SPX FLOW APV GPHE Installation, Operation And Maintenance Manual

Gasketed plate heat exchanger

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Installation,

Operation

and

Maintenance

Manual

MODELS:

Gasketed PHE's

FORM NO.: GPHE IOM

REVISION: 01

READ AND UNDERSTAND THIS MANUAL PRIOR

TO OPERATING OR SERVICING THIS PRODUCT.

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Page 1 Installation, Operation Maintenance Manual MODELS: Gasketed PHE’s FORM NO.: GPHE IOM REVISION: 01 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
Page 2 INDEX APV GASKETED PLATE HEAT EXCHANGER (GPHE) INTRODUCTION SAFETY SYMBOLS and DEFINITIONS SAFETY PRECAUTIONS General Operating Zone Installation Startup and Shutdown Instructions General Operating Safety Service and Maintenance Safety Safe Cleaning Procedures Specific Safety Precautions MAIN COMPONENTS CONSTRUCTION Standard Design Frame Plates Gaskets...
Page 3: Table Of Contents
Tie Bar Installation Closing Tie Bar Frames Opening Tie Bar Frames STORAGE 10.1 Short Term Storage (less than 6 months) 10.2 Long Term Storage (more than 6 months) STARTUP, OPERATION and SHUTDOWN 11.1 General 11.2 Startup and Shutdown 11.3 Operation MAINTENANCE 12.1 Disassembly...
Page 4 INTRODUCTION WARNING These operating instructions must be read and thoroughly understood for the safe commissioning, operation, and maintenance of the APV brand Gasketed Plate Heat Exchanger. The following procedures must be performed by qualified, trained personnel who are familiar with this equipment. While every attempt has been made to ensure clarity, the intent of this document is to provide basic guidance and it is the responsibility of the end user to review each application thoroughly for suitable usage.
Page 5 The necessary actions to avoid an accident with or any damage to the GPHE are: Before putting an SPX FLOW GPHE into operation, the operator shall analyze the application for all foreseeable risks, their likelihood to occur and the potential consequences of the identified risks as per the current revision of ISO 31000 and ISO/IEC 31010.
Page 6 SPX FLOW can supply information upon request to assist the user in making these decisions. Consult your nearest SPX FLOW facility. (Listed on www.spxflow.com) 6 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 7 Important! In addition to this instruction manual, the following key documents are included with your APV GPHE. In case of conflict between this instruction manual and the order and product documents, the order and product specific documents take precedence.  APV GPHE plate arrangement diagram ...
Page 8 Further details can be found in Section 7.0: “Receiving of Equipment”. How to contact SPX FLOW: Your nearest SPX FLOW office is listed on our website www.spxflow.com. Information regarding our Service and Spare Parts offerings can also be found on the website.
Page 9 d. Never remove “Warning” tags displayed on the heat exchanger. Torn or worn labels should be replaced. e. Do not start the heat exchanger until all personnel in the area have been advised and have moved outside the operating zone. f.
Page 10 (See page 54) i. Sudden changes in the operating pressures and temperatures must be avoided. Shock cooling of the APV GPHE may cause leakage, due to sudden contraction of the sealing gaskets. (See page 55) j.
Page 11 a. Leakage from an APV DuoSafety plate is always the early warning for the user to act. (See page 23) b. Do not exceed the maximum operating pressure or temperature listed on the customer drawing or damage to the heat exchanger and personnel serious injury or death may result.
Page 12 45) g. A heat exchanger which has been in storage for more than five (5) years should be inspected by a qualified SPX FLOW representative prior to preparing it for operation. (See page 49) h. Prior to startup, all pipework must be inspected and flushed clean. Strainers are recommended to prevent debris from entering the heat exchanger.
Page 13 MAIN COMPONENTS Figure 1: A typical APV industrial GPHE Figure 1: Main components of APV GPHE, industrial design Head for connections and clamping the plate pack Follower for clamping the plate pack and any additional connections End support for supporting the top and bottom bars...
Page 14 Figure 2: A typical SPX FLOW sanitary GPHE Figure 2: Main components of typical APV sanitary GPHE. Head for connections and clamping the plate pack Follower for clamping the plate pack End support for supporting the top and bottom bars...
Page 15 CONSTRUCTION 5.1. Standard Design The APV GPHE is designed to provide maximum efficiency and cost effectiveness in handling heat transfer duties. The GPHE minimizes maintenance downtime and requires little floor space compared with other types of heat transfer equipment. The heat transfer plate is a thin, corrugated metal sheet that transfers heat between the fluids on either side.
Page 16 Sanitary GPHE’s are equipped with adjustable ball feet, which provide a point contact, for levelling the plate heat exchanger to ensure the GPHE can fully drain. A sanitary GPHE that can be fully drained meets one of the requirements for stamping a GPHE with the 3-A logo.
Page 17 Figure 3: Flow pattern INSTALLATION, OPERATION and MAINTENANCE MANUAL | 17...
Page 18 Figure 4: Industrial GPHE frame Figure 5: Sanitary GPHE frame Divider plates may be used to divide a heat exchanger into separate operating sections. Divider plates have no connections but may allow flow from one section to the next. Connector grids (Figure 6) may be used to divide a heat exchanger into separate sections to accommodate multiple duties within a single frame.
Page 19 Figure 6: Connector Grid 5.3. Plates APV heat exchanger plates come in multiple sizes and corrugation patterns. This allows the heat exchanger to be matched closely to a specific duty. The corrugations cause turbulence in the liquids as they flow in a thin stream in the passage between each plate (Figure 7).
Page 20 Figure 7: Turbulent Flow Figure 8: Countercurrent flow pattern 20 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 21 Plate Construction All plates are designated as either diagonal flow or vertical flow (Figure 9) based on their flow pattern. Vertical flow plates have both flow inlet and outlet ports on the same side, e.g., left side for the hot medium and right side for the cold medium. For diagonal flow plates, the fluid enters in one corner and exits in the diametrically opposite corner.
Page 22 This is available for many APV GPHE models. Mixing plate angles results in flow passages that differ significantly in their flow characteristics.
Page 23 Leakage from an APV DuoSafety plate is always the early warning for the user to act. Note: APV DuoSafety plates use special gaskets which can be confused with gaskets intended for single plates. Please confirm with SPX FLOW that you have the correct gaskets. Welded Plate Pairs An APV welded plate pair is a right- and left-hand vertical flow plate laser welded together to form a pair.
Page 24 the welded passage cannot be prevented, then a cleaning solution must be circulated. It is recommended that you contact a supplier of cleaning agents for advice. The welded and gasketed chambers of an APV welded plate pair may have different pressure and fluid capabilities. Ensure the fluids are connected correctly.
Page 25 The upstanding lugs (Figure 14) maintain plate alignment in the plate during plate pack closure and operation. The groove form provides 100% peripheral support of the gasket, leaving none of the material exposed to the outside. In addition, the gasket exposure to the process liquid is minimized by the full depth plate gasket groove.
Page 26 5.5. Connector Grid and Bosses The connector grid divides the plate heat exchanger into separate sections that may operate independently. The connector grid is equipped with removable connector bosses (Figure 15). The connector bosses can also form the connections between sections of the plate heat exchanger and provide external connections to and from these sections.
Page 27 Figure 16: Divider plate DRAWINGS 6.1. Customer Drawing A customer drawing is supplied with each APV Plate Heat Exchanger. This drawing provides detailed information concerning design specifications, operating conditions, dimensions, connections, plates and gaskets, plate arrangement diagram and key, bill of material and special notes.
Page 28 6.2. Plate Arrangement Diagram Configuration of the Diagram The plate heat exchanger is designed to perform a duty (or duties) by arranging the plates in a specific sequence. This arrangement is represented schematically by the plate diagram shown on the customer drawing. The schematic represents the fluid flows by heavy lines with arrows and the plates by thin vertical lines.
Page 29 Figure 18: Typical plate arrangement diagram Along the top of this diagram is a listing of each plate required, showing the hand of each plate (Right or Left), the direction the gaskets face (Head or Follower) and the plate punch code (blanking designation). The punch code indicates which ports are open and allow flow.
Page 30 Figure 19: Vertical plate punch codes 30 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 31 Figure 20: Diagonal plate punch codes INSTALLATION, OPERATION and MAINTENANCE MANUAL | 31...
Page 32 The plate punch code will use a five character code as shown in Figure 17 or 18. The obsolete three and four character codes are shown for reference. The connection positions (ports) are numbered as shown in Figure 21. The complete plate identification number is constructed as shown in Figure 22: Figure 21: Position numbering Figure 22: Plate identification number...
Page 33 The head, follower, and connection grid labeling are shown in Figure 25. Note: All possible connections are shown in Figure 25. Only the connection provided will be shown on the customer drawing. Figure 25: Head, follower, and connection grid labeling Examples A typical single pass arrangement using diagonal flow plates with all connections on the head (Figure 26).
Page 34 Figure 26: Single pass arrangement example Figure 27: Two-section arrangement example 34 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 35 RECEIVING of EQUIPMENT 7.1. Receiving Check The APV GPHE is typically shipped fully assembled, skid mounted and wrapped in protective plastic. Other packaging methods could include an open box or seaworthy packaging. See Figure 28. Upon receipt of the equipment, check all received items against the packing list for damage or missing parts.
Page 36 Figure 28: Shipping methods Figure 29: Typical nameplate 8.2. Foundation The foundation pad for industrial heat exchangers should be level and sized correctly for the outline of the frame. It must also be of adequate strength to support the full operating weight of the equipment.
Page 37 The line flexibility may be accomplished by use of expansion joints. If the APV GPHE has liquid connections on the follower, it is important that the compressed dimension is checked against the customer drawing before the pipes are connected.
Page 38 Figure 31: Follower movement 8.5. Pressure Pulsation and Vibration Piston pumps, gear pumps, valves, etc. must not be able to transfer pressure pulsations or vibrations to the plate heat exchanger as this can cause fatigue fracture in the plates. The use of pressure dampers in the pipeline is recommended to minimize this effect. 8.6.
Page 39 Figure 32: Lifting point If the APV GPHE is packed and transported lying flat on the head, care must be taken during removal from the pallet, to avoid sliding and bending of the equipment base or feet (Figure 33).
Page 40 Figure 33: Lifting GPHE shipped lying flat on the head  The lifting equipment must be in good condition and used in full compliance with the manufacturer’s specifications and limitations.  Never exceed 120° between the lifting wires at any time (Figure 34). 40 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 41 When assembling a GPHE, all components must be sufficiently supported to prevent damage. The following steps are recommended to safely assemble an APV GPHE. These instructions refer to the components illustrated in Figure 1 in Section 4.0. It is recommended that assembly be performed at the intended final location of the GPHE.
Page 42 better face on the inside (unless there are features that mandate a specific orientation such as follower guides, labels, etc.). Figure 35: Erect and secure head Figure 36: Position follower Position the top carrying bar between the head and end support and using the bolts provided, fasten it securely (Figure 37).
Page 43 Figure 37: Position top bar Figure 38: Lift follower in place Place a heat transfer plate against the head to check that the port holes in the plate align with the port holes in the head. If the follower is ported, verify plate alignment with the follower in the approximate position the follower will rest on the top bar when the plate pack is at nominal pitch.
Page 44: Tie Bar Installation
installed in the proper sequence, that gaskets are fully or securely seated in their grooves, and there is no debris on the plates or gaskets. Clean the gasket sealing surface with a lint free cloth. Push each plate firmly against the previous one. Use special care with mechanically retained gaskets (gaskets clipped to the plates) to avoid dislodging them (Figure 39).
Page 45: Closing Tie Bar Frames
Check that the tie bar threads are free from damage. Clean the tie bar threads and liberally apply the applicable anti-seize compound along the area where the nuts will travel during tightening. Also apply the compound to both sides of the plain washer under the tie bar nut.
Page 46  Never tighten a GPHE which is under pressure.  Never tighten a GPHE while piping is connected to the follower or connector grids. 3) Install the remaining side tie bars located between the ports (if applicable) and tighten them evenly until the plate dimension is the same at all installed tie bars. 4) Starting with the top installed pair of tie bars (1 and 4), continue tightening equally in 6mm (1/4 in.) increments until the platage dimension measures approximately 5% greater than the final dimension.
Page 47 Opening-up of higher pressure sections can cause leakage of that section. The robustness of the APV GPHE is also linked with the percentage division of plate counts in various sections.
Page 48: Opening Tie Bar Frames
Note: Pneumatic pressure tests using air, helium or nitrogen are not recommended. Pneumatic tests shall only be used when the APV GPHE cannot be completely drained of the hydrostatic test water and the remaining traces of test water are detrimental to the operating fluid(s).
Page 49: Storage
Never tighten the heat exchanger below the minimum pitch. A heat exchanger which has been in storage for more than five (5) years should be inspected by a qualified SPX FLOW representative prior to preparing it for operation. INSTALLATION, OPERATION and MAINTENANCE MANUAL | 49...
Page 50: Startup, Operation And Shutdown
STARTUP, OPERATION and SHUTDOWN 11.1. General Prior to startup, ensure the equipment is correctly assembled and the piping connected properly. Also, check that the plates have been compressed to the correct dimension specified on the customer drawing (Figure 42 and refer to Section 9.0). Correct assembly and tightening are required for safe startup and operation.
Page 51 Figure 43 shows an example of a typical system configuration for a liquid/liquid (Cold/Hot) application. Each circuit (Cold and Hot) has a similar configuration. The exact piping, control arrangement, design and installation is outside of SPX FLOW’s scope and responsibility.
Page 52 Figure 43: Typical liquid / liquid system configuration components Pump, centrifugal Inlet valve Vent valve (always on top line) Drain valve Outlet valve for isolation Bypass valve Pressure gauge at inlet of the GPHE Acceptable startup and shutdown procedure for the configuration in Figure 43: Before startup, check that these conditions are met.
Page 53 Startup process (suffix C is for Cold liquid circuit; H is for Hot liquid circuit) STEP COLD MEDIUM HOT MEDIUM Start pump (1C) Open inlet valve (2C) slowly, building inlet pressure at a rate of less than 1.7 bar (25 psig) every 10 seconds. Monitor (7) and record pressure in at least these intervals.
Page 54: 11.3. Operation
ShutDown Process (suffix C is for Cold liquid circuit; H is for Hot liquid circuit) STEP COLD MEDIUM HOT MEDIUM Close valve (2H) slowly, reducing pressure from operating to atmospheric at a rate of less than 1.7 bar (25 psig) every 10 seconds.
Page 55: Maintenance
 Sudden changes in the operating pressures and temperatures must be avoided. Shock cooling of the APV GPHE may cause leakage, due to sudden contraction of the sealing gaskets.  Temperature and pressure cycling must be limited to the rate changes specified in Section 11-1 (startup and shutdown).
Page 56: Disassembly
5) When using hydraulic tightening tools, ensure that each tie bar is loosened approximately equally (+/- 3mm or 1/8 in.) during opening. 6) When the plate pack is fully released and the tie bars removed, the APV GPHE can be opened by pushing the follower back against the end support.
Page 57: Inspection
Figure 44: Precaution for removal of plates During maintenance, secure the follower to the end support to prevent accidental rolling. Separate the plate pack carefully to avoid damaging the gaskets or the plates. Remove the plates by sliding the bottom portion of each plate backwards and then sideways off the top bar and then removing from the frame (Figure 44).
Page 58: Cleaning
It is recommended to lay the plate on a flat surface during brush cleaning to avoid the risk of bending the plate. If the APV GPHE is heavily fouled, care must be taken to remove all debris from the gasket sealing surfaces when the heat exchanger is reassembled. Any debris will most likely lead to sealing failures.
Page 59: Cleaning-In-Place
After some time of standing, flush the solution with clean water. If the APV GPHE is to be out of operation for a long period of time, it is advisable to empty it, separate the plates, and clean the equipment. After cleaning, lightly re-clamp the plate pack and cover it to protect from dirt and UV light.
Page 60 Excess Nitric acid can seriously damage NBR and other rubber gaskets. Several alternatives to Nitric Acid can be used, e.g., Phosphoric Acid up to 5% maximum concentration and 85°C (185°F) maximum temperature. Consult SPX FLOW to find all the alternative CIP regimes possible.
Page 61: Regular Apv Duosafety Internal Inspection
GPHE must be opened and the APV DuoSafety plate pair separated. Carefully check the inside surfaces for traces of the product/ liquid processed in the APV GPHE. If visual inspection of the surface is difficult (e.g., because the product is transparent) then it is recommended that indicator dye is sprayed onto the inside surface of the plate pairs.
Page 62 Overheating the plates can cause discoloring and damage. PLIOBOND glued gaskets can be loosened and removed by placing the gasketed plate in water at 100°C (212°F). Cleaning To remove remaining traces of old adhesive, grease, or dirt from gasket grooves, use a solvent such as Acetone or a commercial gasket removal product.
Page 63 Attachment of Paraclip Gaskets Non-glued Paraclip gaskets are an alternative to glued in gaskets that simplifies on site re-gasketing. The gaskets have a series of small nubs or projections molded into the underside of the gasket. These projections fit into corresponding slots located around the periphery of the plate and port areas, securing the gasket to the plate (Figure 46).
Page 64 the gasket to the plate (Figure 47). When the plate heat exchanger is tightened, a complete and secure seal is assured. To attach an EasyClip gasket, the gasket is laid out on the plate in its correct position. The projections are firmly pressed into the corresponding slots in the plates. After installing the gasket, the plate may be immediately installed in the frame in preparation for tightening.
Page 65: Re-Assembly
areas, securing the gasket to the plate (Figure 48). When the plate heat exchanger is tightened, a complete and secure seal is assured. To attach a Double Clip gasket, the gasket is laid out on the plate in its correct position. The projections are firmly pressed into the corresponding slots in the plates.
Page 66: 12.10. Maintenance Of In-Line Filter
The in-line filter, when supplied, needs to be cleaned at regular intervals (Figure 49). The frequency depends on the content and size of debris in the fluid being filtered. An increase in the pressure drop over the APV GPHE indicates the need for cleaning. Clean the in-line filter in this sequence: ...
Page 67: 12.11. Preventative Maintenance
Figure 49: In-line filter 12.11. Preventative Maintenance A preventative maintenance program will help keep APV GPHE’s running at optimal levels. The frequency of the maintenance inspections is dependent on a variety of reasons, some of which are:  Production hours.
Page 68: Power Tightening Equipment
13.2. Power Tightening Equipment Pneumatic Wrench To facilitate the closing and tightening of large heat exchangers or plate heat exchangers containing a large number of plates, pneumatic tightening wrenches (single or dual wrenches) are available in two models. Table 2 shows the pneumatic power tighteners recommended for small heat exchangers with port opening <= 6 inch and large heat exchangers with port openings >...
Page 69: In-Line Filter
The in-line filter mesh size is typically between 2.0mm (0.08 in.) – 2.5mm (0.1 in.) and is, dependent on the heat transfer plate gap. Where an in-line filter is purchased for an existing APV GPHE, please check whether the plate heat exchanger is prepared for the installation of an in-line filter. Additional modifications may be necessary.
Page 70: Insulation Jacket
Figure 52 or clamp lengths in Figure 53. A drip tray can be installed when the APV GPHE is insulated (see Section 13.6). The drip tray (Figure 54) has support blocks attached to the bottom surface of the drip tray and these blocks are attached beneath the plate heat exchanger feet with the drip tray resting on the floor.
Page 71 Figure 53: Drip tray INSTALLATION, OPERATION and MAINTENANCE MANUAL | 71...
Page 72 Figure 54: Drip tray Figure 55: Insulation Jacket 72 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 73: Spare Parts, Identification And Ordering
For gaskets and plates see item numbers on APV GPHE plate arrangement diagram. On some APV GPHE plates, the last four digits of the item number are also stamped near one end of the plate. On some gaskets, the part number may be molded on the gasket.
Page 74: Troubleshooting
Figure 57: Right and left hand plate 1 5 . T RO UBLE S HO OT ING T RO UBLE S HO OT ING P LAT E HE AT E X CHANG E RS P RO BLE M P O S S I BLE CAUS E S S UG G E ST E D S O LUT I O NS 1 .
Page 75 d i m e n s i o n s g i v e n i n t h e c u s t o m e r d r a w i n g . I f l e a k s c o n t i n u e , s e e p a r a g r a p h b e l o w .
Page 76: Appendices
APPENDICES AP P E NDI X 16 . 1 – Mul ti -pi e c e G as kets AP P E NDI X 16 . 2 – P r e ve nta ti v e Mai nte na nc e Chec k li s t 76 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 77 AP P E NDI X 16 . 1 – Mul ti -pi e c e G as kets Fl ow G a sk e ts Flo w g a sk e t s, u sed o n t he f lo w p la t e a n d s e a l p la t e, a re t yp ica lly m a nu f a ct u re d a s sin g le p ie ce ga ske ts.
Page 78 Figu re 58 : Mu lt i-p ie c e f lo w gas ke t 78 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 79 Figu re 60 : Ga sk e t co rne r s e ct ions Fig u re 5 9: G a s ke t m a in se ct io n INSTALLATION, OPERATION and MAINTENANCE MANUAL | 79...
Page 80 Fig u re 6 1 : Two -p ie ce en d g aske t 80 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 81 Figure 62: Multi-piece end gasket INSTALLATION, OPERATION and MAINTENANCE MANUAL | 81...
Page 82 AP P E NDI X 16 . 2 – P r e ve nta ti v e Mai nte na nc e Chec k li s t 82 | INSTALLATION, OPERATION and MAINTENANCE MANUAL...
Page 83: Preventative Maintenance Checklist
P L AT E H E AT E XC H A N G E R S Implementation of a preventive maintenance plan keeps SPX FLOW products running at optimal levels and protects your product investment. Use the below checklist to schedule regular product inspections and part replacements using SPX FLOW genuine spares to extend your products lifecycle.
Page 84 • Testing is completed without opening the plate pack Based in Charlotte, North Carolina, SPX FLOW, Inc. (NYSE: FLOW) is a multi-industry manufacturing leader. For more information, please visit www.spxflow.com 611 Sugar Creek Road, Delavan, WI 53115 S PX F LOW P: (262) 728-1900 or (800) 252-5200 E: leads@spxflowleads.com •...
Page 85 Delavan, WI 53115 U.S.A. P: (262) 728-1900 P: (800) 252-5200 E: apv.phe.americas.am@spxflow.com www.spxflow.com Improvements and research are continuous at SPX FLOW, Inc. Specifications may change without notice. ISSUED 02/2024 Form No.: GPHE IOM Revision: 01 Copyright ©2022 SPX FLOW, Inc.