Kelvion KBloc Operating Instructions Manual
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Kelvion KBloc Operating Instructions Manual

Fully welded plate heat exchangers
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Operating Instructions - Vers 2.2 01.2016
K°Bloc – Fully welded plate heat exchangers

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Summary of Contents for Kelvion KBloc

  • Page 1 Operating Instructions - Vers 2.2 01.2016 K°Bloc – Fully welded plate heat exchangers...
  • Page 2 In the future, GEA Heat Exchangers products will be sold under a new brand name: Kelvion. However, the familiar performance and quality will remain constants. The name of Kelvion is indeed new, but we are continuing a successful business as global experts for plate heat exchangers. We wish to enjoy your full confidence in all we do.

  • Page 3: Table Of Contents

    Content Content 1 PRODUCT INFORMATION ............... 6 1.1 TECHNICAL DATA................ 6 1.2 NAME PLATE ................6 1.3 TECHNICAL DOCUMENTATION..........7 2 USER INFORMATION................8 2.1 ABOUT THESE OPERATING INSTRUCTIONS ......8 2.2 VALIDITY..................9 2.3 DRAWINGS AND FIGURES ............9 2.4 EMPHASIZED TEXT SECTIONS..........
  • Page 4 5 SETTING UP AND CONNECTING THE K°BLOC ........28 5.1 INSPECTING THE EQUIPMENT UPON DELIVERY ....28 5.1.1 TRANSPORT VARIANTS ......... 28 5.1.2 TRANSPORT PARTICULARITIES......29 5.2 SPACE REQUIREMENT AT THE PLACE OF INSTALLATION .. 29 5.3 REMOVING AND DISPOSING OF TRANSPORT PACKAGING................
  • Page 5 Content 7.8 CLEANING BY REVERSE FLUSHING ........96 7.9 CLEANING THE PLATE PACK WITH THE K°BLOC OPENED..................96 7.9.1 CLEANING PLATES WITH A CHEVRON PATTERN..............96 7.9.2 CLEANING PLATES WITH "DOUBLE DIMPLE" PATTERN..............98 8 TROUBLESHOOTING................99 8.1 INSUFFICIENT PERFORMANCE ..........99 8.2 LEAKS ..................

  • Page 6: Product Information

    The technical data of your K°Bloc can be taken from the technical documen- tation that is included in the delivery. 1.2 NAME PLATE Every K°Bloc manufactured by Kelvion has a rating plate. The K°Bloc name plate is fitted on one of the panels. The K°Bloc name plate gives you the following information: •...

  • Page 7: Technical Documentation

    Chapter 1 Product information 1.3 TECHNICAL DOCUMENTATION An assembly drawing is delivered with every K°Bloc unit. This assembly drawing includes among other information: • the outer dimensions, • tensioning parameters of threaded bolts to be respected, • weight and • type, size and position of piping connections K°Bloc –...

  • Page 8: User Information

    2 USER INFORMATION This chapter gives you information on the use of the Operating instructions: • About these Operating instructions (page 8) • Validity (page 9) • Drawings and figures (page 9) • Emphasized text sections (page 9) 2.1 ABOUT THESE OPERATING INSTRUCTIONS These Operating instructions contain important information on how to •...

  • Page 9: Validity

    • all instructed persons working on or with the K°Bloc, • all K°Bloc types manufactured and delivered by Kelvion. 2.3 DRAWINGS AND FIGURES The drawings used in these Operating instructions serve as examples. Many details are simplified. The actual conditions of an individually manufactured K°Bloc cannot be reflected here.

  • Page 10: Safety Note

    2.4.1 SAFETY NOTE Safety instructions: Special note for an informative section. Explanation of note. • The dot marks measures that consider this note. 2.4.2 SAFETY INSTRUCTION SAFETY INSTRUCTION To carry out the work safely, follow precisely the steps described below: Step one of a safety instruction.

  • Page 11: Warnings

    Chapter 2 User information 2.4.3 WARNINGS DANGER Warning of injuries resulting in death Failure to observe the safety note causes very serious damage to your health including death.  The arrow marks a precautionary measure you have to take in order to avoid the hazard.

  • Page 12: Procedure Instruction

    2.4.4 PROCEDURE INSTRUCTION Carry out the following steps: = Start of a procedure instruction. Step one in a sequence of steps. Required settings ......Setting values Second step in a sequence of actions.

  • Page 13: Tip

    Chapter 2 User information Partial goal of the second sequence of actions Carry out the following steps: = Start of second procedure instruction.  The only step of the first sequence of action. Problem. A fault that was to be expected has occurred. Origin of fault.

  • Page 14: Overview And Description

    The same applies to unauthorized modifications on the K°Bloc. Please contact your Kelvion Sales Office for verifying such requirements and the possibly required modifications. K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...

  • Page 15: Functional Description

    Chapter 3 Overview and description The intended use also includes: • compliance with the present operating instructions and the technical documentation included in the delivery; • that the K°Bloc is in technically flawless condition, i.e. it shows no appa- rent defects, e.g. loose or missing threaded bolts and/or nuts or defective connections.

  • Page 16: Basic Design

    3.3 BASIC DESIGN The basic structure of a K°Bloc is shown below. The specific execution depends on the application. Components of the K°Bloc Legend Designation Threaded holes for lifting equipment Top head with lifting lug Threaded bolt Column Baffle plate bracket Threaded holes for push-off bolts Nuts and washers K°Bloc –...

  • Page 17: Panel Gaskets

    Chapter 3 Overview and description Legend Designation Panel Connections Gasket Plate pack Bottom head Baffle plate Foot 3.4 PANEL GASKETS The panel gaskets are wear parts and sensitive to chemical, thermal and mechanical damage. The gasket material and its properties are selected on the basis of the customer's specifications (pressure, temperature, media).

  • Page 18: Important Safety Information

    4 IMPORTANT SAFETY INFORMATION This chapter gives you information on how to operate the K°Bloc safely: • Operational safety (page 18) • Residual hazards on the K°Bloc (page 24) • Personnel qualification (page 23) • Obligations of unit operating company (page 22) •...

  • Page 19: Safety Information

    Chapter 4 Important safety information 4.2 SAFETY INFORMATION 4.2.1 INFORMATION ON TRANSPORTATION AND SETTING UP A safety-conscious approach by personnel and acting with foresight avoids dangerous situations while setting up and connecting the K°Bloc. The fundamental rules below apply to transportation: •...

  • Page 20: Operational Information

    Prepare a time schedule for regular maintenance work in order to enable reliable unit operation. • Prior to K°Bloc maintenance, we recommend that you contact your Kelvion Sales Office (see rear cover). K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...

  • Page 21: Dismounting Information

    Chapter 4 Important safety information 4.2.4 DISMOUNTING INFORMATION When performing maintenance work on the K°Bloc, never remove the corner bolts. Removing the corner bolts will void the warranty. Corner bolts (variant 1 and variant 2) K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...

  • Page 22: Obligations Of Unit Operating Company

    4.3 OBLIGATIONS OF UNIT OPERATING COMPANY The operating company is responsible for the safe operation of the K°Bloc. 4.3.1 ENSURING SAFE OPERATION As the operating company, you must ensure that: • the K°Bloc is operated in line with its intended use exclusively; •...

  • Page 23: Personnel Qualification

    Chapter 4 Important safety information 4.4 PERSONNEL QUALIFICATION Persons entrusted with setting-up, transportation, installation, commissio- ning, operation, dismounting or maintenance of the K°Bloc must have the following knowledge: • basic mechanical knowledge, • knowledge of the plant into which the K°Bloc is integrated, •...

  • Page 24: Additional Protective Equipment

    4.6 ADDITIONAL PROTECTIVE EQUIPMENT Depending on the type of flow media used, you have to fit additional protec- tive equipment. Hazardous flow media: • Fit a tray with a sufficient volume beneath the K°Bloc for collecting its entire content. This tray must be made of a material that resists the flow media permanently.
  • Page 25 Chapter 4 Important safety information Residual hazards on the K°Bloc and measures Hazard Cause Measure Danger of injury The K°Bloc is heavy. If Transport the K°Bloc to its it falls over or falls down intended position with the trans- during transport, port packaging if possible.

  • Page 26: Notes / Decals On The K°Bloc

    Residual hazards on the K°Bloc and measures (Cont.) Hazard Cause Measure Danger of cuts Burrs and threads Wear protective equipment at all involve danger of cuts. times when working on the K°Bloc. 4.8 NOTES / DECALS ON THE K°BLOC Overview of notes / decals on the K°Bloc Notes / decals Meaning Indication of marked slinging points for lifting:...
  • Page 27 Chapter 4 Important safety information Overview of notes / decals on the K°Bloc (Cont.) Notes / decals Meaning Transport safeguard: An eye marked with this decal can be used as trans- port safeguard for securing the loaded K°Bloc unit against slipping. Use this lug for fastening during transport only K°Bloc –...

  • Page 28: Setting Up And Connecting The K°Bloc

    5 SETTING UP AND CONNECTING THE K°BLOC This chapter gives you information on how to set up and connect the K°Bloc: • Inspecting the equipment upon delivery (page 28) • Space requirement at the place of installation (page 29) • Removing and disposing of transport packaging (page 30) •...

  • Page 29: Transport Particularities

    INSTALLATION Ensure sufficient free space around the K°Bloc. The required free space of at least 1 m on all sides is a guideline value and recommended by Kelvion. This free space enables sufficient access to the K°Bloc and makes mainte- nance work easier.

  • Page 30: Removing And Disposing Of Transport Packaging

    If necessary, dismount inlet/outlet lines to provide enough space for manoeuvring at the place of installation. 5.3 REMOVING AND DISPOSING OF TRANSPORT PACKAGING Transport the packaged K°Bloc in its transport packaging as long as possible. This is to prevent damage to the K°Bloc on its way to the place of installation.

  • Page 31: Transporting The K°Bloc To The Place Of Installation And Setting It Up

    Chapter 5 Setting up and connecting the K°Bloc 5.4 TRANSPORTING THE K°BLOC TO THE PLACE OF INSTALLATION AND SETTING IT This chapter gives you information on how to transport the K°Bloc to its place of installation: • Transporting and setting up a K°Bloc delivered in upright position (page 31) •...
  • Page 32 Fastening a vertical-type K°Bloc delivered in upright position properly WARNING Danger of injury by heavy weight of K°Bloc! The K°Bloc may slip off and fall down during transport when incorrectly fastened. You may suffer serious injuries and bruises in such an accident. ...
  • Page 33 Chapter 5 Setting up and connecting the K°Bloc Guide a suitable round sling through each of the installed shackles. Hang the round slings into the hook of the lifting equipment. The vertical-type K°Bloc delivered in upright position has now been properly fastened to the lifting equipment.
  • Page 34 Transporting a vertical-type K°Bloc delivered in upright position to the place of instal- lation Carry out the following steps: Carefully lift the K°Bloc. Make sure that you lift the K°Bloc only as high as necessary. Transport the K°Bloc carefully to its intended place of installation. Make sure that you lift the K°Bloc only as high as necessary.
  • Page 35 Chapter 5 Setting up and connecting the K°Bloc Setting up a vertical-type K°Bloc delivered in upright position at the place of installa- tion Carry out the following steps: Remove the transport packaging, see section „5.3 Removing and disposing of transport packaging“ (page 30). Carefully lift the K°Bloc.

  • Page 36: Transporting And Setting Up A K°Bloc Delivered In Horizontal Position

    Remove the shackles and round slings from the lifting eyes. The vertical-type K°Bloc delivered in upright position has now been set up at its place of installation.  Done. 5.4.2 TRANSPORTING AND SETTING UP A K°BLOC DELIVERED IN HORIZONTAL POSITION All horizontal-type K°Bloc are transported in horizontal position.
  • Page 37 Chapter 5 Setting up and connecting the K°Bloc 5.4.2.1 HORIZONTAL-TYPE K°BLOC | STANDARD K°BLOC The horizontal-type K°Bloc can be fastened and transported either with a cross-beam or with round slings and shackles. The section below describes how to properly fasten and transport the unit using round slings and shackles.
  • Page 38 Fit one shackle each to the lifting eyes above the support angles of the horizontal-type K°Bloc | standard K°Bloc. Guide one suitable round sling each through one of the two installed shackles. K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...
  • Page 39 Chapter 5 Setting up and connecting the K°Bloc Hang the two round slings into the hook of the lifting equipment. The horizontal-type K°Bloc delivered in horizontal position | standard K°Bloc has now been properly fastened to the lifting equipment. Transporting a horizontal-type K°Bloc delivered in horizontal position | standard K°Bloc to the place of installation Carry out the following steps: Carefully lift the K°Bloc.
  • Page 40 Setting up a horizontal-type K°Bloc delivered in horizontal position | standard K°Bloc at the place of installation Carry out the following steps: Remove the transport packaging, see section „5.3 Removing and disposing of transport packaging“ (page 30). Carefully lift the K°Bloc. Make sure that you lift the K°Bloc only as high as necessary.
  • Page 41 Chapter 5 Setting up and connecting the K°Bloc 5.4.2.2 HORIZONTAL-TYPE K°BLOC | SPECIAL-DESIGN K°BLOC The horizontal-type K°Bloc can be fastened and transported either with a cross-beam or with round slings and shackles. The section below describes how to properly fasten and transport the unit using round slings and shackles.
  • Page 42 Fit two shackles each to the support angles of the horizontal-type K°Bloc | special-design K°Bloc. Guide one suitable round sling each through one of the four installed shackles. K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...
  • Page 43 Chapter 5 Setting up and connecting the K°Bloc Hang the two round slings on each side into the respective hook of the lifting equipment. The horizontal-type K°Bloc delivered in horizontal position | special-design K°Bloc has now been properly fastened to the lifting equipment. Transporting a horizontal-type K°Bloc delivered in horizontal position | special-design K°Bloc to the place of installation Carry out the following steps:...
  • Page 44 Setting up a horizontal-type K°Bloc delivered in horizontal position | special-design K°Bloc at the place of installation Carry out the following steps: Remove the transport packaging, see section „5.3 Removing and disposing of transport packaging“ (page 30). Carefully lift the K°Bloc. Make sure that you lift the K°Bloc only as high as necessary.
  • Page 45 Chapter 5 Setting up and connecting the K°Bloc 5.4.2.3 VERTICAL-TYPE K°BLOC - DELIVERED IN HORIZONTAL POSITION The vertical-type K°Bloc can be either transported with a fork lift truck when fastened to the transport pallet or fastened and transported with round slings and shackles.
  • Page 46 Carry out the following steps: Ensure that the transportation lifting lug on the K°Bloc is in a vertical position. Fit the following: one shackle at the transport lifting eye for the vertical K°Bloc of the  "single eye" version; one shackle at the upper transport lifting eye for the vertical K°Bloc of ...
  • Page 47 Chapter 5 Setting up and connecting the K°Bloc Guide a suitable round sling through each of the installed shackles. Hang the round slings on each side into the respective hook of the lifting equipment. The vertical-type K°Bloc delivered in horizontal position has now been properly fastened to the lifting equipment.
  • Page 48 Straightening up a vertical-type K°Bloc delivered in horizontal position at the place of installation Carry out the following steps: Carefully lift the K°Bloc on both sides. Make sure that you lift the K°Bloc only as high as necessary. Move the K°Bloc to a vertical position by suitably lifting (at the Transport lifting eye) and lowering (at the foot) the lifting equipment.
  • Page 49 Chapter 5 Setting up and connecting the K°Bloc Lower the lifting equipment at the foot so that you can remove the two shackles from the foot. Remove the corresponding shackles and round slings. Put down the K°Bloc carefully with the lifting equipment fastened to the lifting eye.
  • Page 50 Anchor the K°Bloc to the foundation, using suitably dimensioned bolts and nuts. Remove the shackle and round sling from the lifting eye. The vertical-type K°Bloc delivered in horizontal position has now been set up at its place of installation.  Done.

  • Page 51: Connecting The K°Bloc

    Chapter 5 Setting up and connecting the K°Bloc 5.5 CONNECTING THE K°BLOC This chapter gives you information on how to connect the K°Bloc: • Optional safety accessories (page 51) • Installing piping (page 52) 5.5.1 OPTIONAL SAFETY ACCESSORIES If you wish to use the K°Bloc with hazardous flow media (e.g. explosive, flammable, caustic, toxic, under high pressure, very hot or very cold), ensure that the safety accessories below are provided or fitted: Required safety accesso-...

  • Page 52: Installing Piping

    Legend Description Symbol Surface temperature below 0 °C Surface temperature above +50 °C 5.5.2 INSTALLING PIPING Requirement:  All inlet and outlet lines to/from the K°Bloc are closed and secured against unintended opening. Tools required:  Standard tool set K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...
  • Page 53 Chapter 5 Setting up and connecting the K°Bloc WARNING Danger of injury due to hazardous flow media! When using hazardous flow media (explosive, flammable, corrosive, toxic, high pressure, very hot or very cold) in the K°Bloc, you may suffer serious injuries.
  • Page 54 IMPORTANT NOTE Damage to piping connections and to K°Bloc due to exces- sive forces and torques! When excessive forces and torques are transmitted on the K°Bloc connec- tions through the piping, the piping connections and/or the K°Bloc may be damaged. ...

  • Page 55: Commissioning And Decommissioning, Operation

    Chapter 6 Commissioning and decommissioning, operation 6 COMMISSIONING AND DECOMMISSIONING, OPERATION This chapter gives you information on how to put the K°Bloc into and out of operation and how to operate it: • Commissioning (page 55) • Operation (page 60) •...

  • Page 56: Pre-Conditions

    6.1.1 PRE-CONDITIONS Before commissioning the K°Bloc, you must ensure that you are able to answer the questions below with "Yes": • Have all necessary safety equipment items been installed and do they work flawlessly? (See chapter „Setting up and connecting the K°Bloc“ > „Optional safety accessories“...
  • Page 57 Chapter 6 Commissioning and decommissioning, operation WARNING Danger of injury due to hazardous flow media! When using hazardous flow media (explosive, flammable, corrosive, toxic, high pressure, very hot or very cold) in the K°Bloc, you may suffer serious injuries.  Check the safety accessories fitted on the K°Bloc, see chapter „5.5.1 Optional safety accessories“...
  • Page 58 IMPORTANT NOTE Damage to the K°Bloc due to sudden temperature changes and temperature differences! Sudden temperature changes and major temperature differences of the flow media may damage the inside of the K°Bloc.  Bring the K°Bloc to the operating temperatures of the two circuits by means of the flow media at low pressure.
  • Page 59 Chapter 6 Commissioning and decommissioning, operation Carry out the following steps: Check on the K°Bloc if all safety accessories required for the flow medium used are fitted, see chapter „5.5.1 Optional safety accessories“ (page 51). Check if all nuts have been tightened to the torques or tightening dimen- sions specified in the technical documentation and correct if necessary.

  • Page 60: Operation

    6.2 OPERATION Safety instructions: Functional failure of gaskets! Operation at unpermitted pressure and temperature levels and with unper- mitted media may cause direct functional failure of the gaskets. Hazardous media may escape under high pressure and high or low temperatures and injure persons.

  • Page 61: Decommissioning

    Chapter 6 Commissioning and decommissioning, operation 6.3 DECOMMISSIONING Before putting the K°Bloc out of operation, read the chapter „Important safety information“ > „Important safety information“ (page 18). 6.3.1 SHORT-TERM PUTTING OUT OF OPERATION WARNING Danger of injury due to hazardous flow media! If hazardous media (explosion-hazardous, flammable, caustic, toxic, high pressure, very hot or very cold) flow through the K°Bloc, you may get seri- ously injured.
  • Page 62 IMPORTANT NOTE Damage to the K°Bloc due to sudden temperature changes and temperature differences! Sudden temperature changes and major temperature differences of the flow media may damage the inside of the K°Bloc.  Bring the K°Bloc to the operating temperatures of the two circuits by means of the flow media at low pressure.

  • Page 63: Decommissioning - Maintenance

    Chapter 6 Commissioning and decommissioning, operation Carry out the following steps:  Stop the media feed into the K°Bloc slowly and evenly. Ensure that no media can escape during the standstill phase of the K°Bloc.  Done. 6.3.2 DECOMMISSIONING - MAINTENANCE Carry out the following steps: Put the unit out of operation by the short-term procedure, see chapter „6.3.1 Short-term putting out of operation“...

  • Page 64: Long-Term Putting Out Of Operation

    6.3.3 LONG-TERM PUTTING OUT OF OPERATION IMPORTANT NOTE Damage on the K°Bloc due to corrosion of heat exchanger plates! Flow media remaining inside the K°Bloc during extended standstill periods may cause corrosion of the heat exchanger plates.  Drain the flow media completely! ...

  • Page 65: Storage

    In case of parts contaminated with dangerous substances, observe the particular local and legal regulations. Upon request, Kelvion will take care of disposing of your K°Bloc. The K°Bloc will be dismounted, transported away and disposed of properly by our employees against payment of the expenses incurred. If part of the K°Bloc are contaminated, Kelvion cannot take care of disposal.

  • Page 66: Maintenance

    7 MAINTENANCE This chapter gives you information on how to maintain the K°Bloc: • Opening the K°Bloc (page 67) • Replacing the gaskets (page 76) • Removing the baffle plate bracket (page 77) • Closing the K°Bloc (page 78) • Leakage test (page 93) •...

  • Page 67: Opening The K°Bloc

    Chapter 7 Maintenance 7.1 OPENING THE K°BLOC 7.1.1 PREPARATIONS Carry out the following steps: Put the K°Bloc out of operation, see chapter „Commissioning and decommissioning, operation“ > „Decommissioning - maintenance“ (page 63). Clean the threaded bolt threads. Apply a little grease to the visible threads of the threaded bolts. ...
  • Page 68 Mark the panel to be dismounted. This ensures that the panels are fitted at their initial positions during as- sembly at a later date.  Done. K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...

  • Page 69: Dismounting The Panel

    Chapter 7 Maintenance 7.1.2 DISMOUNTING THE PANEL Single or several panels can be dismounted for maintenance and cleaning work. Only two opposite panels may be dismounted at the same time. This section describes the dismounting procedure of a single panel. Removal of the second opposite panel is in the same way.
  • Page 70 WARNING Danger of injury from the movable loose plates! You may suffer serious injuries when shifting or moving the panels.  Secure the K°Bloc panels against tipping over unexpectedly. IMPORTANT NOTE Faulty function of K°Bloc due to damaged nuts, washers and threaded bolts! During maintenance work, many nuts and washers need to be dismounted.
  • Page 71 Chapter 7 Maintenance IMPORTANT NOTE Damage of K°Bloc by slackening off/removing the corner bolts! Simultaneous removal of one or more corner bolts may cause malfunctions or damage to the K°Bloc.  Never remove or slacken off the corner bolts. Carry out the following steps: Slacken off the marked nuts at the adjoining panels so that no play will result.
  • Page 72 Slacken off the marked nuts at the panel to be dismounted so that no play will result. Slacken off the nuts alternatingly, moving from the outside towards the centre. Slacken off the marked nuts so that play results, but do not remove the nuts.
  • Page 73 Chapter 7 Maintenance Slacken off and remove the marked nuts along with the associated washers and store them carefully. Slacken off and turn the marked nuts up to the end of the respective threaded bolt. Secure the panel so it will not fall down. Attach sufficiently dimensioned and undamaged lifting slings to the lif- ting points / screw-in lifting eyes.
  • Page 74 Move the panel away carefully. Removing the panel is easier on larger K°Bloc units because of the threaded holes provided for push-off bolts. Slacken off and remove the marked nuts along with the associated washers. K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...
  • Page 75 Chapter 7 Maintenance Remove the panel attached to the lifting sling carefully. When removing, ensure that the threaded bolts are not damaged. Put down the panel so that the connections are not exposed to a load.  The remaining nuts were slackened off and the panel was removed and put down as well.

  • Page 76: Replacing The Gaskets

    Deviating from the "K°Bloc gasket replacement" technical maintenance manual, from the gasket material and its original dimensions may cause leaks and/or irreversible damage to the K°Bloc.  When replacing gaskets, use only original gaskets by Kelvion. Carry out the following steps: ...

  • Page 77: Removing The Baffle Plate Bracket

    Chapter 7 Maintenance 7.3 REMOVING THE BAFFLE PLATE BRACKET Safety instructions: Danger of damage to the plate pack and/or the baffle plate bracket with baffle plates! Mechanical forces resulting from removing the baffle plate bracket may damage the plate pack, the baffle plate bracket and/or the baffle plates. •...

  • Page 78: Closing The K°Bloc

    Observe the following note on removing the baffle plate bracket: • Bear in mind that the plate pack and the baffle plate bracket are sensitive to the action of lever forces. • Document the installation position and alignment clearly before removing a baffle plate bracket so you can refit it properly afterwards.

  • Page 79: Installing A Single Panel

    Chapter 7 Maintenance 7.4.1 INSTALLING A SINGLE PANEL WARNING Danger of injury from removable panels! You may suffer serious injuries when shifting or moving the panels.  Secure the K°Bloc panels against tipping over unexpectedly. IMPORTANT NOTE Damage and malfunction of K°Bloc by incorrect installation of baffle plate bracket! When the baffle plate bracket is incorrectly installed, the K°Bloc may be damaged when installing the panels or during operation.
  • Page 80 Approach the panel carefully to the K°Bloc over the threaded bolts. Ensure that the threads of threaded bolts and the gasket will not be da- maged when positioning the panel. Ensure that all end plate collars and columns engage in the panel reces- ses and that the gasket has not slipped.
  • Page 81 Chapter 7 Maintenance Tighten all nuts to suit the respective gasket type. Tighten to the specified torque, see „7.4.2.1 Tightening the panel – to  the specified torque on panels with corner bolt hole“ (page 82). Tighten to the specified torque, see „7.4.2.2 Tightening the panel – to ...

  • Page 82: Tightening The Panel

    7.4.2 TIGHTENING THE PANEL Depending on the gasket used, the panels are either tightened to the speci- fied torque or to a gap dimension. Please consult the technical documenta- tion or the name plate to learn in which way the panels of this K°Bloc must be tightened.
  • Page 83 Chapter 7 Maintenance Tighten the nuts framed in figures Figure 7.4.2.1.b and Figure 7.4.2.1.c on the two adjoining panels "II" and "III" to 20 % of the maximum torque. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "II"...
  • Page 84 Tighten all nuts of panel "I" (see Figure 7.4.2.1.a) crosswise to 40 % of the maximum torque (here: 1 to 20). The coloured corner bolts of panel "I“ (here: 21 and 22) may be tighte- ned only to 25 % of the allowed torque . Tighten the nuts framed in figures Figure 7.4.2.1.b and Figure 7.4.2.1.c on the two adjoining panels "II"...
  • Page 85 Chapter 7 Maintenance When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "III" towards the outside. The corner bolts marked in Figure 7.4.2.1.b red may be tightened only to 25 % of the permitted torque. Tighten all nuts of panel "I"...
  • Page 86 7.4.2.2 TIGHTENING THE PANEL – TO THE SPECIFIED TORQUE ON PANELS WITHOUT CORNER BOLT HOLE Requirement:  You must know the permitted tightening torques. You can find these in the technical documentation or on the name plate of the K°Bloc. Carry out the following steps: Tighten all nuts of panel "I"...
  • Page 87 Chapter 7 Maintenance Tighten the nuts framed in figures Figure 7.4.2.2.b and Figure 7.4.2.2.c on the two adjoining panels "II" and "III" to 20 % of the maximum torque. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "II"...
  • Page 88 Tighten the nuts framed in figures Figure 7.4.2.2.b and Figure 7.4.2.2.c on the two adjoining panels "II" and "III" to 40 % of the maximum torque. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "II" towards the outside. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "III"...
  • Page 89 Chapter 7 Maintenance Tighten the nuts framed in figures Figure 7.4.2.2.b and Figure 7.4.2.2.c on the two adjoining panels "II" and "III" to 100 % of the maximum torque. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "II"...
  • Page 90 7.4.2.3 TIGHTENING THE PANEL - TO A GAP DIMENSION The gap is measured between the panels and the columns and end bottom/top heads. Requirement:  Take the permitted gap size from the technical documentation or the name plate. Carry out the following steps: Tighten all nuts of panel "I"...
  • Page 91 Chapter 7 Maintenance Tighten the nuts framed in Figure 7.4.2.3.b and Figure 7.4.2.3.c on the two adjoining panels "II" and "III" to a gap size of 5 mm. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "II"...
  • Page 92 Tighten the nuts framed in Figure 7.4.2.3.b and Figure 7.4.2.3.c on the two adjoining panels "II" and "III" to a gap size of 4 mm. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "II" towards the outside. When tightening, proceed alternately from the centre of the line of bolts framed in red of the adjoining panel "III"...

  • Page 93: Leakage Test

    Chapter 7 Maintenance 7.5 LEAKAGE TEST After having opened the K°Bloc, a leakage test must be carried out. Here the tightness test pressure is equal to the max. permitted pressure specified on the rating plate and must be applied to the K°Bloc on both sides evenly at the same time.

  • Page 94: Outside Cleaning

    Carry out the following steps:  Carry out the leakage test at the maximum permitted pressure specified on the name plate. Does the pressure drop? The pressure on the K°Bloc side to be tested may drop due to compres- sion of the gas inside the unit or due to a slight maladjustment of the plates.

  • Page 95: Cip Cleaning

    Chapter 7 Maintenance 7.7 CIP CLEANING Safety instructions: Aggressive cleaning media! The use of aggressive cleaning media involves a poisoning hazard and danger of chemical burns. The chemical cleaning process may attack the plate pack and gasket mate- rials and cause leaks. In addition, aggressive cleaning media may escape into the environment and cause environmental damage.

  • Page 96: Cleaning By Reverse Flushing

    The CIP cleaning process ("Cleaning in Place") removes soiling by the solving capacity of the cleaning medium and by the mechanical effect of turbulent flow. 7.8 CLEANING BY REVERSE FLUSHING Reverse flushing is employed when the flow media contain coarse dirt particles plugging the manifold spaces.
  • Page 97 Chapter 7 Maintenance WARNING Danger of injury due to aggressive cleaning media! When using aggressive cleaning media, you may suffer from intoxication, chemical burns and burns.  Wear your personal protective equipment.  Make yourself familiar with the handling of aggressive cleaning agents. ...

  • Page 98: Cleaning Plates With "Double Dimple" Pattern

    7.9.2 CLEANING PLATES WITH "DOUBLE DIMPLE" PATTERN Requirement:  The K°Bloc was opened, see chapter „7.1 Opening the K°Bloc“ (page 67). IMPORTANT NOTE Danger of material damage on the K°Bloc from hard cleaning tools! Hard cleaning tools (e.g. metal brushes) damage the metal surfaces. This may cause corrosion.

  • Page 99: Troubleshooting

    Chapter 8 Troubleshooting 8 TROUBLESHOOTING Safety instructions: Before rectifying faults You should contact your Kelvion Sales Office before removing faults in order to avoid improper work on the K°Bloc and its consequences. 8.1 INSUFFICIENT PERFORMANCE Fault Cause Remedy Reduced heat transfer Deposits on the plate Open the K°Bloc and clean...

  • Page 100: Leaks

    8.2 LEAKS Fault Cause Remedy Leaks visible from the Incorrect tensioning of Check the correct tensioning outside threaded bolts values against the data in the technical documentation and the tensioning procedure and correct if necessary. Excessive operating pres- Check operating pressure sure levels according to rating plate data.
  • Page 101 Chapter 8 Troubleshooting Fault Cause Remedy Leaks visible from the Excessive load from pipe- Reduce connecting loads to outside work permitted values. Check if metal components are damaged and contact your Sales Office if required. Defective metal compo- If a defective gasket can be nents excluded, contact your Sales Office.

  • Page 102: Technical Terms

    9 TECHNICAL TERMS Term Meaning Chevron plates The plates of the plate pack have a diagonal pattern. Gasket Seal between panel and sealing faces of the K°Bloc heart Double Dimple The plates of the plate pack have round embossings in both plates directions of the plate surface.
  • Page 103 Chapter 9 K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016...
  • Page 104 www.kelvion.com...

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