USER MANUAL KLIMA

PLATE HEAT EXCHANGER

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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: +32 (0)2-7206026 Telefax: +32 (0)2-7203407 E-mail 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: +33 (0)320-65-91-65 Telefax: +33 (0)320-65-91-60 E-mail Klima.france@klima.com

Publication: 16.12.2002

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Table of Contents 1 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

2 Safety ..............................................................................................12 2.1 General Safety.................................................................12 2.2 Protection: .......................................................................13

3 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

4 Installation .......................................................................................16 4.1 Safety Measures and Facilities on the Heat Exchanger / Installation. ....................................16 4.2 Preparation for Installation...............................................17 4.3 Installation .......................................................................18

5 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

6 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

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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

7 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

8 Customer Service:...........................................................................32 8.1 Ordering Spare Parts.......................................................32 8.1.1 rebuilt...............................................................................32 8.2 Complaints Procedure: ....................................................32

9 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

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1 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 can’t 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.

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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.

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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

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

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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

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1.5 Installation Composition

Fig. 2

1. Lower pipe 2. Upper pipe 3. Plate Heat Exchanger 4. Compensator 5. Valve 6. Connecting flange 7. drain 8. Vent

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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.

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2 Safety

2.1 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.

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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 un-insulated parts of the installation, which present risk of burns or other injury and/or damage.

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3 Transport, Storage and Installation Site.

3.1 Instructions for Transport and Hoisting

Fig. 3

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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.

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4 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.

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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

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• 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.

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5 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 start-up. 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.

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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.

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6 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 shut-down 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.

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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 35°C. lf the plate heat exchanger is opened at a temperature higher than 35°C, 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.

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Fig. 8

1. Head 2. Follower 3. Carrying bar 4. Guiding bar 5. Column 6. Plate pack 7. Clamping bolts

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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. 85°C. 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. 65°C. 1.5% concentration = 2.4 Itr. 62% (HNO) per 100 ltr. water.

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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).

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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.

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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.

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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”.

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7 Malfunctions / Trouble-Shooting Guide

7.1 Identification and Correction of Malfunctions. Malfunction Possible cause Correction of the malfunction

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.

The operating conditions deviate from those stated in the technical specification sheet.

Adjust the operating conditions to the specified / design conditions.

The heat exchanger is fouled.

Clean the heat exchanger (see Chapter: Cleaning the Heat Exchanger).

Heat exchanger has insufficient capacity.

The connections have been interchanged.

Correct the connections.

Malfunction Possible cause Correction of the malfunction

If the liquid is mixed it is due to holes in one or more plates.

The leaks can only be repaired by changing the defective plates.

Defective gasket. Replace gasket. External forces. Assemble the installation to be

stress-free.

Mediums becoming mixed. (Inside leakage)

The operating conditions deviate from those stated in the technical specification sheet.

Adjust the operating conditions to the specified / design conditions.

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Malfunction Possible cause Correction of the malfunction

Gasket faces dirtied or damaged.

Clean gasket faces. In case of damaged gasket faces, contact your supplier.

Defective gasket. Replace gasket. Bolt tightened insufficiently. Check the connection and

carefully re-tighten. External forces (expansion of pipes) on the heat exchanger.

Assemble pipes stress-free.

Maybe the plate heat exchanger is running with a higher working pressure than mentioned on the name plate

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.

plate heat exchanger is pressureless

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.

Check that the plates are without scaling and undeformed. Check the gaskets. They have to be elastic, undeformed and to have a clean surface.

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.

Heat exchanger is leaking. (External leakage)

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.

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

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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.

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8 Customer Service:

8.1 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 supplier’s, service department.

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9 Accessories / Annexes:

9.1 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 Steel 1.0 m/s 3.0 m/s Copper 1.0 m/s 1.5 m/s Stainless Steel 316L 1.0 m/s 3.0 m/s CuNi10 1.0 m/s 2.0 m/s CuNi30 1.0 m/s 3.0 m/s Chemical value for neutral water (fresh water). pH –value : 7< pH.< 11 Chloride level 10 - 50 mg/l at 80ºC < 250 mg/l at 40ºC Ammonium level NH3 = 0 Hardness (calcium) maximum: 40 French degrees or 22 German degrees at 40ºC -� 400 ppm 1 French degree or 0.5 German degree at 80ºC (softened water) --� 10 ppm Material values: Stainless Steel: AISI 304(L), 316(L), DIN17440 14306,14404 Danger from: -Stress corrosion by chlorides at temp. > 70ºC (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 Steel Stainl.St.316L Copper alloys Ammonium NH4 0.00 oz/l 10-50 mg/l 250 mg/1 Ammonium NH4 10 mg/l 0.00 oz/s PH-value >8 6-8 6-8

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9.3 Technical Specifications / Documentation Technical specification sheet must be added here.

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