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MAINTENANCE
GUIDE
HISAKA Plate Heat Exchanger
Maintenance Guide
1
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
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
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
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
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>
Model 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.
Material...304:SUS304 304L:SUS304L
316:SUS316 316L:SUS316L 6J1L:SUS316J1L For a rubber boot type, a piping gasket is not
A B 035 001
HC22: Hastelloy C-22 HC276: Hastelloy C-276
NNCP: NC-NI
Manufacturing number for each month 1-999
10 11
3— Maintenance
¢Deterioration of gaskets P = α ε +β 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 [%] = × 100
t0 relationship between operating time and 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 Visual 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 Hardness … passed
and time θ [h] increases further, the gasket will reach Hardness is to be between 65° to 93°.
C/S = γ θ ζ 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
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>
There were no external defects on the
12 13
3— Maintenance
14 15
4— Introduction of Maintenance Services
BEFORE AFTER
Before work/after work
Disassembly
Sampling of plate
Gasket removal
Cleaning
Gasket gluing
Assembly
leakage test
Pneumatic
Final inspection
Shipment
test
Dye penetration
NG
plates
Replacing of
Records of maintenance and replaced
Frame overhaul
Painting
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
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.
20 21
5— Fault Detection
(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
Normal 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)
22 23
5— Fault Detection
24 25
5— Fault Detection
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
30 31
5— Fault Detection
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.
34 35
For Maintenance call.
36 HE-ME000302
14.06.0000.AIB