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Related Manuals for Alfa Laval COMPABLOC CP15
Summary of Contents for Alfa Laval COMPABLOC CP15
- Page 1 COMPABLOC Installation, Operation and Maintenance Manual IMCP0002 Rev. J / ENGLISH...
- Page 2 Visit our website at www.alfalaval.com Original Instructions: Alf a Laval reserves the right to change specif ications without prior notif ication. This publication or any part thereof may not be reproduced or transmitted by any process or means without the prior written permission of Alf a Laval.
- Page 3 CPF15, CPF20 and CPF30 IMPORTANT: All other specific information on the general arrangement drawing or other specific documents provided by Alfa Laval with the equipment takes precedence over information in this document. If there is a QR Code on the nameplate of the Compabloc, scan it to access this Instruction Manual and to Troubleshooting assistant.
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Page 4: Table Of Contents
TABLE OF CONTENTS 1 - Description ............................3 1.1 - General description ..........................3 1.2 - Function & duty ..........................4 1.3 - PED/Risk Analysis ..........................4 2 - Installation ............................. 5 2.1 - General requirements & precautions ....................5 2.2 –... -
Page 5: Description
Description 1.1 - General description Compabloc is a welded plate heat exchanger without interplate gaskets allowing a large heat transf er area within a very compact space (low f ootprint). It is made f rom stacks of welded plate packs inserted in a rigid rectangular bolted f rame f or mechanical strength and the separation of the various circuits. -
Page 6: Function & Duty
1.2 - Function & duty The Compabloc is a heat exchanger used f or heating or cooling (with or without heat recovery), steam heater, condenser, 2-pass process condenser, ref lux condenser, reboiler, gas cooler, etc ... Each of those duties requires a specif ic installation and the installation m ust be in conf ormity with the thermal data sheet and the general assembly drawing of the unit. -
Page 7: Installation
Installation 2.1 - General requirements & precautions • To allow maintenance and inspection, we recommend leav ing a 50 to 120 cm (19 to 48") wide space all around the Compabloc unit to f acilitate panel dismantling. At the top of the exchanger, it is necessary to have a 100cm (40”) f ree space to allow the possible setting of a panel-lif ting device. - Page 8 • By-pass The connecting pipework should be provided with valves in order to isolate the unit and with by-pass valve for start-up and shutdown on each side. The isolation valves f or the process circuits should be positioned in such a way as to enable the panels to be dismantled without having to remove the valves.
- Page 9 • Case of condensers For unit operating in the mode of condenser, it is recommended that the valve at the drain nozzle be open as much as possible in order to prevent condensate accumulation. • Filters If the service conditions require it, or if the f luid is loaded with particles, install a f ilter with maximum mesh of 3 mm (1/8") f or all Compablocs, except the CP15 which shall have a maximum f ilter mesh of 2 mm (1/12"), upstream of the exchanger.
- Page 10 2.3 - Control system • Control system for liquid/liquid applications A classical system where the outlet process temperature drives the control valve at the service inlet is good as long it is an automatic control such as a PI or PID system and the control valve is correctly sized. An oversized control valve creates the risk of ON/OFF operation which is not good , thereby causing f atigue and stress.
- Page 11 • Control system on Process condensers To avoid a sudden vacuum inside the echanger, due f or example to an emergency shut down, it is strongly recommended to install a vacuum breaker valve (saf ety valve) on the vapour inlet line near the Compabloc inlet. •...
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Page 12: Lifting
2.4 – Lifting The handling of heat exchangers Compabloc should be done by using certif ied straps, slings and shackles, and also by appropriate lif ting means (jib or bridge crane). The nozzles must never be used for handling purposes. Do not use the welded or screwed lifting lugs located on the panels for lifting of the complete unit, these are for lifting individual panels only! It is very important to check that the capacity of the lifting means correspond to the... -
Page 13: Storage
Remark: For saf ety reasons during transportation, many big units are delivered in horizontal position. If needed, handling & tilting procedures are available: f or CP50 & CP75, please ref er to procedure CLIB1001 f or CP120, please ref er to procedure CPPB1103 You can obtain these procedures by scanning the QR code available on the equipment or by scanning now the QR codes which are on this page. -
Page 14: Operation
Operation 3.1 - Before start-up (& before eventual insulation) • Check of panel bolt torques Bef ore start-up, make sure the unit is correctly installed and make a check of the tightening torques of the panel bolts as per the values in appendix 2. Values must be at least equal to nominal tightening f orces. -
Page 15: Unit In Operation
Start-up must be gradual and heat rate shall not exceed 60°C per hour to avoid thermal shocks or unnecessary stress on the unit. Pressure buildup rate must not exceed 1 bar/min. 3.3 - Unit in operation General technical equipment operating rules should be observed. During operation, the f ollowing shall be checked: •... - Page 16 • If the Compabloc is shut down f or several days, it must be drained. Draining must also be done if the process is shut down and the ambient temperature is below f reezing temperature of the media. Draining is a simple operation because the lower nozzles allow a self draining f or the CP15 to CP40, while f or CP50 to CP120 models, f langed drains have to be used.
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Page 17: Maintenance
Maintenance Please f ind below the preventive maintenance program recommended by Alf a Laval. It is strongly recommended to always keep as spare parts a set of gaskets and 10% of bolting f or preventive maintenance. Recommended № Type of operation Notes periodicity If a contamination of media is observed, it is necessary to carry... -
Page 18: Chemical Cleaning
4.1 - Chemical cleaning Chemical cleaning must be carried out by authorized and qualified personnel. Take all necessary protection & precautions for health, safety and environment regarding chemicals. Chemical cleaning is the most ef f icient way to clean the unit. In general, inorganic deposits are c leaned with acidic cleaning solutions and organic deposits with alkaline cleaning solutions. -
Page 19: Mechanical Cleaning
4.2 - Mechanical cleaning If chemicals cannot be used f or cleaning, the panels and possibly the baf f le cage can be removed to permit access to the heat transf er surf aces. Follow instruction as per chapter 4.3 f or opening your Compabloc . In most cases, it is not necessary to remove the baf f le cage f or cleaning the plate pack . - Page 20 Figure 6 4.3.2 - Dismantling procedure for the 4 panels Progressively loosen the nuts, one girder af ter the other. When all the nuts of the girders are rel axed, loosen the nuts of the bottom, one panel af ter the other. For models CP15/CP20/CP30/CP40, never unscrew the stud bolts used for the girder assembling to the top and bottom heads.
- Page 21 Depending on the Heat Exchanger duty, gasket material can be either Modif ied PTFE or Reinf orced Graphite. The large gaskets may be supplied in several pieces. Compabloc sealing can be assured only with gaskets supplied by Alfa Laval. Always put the old gaskets in an appropriate waste container.
- Page 22 4.3.3.2 - Panels re-assembly & pre-tightening Pre-tightening must be realized at around 50%-60% of nominal torque values given in Appendix2. • Re-place the panels on the threaded rods in accordance with general drawing. • If visible, check interlocking of panels on girders is OK bef ore going on (f igure 14) Figure 14 •...
- Page 23 • Pre-tighten all nuts of “circling around the top of the unit” with impact wrench (f igure 17 & 18). Figure 17 Figure 18 • Respect pre-tightening sense as on f igure 18. • Pre-tighten all nuts of “circling around the bottom” with impact wrench (f igure 19 & 20). Figure 20 Figure 19 •...
- Page 24 • Pre-tighten all nuts of girders with impact wrench f rom down to up or up to down (f igure 21). Figure 21 4.3.3.3 - Panel tightening Then f ind the recommended tightening torque in Appendix 2 “Nominal tightening f orces of threaded panels (Nm)”. We strongly recommend the use of a hydraulic torque wrench f or f inal tightening •...
- Page 25 A heat exchanger is leaking when a leak is observed between 2 circuits or when it leaks externally. If leakage occurs, retighten at nominal torque around the leak area. If leakage still occurs, please contact Alfa Laval Service Center or your Alfa Laval representative. IMCP0002 Rev.J...
- Page 26 4.3.5 Baffle dismantling and reassembly procedure It may be necessary to dismantle the baf f le cage f or inspecting the plate pack or f or tough mechanical cleaning , once the panel are removed. Prior to dismantling the baf f les, locate their position in the block, in order to reassemble them in the correct position. It may be dif f icult to put back the baf f le cage (baf f les + their support) as one piece, as the platepack may have bent a little af ter use.
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Page 27: Trouble Shooting
Poor performance for assistance during operation Changes in operating Check with Alfa Laval for the performance of the Contact Alfa Laval parameters Compabloc at new operating parameters. for assistance Internal leakage, cross Further inspection is required. Repair or replace... -
Page 28: Duty Summary For Compabloc
Duty summary for Compabloc Compabloc Vertical position duties : Liquid/liquid duty Condensation with subcooling Compabloc Horizontal position duties : Horizontal one pass condenser Horizontal two pass condenser Horizontal reboiler IMCP0002 Rev.J... -
Page 29: Waste Management And Scrapping
Waste management and scrapping Throughout the lif ecycle of the Compabloc, the owner is responsible f or managing the waste related to any equipment or material delivered by Alf a Laval (e.g. packing material of the delivered Compabloc, packaging of spare parts, used spare parts like gaskets, etc.) according to the applicable local regulations regarding the protection of the environment. -
Page 30: Appendix 1: Panel Weights (Kg (Lbs))
Appendix 1: Panel weights (kg (lbs)) The weight of each panel may be indicated on the GA drawing provided by Alf a Laval: IMCP0002 Rev.J... - Page 31 You can also use the f ollowing tables with the maximum estimated weight (kgs(lbs)) f or each panel depending on number of plates and thickness. Remark: Cell in grey = obsolete models (not available for Capital Sales anymore). CP15 MODEL NUMBER OF PLATES PANEL Thickness 30 mm (1”...
- Page 32 CP40 MODEL NUMBER OF PLATES PANEL Thickness 60 mm (2” 3/8”) 171 (377) 218 (481) 265 (584) 80 mm (3” 1/8”) 235 (518) 299 (659) 364 (802) 100 mm (4”) 297 (655) 380 (838) 462 (1019) CP50 MODEL NUMBER OF PLATES PANEL Thickness 60 mm (2”...
- Page 33 CP120 MODEL NUMBER OF PLATES PANEL Thickness 90 mm (3 ½”) 1429 1733 2098 2342 2646 2949 3252 (3150) (3821) (4625) (5163) (5833) (6501) (7169) 100 mm (4”) 1585 1924 2263 2601 2938 3275 3611 (3494) (4242) (4989) (5734) (6477) (7220) (7961) 110 mm (4 ½...
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Page 34: Appendix 2: Nominal Tightening Forces Of Threaded Panels (Nm)
For bolting f eatures (material,coating and or diameters) or gasket material not mentionned in this table, please contact your AL representative. If leakage occurs after tightening at the above nominal torques + 15%, please contact your Alfa Laval representative. IMCP0002 Rev.J... -
Page 35: Appendix 3: Compabloc Nameplate
Appendix 3: Compabloc nameplate A nameplate is f ixed to the f rame of the heat exchanger with the f ollowing data: - 1: manuf acturer - 2: type of Compabloc - 3: serial number - 4: year of built - 5: f luid group - 1 f or dangerous f luid and 2 f or non-dangerous f luid - This f ield is related to PED regulation and is f illed only f or units submitted to PED (=installed in Europe Union) - Page 36 IMCP0002 Rev.J...
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Page 37: Appendix 4: Compabloc Troubleshooting Questionnaire
Appendix 4: Compabloc Troubleshooting questionnaire If the Compabloc f ails, f ollowing documents are requested f or analysis/ expertise: ✓ Trouble shooting questionnaire / GEFA1090 ✓ Process Flow Diagram ✓ Design Datasheet (CAS print out) ✓ Pictures of the f ailures Thank you in advance f or sending these as soon as possible, in order f or us to have as many details as possible to handle the problem and help you out. - Page 38 4 – Process Description Pressure Temperature Cyclic Duty (if applicable) Steady Unsteady Operation Frequency cycles/week Amplitude bar/min or °C/min Start-up ramp bar/h °C/h Shut down ramp bar/h °C/h Manual Automatic Control system Vent/drain connected Upstream Downstream Pump/compressor location → Specif y type of pump and/or compressor Risk of f ull vacuum →...
- Page 39 From day 1, Alfa Laval is here with service to keep you growing. Please discover our unique Service program composed of both preventive and reactive services to keep your equipment performing and your business increasing ✓ Commissioning supervision ✓ Cleaning ✓...
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