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USER MANUAL

KLIMA
PLATE HEAT EXCHANGER

Supplier information:
Homepage:
www.Klima.com
The Netherlands:
Klima Thermo-Tech B.V.
Rogier van de Weydenstraat 45
5642 JG Eindhoven
Postbus 300
5600 AH Eindhoven
Telephone:
+31 (0)40-2981818
Telephone service:
+31 (0)40-2981858
Telefax:
+31 (0)40-2981800
E-mail
info@klima.com
Supplier Belgium:
S.A. Klima Belgium N.V.
Leuvensesteenweg 49c
1932 Zaventem
Telephone:
Telefax:
E-mail

+32 (0)2-7206026
+32 (0)2-7203407
Klima.belgium@klima.com

Supplier Belgium:
Klima warmtetechniek N.V.
Buitenheide 4
3930 Hamont-Achel
Supplier France:
Klima S.A.R.L.
Chateau Rouge - 276
Avenue de la Marne
59708
Marcq-en-Baroeul
Telephone:
Telefax:
E-mail

+33 (0)320-65-91-65
+33 (0)320-65-91-60
Klima.france@klima.com

Publication: 16.12.2002

Table of Contents
1

2
3

General Information...........................................................................5
1.1
Product Information ...........................................................5
1.1.1
Design and Function..........................................................5
1.1.1.1 Plate Heat Exchangers ......................................................5
1.1.1.2 The Plate Stack - Medias...................................................6
1.1.1.3 Intermediate Frames..........................................................6
1.2
The Plates .........................................................................7
1.2.1
The Corner Holes of The Plates .......................................7
1.2.2
Code ..................................................................................7
1.2.3
Changing of Plates ............................................................7
1.3
Schematic Flow Diagram...................................................8
1.4
Placing of Connections ......................................................9
1.5
Installation Composition...................................................10
1.6
Prohibitions to (putting into) Operation ............................11
1.7
Guarantee........................................................................11
Safety ..............................................................................................12
2.1
General Safety.................................................................12
2.2
Protection: .......................................................................13
Transport, Storage and Installation Site. .........................................14
3.1
Instructions for Transport and Hoisting ............................14
3.2
Transport and Packaging.................................................15
3.3
Storage: ...........................................................................15
3.4
Installation Siting:.............................................................15
Installation .......................................................................................16
4.1
Safety Measures and Facilities on
the Heat Exchanger / Installation. ....................................16
4.2
Preparation for Installation...............................................17
4.3
Installation .......................................................................18
Start-up............................................................................................19
5.1
Inspection before putting the unit into operation ..............19
5.2
Filling and Venting. ..........................................................19
5.2.1
Filling a heat exchanger compartment with a liquid. ........19
5.2.2
Filling a heat exchanger compartment with a gas............19
5.2.3
Filling a heat exchanger compartment with steam...........20
5.3
Inspection after Start-up: .................................................20
5.4
Leakage during Start Up..................................................20
5.5
Shut Down of the Installation: ..........................................20
Maintenance and Inspection:...........................................................21
6.1
Inspection ........................................................................21
6.2
Cleaning of the Heat Exchanger. .....................................22
6.2.1
Disassembly of the Heat Exchanger................................22
6.2.2
Cleaning the Heat Exchanger..........................................24
6.2.2.1 Chemical Cleaning...........................................................24
6.2.2.2 Mechanical Cleaning .......................................................25
6.2.3
Control of Cleaning ..........................................................25
3

6.2.4
Assembly of the Heat Exchanger.....................................25
6.2.4.1 Gasket Construction ........................................................26
6.2.5
(Re)pressurizing of the Heat Exchanger..........................28
Malfunctions / Trouble-Shooting Guide ...........................................29
7.1
Identification and Correction of Malfunctions. .................29
7.1.1
A suspected leakage can be located in one
of the following ways:.......................................................31
7.2
Safety Measures / Facilities:............................................31
Customer Service:...........................................................................32
8.1
Ordering Spare Parts.......................................................32
8.1.1
rebuilt...............................................................................32
8.2
Complaints Procedure: ....................................................32
Accessories / Annexes: ...................................................................33
9.1
Instructions for Transporting and Hoisting. ......................33
9.2
General Information about Material and Mediums ...........33
9.3
Technical Specifications / Documentation .......................34

General Information

Pictograms used in this manual


Dangerous situation with possibility of personal injury as well
as damage to the equipment.
Reference to tips, comments and supplements with regard to
using the equipment.
The general standards apply to symbols that are applied to the installation by
the owner.
This manual supplies information and instructions for the correct and safe
use of the device.
Many accidents are the result of incorrect use.
Instructions in this manual must therefore always be followed.
The safety instructions must also always be observed when work is done on
the equipment.
The complete manual must be carefully read.
If, after reading this manual, questions still exist, you must contact the
supplier / contractor for more information.
The installation may NOT be put into operation before all
unclear issues have been resolved.

1.1

Product Information
Product
: Plate-Heat Exchanger
Type
: See Technical Specification Sheet or type plate

All the information that is present in this user manual concerns the plate-heat
exchanger that can be disassembled.
The information in this manual except the chapters referring to the
disassembly and assembly of the heat exchanger also concerns the brazed
plate-heat exchanger that cant be disassembled.
1.1.1

Design and Function

1.1.1.1 Plate Heat Exchangers


The plate heat exchanger consists of a frame, which consists of a head,
follower, column, carrying bar, guiding bar, and a number of clamping bolts.
In between head and follower a varying number of pressed plates are
clamped together.

Each plate is supplied with a gasket, so that the plates form a closed system
of parallel flow channels, through which the medias flow alternately at every
second interval. (Fig. 8).

Fig. 1

1.1.1.2 The Plate Stack - Medias


The gaskets are glued or clicked on the plates, securing tightness between
medias and the atmosphere. Between the different medias there are double
gaskets, which have intermediate drain areas, meaning that mixing of the
two medias is impossible.
Every second plate in the stack has to be turned 180, so that the plates
form a closed system of parallel flow channels, through which the medias
flow alternately at every second interval. (Fig. 1).

1.1.1.3 Intermediate Frames


lf the plate heat exchanger works with several medias at the same time, it
can be necessary to insert intermediate frames.
The intermediate frames are equipped with corner blocks, forming
connections between the different sections. Two connections can be placed
in the same corner block, having connection to two different sections in the
plate heat exchanger.
6

1.2

The Plates

1.2.1
The Corner Holes of The Plates
Depending on the required liquid flow in the plate heat exchanger the 4
corner holes have to be opened. The corner holes named with numbers
starting left side on the top of the plate (to be seen from the gasket side) as
no. 1 after that continues no. 2, 3 and 4 clockwise. The corner holes are
opened as you see on the diagram drawings, describing the liguid flow in the
plate heat exchanger.
The opening of the corner holes are described in a code. For instance: 1234
means that all the corner holes are opened. Code 0204 means that hole 2
and hole 4 are open, and the holes 1 and 3 are closed.
1.2.2
Code
The plates are designed so they can be used both as right and as left plates.
The plates just have to be turned 180.
Right and left plates: On a right plate the flow runs from hole 2 to hole 3 or
reverse from hole 3 to hole 2. On a left plate the flow runs from hole 1 to hole
4 or reverse from hole 4 to hole 1. (Fig. 2.)

Fig. 2
1.2.3
Changing of Plates
Changing and mounting of new plates can be done after disconnection and
removal of the assembling bolts. Before mounting of spare plates check if
the plates are identical with the ones you want changed. Reduction of the
number of plates is possible, but it is a condition that the plates are removed
7

two by two so that the plate stack after reduction is still mounted by turns
right and left plates. The removed plates have to have all 4 corner holes
open. It is necessary to correct the minimum tightning measure after a
possible reduction.
Note! A reduction of the number of plates means that the transmission area
of the plate heat exchanger is reduced corresponding to the plates being
removed. A removal of plates will cause a rise of the pressure drop over the
plate heat exchanger.

1.3

Schematic Flow Diagram

The diagram shows the plate heat exchanger from the side, fig. 6. lt shows
the plate composition and the liquid flow in the plate stack. There are 4 lines
going horizontal, showing the 4 corner holes. The long vertical lines show left
plates. The short vertical lines show right plates.
On the diagram a left and a right plate are shown. On the left plate the f low
runs from hole 1 to hole 4 or from hole 4 to hole 1. On the right plate from
hole 2 to hole 3, or from hole 3 to hole 2.
The number codes over the vertical lines show the corner holes which are
open in the plates, to give the liquid flow wanted in the plate heat exchanger.
F = Head
B = Follower
M = Intermediate frames
H = Horizontal
V = Vertical
Example:
M
1

V
Vertical connection
Corner hole number
Intermediate frame from head
Intermediate frame

1.4

Placing of Connections

On the symmetrical drawing under the flow diagram, the placing of the
connections is shown. (Fig. 3).
The dot-and-dash intermediate frames are drawn up according to the
number of the intermediate frames in the plate heat exchanger.
The connections are marked with a letter and a numbercode.

Fig. 3

1.5

Installation Composition

Fig. 2
1.
2.
3.
4.
5.
6.
7.
8.

Lower pipe
Upper pipe
Plate Heat Exchanger
Compensator
Valve
Connecting flange
drain
Vent

10

1.6

Prohibitions to (putting into) Operation


It is Prohibited to operate the Unit beyond Design Conditions

The equipment is designed according to the design parameters as


stated in the enclosed technical specification sheet. If these parameters
are exceeded then it is PROHIBITED to put the installation into operation
without prior consultation with the manufacturer.
Moreover all continued use in such a non-design situation is considered
contrary to the regulations. The manufacturer is not liable for any
material damage or personal injury that results from further use : this
risk is solely the responsibility of the owner / user.
Klima has advised in the choice of materials, the user remains responsible
for the media used with regard to corrosion. Some information on materials
and mediums that Klima has collected during many years of experience can
be found in Chapter 9.2. This is purely informative. The user remains
responsible for the mediums and materials that he uses.

1.7

Guarantee

Unless covered by a separate agreement, Klima guarantees the products


supplied by the company to be sound and in good working order, according
to the technical specifications, for a period of 6 months after being put into
operation, up to a maximum of 12 months after delivery.
The General Terms of Sale and Delivery can be requested from your
supplier.
Any damage and/or decrease in capacity due to non-observance of this user
manual are not covered by the guarantee.
The guarantee expires if any adaptations or changes are made to the heat
exchanger.
The equipment must always be inspected upon delivery for damage to the
equipment during transport.
The manufacturer must immediately be notified of any damage during
transport.

11

2
2.1

Safety
General Safety
Physical injuries
Physical injuries can be caused by:

Burning, by touching the heat exchanger or other parts of


the installation.

The accidental release of a medium under pressure,


which presents a risk for burns and other injuries
because of the high pressure.

Contact with escaping chemicals.

Contact with sharp parts of the installation.


Damage to the equipment
Damage to the equipment can be caused by:

External forces.

Corrosion.

Chemical corrosion.

Erosion.

Fatigue.

Steam shock.

Pressure / temperature too high.

Impact load.

Freezing.

Transport
For transport See: Instructions for Transport and Hoisting
If handled incorrectly there is a risk for physical injury and/or
damage to the equipment.
Even after switching off the installation the heat exchanger
surface can still be hot.
The unit may only be fed with the mediums stated in the
technical specification sheet.
No fatigue analysis has been taken into account and therefore
the unit should only be used for static load.
A hot medium may NOT flow through the heat exchanger
without a cold medium also flowing through the heat
exchanger. This is to prevent damage to the heat exchanger.

12

If a cold medium is present in the heat exchanger but is not


flowing whilst a hot medium is flowing through the heat
exchanger, then the cold medium may start boiling and the
heat exchanger will be damaged.
Sudden changes in pressure and temperature must be
avoided.
The values stated in the technical specification sheet must not
be exceeded.
This manual describes other safety instructions than those
safety instructions related to the chapter in which they occur.
The complete manual must therefore be read to be aware of
all safety provisions and measures to be taken when using
this installation.
Danger of freezing. When an idle heat exchanger (filled with
water or a water mixture not of an anti-freeze type ) is
exposed to temperatures below zero, the plate stack can be
deformed. In cases where a danger of freezing may exist all
of the medium must be drained from the heat exchanger.

2.2

Protection:

For the protection of others place the heat exchanger out of reach, in a
closed space, e.g. a boiler house, only accessible to authorized staff
acquainted with the safety requirements applying to the equipment stored
there.
If the heat exchanger is set up close to people, presenting a risk of burns,
insulation of the heat exchanger is mandatory.
The user must take care to provide adequate danger signs on exposed uninsulated parts of the installation, which present risk of burns or other injury
and/or damage.

13

Transport, Storage and Installation Site.

3.1

Instructions for Transport and Hoisting

Fig. 3

14

3.2

Transport and Packaging


For transport see: Instructions for Transport and Hoisting

Always use the appropriate hoisting facilities and equipment.

Respect the prescribed safety norms and regulations.


If handled incorrectly, danger for physical injury and/or
damage to the equipment exists
Any packaging must be removed carefully and disposed of in
an environmentally friendly way.

3.3

Storage:

The device must be stored covered and dry.


A plate heat exchanger, which is out of work for a longer period, ought to be
emptied and cleaned. After emptying and cleaning the plate heat exchanger
is tightened gently and covered with black plastic to prevent the gaskets from
being damaged by daylight. Before the plate heat exchanger is put to work
again it must be tightened according to minimum measure. See chapter
6.2.4 under Mounting and Assembling.

3.4

Installation Siting:

General conditions on installation siting / location should satisfy:

The device satisfies the EC directives of the EC-pressure equipment


97/23/EG, article 3, paragraph 3.

Sufficiently firm and level ground or construction, adapted to the load


that is expected.

Sound construction and vibration-free installation of the device.

See the technical specification sheet for product-related information.

Protect if necessary against possible damage by e.g. internal transport.


The plates especially need to be protected in such a manner that there
is no risk that they will be damaged.

For safety in general see chapter 2.2 under Safety.

The location where the equipment is placed must have enough space
for installation, maintenance and cleaning. See the relevant chapters.

The unit is anti seismic to maximum earthquake intensity in accordance


with eurocode 8.
15

Installation
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
installer.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.

4.1

Safety Measures and Facilities on the Heat


Exchanger / Installation.

Installation must be carried out in such a manner that all likely risks are
excluded.
To achieve this, the following points must at least be observed:

The necessary fittings must be attached so that filling and emptying the
equipment can take place safely.

The installation must be fitted with adequate drainage and venting


facilities.

There must be sufficient valves in the supply and return pipes, close to
the heat exchanger, so that the whole system does not have to be
drained if work needs to be carried out. .

A pressure-limiting device must be fitted, adjusted to the maximum


pressure allowed for in the design and registered on the type plate.

A temperature-limiting device must be placed in the circuit to protect


against excessive temperatures.

The fitting of inspection and checking facilities such as temperature and


pressure gauges.

For heat exchangers using steam as a medium one must ensure that
they are fitted with a correctly functioning system for condensate
drainage.

For the choice of a steam trap and other fittings it is advisable to seek
advice from the suppliers.

16

4.2

Preparation for Installation

General:

The plate heat exchanger requires space enough for it to be opened for
inspection or repairs without problems, (fig. 6).

fig 6

It is necessary for the plates and the assembling bolts to have so much
space that they can be mounted and dismounted without problems.
The follower has to be pulled back to the column before opening for
service can be done without problems. (Fig. 7).

Fig. 7
17

By construction of the pipe installation it must be con- sidered that the


rubberliners in the head of the plate heat exchanger can be removed.
The pipe connection always has to be mounted in a way, preventing the
plate heat exchanger from being overloaded. The pipe connection must
be so flexible that an extra tightning of the plate heat exchanger can be
made.
Remove the plastic caps from the connecting holes.
Before the heat exchanger can be connected, the tubes must be clean
so that no pollutants can enter the unit.
The gaskets used must be suitable for the medium, temperature and
pressure to be applied.
The bedplate, construction and mounting must be of sufficient strength.
Pressure impulses, pulsations and mechanical vibrations in the heat
exchanger should be avoided.
The design specifications, stated in the technical specification
sheet must always be respected. If the user deviates from
these values, the responsibility is his.

4.3

Installation
The instructions for transport and hoisting must be observed when
placing or moving the equipment.
During assembly of the piping all pipes / flanges must be mounted
stress-free to the heat exchanger.
Pipes must be able to expand. If necessary compensators must be fitted
to the pipes.
Bolt-nut connections must be clean and lightly oiled.
Gasket used: reinforced graphite gasket 1,5 mm.

18

Start-up
The assembly and start-up must be carried by a suitably
qualified person appointed by the buyer or by a qualified
installer.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.
Pump start always has to be done with closed valves. After
that the manoeuvring of the valves must take place slowly in
the order to avoid liquid and pressure chocks.

5.1

Inspection before putting the unit into operation

As a rule the safety devices in the system to guard against excesses in


pressure and temperature must be properly adjusted and tested before startup. The entire circuit must also be inspected to check whether all
connections have been properly made.
All relevant safety regulations must be observed both before and during
start-up.
The unit has been tested by Klima in accordance with the test
pressure stated on the type plate

5.2

Filling and Venting.

5.2.1
Filling a heat exchanger compartment with a liquid.
Proceed as follows:

Open vent.

Slowly feed the medium.


If a cold medium is present in the heat exchanger but is not
flowing whilst a hot medium is flowing through the heat
exchanger, then the cold medium may start boiling and the
heat exchanger will be damaged.

Ensure that all air has been allowed to escape from the unit.
Allow the circuit to pressurize and open the return valve so the medium
can flow through.
Check for leakages. In case of leakage see Chapter 7.

5.2.2
Filling a heat exchanger compartment with a gas.
Proceed as follows:

Slowly feed the medium.

Allow the circuit to pressurize and open the return valve so the medium
can flow through.

Check for leakages. In case of leakage see Chapter 7.


19

5.2.3
Filling a heat exchanger compartment with steam.
Proceed as follows:

The cold medium must always circulate through the heat exchanger
first.

As soon as steam enters the cold tube a lot of condensate is formed.

When the pressure in the heat exchanger rises too fast, the condensate
is forced through the tubes, possibly leading to water hammer. Heating
therefore needs to happen slowly, so the installation will heat up evenly.

Open the valves at the drainage points and let the steam enter the tube
very gradually, causing the pressure to slowly rise.
When the initial condensate has been drained and steam starts to
escape, then shut the valves again.
During the heating up phase, water hammer must not occur because it
can damage the installation.

Heat exchangers using steam as a medium one must have a properly


working system for condensate drainage.
Check for leakages. In case of leakage see Chapter 7.

5.3

Inspection after Start-up:

After heating the heat exchanger for a certain period of time, all connections
must be inspected for leakage. In case of leakage they must be repaired.
See Chapter 7.
Check whether the settings of the measuring and control devices reflect the
expected values.

5.4

Leakage during Start Up

Leakage during start up can arise.


This stops when gaskets and plates have obtained running temperature and
when the pressure has equalized in the whole plate heat exchanger.

5.5

Shut Down of the Installation:

To shut down the heat exchanger the supply and return flows of the circuit
must be closed.
First close the supply of hot medium and then, only when the
heat exchanger has reached the temperature of the cold
medium, close the supply of the cold medium.
Danger of freezing.
When an idle heat exchanger (filled with water or a water
mixture not of an anti-freeze type) is exposed to temperatures
below zero, the pipes may burst and the covers may be
deformed. If there is a danger of freezing all the medium must
be drained from the heat exchanger.
20

Maintenance and Inspection:


The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.
The owner must post warnings against environmental factors
that can pose a threat. Preferably using pictograms and/or
text.
The owner must enforce the wearing of protective clothing
and gloves by the personnel wherever necessary.
Maintenance, cleaning etc. must only take place on a shutdown device.
Special measures apply for a shutdown device. See Chapter
5.5.

Depending upon operating conditions, maintenance should be carried out


every 1000 hours of operation or minimally 1x per year.

6.1

Inspection

To guarantee a high degree of operational reliability regular inspection of the


equipment by the maintenance and operating personnel is necessary for the
following:

Leakage.
Pressure and temperature within the permissible limits.
Presence of air in a system where a liquid medium is being used.
If applicable, the presence of adequate condensate drainage.
Fouling of the heat exchanger (drop in capacity).
Vibrations / strange noises.
General condition of the installation.
Corrosion.
Functioning of the safety devices.

21

6.2

Cleaning of the Heat Exchanger.

6.2.1

Disassembly of the Heat Exchanger.


Without Pressure and Cooled
Before opening the plate heat exchanger be sure that there is
no pressure in it and that the temperature is cooled down to
35C. lf the plate heat exchanger is opened at a temperature
higher than 35C, the gaskets can get loose from the plates.

(For Parts See Fig. 8.)


Proceed as follows:

Close the supply and return flows of the circuit.


Firsts close the supply of hot medium and only when the heat
exchanger has cooled to the temperature of the cold medium
close the supply of the cold medium.

Wait until the heat exchanger has cooled down!


Drain the medium (vent open).
Where necessary mark the position of the parts to be disassembled.
Remove the supply and return pipes and disassemble the cover.
By opening the plate heat exchanger the bolts have to be
loosened equally. (I.e. that the follower shall have a straight
moving by opening). The last distance of the opening can be
made by 2 bolts. After that, the follower is pulled back towards
the column. lf the plate heat exchanger is installed onboard a
ship the follower has to be fastened to the column.
Beware!
When disconnecting or disassembling the heat exchanger it is
possible that residual medium may seep from the heat
exchanger. To avoid damage to underlying parts or floor it is
necessary to catch the medium in, for example, a drip tray.

22

Fig. 8
1.
2.
3.
4.
5.
6.
7.

Head
Follower
Carrying bar
Guiding bar
Column
Plate pack
Clamping bolts

23

6.2.2
Cleaning the Heat Exchanger
As well the capacity as the corrosion resistance of the plate heat exchanger
are depending on the cleaning of the plate heat exchanger.
6.2.2.1

Chemical Cleaning

To use GIP cleaning (cleaning in place) it is a condition that the scalling on


the plates is soluble. All materials in the whole circulation system of course
have to be resistant to the cleaning material.
The cleaning can be done without circulation, too. This is done by filling up
the plate heat exchanger with a qualified cleaning material. After some time
the cleaning material is washed out with clean water.
The heat exchanger can be cleaned by rinsing with a detergent or chemical
solvent. When using chemicals we advise you to contact a company that
specialises in chemical cleaning. Klima can if necessary advise you on this.
If chemicals are used the equipment (material) can be affected. Be
especially careful that the gaskets used are resistant to the chemicals used.
Example GIP cleaning:
-product rests and cooling/heating liquids are drawn off
-rinse with cold or tepid water
-warm cleaning fluid circulates
-rinse with cold or tepid water
-rinse with water added a chemical
-rinse with cold or tepid water
The heat exchanger can be cleaned by rinsing with a detergent or chemical
solvent. When using chemicals we advise you to contact a company that
specialises in chemical cleaning. Klima can if necessary advise you on this.
If chemicals are used the equipment (material) can be affected. Be
especially careful that the gaskets used are resistant to the chemicals used.
Cleaning Materials:
A qualified cleaning material can shortly be defined as scalling on the plates
is being removed without damaging plates and gaskets.
Stainless steel has a passivated (protecting) film. This film must not be
destroyed, as the film assists in preserving the resistance of the stainless
steel.
Fitted Cleaning Materials:
0il and grease is removed with a water emulsifying oil solvent i.e. BP system
cleaner.
Organic and grease cover is removed with sodium hydroxide (NaOH)
maximum concentration 1.5% - max. temp. 85C. Concentration = 5.00 Itr.
30% NaOH per 100 ltr. water.
Stone - and limestone is removed with nitric acid (HNO) - max concentration
1.5% - max. temp. 65C. 1.5% concentration = 2.4 Itr. 62% (HNO) per 100
ltr. water.
24

Nitric acid also has an effective build up effect on the passivation film of
stainless steel!
6.2.2.2
Mechanical Cleaning
The plate heat exchanger is separated and the plates are pulled from each
other. Use a soft brush and a qualified cleaning material for cleaning the
plates.
lf the cover is thick, from scale or organic material the plates are put in a vat
with a qualified cleaning material. Wire brush, sandpaper, metalscraper etc.
must not be used. Neither the plates nor the gaskets can bear heavy-handed
/ robust treatments.
A high-pressure-cleaner can be used but with absolute care, and never add
abrasives.
6.2.3
Control of Cleaning
Cleaning is an important part, influencing on the effectiveness of the plate
heat exchanger. Therefore the plate heat exchanger has to be separated for
inspection - and especially in the commissioning period. You will obtain
important experience concerning circulation times, temperatures, and
chemical concentrations.
Reasons for insufficient cleaning often have to be looked for among the
following:
- too low circulation quantity
- too short cleaning period
- too low chemical consumption compared to the scaling of the plates
- too long running intervals between the cleanings
6.2.4

Assembly of the Heat Exchanger.

The plates and the gaskets are checked carefully before mounting - the
plates have to be clean and the gaskets have to be without fatty substance
and other uncleanness. A grain or sand on the gasket can cause leak ness
during running and damage of gaskets. It is recommended to use new
gaskets.
The plates are being mounted according to the diagram - the gaskets always
have to be turned towards the head of the plate heat exchanger. lf the
gaskets have been changed or the plate heat exchanger has just been
delivered the plate heat exchanger is assembled according to the minimum
measure stated on the name plate and the enclosed drawings + 0.1 mm per
plate.
During the assembling the head and the follower have to be parallel. It is
therefore necessary to measure the assembling on the top and the bottom
on both sides. (Fig. 9).

25

Fig. 9

Make sure that all gasket faces are clean and undamaged.
Always use new gaskets.
Apply the gaskets.

6.2.4.1 Gasket Construction


New Gaskets
On the enclosed diagram an order list for the gaskets is shown.
The first plate after the head and intermediate frames is to be mounted with
a gasket in all the gasket grooves.
These gaskets are cut out of ordinary gaskets. Therefore please note the
cutting out of the old gaskets be- fore removing them. (See fig.10).
Glue Less or Glued Gaskets.
Some plate heat exchangers are delivered with glue less >Sonder Snap<
gaskets. In these units it is possible to change the gaskets without using
glue. However, the gasket on the first plate after the head and intermediate
frame should be glued on as shown in fig. 10.

26

Fig. 10
Glue Type
PLIOBOND 25 / SCOTCHGRIP 847 are nitrile rubber glues on soluble basis
(25% solid materials).
The glues are partly thermoplastic so that old gaskets can be unsticked by
boiling-water heating.
Detergent
For cleaning and degreasing new gaskets and gasket grooves
use,>ACETONE<. It is very important that every detergent is evaporated
before putting glue on.
Beware!
Solvents are dangerous to inhale!
Avoid contact of the solvent with the eyes and the skin!
Glueing.
After wiping gaskets and gasket grooves with a cloth moistened with
degreasing substance the glueing itself can begin. The glueing areas must
be quite clean - free from fingerprints etc. The gaskets are covered by a
brush with a thin coat of glue on the glueing area and are placed on a clean
and dry place in order to dry.

27

The gasket grooves, too, are supplied with a thin coat of glue, after which the
gaskets are pressed down equally all over in the groove. The glueing starts
in the plate ends and then continues along the straight edges.
The glueing process is done easiest on a solid table. After the gaskets have
been put into the plate gasket grooves the plates are stacked.
When the glueing is finished the plates are hung into the frames again and
the plate heat exchanger is clamped together. See description -Opening and
Assembling. The plate heat exchanger can be warmed up by hot water if the
glue is to dry quickly - but without pressure on the water
Drying time:
-Approximately 2hoursat80-100'C(194-212'F)
-Approximately 24 hours at 40-50'C (104'F)
-Approximately 48 hours at room temperature.
lf it is not possible to heat the plate heat exchanger it must be placed as
warmly as possible and in order to let off glue vapour from the plate heat
exchanger the connections are to be dismounted.
6.2.5

(Re)pressurizing of the Heat Exchanger.

Proceed as follows:

Close the supply and return flows of the circuit.


First close the supply of hot medium and then, only when the
heat exchanger has cooled to the temperature of the cold
medium, close the supply of the cold medium.

Drain the heat exchanger (vents open).


Remove the supply and return pipes.
Blind de cover flange with blind flanges.
Fill the heat exchanger through a feeder with unheated, clean medium,
using the medium as specified in the technical specification sheet.
Pressurize the system for 30 minutes (at room temperature) to the
design pressure as specified on the type plate.
Inspect for leakage. See Chapter 7.
Slowly de-pressurize the heat exchanger to atmospheric pressure.
For assembly, See: Assembly of the Heat Exchanger.

28

7
7.1

Malfunctions / Trouble-Shooting Guide


Identification and Correction of Malfunctions.

Malfunction

Possible cause

Correction of the malfunction

Heat
exchanger
has
insufficient
capacity.

There is air in the


installation.

Inspect the pipe work for


possible air pockets.
- Remove any air in the liquid.
- Then bleed the heat exchanger
thoroughly and if necessary fill
up the medium.
Adjust the operating conditions
to the specified / design
conditions.

The operating conditions


deviate from those stated in
the technical specification
sheet.
The heat exchanger is
fouled.
The connections have been
interchanged.
Malfunction
Mediums
becoming
mixed.
(Inside
leakage)

Possible cause
If the liquid is mixed it is
due to holes in one or
more plates.
Defective gasket.
External forces.
The operating conditions
deviate from those stated in
the technical specification
sheet.

29

Clean the heat exchanger (see


Chapter: Cleaning the Heat
Exchanger).
Correct the connections.

Correction of the malfunction


The leaks can only be repaired
by changing the defective plates.
Replace gasket.
Assemble the installation to be
stress-free.
Adjust the operating conditions
to the specified / design
conditions.

Malfunction
Heat
exchanger is
leaking.
(External
leakage)

Possible cause
Gasket faces dirtied or
damaged.
Defective gasket.
Bolt tightened insufficiently.
External forces (expansion
of pipes) on the heat
exchanger.
Maybe the plate heat
exchanger is running with
a higher working pressure
than mentioned on the
name plate
plate heat exchanger is
pressureless

Check that the plates are


without scaling and
undeformed.
Check the gaskets. They
have to be elastic,
undeformed and to have a
clean surface.
lf there is a leakage
through the drain holes of
the gaskets the reason can
be a defective gasket in
the drained zone or a
corroded plate in the
drained zone.

30

Correction of the malfunction


Clean gasket faces. In case of
damaged gasket faces, contact
your supplier.
Replace gasket.
Check the connection and
carefully re-tighten.
Assemble pipes stress-free.
In that case the pressure has to
be controlled and if too high it
has to be reduced immediately
to what is written on the name
plate.
Tighten the plate heat exchanger
to the minimum measure which
is mentioned on the name plate.
It goes without saying that the
plate heat exchanger has to be
pressureless before tightning.
The plate heat exchanger is
separated for inspection.
All gaskets and plates are
cleaned carefully - even a grain
of sand on the gasket surface
can cause a leak.
A plate stack, assembled to a
minimum measure after
cleaning, has to be tight.
lf a leakage is still present the
gaskets normally have to be
changed

7.1.1

A suspected leakage can be located in one of the following


ways:

- Remove a pipe on one of the bottom pipe connections - then Put the
opposite side under pressure.
After the pressure is stabilized the liquid must not run off from the removed
pipe connection. lf the liquid continues to run off there is a leak on one or
more plates. The plate stack is demounted and every single plate is
examined carefully.
The plate heat exchanger is separated and all the plates are dryed, After
drying the plates are put into the plate heat exchanger and assembled. Now
the liquid is circulated with full capacity but only on one side (every second
plate interval). The other half of the plate interval is kept without pressure
and without liquid.
The circulation is stopped after a few minutes and the plate heat exchanger
is opened carefully so that no water is sprayed on the dry plate side.
The plates are examined carefully and thus it is possible to find the wet
areas on the dry plates. The areas have to be controlled with capillary liquid.
The plate heat exchanger is separated and all plates are controlled with the
capillary liquid.

7.2

Safety Measures / Facilities:

Facilities must be provided (ladders, steps, cat ways etc.) to be able to safely
reach all places to make adjustments and to perform maintenance and
repair.

31

8
8.1

Customer Service:
Ordering Spare Parts

When ordering spare parts it is important to provide the correct data.


One should at least state:

Project and order number.

Complete description of product / type (See Technical Specification /


type plate).

Required part (for name see documentation).


The type designation of the plate heat exchanger and the manufacture
number (is on the name plate which is placed on the head cover) ought to be
mentioned by ordering spare parts. This to prevent fault delivery.
By ordering plates it is important to mention the right pattern code and if it is
right or left plates - see chapter.1.2
By ordering a complete set of gaskets and the glue for these and the
cleaning fluid it is enough to mention the manufacture number or the number
of the drawing.
Ordering single gaskets it is important to mention the correct quality.
The quality appears from the diagram and the colour marks on the gasket.
By ordering assembling bolts it is necessary to measure the old assembling
bolts to secure delivery of the right size of bolts.
8.1.1
rebuilt
The plate heat exchanger is module built up and therefore flexible as regards
enlargements or reductions. I.e. it is easy to change the capacity by
respectively enlarging or reducing the number of plates.
We gladly forward suggestions/quotations concerning rebuild of an existing
plate heat exchanger.
Klima only has to know the manufacture number stamped on the name plate
and the modifications you want

8.2

Complaints Procedure:

For complaints, requirements, or imperfections of the device, please contact


Klima, or your suppliers, service department.

32

9
9.1

Accessories / Annexes:
Instructions for Transporting and Hoisting.

See Chapter 3.1

9.2

General Information about Material and Mediums

This data has been collected through years of experience and is merely
indicative and for information. The user of the unit remains responsible for
the mediums and materials he uses with regard to corrosion etc.
For your information
Materials:

Medium velocity:
Minimum
Maximum
1.0 m/s
3.0 m/s
1.0 m/s
1.5 m/s
1.0 m/s
3.0 m/s
1.0 m/s
2.0 m/s
1.0 m/s
3.0 m/s

Steel
Copper
Stainless Steel 316L
CuNi10
CuNi30

Chemical value for neutral water (fresh water).


pH value : 7< pH.< 11
Chloride level 10 - 50 mg/l at 80C
< 250 mg/l at 40C
Ammonium level NH3 = 0
Hardness (calcium) maximum:
40 French degrees or 22 German degrees at 40C - 400 ppm
1 French degree or 0.5 German degree at 80C (softened water) -- 10 ppm
Material values:
Stainless Steel:
AISI 304(L), 316(L), DIN17440 14306,14404
Danger from: -Stress corrosion by chlorides at temp. > 70C (maximum 10-50 mg/l
Chloride) and stress in the material.
-Biological corrosion from stagnant water.
Copper and copper alloys:
Sf-Cu, CuNi10, CuNi30, CuZn38SnAl
Danger from: - Ammonium compounds
- Low strength at high temperatures.
- Electroplated corrosion on carbon steel.
Steel: St.35.8, P265GH,
Danger from: -General corrosion
-Pitting corrosion by oxygen 02 and CO2
-Stress corrosion (lye pH < 8)
Maximum value
Ammonium NH4
Ammonium NH4

PH-value

Steel
0.00 oz/l
10 mg/l

>8

Stainl.St.316L Copper alloys


10-50 mg/l
250 mg/1
0.00 oz/s

6-8
33

6-8

9.3

Technical Specifications / Documentation

Technical specification sheet must be added here.

34

35

36

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