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Summary of Contents for Vahterus Plate & Shell Fully
- Page 1 OPERATION & MAINTENANCE MANUAL for Vahterus Plate & Shell Heat Exchangers ENGLISH...
- Page 2 All rights reserved. It is not permitted to copy, photograph or publish in any other way this manual for any purpose without the permission of Vahterus Oy. Plate & Shell is registered trademarks of Vahterus Oy. C303-3-rev.6 /16.4.2018...
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Page 3: Table Of Contents
GENERAL ...................... 5 INTRODUCTION ....................5 PRODUCTS ...................... 5 STRUCTURE ..................... 6 TECHNICAL CHARASTERISTICS ..............6 ASSEMBLY OF THE HEAT EXCHANGER .............. 7 LIFTING ......................7 PIPES ........................ 8 2.2.1 GENERAL ..................... 8 2.2.2 STEAM APPLICATIONS (CONDENSER) ..........9 INSULATION ....................10 PRESSURE TEST ................... - Page 4 OPENABLE MODEL ..................23 5.3.1 PREPARATIONS ................. 23 5.3.2 OPENING THE EXCHANGER AND REMOVING THE PLATE PACK . 24 5.3.3 MOUNTING THE PLATE PACK ............25 5.3.4 BOLT/ NUT TIGHTENING PATTERN ..........25 EXPANDABLE PLATE PACK ..............26 SPARE PARTS / SPECIAL TOOLS ............. 26 PACKING AND STORAGE ................
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Page 5: General
This manual is your general guide to the proper installation, operation and maintenance of the Vahterus Plate and Shell Heat Exchanger and PSHE droplet separator. Please read it and fol- low the instructions given. PSHE is a totally welded plate heat exchanger without any gaskets between the plates. -
Page 6: Structure
Vahterus Plate and Shell Heat Exchangers are designed and manufactured in compliance with legislation relating to pressure equipment. The design code used is given on the Vahterus Technical Data sheet. The codes generally used are: • ASME VIII Div.1, based on an individual design for each heat exchanger. -
Page 7: Assembly Of The Heat Exchanger
Pressure: • 10 / 16 / 25 / 40 / 60 bar(g) standard range • up to 170 bar(g) on request Materials: • Carbon Steel (P235GH, P265GH, P355NL2, SA516Gr70, SA333 etc.) • AISI 316/316L, 1.4404 / 304L, 1.4403 • Titanium Gr. 1 •... -
Page 8: Pipes
If necessary the combination can have permanent extra support by the lifting lugs in the sur- rounding support structures. Do not use the mounting brackets or nozzles to lift the heat exchanger. Vahterus will assist in planning of the liftings if needed, and separate lifting instructions are available at Vahterus. Please contact Vahterus Service. WARNING Do not weld anything to the heat exchanger (including the shell, end plates and the sides of the pipes) without the manufacturer’s permission, since this could harm the durability of... -
Page 9: Steam Applications (Condenser)
If there are solids in the process fluids, the use of filters is recommended. Further informa- tion is available from Vahterus Service. The piping must be equipped with a relief valve to prevent unintentional excess of design pressure. -
Page 10: Insulation
Never apply pressure to the plate pack outside the shell. MOUNTING BRACKETS Vahterus standard brackets are only designed to bear the weight of the heat exchanger. The design does not allow for specific requirements, such as stress and strain caused by the piping, wind load or earthquakes. -
Page 11: Fluids
FLUIDS The structural materials are selected based on the information (media, temperatures, flows) provided by the customer. You can also contact Vahterus for material and flow director material options. If the heat exchanger is used in conditions that differ from what it has been designed for (tech- nical data sheet), its ability to function needs to be checked. -
Page 12: Flow Rates
General recommendation for water quality when AISI 316L plate material is used in +20 °C. Recommended quality limits for water for Variable Unit AISI 316L Hydrogen ion concentration Alkalinity (as CaO3) mg/l < 300 < 500 mg/l at 25°C < 200 mg/l at 50°C Chloride mg/l <... -
Page 13: Liquid - Liquid
Structure of the Vahterus Plate and Shell® heat exchanger: The plate and shell® heat exchanger consists of circular plates welded into a pack, which is then mounted in a pressure vessel. The flow on the plate side is through the connections on the end plates via the plate pack. -
Page 14: Condenser
4.1.2 CONDENSER HOT IN COLD OUT COLD IN HOT OUT In condensing applications, the steam is on the shell side, with the cold side on the plate side. Shell side (steam) flow enters the exchanger at the top of the shell and the condensate exits at the bottom. -
Page 15: Flooded Evaporator
4.1.4 FLOODED EVAPORATOR COLD OUT HOT OUT HOT IN COLD IN 1-pass eccentric Evaporation generally takes placed on the shell side. With special applications, however, it can take place on the pack side. 4.1.5 DROPLET SEPARATOR The heat exchanger system is the same as in 4.1.4, with the addition of a droplet separator and recirculation pipe. -
Page 16: Steam Generator (Kettle)
4.1.6 STEAM GENERATOR (KETTLE) Plate pack positioned in large shell. Steam generator application. 4.1.7 EXHAUST GAS ECONOMICER (EGE) COLD OUT HOT IN HOT OUT COLD IN For cooling or heating gases. GENERAL START-UP Following instructions are general and process specific demands have to take in count by the user. Check the following before start-up: •... -
Page 17: General Shut Down
General heating rate is max. 5°C/minute. The pressure may be increased to operating gradually. See also section 3.2. Check system for pressure pulses caused by pumps or controls valves. Continuous pulsing and vibration may cause fatigue in the plates. To start the heat exchanger process, follow steps a–f, starting first on the cold side. Then repeat for the hot side. - Page 18 After that, the heating rate can be according to the position 3. ATTENTION! • It is not possible to measure the condensate level over the Vahterus PSHE unit • In condensate controlled units, the capacity control is made by controlling the conden-...
- Page 19 ture cannot be used to control the condensate level inside the unit. Fig. 1. When the rate of temperature increase is higher than 5°C/minute, the time between the incremental steps has to be taken into account. Fig. 2. When the rate of temperature increase is lower than 5°C/minute, the temperature can be increased immediately after it has reached the adjusted temperature.
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Page 20: Recommended Periodical Inspections Of Pshe Heat Exchangers
shocks. Open inlet valve of the primary side allowing liquid to enter the generator. After that, open the outlet valve (start-up valve if any). If the unit is cold. The correct heating speed is 100°C/hour for the first 100°C. After that the heating rate can be doubled. -
Page 21: Recommendations For Cleaning
RECOMMENDATIONS FOR CLEANING X = cleaning with chemicals Y = cleaning with backwards flow A = Vaherus heat exchanger 1 – 2 = heat or cold users or suppliers 1.1 – 1.4 = system shut off valves 3 = circulating tank 2.1 –... -
Page 22: Chemical Cleaning
• Check that organic compounds and dirt are removed. • Stop the water flow, close valve 2.1. • Fill the heat exchanger with system liquid in accordance with the mentioned start-up pro- cedure, close valve 2.2. If it is impossible or insufficient to clean the surface in this way a specific detergent should be used. 5.2.2 CHEMICAL CLEANING A chemical cleaning company experienced in cleaning of plate heat exchangers is recommended to use with chemical cleaning. -
Page 23: Mechanical Cleaning
5.2.3 MECHANICAL CLEANING Openable and EGE models is possible to clean mechanically by high pressure water jet with cold or hot water. Contact Vahterus for further information. WARNING The high pressure water jet may compress the dirt and impurities into the plate gaps and block the flow passages. -
Page 24: Opening The Exchanger And Removing The Plate Pack
5.3.2 OPENING THE EXCHANGER AND REMOVING THE PLATE PACK Option 1 (recommended) Move the unit to a more specious area and turn it so that the end plate connections are facing upwards (plate pack vertical). Remove some of the bolts from the cover plate and install guide bars (4-6) in the bolt holes before removing the remainder of the bolts. -
Page 25: Mounting The Plate Pack
Support Guide bar Pull Wood blocks Fig. 5. 5.3.3 MOUNTING THE PLATE PACK Before reinstalling the plate pack, the flow directors must be checked and corrected if necessary. If the flow director rubbers are damaged and need replacing, contact the manufacturer. Change the gasket between the cover plate and flange;... -
Page 26: Expandable Plate Pack
The tightening toque on lubricated bolts is stated in the GA drawing supplied with the exchanger. EXPANDABLE PLATE PACK An openable pack model may be expandable to facilitate the cleaning of the pack, for which separate instructions are available. Contact Vahterus for further information. SPARE PARTS / SPECIAL TOOLS Openable heat exchanger •... - Page 27 Fig. 6. Standard packing The wood is free from quarantine pests and practically free from other injurious pests. The wood is ISPM15 compliant and supplied with the following saw-mill stamp. Fig. 7. IPPC-stamp for wooden boxes. The packing materials are recyclable into energy or other purposes.
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Page 28: Troubleshooting
TROUBLESHOOTING If the heat exchanger is not working properly after start-up, check the following: PROBLEM CAUSE CHECKS ACTION Poor Exchanger/ Check flow Change performance connections directions of the piping connected connections. connections. wrongly. Do they comply Change with the design/ direction of drawing? flow. - Page 29 If the shell model). side is clean, fouling of the plate side is responsible for the retardation of heat transfer. If, after checking, the heat transfer capacity and or pressure loss are at an unacceptable level, contact your Vahterus representative.
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Page 30: Complaints Report
COMPLAINTS REPORT If you need to complain about a Vahterus product, ask for a notification of defect report at sales@vahterus.com Please include as many details as possible, and especially the following: • General information (serial number) • Design and operation •... -
Page 31: Recycling
• Corrosion cracking of the metal in the zone of welds, as well as in the field of corrosion pits. • Damage to the gaskets of flange connections or weakening of bolting. 10 RECYCLING The metals from the heat exchangers are recyclable, for example to make steel. The rubber from flow directors are not recyclable and they are to be disposed of according to local waste disposal regulations. - Page 32 CE and SAFETY Before a Vahterus heat exchanger may be put into operation the contractor or customer must be sure that: • Sufficient safety valves are installed and adequate safety measurements are taken into account. • A plate stack or plate insert of an openable unit never may pressurised outside the shell.
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