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Plate Heat Exchanger

MAINTENANCE
GUIDE
HISAKA Plate Heat Exchanger
Maintenance Guide


Forward C O N T E N T S

Thank you for choosing the HISAKA plate heat 1— Construction of Plate Heat Exchanger
Mechanism................................................... ˜4
exchanger.
2— Maintenance for Equipment......................... ˜6
The HISAKA plate heat exchanger is a relatively
¢Performance......................................... ˜7
trouble free, high performance equipment, but prop- 3— Maintenance................................................. ˜8
er maintenance will further increase its reliability, ¢Spare parts........................................... ˜8

and extend its life. ¢Deterioration of gaskets........................ ˜12


¢Cleaning methods................................. ˜14
This booklet is a compilation of knowledge gathered
4— Introduction of Maintenance Services.......... ˜6
over the years at HISAKA, as the sole domestic
¢"Full Service Package"......................... ˜16
plate type heat exchanger manufacturer in Japan.
¢Other services....................................... ˜17
Please utilize the booklet to avoid troubles and to 5— Fault Detection............................................. ˜18
improve productivity of the plate heat exchanger. 5-1 Scaling................................................... ˜18
¢Langelier saturation index and scaling. ˜18
¢Marine growth....................................... ˜20
¢Seawater strainer.................................. ˜22
5-2 Corrosion of Plate.................................. ˜24
¢General corrosion................................. ˜24
¢Pitting corrosion.................................... ˜25
¢Crevice corrosion.................................. ˜27
¢Erosion corrosion.................................. ˜29
¢Stress corrosion cracking..................... ˜30
5-3 Other Fault Detections........................... ˜32
¢Fatigue crack........................................ ˜32
¢Plate deformation.................................. ˜33
6— Overhauling.................................................. ˜34
HISAKA WORKS, LTD. 7— To Extend the Lifetime of Your Heat
Exchanger.......................................................... ˜35
Heat Exchanger Division

˜2 3˜
1— Construction of Plate Heat
Exchanger Mechanism
Ever since its debut as a product in 1953, HISAKA plate heat exchanger has been highly Tightening lengths
reputed for its "high performance", "lightweight, compact design", "energy saving" and The dimension between the fixed and mov- Caution Warning
"easy maintenance characteristics", and have been widely applied in a variety of indus- able frame is called the tightening dimen-
tries including chemical, HVAC (heating, ventilation, air conditioning), food, power station, sion, and the unit is tightened between the
shipbuilding, steel, mining, semiconductors and for environmental applications. maximum dimension and the minimum Knife edge hazard
Plate edge sharp as knife.
Drop & fall down hazard
Top heavy
dimension. The tightening lengths is shown Can cause cut fingers or hands.
Don't touch edge without safety gloves like
a "Cut-Resistant" gloves and arm cover.
Don't lift and sideslip exchanger
by amateur transporter.

precisely designed so that they work maxi- on the assembly drawings and on the
Construction Glued to the Glued to the both
mum performance in each process. nameplate of the unit.
The heat transfer plate, is manufactured E-frame outside. E-frame and packing
by press forming thin sheets of corrosion- The heat transfer plate and gasket are high case outside.
resistant metals such as stainless steel and precision formed products, and tightened
with uniform force in order to achieve high Manufacturing number
titanium. A plate element consists of this heat
sealing performance. When contacting us in regards to mainte-
transfer plate with its peripheral area sealed
nance, please notify us of the manufactur-
with a synthetic rubber gasket. In the plate
Guide bar support ing number. It is possible to understand
heat exchanger, the required number of plate
all specification of the unit, just with the
elements are suspended on a guide bar, and
manufacturing number. The manufacturing Glued to the Glued to the package
sandwiched between fixed steel E-frame
number is shown on the drawings and on E-frame inside. Instruction manual in
frame and movable steel frame Upper guide bar inside.
the nameplate on the unit.
and tightened together with bolts/
nuts. There are over 40 types
of plate elements, and each are

Construction plate heat Tightening


Length
exchanger
S-frame
Manufacturing
Number

Hot side inlet

Cold side outlet


TEL: +81-72-966-9601
FAX: +81-72-966-9602

Lower guide bar HEAT EXCHANGER DIVISION

Gasket Maintenance call sticker


Hot side outlet This sticker which is labeled on to
Plate each unit shows our maintenance
Cold side inlet service number.
Baseplate Tightening bolt and nut

˜4 5˜
2— Maintenance for Equipment

There are no moving parts on a plate heat exchanger, making it a device with a low num- Main reasons for reduction in performance and leakages of the plate heat exchanger,
ber of component parts, and relatively free of malfunctions or other trouble. However, with include the scaling by water inside the heat exchanger and deterioration of the gasket
extended periods of operation, there may be deterioration of gaskets, scaling by water due to extended use. For the problem with scaling by water residue, we recommend that
residue and other debris, and corrosion and cracking may occur. If left as is, this will lead decreasing the performance be monitored, and to perform periodic opening and cleaning
to a reduction in performance, intermixing of fluids and leakages, and can ultimately lead accordingly.
to stopping of the unit and the entire plant. In order to prevent this, it is necessary to peri-
odically disassemble the unit, and perform inspection and cleaning.
¢Performance
When the heat exchanger is used for extend-
ed lengths of time, scale will adhere inside,
and the overall heat transfer coefficient will
down over time. The initial performance is
restored by periodically opening and cleaning
the unit.

Scale accumulated on the plate surface Hard scale inside the plates

Changing of overall heat transfer coefficient


7,000

Overall heat transfer coefficient [W/m2℃]


6,000

5,000

4,000
Design
3,000
Cracking visual inspection (top) Heat exchanger left alone without changing the
Cracking detection by dye penetration test gasket (top), crevice corrosion occurring at the 2,000
(bottom) gasket line (bottom)
1,000

0
Maintenance Operating time

˜6 7˜
3— Maintenance

The maintenance of the plate heat exchanger is largely divided into spare parts and plate
cleaning. Spare parts consist of gaskets, plates, and frames, and methods of plate clean- Gasket material symbols and list of colors
ing include mechanical cleaning and chemical cleaning.
Material
Color marking Product name
Abbreviation Symbol
¢Spare parts NBR H Yellow, 1 point Nitrile-butadience rubber
Gasket
<Gasket> G-NBR NBR Yellow, 1 point
Spare parts Plate
The reliability of the gaskets has been NBR Yellow, 2 points
Frame
proven through years of research, experi- Maintenance NBR Yellow 1, Green 1
Mechanical
ence, evaluation and actual performance cleaning NBR for Food HF Pink, 1 point Food approved NBR
Cleaning
at HISAKA. Though a plate gasket seems Chemical
NBR Yellow, 2 points
cleaning
simple, there are many technical ideas in EPDM NE Pink, 2 point Ethylene-propylene Diene-Methylene Linkage
the shape, thickness, width, material, and YE Pink, 2 point
are nothing like the ordinary piping flange E Pink, 2 point
gaskets punched out from a rubber sheet EE Pink, 2 point
material. E Green, 1 point
The selection of the synthetic rubber com- G-EPDM EPDM Pink, 2 points
pound that is provided as the product, is E Pink, 2 points
closely evaluated for its cost, chemical EPDM for Food NE Pink, 2 points Food approved EPDM
resistance, heat resistance, and anti crack- EPDM Pink, 2 points
ing performance. From several thousand R-EPDM ER Green, 2 points High temperature EPDM
compounds, we select those that clear IIR V Blue, 1 point Chloro-isobuthene-isoprene rubber
these evaluation factors at the highest With the lot number and yellow marking, it can G-IIR IIR Red, 2 points Butyl (isobuthene-isoprene)rubber
level. In addition, they are repeatedly be confirmed that this material is NBR.
N-IIR T Brown, 1 point
checked in various endurance tests before
FPM FV N. A. Fluorinated rubber
the final decision, and are vulcanized and
R-FPM RV White, 1 point
mold formed in precision dies that take into
G-FPM FPM Purple, 1 point
account amount of shrinkage for the final
FPM Purple 1, White 1
dimensions.
FPM Purple, 4 points
The gaskets are the only consumable part
Si SS N. A. Silicone rubber
in the maintenance of plate heat exchang-
The symbols and colors are current as of April 2005. For those that do not appear on this list, please contact us.
ers. A lot number is shown on the gasket,
making it possible to identify the date of Guideline for regasketing
manufacture, the die used, and material. As an additional condition, if there are applicable laws
Operating temperature Guideline for regasketing
For the material, color marking is utilized to and regulations such as for Japanese Pressure Vessel
Class 1 and high pressure gas safety laws, perform
make it easy to identify visually. 100°C ≤ 1-3 years disassembly and inspection according to the applicable
30°C ≤ and 100°C 5-7 years legislation or regulation. Refer to the separate page for
Gaskets are manufactured based on precision regasketting. Make overall considerations including the
≤ 30°C within 7-10 years corrosion resistance of the gasket for the fluid as well,
design.
and set a regasketing period.

˜8 9˜
3— Maintenance

<Plate> and manufacturing date can be found, and <Frame> <Tightening bolts>
The heat transfer plate is formed in the makes it possible to track down the mill The frame plate is a pressure retaining part Tightening bolts and nuts will also begin
press facilities of HISAKA which have the certificate plate material by mill certificate. that maintains the sealing of the unit by tight- to rust depending on the circumstance of
largest 40,000 ton press machine in the ening together the plates with uniform tight- the unit, so we recommend that periodic
world and other unique press machine. ening force. Because of this, if there is cor- greasing be performed for rust prevention.
In order to press the plates under optimal rosion or deformation, it will require periodic Also, a bolt cover to protect the bolts, is
conditions, the plate die is checked every overhaul. There is also a model with rubber available as an option.
few thousand to 10 thousand shots. lined (NJ/NP type) on the connection holes
of the frame plate to prevent the carbon steel
The plates in the plate heat exchanger are
material from corrosion by fluid. This rubber
thin and of 0.5mm to 1.0mm in thickness.
lined is called a rubber boot, and requires
In order to press these thin plates without
replacement if deterioration is found.
press defects such as flaw, necking, the
high pressing tools design and manufactur- Flange

ing technology, and pressing technology of Stud bolts/nuts


S-frame

Lot number
HISAKA are absolutely essential.
Indicates that model LX-026, S316 is made of Piping Rubber boot
These plates are printed with a lot num- SUS316.
ber using an electronic marker as well as
gaskets, and the plate thickness, material,
<Other spare parts>
ŒModel type...(example) LX12:LX-12
The plates and gaskets of the plate heat
Plate thickness...Shows the last digit of the exchanger can be supplied, and tighten-
plate thickness below the decimal point. However,
ing bolts, nuts, rubber boots, and adhesive
not displayed on models with only 1 type of plate
thickness such as EX type. (example) 5:t0.5 0:t1.0 glues can be also supplied for maintenance.

ŽMaterial...304:SUS304 304L:SUS304L
316:SUS316 316L:SUS316L 6J1L:SUS316J1L For a rubber boot type, a piping gasket is not

LX-12  5  316 30AC:NTK-30AC Carpenter 20 T270:TP270


T270PD:TP270-Pd HB:Hastelloy B
necessary.

Lot number HG: Hastelloy G HB2: Hastelloy B-2

A  B   035  001
HC22: Hastelloy C-22 HC276: Hastelloy C-276
NNCP: NC-NI
’Manufacturing number for each month 1-999

‘Year/month of manufacture (example) 2003


May:035 2003 October:03X 2003 November:03Y
2003 December:03Z
Press facility Maintenance parts
Mill supplier

˜10 11˜
3— Maintenance

¢Deterioration of gaskets P = α Ÿε +⠞žžžžž From this relationship, it will be possible to gasket such as bubbling, cracking, sticki-
Although high quality synthetic rubber is Here, a and b are constants regardless of predict the gasket thickness t1 [mm] after a ness, melting or wrinkles, and there is no
used for gaskets, deterioration due to aging plate type, and compression ratio ε [%] can certain amount of time has passed. … (Fig. leakage from the unit.
is still unavoidable. Deterioration such as be shown by equation ‚. 2) Bending the gasket 180°, no cracks is on
loss of elasticity, cracking or carbonization (t0–t) Using this relationship, Fig. 3 shows the the gasket surface.
for rubber will decrease the sealing force, ε [%] = × 100žžžžž‚
t0 relationship between operating time and Ž When measured gasket hardness, the
and will cause fluid leakage. t0: Compression free gasket thickness allowable operating pressure. When the result was 80°.
before operation [mm] permanent compression set of the gasket With the operating pressure of 0.5MPaG,
t : Gasket thickness when tightened [mm] increases from operation start, and the when the gasket thickness was 3.1mm, and
When using this relationship, it is possible to allowable operating pressure goes down tightening is to be performed at the mini-
predict the minimum compression free gas- below the operating pressure, the initial mum gasket thickness of 2.6mm.
ket thickness t0 [mm] that will be required at leakage will occur. By retightening there- <Judgment>
the allowable operating pressure. … (Fig. 1) after, the compression ratio of the gasket ŒVisual inspection … passed
In addition, will be revived and it will be usable again, Bending test … passed
(2) Permanent compression set C/S [%] but when the permanent compression set ŽHardness … passed
and time θ [h] increases further, the gasket will reach Hardness is to be between 65° to 93°.
C/S = 㠟 θ ζ žžžžžžƒ the limit of sealing and it will need to be Operating pressure … passed
Here, γ and ζ are constants that are depen- replaced. The allowable operating pressure is checked
Deteriorated gasket dant on gasket material and temperature, Allowable operating pressure VS ε [%] from in equation ‚ and Fig. 4.
and the permanent compression set is gasket deterioration (Fig. 3) (3.1 – 2.6)
ε= × 100 = 16.1%
<Gasket life time> defined in equation „. 3.1

Allowable operating pressure MpaG


It is known that the following relationship (t0–t1) Operation start
C/S[%] = (t –t) × 100žžžžžž„ From Fig. 4, the allowable operating pres-
exists in plate gaskets. 0 Limit of scaling
sure 0.92 [MPa] > operating pressure 0.5
Initial leakage Retightening
(1) Compression ratio ε [%] and allowable t1: Compression free gasket thickness after [MPa]. From Œ~ here, this gasket is pos-
operating pressure P [MPa] operation [mm] sible to use.
Allowable operating pressure and
Operating pressure and Relationship of permanent
compression ratio (Fig. 4)
compression ratio (Fig. 1) compression set and time (Fig. 2)
Operating time h 1.4
Allowable operating pressure P MPaG

Permanent compression set C/S%

1.2

Allowable operating
o o
180 C 100 C

pressure MPaG
1.0
<Regasketing guideline> 0.8
60oC Also, using the relationship of the previous 0.6
section (1), it is possible to judge whether 0.4
C/S=γ・θζ the gasket should be replaced by measur- 0.2
ing the thickness of a gasket that has been 0
5    10   15   20    25
used for a certain period of time. (Example Compression ratioε%
Timeθhours of the judgment procedure)
Compression ratio ε%
<Observation>
ŒThere were no external defects on the

˜12 13˜
3— Maintenance

¢Cleaning methods Setting the plate <Chemical cleaning>


<Mechanical cleaning> Soaking ž ž ž The plates are soaked in a
Remove the gasket from the plates, and chemical bath. In this case, it is necessary
clean with a deck brush, or water jet. In a to control the process, being very careful
case of water jet, to avoid deformation of Plate of the chemical temperature, concentra-
the plate and damage to sealing surfaces, Flat panel tion and washing time so that the plates
(Plywood board, etc.)
set on a flat panel and a reinforcement are not corroded by the chemicals.
Reinforcement panel
panel, and the water jet should be from a
distance of 200mm or more.

Allowable water jet pressures for plate


Plate Plate Max. water jet Plates after cleaning
thickness material pressure
Cleaning-in-place (CIP)žžž After washing
mm MPa
through the heat exchanger by hot water
0.5 Titanium 3
with a higher flow rate than designed,
0.6 Titanium 5
a chemical (acid, alkali) is circulated for
0.8 Titanium 10 chemical cleaning. After chemical clean-
1.0 Titanium 15 ing, rinse thoroughly with fresh water not to
Water jet 0.5 Stainless steel 5 Plates before cleaning
remain a chemical residue.
0.6 Stainless steel 8
0.8 Stainless steel 15
1.0 Stainless steel 20

Soaking in a chemical bath to remove hard


Brush cleaning Cleaning-in-place (CIP) Unit…A simple mobile
scale.
CIP unit with caster wheels, and CIP cleaning for
plate heat exchangers without disassembly.

˜14 15˜
4— Introduction of Maintenance Services

¢"Full Service Package" ¢Other services


The "Full Service Package" is a service ˜Plate cleaning…The plate cleaning work,
that is provided as a full course menu for which is the main part of the "Full Service
maintenance of the plate heat exchanger. Package", is provided as a stand-alone ser-
The plate heat exchanger in the plant vice.
is returned us as is, and we perform all ˜Maintenance service on site…A service
maintenance work including disassembly, engineer visits to support maintenance work
inspection, cleaning, regasketing assembly, on site.
and inspection. When completed, the unit is
returned to the customer.

Maintenance service on site

BEFORE AFTER
Before work/after work

Flowchart of “Full Service package”


Arrival of the unit

Visual inspection of the unit

Disassembly

Sampling of plate

Gasket removal

Cleaning

Gasket gluing

Assembly

leakage test
Pneumatic

Final inspection

Shipment
test
Dye penetration
NG

After completion of “Full Service pack-


age”, the certified sticker is put on the unit.

plates
Replacing of
Records of maintenance and replaced
Frame overhaul

Painting

parts are registered in the HISAKA data-


base, and will be utilized in future mainte-
nance. NG

˜16 17˜
5— Fault Detection

Faults occurring in plate heat exchangers are scaling, marine growth due to usage of Index table for A, B, C, D
seawater, corrosion of plates, fatigue cracking of plates, and plate deformation. Typical Evaporation Calcium
A C Alkali level D
examples are introduced here, along with the optimum action to correct for each case. residue hardness
mg/l mgCaCO3/l mgCaCO3/l
5-1 Scaling How to derive the saturation index 50 ∼ 300 0.1 10 ∼ 11 0.6 10 ∼ 11 1.0
There are a lot of applications for plate heat (SI) 400 ∼ 1000 0.2 12 ∼ 13 0.7 12 ∼ 13 1.1
exchangers, and various types of scaling 14 ∼ 17 0.8 14 ∼ 17 1.2
will be occurred on the plate surfaces. Here, pHs (saturation pH) = (9.3+A+B) – (C+D)
Temperature°C B 18 ∼ 22 0.9 18 ∼ 22 1.3
the scaling by industrial water and scaling
seawater are explained. A: Evaporation residue index 0∼1 2.6 23 ∼ 27 1.0 23 ∼ 27 1.4
B: Temperature index 2∼6 2.5 28 ∼ 34 1.1 28 ∼ 35 1.5
C: Calcium hardness index
¢Langelier saturation index and scaling 7∼9 2.4 35 ∼ 43 1.2 36 ∼ 44 1.6
D: Alkali level
There is water that accelerates corrosion * The index of A, B, C, and D are derived 10 ∼ 13 2.3 44 ∼ 55 1.3 45 ∼ 55 1.7
of piping and equipment, and those that from the analysis values of the water, 14 ∼ 17 2.2 56 ∼ 69 1.4 56 ∼ 69 1.8
deposit calcium carbonate to form scale. To and the following conversion table. 18 ∼ 21 2.1 70 ∼ 87 1.5 70 ∼ 88 1.9
avoid the corrosion and scaling, it is neces-
sary to have a balanced carbonate condi- SI = pH (actual pH of the water) 22 ∼ 27 2.0 88 ∼ 110 1.6 89 ∼ 110 2.0
tion as in the following equation. – pHs (saturated pH) 28 ∼ 31 1.9 111 ∼ 138 1.7 111 ∼ 139 2.1

CaCO3+CO2+H2O⇔Ca(HCO3)2 32 ∼ 37 1.8 139 ∼ 174 1.8 140 ∼ 176 2.2


If SI > 0, scaling
In methods for applying carbonate balance 38 ∼ 43 1.7 175 ∼ 220 1.9 177 ∼ 220 2.3
If SI < 0, corrosion accelerating
in water treatment, the study published by If SI = 0, no corrosion, no scaling tendency 44 ∼ 50 1.6 230 ∼ 270 2.0 230 ∼ 270 2.4
Langelier of the United States in 1936 is 51 ∼ 56 1.5 280 ∼ 340 2.1 280 ∼ 350 2.5
well known. He devised a graph for calcu- Most water in Japan is indicate SI < 0,
57 ∼ 63 1.4 350 ∼ 430 2.2 360 ∼ 440 2.6
lating the saturation pH (pHs) for water at and have corrosion accelerating ten-
equilibrium, and proposed the saturation dency. To improve this tendency, "cal- 64 ∼ 71 1.3 440 ∼ 550 2.3 450 ∼ 550 2.7
index for determining corrosions or scale cium hydroxide injection" and "calcium 72 ∼ 81 1.2 560 ∼ 690 2.4 560 ∼ 690 2.8
tendencies. hydroxide/carbon dioxide gas injection" 700 ∼ 870 2.5 700 ∼ 880 2.9
Later, other researchers added corrections are well known.
to the calculations of Langelier, and this 880 ∼ 1000 2.6 890 ∼ 1000 3.0
table for deriving the saturation index has
been used in Japan since the latter half of
the 1950's.

˜18 19˜
5— Faults detection

¢Marine growth
System chart of the anti-fouling system
When using seawater as the cooling fluid,
slime, wood chip/fiber, seaweeds and other
ocean life can clog to the port holes and
accumurate on the heat transfer plates,
decreasing seawater flow rate and heat
transfer performance.
Because of this, many plants periodically
perform disassembly cleaning (generally
once a year), but this is time consuming and
costly. Therefore, as an anti-fouling system,
HISAKA recommends using a combina-
tion with "Hot water circulation" system in
which hot water is circulated for a certain
amount of time, and "Air bubbling" in which
compressed air is blown through the heat
exchanger.

In this example, a stand-by PHE


is installed, and it is possible to
perform anti-fouling of the stand-
Heat exchanger Seawater inlet port hole by unit while the operation is
Wood chips, seaweeds and shellfish are blocking continued. If a stand-by unit is not
the flow channel, and causing poor flow in the installed, one unit is stopped dur-
ing plant maintenance or during
unit. low load conditions, to perform the
anti-fouling operation.

Plate heat transfer surface


Slim and ocean life have accumulated,
and is causing poor heat transfer.
Commercial facility Y, K Company Power plant I, D Company

˜20 21˜
5— Fault Detection

¢Seawater strainer Recommendation of strainer mesh size


Objectives…Foreign objects such as sea-
Model Mesh size (mm) Model Mesh size (mm)
weeds, shellfish, wood chip/fiber, etc. in
seawater are removed so that they do not EX-11 2.8 or less RX-00 1.8 or less
enter the plate heat exchanger, and pre- EX-15 2.9 or less RX-30 2.1 or less
vents the clogging of the inlet port hole.
UX-005 1.4 or less RX-13 1.9 or less
Operation principles…By switching the
flow direction inside the filter (strainer) ele- UX-01 1.8 or less RX-70 2.9 or less
ment, foreign objects are discharged from UX-10 1.5 or less RX-90 2.6 or less
the backflushing valve.
UX-30 1.8 or less SX-41 1.7 or less
Feature…(1) Backflusing is automatically
performed with a pressure differential gauge UX-40 2.5 or less SX-43 1.1 or less
and timer setting. UX-90 3.1 or less SX-70 1.6 or less
Backflushing of the strainer
(2) The amount of water in the backflushing Punching metal (aft)
UX-100,130 3.1 or less SX-90,90S,90M,90L 2.4 or less
is 10% of normal flow, and cleaning is pos- Seawater outlet
V1
sible during operation. Punching metal (forward)
LX-00 2.5 or less WX-50 2.5 or less
(3) Because a cylindrical punched metal is LX-10 2.9 or less WX-90 3.1 or less
Seawater
used, the straining area is large. inlet

(4) Maintenance of the punching metal part LX-30 3.3 or less FX-01 1.8 or less
can be performed without disconnecting the LX-50 3.3 or less FX-03 2.7 or less
V2
main piping.
Punching metal (aft)
FX-05 2.7 or less
Backflusing of the strainer
ŒNormal operation period…V1 full open/V2 full
Seawater outlet
V1
Punching metal (forward)
YX-80A/B 1.7/2.0 or less
closed condition
The foreign objects flowing in from the seawater inlet
Seawater
nozzle is removed at the strainer zone, and strained inlet ¢Inner strainer
seawater flow through the seawater outlet to the heat This is an inner strainer made of punched
exchanger.
Backflushing operation period…V1 full closed/V2 V2 metal with mesh diameter of 2-3mm. This
full open condition Backflushing water discharge outlet
is inserted in the inlet port of the plate heat
With the pressure differential gauge or timer, by clos- Punching metal (aft)
exchanger, to remove foreign objects and
ing V1 and opening V2, the seawater stream direc- Seawater outlet debris in the fluid.
tion is forcing to change from outside of strainer zone V1 Punching metal (forward)

to inside, at the time the strainer zone is backflushed


and a part of seawater is discharged with foreign Seawater
objects from V2. inlet

ŽNormal operation period…V1 full open/V2 full


closed condition
The system will return to normal operation by the V2
timer (backflushing time: approximately 10 seconds).
At the time, the foreign objects in the inside of the
strainer zone are moved to the backward of strainer.

˜22 23˜
5— Fault Detection

5-2 Corrosion of Plate <Example> ¢Pitting corrosion


˜ Operating time…Approx. 8 years This is a typical localized corrosion in stain-
Corrosion is a condition where the metal ˜ Plate material…SUS316 (Stainless Steel less steel. Under conditions where halogen
is chemically or electrochemically invaded 316) ions (mainly Cl–) that destroy the passive
due to the surrounding environment. The ˜ Duty…Chromium acid plating fluid/ cool-
film on the metal surface exist, dotted cor-
plates of the plate heat exchanger use anti- ing water
rosion is observed. In the pit, metal ions
corrosive materials such as austenite type ˜ Operating temperature…30°C
˜ Cause…Plate material is less corrosion dissolve out as atoms, and Cl– in the fluid
stainless steel and titanium, but corrosion
resistance. concentrates. Furthermore, hydrolysis of
may still occur depending on the operating
˜ Action and correction…After 8 years metal ions occurs, making the hydrochloric
conditions.
operation without fault, and is still pos- acidic condition in the pit and progresses Magnified of the corroded area
In this section, examples of past experi-
sible to operate. But, it is necessary to the corrosion further.
ences in plate heat exchangers are shown,
increase the plate thickness, or change
to describe action and correction on opera-
the material to titanium which is fully <Example 1>
tion. corrosion resistant, etc. A guideline of ˜ Operating time…Approx. 1 year
corrosion rate for material selection ˜ Plate material…SUS304 (Stainless Steel
¢General corrosion should be less than 0.1 mm/y. 304)
Anti corrosion metals such as stainless
˜ Duty…Engine circulation cooling water/
steel have a stable oxide film on the sur-
cooling water
face, called a passive film. In the case of
˜ Operating temperature…90°C
stainless steel, a compound called hydrox-
˜ Cause…The Cl– ion concentration in the
ide chrome forms a even, thin chemi-
circulating fluid was 50ppm which is not a
cally stable film to maintain anti corrosion
concentration that would be corroded, but
characteristics. In an general corrosion,
localized concentration of Cl– between
corrosion progresses without this passive
deposit of scale and plate surface causes
film forming, and the corrosion progresses
pitting corrosion.
across the entire surface evenly, so the
˜ Action and correction…It is necessary
surface loses its metallic gloss, and a Magnified of the port hole of plating fluid side
to grade up the steel grade to SUS316,
rough surface is observed.
etc., with increased Cr, and Mo added.
Also, periodic disassembly inspection
and regeneration of the passive film
through scale removal, and water quality
control for the fluid, are recommended.

Port hole of plating fluid side

˜24 25˜
5— Fault Detection

<Example 2> ¢Crevice corrosion


˜ Operating time…Approx. 5 years This is another typical corrosion as pitting
˜ Plate material…SUS304 (Stainless Steel corrosion found in stainless steel, and is
304) fequently occurring in plate heat exchang-
˜ Duty…Steam / city water ers. This is a type of corrosion occurs at
˜ Operating temperature…140°C gaps formed due to the structure, or nar-
˜ Phenomenon…A tiny leak from the shoul- row gaps between gasket seal surface and
der area of the plate on the steam side plate, and at gaps between sediments, and
by deterioration of the gasket entered the the mechanism is similar to pitting corro-
Stress cracking (later noted) also occurred
double seal area of the plate, and with the under rust deposit sion. Because the environment at gaps tend
concentration of CI– ions which are factors to be lacking in dissolved oxygen, the pas-
of corrosion, corrosion attacks penetrated sive film is destroyed over time, and corro-
the plate. Consequently, the city water sion progresses.
leaked from the double seal area of plate.
˜ Cause…This is a pitting corrosion due
to concentration of Cl– ions, caused by <Example>
leaving the tiny leakage from the steam ˜ Operating time…Approx. 6 months
side. ˜ Plate material…Carpenter20 equivalent
˜ Action and correction…Replace the gas- (High nickel Alloy)
˜ Duty…98% sulfuric acid / circulating
ket periodically, and change to higher
cooling water
grade plate material like SUS316, etc. Penetration cracking in red areas (the Cooling water side
˜ Operating temperature…60°C
developing fluid by DPT)
˜ Cause…It was found that the crevice
corrosion is occurred by high concentra-
tion of Cl– ions at the tiny gap between
the cooling water side gasket and plate.
Also in this case, as the crevice corro-
sion penetrated through the plate, 98%
H2SO4 and cooling water were mixed
and changed to the dilute sulfuric acid.
Consequently, dilute acid made general Crevice
corrosion
corrosion collaterally.
˜ Action and correction…It is necessary to
change the plate material to HastelloyC
Magnified of the cooling water side
equivalent, and improve control to pre-
vent concentrating the Cl– ion concentra-
Steam side
tion in the cooling water.

˜26 27˜
5— Fault Detection

¢Erosion corrosion
Guideline curve for risk of crevice corrosion for
When the metal surface is eroded due to
stainless steel
continuous collision of slurry, etc. in the fluid
and that area becomes deeply intruded, this
is called erosion corrosion. Typically this
frequently occurs at narrowing or bending
sections of a pipe, where the fluid velocity
increases locally. Its progress depends on Decreasing the plate thickness due to severe
the type of metal or fluid, temperature, and erosion corrosion
the flow conditions of the fluid.
1000

SUS317 <Example>
(Stainless Steel 317) ˜ Operating time…Approx. 4 years
500 ˜ Plate material…TP270 (Ti) (Stainless
400 Steel 304)
˜ Duty…20% NaOH / industrial water
Chlorine ion concentration (ppm)

300
˜ Operating temperature…30°C
Erosion corrosion at the plate contact points
200 ˜ Phenomenon…A severe general corro- and near contact points
sion, penetrating pit and fluid leaks were
found at the wet surface of 20% NaOH
SUS316 ¢Crevice corrosion
100 (Stainless Steel 316) resistance of stainless
side.
90 steel ˜ Cause…Deep erosion corrosion was
80
The main factor of crevice found around the plate to plate contact
70
60 corrosion and pitting corro-
sion in austenite stainless
points and part, and it was judged that
50 erosion corrosion had progressed.
steel, is the concentration of
40 CI– (chlorine ions) in water. ˜ Action and correction…Decreasing of
If the CI– concentration in
30 the fluid is known, please
the fluid velocity by increasing the num-
SUS304 refer to this curve to select ber of plates, and removal of the slurry,
(Stainless Steel 304) the material. and in addition, using the thicker plate
20
Example) For cooling water
where the CI– Ion concen-
is recommended. It is also necessary
tration is 100ppm or less, to check the corrosion resistance of the
and the maximum tempera- plate material.
10 ture is 40°C.
0 50 100 150
Temperature (oC) There would be a slight
concern for risk of corrosion
with SUS304, so SUS316 is
preferable.

˜28 29˜
5— Fault Detection

¢Stress corrosion cracking <Example 2>


In the case that tensile stress exists in ˜ Operating time…Approx. 3 years and 7
the material, stress corrosion cracking is months
occurred from corrosion part. In the part ˜ Plate material…TP270 (Titanium 270)
being existing tensile stress, destruction of ˜ Duty…Mixed organic vapors / ethylene
the passive film, movement of atoms and glycol solution
voids are more likely to occur, and when ˜ Operating temperature…99°C
that area is exposed to a corrosive environ- ˜ Phenomenon…A crack occurred on the
ment, corrosion will especially progress in plate, and leakage was found.
this area. The corrosion will then acceler- ˜ Cause…Used as a condenser for mixed
ate due to the stress, and lead to cracks. organic vapors (toluene, methanol, ace-
tone, etc.). It is supposed that a crack
<Example 1> occurred due to the methanol in the
˜ Operating time…Approx. 2 years
vapors, and stress corrosion cracking
˜ Plate material…SUS304 (Stainless
occurred.
Steel 304) ˜ Action and correction…Austenite type
˜ Duty…Primary water / secondary water
stainless steel is suited for methanol
˜ Operating temperature…90°C
existing circumstance. We recommend
˜ Phenomenon…There was an occur-
changing material to the type to SUS316.
rence of rust deposit on the back side of
the gasket, and a crack occurred at the
gasket seal line.
˜ Cause…It is possible that when chloride
ions in the fluid was exposed to high
temperature conditions, it was concen-
trated at gasket areas where the flow Plate
rate is slow, and the plate was corroded Vapor side
here rapidly. The crack can be deter-
mined to be stress corrosion cracking
due to the rust deposit occurrence and
branch shape crack. Magnified of the vapor side
˜ Action and correction…Because the
plate surfaces are also corroded, using
SUS304 may be corroded by this
water quality. We recommend to use
Cracking
the material to the molybdenum added at the gasket
SUS316, which is anti-chloride material. groove

˜30 31˜
5— Fault Detection

5-3 Other fault detections <Example> ¢Plate deformation <Example>


˜ Operating time…Approx. 13 years and 8 Main causes of plate deformation is due to ˜ Operating time…Approx. 13 years and
¢Fatigue crack
months excessive tightening, gasket expansion, etc., 4 months
A condition where damage occurs from
˜ Plate material…SUS316 (Stainless Steel but there are also cases in which it occurs ˜ Plate material…SUS316 (Stainless
repeated stress on a material. Even low
316) from water hammering. Water hammering Steel 316)
loads that would normally not be damaged
˜ Duty…Steam / thermo oil occurs when water flow in a pipe is sud- ˜ Duty…0.2MPaG steam / hot water
can cause localized plastic deformation
˜ Operating temperature…130°C denly shut off, the momentum of flow makes ˜ Operating temperature…170°C
(deformation that will not return to the origi-
˜ Phenomenon…When brine instead of a shock and vibrational water pressure ˜ Phenomenon…Deformation was found
nal form even when the external force is
steam and thermo oil was periodically through the pipe. In a plate heat exchanger, at the gasket groove of the plate on the
removed), and small cracks can progress
used through the unit alternatingly, a inter- this occurs when pump startup and stop, hot water side.
to cause major damage.
mixing of brine and thermo oil occurred. valve opening/closing occurs too fast. This ˜ Cause…Because no corrosion or stress
In the 5 plates, a crack was found near can cause severe problems, deforming the concentrations can be seen, water ham-
the end of the center of the heat transfer gasket grooves or contact points on the plate mering made this damage.
zone, at lower part of the plate. surfaces, etc. ˜ Action and correction…In this condi-
˜ Cause…Because there are no traces of tion, the gasket cannot be compressed
corrosion on the plates, and the position by plate deformation, and sealing is not
of the cracks of each plate is the same, possible. The plates were damaged, so
and because this is a position where all plates were replaced. It is necessary
stress will concentrate and the load is to improve the operating condition, to
high, fatigue crack is concluded to be the avoid water hammering.
cause.
˜ Action and correction…It is concluded
that fatigue crack occurred because this
unit was used for long years. To increase
Port hole (from the back side of the plate) can be
the strength of the plates, a thicker plate seen to be severely deformed.
is recommended.

Steam side (left)


Thermo oil side (right)

It can be seen that the double seal area (from the


back side of the plate) is hollowed.

Magnified of the fatigue crack

˜32 33˜
6— Overhauling 7— To Extend the Lifetime of Your Heat
Exchanger
In order to extend the lifetime of the plate heat exchanger, it is important to watch changes The ease of maintenance is one of the
in conditions. Frequently observed faults and causes are summarized below. If those major benefits of the plate heat exchanger.
faults are detected, please contact us and inform manufacturing number of the unit. It is possible to open the unit by just remov-
ing the tightening bolts, and the plates can
Faults Decreasing of Heat transfer performance be inspected visually. However, finding
performance small corrosions and pinholes, and thor-
It is necessary to clean the plates and remove
oughly cleaning tough scaling without dam-
scale, because of supposing scaling on the
heat transfer surface. aging the thin plates require experienced
skill.
As a technical supporter providing "relief"
Flow performance
and "reliability" in maintenance service, we
Clogging of the port holes inlet and/or scale
will work to help extend the life of the plate
deposition on the heat transfer surfaces may be
supposed. It is necessary to clean the unit and heat exchanger as long as possible. Please
remove scale. utilize our services for your maintenance.

Leakage of fluids From plate pack Detailed information regarding maintenance


Insufficient tightening the plate pack, damage is also available on our website's mainte-
or deterioration of gaskets, plate gasket groove nance page.
or double seal area corrosion, wrong plate ar-
http://www.hisaka.co.jp/english/support/
rangement, foreign object caught between gas-
ket seal surfaces, gasket twisting or overlap- heatexchanger/check/index.html
ping from the groove may be the supposed.
Correct each fault or replace gaskets and/or
plate.

Intermixing of From the S-frame


two media The D-plate gasket, rubber boots, D-plate or S-
It is possible that corro- nozzle may be damaged. Replace the dam-
sion or damage to the aged part.
intermediate plate has
penetrated the plate.
Replace the damaged From the E-frame
plate. The E-nozzle gasket, E-nozzle, rubber boots,
or E-plate may be damaged. Replace the dam-
aged part.

˜34 35˜
For Maintenance call.

Osaka TEL. +81-72-966-9601


Tokyo TEL. +81-3-5250-0760
Nagoya TEL. +81-52-217-2491
Please inform the manufacturing number of the unit.
˜ For questions regarding content of services or products,
please contact the sales department.

˜36 HE-ME000302
14.06.0000.AIB

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