PLATE HEAT EXCHANGER INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Contents
1. General Description and Terminology
1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.1 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 5.1 6.1 7.1 Frames Terminology for Connections Terminology for Intermediate Grids Heat Exchanger Drawing Plates and Gaskets Gasket Orientation Special Plates

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2. Frame Assembly
Frame Assembly

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3. Gasket Attachment to Plates

Glued Gasket System Preparation for Gluing Gaskets Gluing Gaskets Ballplate - Glueless Gasket System T-Tab - Glueless Gasket System Clip Style - Glueless Gasket System Plate Preparation for Gasketing T-Tab 4-Corner Gaskets

4. Plate Installation
Positioning of Plates Installation of Plates Model T2 T8 Installation of Plates Model T13 Larger

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5. Tightening of Plates
Manual Tightening

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6. Hydrostatic Testing
Hydrostatic Testing Installation and Operation Start up

7. Installation and Operation 8. Starting Up

8.1 9.1 9.2 9.3 9.4 9.5 10.1 10.2 10.3

9. Maintenance
Chemical Cleaning / Clean In Place Manual Cleaning Replacing a Gasket Replacing a Plate Installing New Plates

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10. Storage of Spare Parts

Plate Storage Gasket Storage Glue Storage

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11. Additional Information

11.1 11.2 11.3 11.4 Ordering Parts Damaged Shipments Returned Material Contact Information 1

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Section 1 General Description and Terminology

1.1 Frames
FIXED AND MOVABLE HEADS are made of thick, rigid, high quality stainless steel plates. They are used to compress the plate pack.

- TOP RAIL is attached to the fixed head only, on MST style frames. TOP RAIL is attached to the fixed head and end support on AL, ALA, ALI or Automated style frames. It is used to support and align the plate pack. BOTTOM RAIL is used to support and align the bottom of the plate pack. TIE BARS are evenly spaced around the periphery of the fixed and movable heads and are used to compress the plate pack. END SUPPORT is used to support the back end of the heat exchanger. Located on AL, ALA, ALI and Automated style frames. UNIVERSAL MOUNTING BRACKET is used to mount MST style frames from the top, side, or bottom of heat exchanger.

Figure 1: Typical AL and MST style frames.

Note: Heat exchangers are top heavy. Center of gravity is towards the fixed head. Use CAUTION when lifting.

1.2 Terminology for Connections on Fixed and Movable Heads

- Connection nozzles are designated by a letter and a number on both the fixed and movable heads.
F is for fixed head M is for movable head

FIXED HEAD

MOVABLE HEAD

Figure 2: Connection nozzle location.

1.3 Terminology for Connections on Intermediate Grids

- Letters designate which sections the grids are between i.e.; AB, BC,CD, etc. - The number designates which corner the nozzle is located which also matches the fixed head nozzle location. - The last letter designates a horizontal H or vertical V positioned nozzle.

Figure 3: Intermediate connector grid connection nozzle location.

1.4 Heat Exchanger Drawing

On the last pages of this manual you will find the heat exchanger drawing. It provides useful information such as the serial number, bill of materials, and thermal duty. The assembly diagram which includes height, width, length, and tightening dimension (see Fig. 4). Also included is the plate arrangement/ flow diagram (see Fig. 5) and an isometric view of the heat exchanger (see Fig. 6) that helps illustrate connection location which can be difficult to interpret from the flow diagram alone.

Figure 4: Assembly diagram.

Figure 5: Plate Arrangement/Flow Diagram .

Figure 6: Isometric View.

1.5 Plates and Gaskets

Plates are mounted with gaskets facing the fixed head. Ends of each plate are labeled with N for north and S for south.

- The first plate is mounted with N at the top, second plate with S at the top, third plate with N at the top, etc.
Same Side (Vertical) Flow Leak Detect Vents to Atmosphere Diagonal Flow Leak Detect Vents to Atmosphere

Leak Detect Vents to Atmosphere

Leak Detect Vents to Atmosphere

Leak Detect Vents to Atmosphere

Leak Detect Vents to Atmosphere

Fluid Flow Is Vertical

Leak Detect Vents to Atmosphere

Fluid Flow Is Diagonal

Figure 7: Fluid flow between plates.

1.6 Gasket Orientation

The first plate is equipped with a special 4 corner gasket which isolates the 4 port openings and prevents fluid passage between the first plate and the fixed head. All other plates are equipped with standard gaskets. All gaskets are equipped with vents to prevent fluid intermixing if a leak occurs. Multiple pass units are supplied with either flat port gaskets that are glued to the movable head or O rings which seat into a groove on the movable head or intermediate grid, depending on the size of your heat exchanger.

1.7 Blocked Plates

- Usually blocked plates are odd plates, with N at the top. - A standard plate is a plate with 4 openings. All plates with ports that are blocked off are called blocked plates in the nomenclature on the heat exchanger drawing. Each plate has a four digit identifier. Open ports are numbered 1, 2, 3 and 4 starting at the top left and continuing clockwise around the plate. Blocked ports are labeled 0. - See Figure 8 for examples.

Figure 8: Different configurations of plates.

Section 2 Frame Assembly

2.1 Frames Assembly
- Assemble the fixed head, top rail, and bottom rail. - Install the movable head (and intermediate grid if applicable). - Install the end support if you have an AL frame or the universal bracket if you have an MST frame. - Install the plates as per the plate arrangement drawing provided, ensuring that plates are aligned properly and evenly. This is necessary for a uniform plate pack and a leak free exchanger. - When the heat exchanger has openings on the movable head or intermediate grid, either flat port gaskets or O-rings (depending on exchanger model) must be in place in order to prevent leakage between the last plate and the ports. Note: Plate edges are sharp! Wear adequate hand protection when handling plates. Use CAUTION when handling!

Section 3 Gasket Attachment to Plates

Thermaline Inc. plate heat exchangers, depending on model, are available with either glued or glue-less gasketing system. Please check your plate arrangement drawing for the gasketing system in your heat exchanger. 3.1 Glued Gasket System - Original and spare plates are supplied with gaskets glued on. Gaskets can also be supplied loose, in which case the user must glue them to the plates using the following method. 3.2 Preparation for Gluing Gaskets
- Prior to gluing, it will be necessary to understand gasket terminology per section 1.2, i.e. 4 corner gaskets, and standard gaskets glued in odd or even positions. The gasket grooves on the plates must be dry, undamaged, and clean of any foreign material. - The side of the gasket to be glued should first be roughened using emery cloth or sand paper. Do not roughen the side of the gasket which will not be glued.

3.3 Gluing Gaskets

- Glue should be applied with a small, round pure bristle brush. Use a minimum amount of glue, applied evenly over the entire gasket groove. - It is recommended to use 3M Glue EC 1099 or equivalent. - Allow the glue to set for a few minutes, or as recommended by the manufacturers instructions. When glue is tacky line up the gasket with the groove and press the gasket into place. Do not force or stretch the gasket. It is necessary to ensure that no foreign matter is left between the gasket and plate, as this will cause leakage. To ensure proper gasket seating, the gasket can be lightly tapped into place with a soft-faced mallet. - Glue must be completely dry before the plate pack is placed into service. - Stack the plates horizontally on a support so that the plates are centered. Ensure that the gaskets remain in the grooves. If a support is not available, the heat exchanger frame, placed horizontally, may be used. Place a uniform weight on the top plates and allow it to sit for at least 24 hours to ensure proper glue adhesion. - Glue should be allowed to cure in warm (150F Maximum dry air.) Do not cure with steam. Poor adhesion will result if the glue is cured below 60F.

Note: Consult glue manufacturer for material safety data sheet. Follow manufacturers instructions when using glue.

3.4 Glue-less Gasket System (Ball Plate Gasket Replacement)

- Balls made of the same material as the plate are strategically positioned and welded inside the gaskets groove, including port areas. - Ballplate gaskets can also be used as glued gaskets but not vice versa. - Ballplate gaskets are installed on the plate simply by pressing the gaskets into the gasket groove, over the balls. To ensure proper gasket seating, the gasket can be lightly tapped into place with a soft faced mallet (see Fig. 10). - See section 3.7 for plate preparation details.

Figure 9: Ballplate Gasket Same Side and Diagonal Flow.

Figure 10: Detail of Ballplate Gasket.

3.5 Glue-less Gasket System (T-TAB Gasket Replacement)

T-Tab gaskets are installed on the plate by pressing the protruding T-tabs into the notches provided around the plate periphery. T-Tab gaskets are available only in Same Side Flow on all models T2 to T100.

- See section 3.7 for plate preparation details.

Figure 11: T-Tab Gasket Same Side and Diagonal Flow.

3.6 Glue-less Gasket System (Clip Style Gasket Replacement)

Clip style gaskets are installed on the plate by pressing the single tab on each clip into the notches provided around the plate periphery. Clip style gaskets are available in Same Side Flow on models T2 to T20 and In Diagonal Flow on models T28 to T100.

- See section 3.7 for plate preparation details.

Figure 12: Clip Style Gasket Vertical Flow.

3.7 Plate Preparation for Gasketing

- Plates must be clean and free of debris, especially in the gasket groove, in order to guarantee proper installation of the gasket. - Plates must receive gaskets in unique position to ensure correct plate pack configuration. Please consult the plate arrangement drawing provided.

3.8 4-Corner Gasket

- Corner gaskets are usually made from two standard gaskets. Special procedures are followed when installing a 4-Corner gasket (see Fig. 12). (Note: T14, T-28 and T45 4Corner gaskets are constructed differently then a typical 4-Courner Gasket. Please contact manufacturer for specific instructions regarding the T14, T-28 and T45 4-Corner gaskets.)

Figure 13: Making 4-Corner Gaskets.

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Section 4 Plate Mounting

4.1 Positioning of Plates
- Plates must be correctly installed for a uniform plate pack and proper gasket seating. Fig. 13 shows a plate correctly positioned on the top rail.

4.2 Installation of Plates: Model T2 T8

- Models T2, T4 and T8 have round top and bottom rails. The plates are supported by the bottom rail and guided by the top rail. Take care to support the plates by hand while installing the plate pack until the movable head is in place and some tie bars are installed.

4.3 Installation of Plates: Model T13 Larger

- Model T13 and T20 plates are suspended by the top rail. - Plates must be installed one or two at a time using the grooved area provided on the top rail (see Fig. 14). Note: Follow Figure 16 instructions for T13 and T20 Heavy-Duty frame plate installation. - T28, T45, T60 and T100 plates may be installed on the top rail at any location along rail in 3 steps (see Fig. 15). 1. Put plate in position 1 on top rail. 2. Rotate the plate following arrow 2 around the top rail. 3. Rotate plate following arrow 3.

Figure 14: Correct Plate Position.

Figure 15: Top Rail Groove.

Figure 16: Plate Installation.

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Section 5 Tightening of Plates

5.1 Manual Tightening
- The plate pack is mounted against the fixed head. Each plate is moved along the top rail and pressed against the preceding plate. - The movable head is pushed into contact with the plate pack. The plate pack is tightened with the tie bars placed into the slots on the heads. - By successively tightening the tie bars, the plate pack dimension indicated on the heat exchanger drawing will be reached. Tie bars should be tightened in a diagonal pattern. Each tie bar should not be tightened more than at a time so as to prevent uneven take up of the moveable head. Uneven take up can cause damage to the movable head. - It is recommended that new plate packs are tightened to the maximum dimension in order to maintain gasket elasticity. At the minimum dimension, the plates are in contact with each other. The remaining tie bars are installed and tightened to ensure an even pressure around the perimeter of the plate pack. Note: The unit should never be tightened to dimensions smaller than the minimum indicated on the heat exchanger drawing to prevent the plates from being damaged.

Section 6 Hydrostatic Testing

6.1 Hydrostatic Testing
- After each disassembly, it is necessary to perform a hydrostatic test. New units are hydrostatically tested to the pressure indicated on the nameplate. - Hydrostatic tests are performed to detect gasket leaks. Leaks from gaskets would appear either at the side of a plate pack or at the leak detector vents, near nozzles. Gaskets leaks always drain to the outside of the unit. It is not possible for one fluid to enter the opposite circuit due to gasket failure. To simplify repairs, the location of a leak should be marked prior to disassembly of the plate pack. - Hydrostatic testing of one circuit enables detection of defective plates. A hole in a plate would allow leakage between circuits. This is visible by water draining into an open circuit. When the plate pack is opened, the defective plate would be 1 of the 2 which are wet on the circuit that was open to the atmosphere. Dye checking of the plates will confirm whether the plate has a leak or not. Note: All tie bars must be in place and properly tightened before a hydrostatic test can be performed.

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Section 7 Installation and Operation

7.1 Installation and Operation
- Heat exchangers are delivered pre-assembled and tested. MST style heat exchangers can be rigidly mounted to the wall or ceiling using the universal mounting bracket. AL style heat exchangers are designed to sit on the floor. The following steps should be taken for correct installation: a. Ensure that the heat exchanger is installed level. b. Locate the heat exchanger in an area not congested with piping or other equipment. c. Approximately 2 or 3 feet of clearance around the exchanger is recommended for easy maintenance. d. Ensure flexibility in piping the system to provide for thermal expansion and accessibility to the movable head for disassembly. e. Process piping should be adequately supported to ensure no tension on the heat exchanger ports. f. Shut-off valves for all connections, and process drain valves for inlet and outlet piping are recommended.

g. Process supply pumps should be provided with throttling valves. When maximum pump discharge pressure exceeds maximum working pressure of the heat exchanger, a safety relief valve should be provided on the supply piping before entering the heat exchanger.

Section 8 Starting Up
8.1 Start Up
- A heat exchanger should be brought on-line gradually with the least severe circuit being opened first. I.e.; lower pressure or temperature. - On steam supplied units, the steam should be turned on last and turned off first. Do not leave steam turned on with the liquid side flow turned off. - Sudden opening and closing of valves may deform plates to the point of being unserviceable. Valves must be set to open and close gradually. Start-ups and shut-downs must be done gradually without shocks.

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Section 9 Maintenance
9.1 Chemical Cleaning / Cleaning In Place
This method is recommended especially where corrosive cleaning chemicals are used. Ensure the cleaning chemical is compatible with plate and gasket material. The following procedure for cleaning in place is recommended: - Drain both sides of the heat exchanger. If this is not possible then flush the process liquids out with water. - It is recommended that the cleaning solution be pumped at a velocity 1-1/2 times the flow rate of the process liquids. - It is not recommended to use temperatures higher than the maximum temperature indicated on the nameplate. Consult your cleaning chemical salesperson for the correct temperature to use with the cleaning chemicals. - Flush cleaning solution out with clean water. Do not allow cleaning solutions to set in the plate pack for long periods of time. i.e. Over night. Note: Do not use Hydrochloric Acid for cleaning plates. Consult your cleaning chemical salesperson for recommendations.

9.2 Manual Cleaning

- It is sometimes necessary to disassemble the exchanger for cleaning. Slide plates apart so they hang separately to allow cleaning by brush or pressurized water. - When using high pressure water lay the plates flat to avoid damage. - Always use a fiber brush (do not use a steel brush or steel wool). Be careful not to scratch gaskets surface. After brushing rinse with water and wipe dry. - After cleaning inspect the exchanger components carefully and reassemble the unit. Note: Plate edges are sharp! Wear adequate hand protection when handling plates. Use CAUTION when handling!

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9.3 Replacing a Gasket

- Remove the plate from the heat exchanger and remove the gasket. - If removal of the gasket proves difficult use a hot air gun to heat the gasket groove from the back. As the adhesive softens pull the gasket off with pliers. Alternatively, the plates may be dipped in liquid nitrogen and then knocked. The gaskets should crumble off. - Clean the plate completely. Any remaining traces of old adhesive should be removed from the gasket grooves with a cloth. Use a solvent such as Toluene, Acetone, or MEK. - If solid particles remain in the gasket groove, remove them carefully with an abrasive cloth. - Install the new gasket as described in Section 3 Gasket Attachment to Plates - Install the plate in its original position.

9.4 Replacing a Plate

- Before removing the plate confirm the plate designation (A or B) and the gasket position, (see Section 3.4 or 3.6 depending on gasket style). A replacement plate should be the same thickness, pattern, designation, and have the same gasket material and position as the original.

9.5 Installing New Plates

- Additional plates or plates with different designations (to modify number of passes) can be installed. Thermaline Inc. can provide new duty calculations and revised plate arrangement drawings concerning location of new plates and performance.

Section 10 Storage of Spare Parts

10.1 Plate Storage
- Spare plates should be stored in their original container or hung up in a protected area.

10.2 Gasket Storage

- Gaskets should be stored in an area sheltered from light at a temperature between 32F and 70F. If gaskets are stored below 32F they must be warmed above 32F prior to handling. - Gaskets should preferably be stored flat. If space is restricted gaskets may be stored folded in half but care should be taken to avoid sharp bends which will cause cracks. Wherever possible gaskets should be stored in their original container.

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10.3 Glue Storage

- It is recommended to stock glue for emergency repairs. Glue should be stored as per manufacturers instructions and shelf life (usually 6 months) should not be exceeded. Generally glue is to be stored in a cool and dry place. Note: Consult glue manufacturer for material safety data sheet. Follow manufacturers instructions when using glue.

Section 11 Additional Information

11.1 Ordering Parts
- Refer to the parts list on the plate arrangement drawing provided with the heat exchanger. - When ordering parts or requesting information always refer to the serial number, model number, and drawing number as provided with the heat exchanger.

11.2 Damaged Shipments

- Our equipment is carefully packaged and is shipped in good condition. Shipments are made at the consignees risk. On receipt of shipments carefully inspect packaging and equipment for damage. All claims for loss/damage etc. shall be made with the carrier.

11.3 Returned Material

- Units or parts are not to be returned without first obtaining permission from Thermaline Inc. Parts authorized for return must be properly packaged and received by Thermaline Inc. in good condition. All credits will be subject to re-stocking and transportation charges.

11.4 Contact Information

- Information concerning the operation, maintenance or care of Thermaline Inc. Equipment is available from our local representative or by contacting Thermaline Inc. at:

Thermaline Inc. 1302 West Main #25 Auburn, WA 98001 Phone: Fax: E-mail: 800-767-6720 253-833-7168 info@thermaline.com

Web Site: www.thermaline.com

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