pressure fatigue Sudden temperature and pressure changes could cause fatigue damage to the heat exchanger. Therefore, the following must be taken into consideration to ensure that the heat exchanger operates without fluctuating pressures/temperatures. Warning! The plate heat exchanger is not intended for cyclic processes, please contact an Alfa Laval Representative for advice.
Operation Recommended limits for Chloride ions, Cl- at pH 7.5 Alloy 304 Alloy 316 100 ppm 1000 ppm at 25 °C / 77 °F 50 ppm 200 ppm at 65 °C / 149 °F 20 ppm 100 ppm at 80 °C / 176 °F 1 2 1. Lower levels of chloride ions may cause corrosion due to other factors. 2. Halogens, e.g. bromides and flourides may also cause corrosion. Insulation If the heat exchanger will be operated at very hot or very cold temperature, take protective actions, such as insulation, to avoid injuries.
Maintenance Maintenance Cleaning can improve the performance of the plate heat exchanger. Cleaning intervals depends on factors such as media and temperatures. General guidelines regarding maintenance EN Plate Sheet material Stainless steel can corrode. Chloride ions are hazardous. Avoid cooling brines containing chloride salts as NaCI and, most harmful, CaCI2.
Maintenance Type of cleaning: • • • Acidic cleaning removes inorganic deposits such as limestone. Alkaline cleaning removes organic deposits. During the process it is important to control the pH value and the recommended pH value is 7.5 - 10. Higher pH values increase risk of the copper oxidizing. Neutralization of cleaning liquids before draining and flushing the unit with potable water. Follow the instructions of the CIP equipment.
Fault tracing Fault tracing Pressure drop problems If the pressure drop has increased. Action 1.Check that all valves are open including non-return valves. - Measure the pressure and the flow rate directly in front of the inlet and after the outlet of the heat exchanger.For viscous media use a membrane manometer with a diameter of at least 30 mm. - Measure or estimate the flow rate if possible. A bucket and a watch showing seconds may be sufficient for small flow rates.
Fault tracing Heat transfer problems The heat transfer capacity is dropping. Action 1.Measure temperatures at inlets and outlets. Also measure flow rates on both media, if possible. On at least one of the media, both temperatures and the flow rate must be measured. Check to see if the transferred amount of heat energy corresponds to the specifications. If great precision is important, it will be necessary to use laboratory thermometers with an accuracy of 0.
