apv paraflow plate hx manual

Solutions and ServicesParaflow Plate Heat Exchanger

Instruction Manual

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TABLE OF CONTENTS Page

1.0 INTRODUCTION 31.1 General1.2 Safety1.3 Design1.4 Receiving and Inspection

2.0 SAFETY INSTRUCTIONS 42.1 General Statement2.2 Hazard Level Identification2.3 Operating Zone2.4 Installation2.5 Safety Instructions2.6 General Operating Safety2.7 Service and Maintenance Safety2.8 Safe Cleaning Procedures

3.0 CONSTRUCTION 73.1 Frame3.2 Plates3.3 Gaskets3.4 Intermediate Connector Grids3.5 General Arrangement Drawing3.6 Plate Arrangement Drawing

4.0 INSTALLATION 184.1 Location4.2 Foundations4.3 Space Requirements4.4 Connections and Piping4.5 Pressure Pulsation and Vibration4.6 Pressure/Temperature Ratings4.7 Hydraulic Shock4.8 Heat Shields4.9 Short Term Storage4.10 Long Term Storage

5.0 ASSEMBLY 205.1 Handling5.2 Lifting5.3 Assembling the Frame5.4 Installation of Plates5.5 Installation of the Tie Bars5.6 Closing Tie Bar Frames5.7 Opening Tie Bar Frames


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6.0 STARTUP AND OPERATION 256.1 General6.2 Startup6.3 Operation6.4 Shut Down6.5 Troubleshooting

7.0 MAINTENANCE 297.1 Opening the Frame7.2 Inspection7.3 Cleaning7.4 Replacement of Plates7.5 Regasketing


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1.0 INTRODUCTION

1.1 General

The purpose of this manual is to provide youwith the information necessary for the safe andproper installation, operation and maintenanceof your APV Paraflow Plate Heat Exchanger.This will ensure many years of satisfactoryperformance. The manual is specific to the tiebar tightened frames. Separate publicationsdeal with Paraflow Plate Heat Exchangerstightened by other means.

1.2 Safety

Safe installation, operation and maintenance ofthe APV Paraflow Plate Heat Exchangerrequires proper procedures and training of allpersonnel. Section 2.0 Safety Instructionsshould be read and understood beforeproceeding. This section discusses generalsafety practices. In addition, specific hazardsare indicated throughout this manual by theappropriate hazard label in bold type.

Warning:

Read and understand the entire manualbefore unpacking the equipment andinstalling it.

It is the objective of APV to clearly identify eacharea of potential hazard and guide workers insafe operation, service and maintenanceprocedures.

1.3 Design

The Paraflow is the original plate type heatexchanger designed by APV to providemaximum efficiency and cost effectiveness inhandling heat transfer duties. The basicconcept is two liquids flowing on either side of athin corrugated metal plate so heat may beeasily transferred between the two. The plateheat exchanger also minimizes maintenancedowntime and requires little floor spacecompared to other types of heat transferequipment. This equipment has manyapplications in a wide range of industries.Typical industries include:

Chemical DairyIndustrial BeveragePetroleum Liquid FoodHVAC PharmaceuticalRefrigeration Health Care

1.4 Receiving and Inspection

APV Paraflow Plate Heat Exchangers areassembled and inspected before shipment andproperly prepared for transportation. APVcannot, however, guarantee safe arrival.Therefore, upon receipt of this equipment checkall received items against the packing list fordamage or missing parts. Damage or lossshould be reported immediately to the carrier.


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2.0 SAFETY INSTRUCTIONS

2.1 General Statement

APV Paraflow Plate Heat Exchangers aredesigned and manufactured with dueconsideration and care for generallyaccepted safety standards. However, likeany mechanical device, the proper and safeperformance of this equipment dependsupon using sound and prudent operating,maintenance and servicing proceduresunder properly trained supervision.

For your protection, and the protection ofothers, learn and always follow the safetyrules outlined in this section. Observewarning signs on machines and actaccordingly. Form safe working habits byreading the rules and abiding by them.Keep this booklet handy and review it fromtime to time to refresh your understandingof the rules.

2.2 Hazard Level Identification

Definitions for identifying the various hazardlevels shown on warning labels or toindicate proper safety procedures in theinstruction manual are provided in thefollowing labels.

Danger:

The use of the word Danger alwayssignifies an immediate hazard with ahigh likelihood of severe personal injuryor death if instructions, includingrecommended precautions, are notfollowed.

Warning:

The use of the word Warning signifiesthe presence of hazards or unsafepractices that could result in severepersonal injury or death if instructions,including recommended precautions,are not followed.

Caution:

The use of the word Caution alwayssignifies possible hazards that couldresult in minor injury or damage toproduct or property if instructions,including recommended precautions,are not followed.

2.3 Operating Zone

An operating zone should be establishedaround all heat exchangers. A brightlypainted guard rail or warning stripe shoulddefine the zone. Only the operator of otherauthorized personnel should be within theoperating zone when machine controlcircuits are energized or the heatexchanger is operating. No tools or otherequipment should be kept within theoperating zone.

2.4 Installation

Utilities, such as water, steam, electric, airand hydraulic, should be installed by trainedand authorized personnel only.Installations must comply with all applicablecodes and standards, including thoseestablished by OSHA.

2.5 Safety Instructions

Before Starting a Machine


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be absolutely positive all necessary guardsand safety devices are installed andoperating properly. This includes heatshields or pressure relief devices.

Be sure all personnel are clear of themachine.

Remove (from the operating zone) anymaterials, tools, or other foreign objects thatcould cause injury to personnel or damagethe machine.

Make certain all alarms, indicating lights,pressure gauges and other safety devicesor indicators are in working order.

After Shutdown

Make certain all water, steam, air, hydraulicand electric utilities are turned off. Makecertain all pressure in the heat exchanger isreleased.

2.6 General Operating Safety

Do not operate this heat exchanger untilyou read and understand the operatinginstructions and become thoroughly familiarwith the heat exchanger and its operation.

Never operate a heat exchanger while asafety device or guard is removed ordisconnected.

Always wear safety glasses, hats, shoes,ear protection or any other required safetyequipment.

Never remove Warning tags that aredisplayed on the heat exchanger. Torn orworn labels should be replaced.

Do not start the heat exchanger until allother personnel in the area have been

warned and have moved outside theoperating zone.

Remove any tools or other foreign objectsfrom the operating zone before starting.

Absolutely do not have loose clothing,neckties, necklaces or unrestrained longhair near an operating heat exchanger.

Do not wear gloves, rings, watches,bracelets or other jewelry near an operatingheat exchanger.

Keep the operating zone free of obstaclesthat could cause a person to trip or falltowards an operating heat exchanger.

Never sit or stand on anything that mightcause you to fall against the heatexchanger.

Horseplay around a heat exchanger atany time is dangerous and prohibited.

Know the EMERGENCY STOP procedurefor the heat exchanger.

Never operate the heat exchanger abovespecified capacity, pressures, ortemperatures.

Keep alert and observe indicator lights andwarnings that are displayed on the heatexchanger.

Do not operate faulty or damagedequipment. Make certain proper serviceand maintenance procedures have beenperformed.

A safe work surface should be providedaround the heat exchanger, includingproper guarding of elevated platforms andthe design and use of ladders.


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2.7 Service and Maintenance Safety

Do not service a heat exchanger until youare thoroughly qualified and familiar withthe tasks to be performed.

Never operate any valves, pumps orcontrols while persons are performingmaintenance work on the heat exchanger.

Do not bypass a safety device.

Always us the proper tools for the job.

Do not enter a confined space without firstchecking for toxic fumes and providingstandby personnel on the site.

2.8 Safe Cleaning Procedures

Manual Cleaning ProceduresDo not use toxic or flammable solvents toclean a heat exchanger.

Always clean up spills around heatexchanger while it is operating.

Cleaning in Place ProceduresMake certain all connections in the cleaningcircuits are tight to avoid contact with hotwater or cleaning solutions.

When the cleaning cycle is controlled froma remote or automated center, establish failsafe procedures to avoid automatic start upwhile servicing equipment in the circuit.

On equipment that includes heat shields,make certain the shields are properlyinstalled prior to starting the cleaning cycle(See paragraph 4.8 and 9.3).


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3.0 CONSTRUCTION

3.1 Frame

A typical Paraflow Plate Heat Exchanger isshown in Figure 1. Figure 2 is anexploded view showing the individualcomponents. The main componentsinclude a stationary cover (head), Item 1,an end bar, item 2, connected by a topcarrying bar, item 3, and bottom guide rail,item 4. These components are boltedtogether to form a rigid frame that supportsthe thin metal heat transfer plates, item 5,and moveable cover (or follower), item 6.Each plate is separated and sealed by agasket. The plates are compressedbetween the head and follower by means oftie bars, item 7, on either side of theexchanger. Liquids are introduced to theheat exchanger through connectionslocated in the head, follower, orintermediate connector grids, whensupplied (as shown in Figure 3 on page 10).


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When Paraflow Plate Heat Exchangers areopened for service, the follower movesback along the top bar to allow full accessto each individual plate. Divider plates andintermediate connector grids also movefreely on the top carrying bar to provideeasy access to individual plates.

Paraflow frames used in industrial dutiesare fabricated in carbon steel and arefinished in a heavy-duty chemical resistantpaint. Industrial frame connections may bestudded with various lining materials ornozzles. The nozzles are fabricated incarbon steel, stainless steel or alternatemetals. Connection types may be lap joint,weld neck or specialty flanges. Sanitarytube connections may also be supplied oncarbon steel frames. The connectionmaterials and types may be mixed on anindividual frame.

Frames used for sanitary duties are usuallyfabricated in solid stainless steel or carbonsteel that is entirely clad with stainlesssteel. The finish is either a #4 polish orglass bead blast depending on the model.Standard connections are sanitary tubefittings at all locations. Industrial fittingsmay be supplied when required.

Divider plates may be used to divide a heatexchanger into separate operating sections.Divider plates have no connections but mayallow flow from one section to the next.

Intermediate connector grids as shown inFigure 3 may be used to divide a heatexchanger into separate sections toaccommodate multiple duties within asingle frame. Connector grids may have upto two connections at any corner.


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3.2 Plates

APV heat exchanger plates come in over60 different sizes and 34 differentcorrugation patterns. This allows the heatexchanger to be matched closely to aspecific duty. The corrugations causeturbulence in the liquids as they flow in athin stream in the passage between eachplate (Figure 4). The plates have ports ineach corner that, when stacked in a platepack, form a manifold for even fluiddistribution to the individual plate passages(figure 5). The ports are gasketed so onlytwo ports on each plate allow flow acrossthe plate (flow ports). The other two portsare though ports and do not allow the liquidflowing in them across the plate. This flowpattern alternated from plate to plate toform right hand and left hand plates.


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Plate ConstructionAll plates are designated as wither diagonalflow or vertical flow (Figure 6) based ontheir flow pattern. Plates are pressedthicknesses between 0.4 1.2 mm (0.016and 0.047 inches) in a variety of materials(see Plate Materials below). The platecorrugation pattern alternates from plate toplate to provide support at the points ofcontact. One type of corrugation patternlooks like a washboard. It provides a widegap between plates with contact pointsevery 1 to 3 square inch of heat transfersurface area.

Another design is the chevron pattern ofrelatively shallow corrugations with supportprovided at peak/peak contact. Alternateplates are arranged so that corrugationscross to provide contact points for every 0.2to 1 square inch of surface. This greaterdensity of contact points in the chevronpattern allows a higher differential operatingpressure for a given plate thickness thanthe washboard pattern.

Mixing PlatesTo obtain optimum thermal and pressuredrop performance while using a minimumnumber of heat exchanger plates, plates oftwo or more corrugation angles may bemixed within the same frame. This isavailable for many APV Paraflow PlateHeat Exchanger models.

Mixing plate angles results in flow passagesthat differ significantly in their flowcharacteristics. This allows the Paraflowdesign to be fine tuned in a single or evenmultiple pass arrangement to closely matchto the thermal and pressure droprequirements of the application.

Plate MaterialParaflow plates may be pressed from 304or 316 stainless steel, Avesta 254SMO or254SLX, Nickel 200, Hastelloy B-2, C-276or G-3, Incoloy 825, Iconel 625, Monel 400,Titanium, Titanium-Palladium or otherspecialty alloys as required to providesuitable corrosion resistance to the liquidsbeing handled.

Duo-Safety PlateThe APV Duo-Safety heat exchanger plateis a double wall plate manufactured fromtwo loose plates pressed together at thesame time to form a pair. Each APV Duo-Safety plate pair is equipped with a non-glue Paraclip gasket, which seals and holdsthe pair together. The two plates can bemade of different materials.

The space between the two plates of theAPV Duo-Safety plate pair serves as asafety zone in case of through-plate leaksfrom corrosion or wear. Should this occur,the liquids will not be mixed, but will bedischarged between the two walls into theatmosphere. This provides a high level ofcertainty that liquids will not be cross-contaminated. The APV Duo-Safety plate


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Materials ApplicationParacil General Purpose material for

aqueous and fatty dutiesEPDM High temperature general

purpose material for chemicaland steam applications

Paraflor Mineral oils, acids, steam andhot water at high temperatures

Paradur Organic solvents, chemicals andsulfuric acid

Paraprene(Neoprene)

pair also can be dismantled for cleaningbetween the two plate walls.

Paraweld PlateThe APV Paraweld plate is a right and lefthand plate laser welded together to form aplate pair. This welded plate is particularlysuited for use with refrigerants such asammonia and Freon, or aggressive liquidsthat would otherwise attack the gaskets in aconventional heat exchanger plate.

The laser weld is done in a twin path foradded security. When the welded pairs areinstalled in a frame, each pair is separatedby elasomeric seals.

3.3 GasketsThe seal between the plates is achieved bya single gasket around the perimeter of theplate and a double gasket around the twothrough ports. This double gasketseparates the port from the heat transferarea with a double barrier. The spacebetween the double gasket is vented toatmosphere to prevent cross contamination.(Figure 7).

Interlocking GasketsAPV Paraflow Plate Heat Exchanger plateshave interlocking gaskets with upstandinglugs and scallops evenly spaced around theoutside edges. These scallops ensure that

there are no unsupported portions of thegaskets and, in combination with thepatented form of the pressed groove,provide mechanical plate-to-plate supportfor the sealing systems. The upstandinglugs (Figure 8) maintain plate alignment inthe Paraflow during plate pack closure andoperation. The groove form provides 100%peripheral support of the gasket, leavingnone of the material exposed to the outside.In addition, the gasket exposure to theprocess liquid is minimized by the full depthplate gasket groove.

Gasket MaterialsAs detailed in Figure 9, various gasketmaterials are available as standard whichprovides chemical and temperatureresistance coupled with excellent sealingproperties. Other gasket materials areavailable for special applications. Gasketmaterial selection must take intoconsideration the chemical composition of tThe fluids involved as well as the operatingconditions.

Figure 9


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Gasket AttachmentAPV Paraflow Plate Heat Exchangergaskets are attached to individual plates byone of two methods, glued or clip in. Theglued in gaskets are attached by athermoplastic adhesive, which is heat curedfor maximum strength.

The clip in gaskets (Paraclip) are attachedto the plates by small nubs around theperimeter of the gasket which snap intomatching holes.

3.4 Intermediate Connector Grids

These intermediate connector grids dividethe plate heat exchanger into separatesections that may operate independently.The connector grids are equipped withremovable connector bosses (Figure 10)that provide connections for the liquidshandled.

The connector grid bosses form theconnecting link between sections of theplate heat exchanger and provideconnections to and from these sections.On some models, two connections can beprovided in the same connector grid bosswith connections to the adjoining sections.

3.5 General Arrangement Drawing

A General Arrangement Drawing issupplied with each APV Paraflow Plate

Heat Exchanger. This drawing providesdetailed information concerning designspecifications, operating conditions,dimensions, connections, plates andgaskets, plate arrangement diagram andkey, bill of material and special notes.

Design SpecificationsThe data list on the design specificationsprovides the key mechanical informationused to design the plate heat exchanger.This includes the design code, maximumand minimum platage dimensions, heattransfer area, frame size, maximum platecapacity, weights, and volume.

Operating ConditionsThis table on the drawing contains the dutyor operating conditions for which the heatexchanger was designed. It specifies eachfluid, the flow rates, the temperatures andthe pressure drops.

Connection ScheduleThe connection schedule identifies the size,material, and type of each connectionsupplied.

Plate and Gasket ListEach general arrangement drawingcontains a summary of all the plates andgaskets used for the plate arrangement.This summary includes plate types, angles,and material, also gasket type, material,and attachment (glued or clip in).

3.6 Plate Arrangement Drawing

Configuration of the DiagramThe plate heat exchanger is designed toperform a duty (or duties) by arranging thenumber and type of plates required in aspecific sequence. This arrangement isrepresented schematically by the platediagram shown on the general arrangementdrawing. The schematic represents the


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fluid flows by heavy lines with arrows andthe plates by thin vertical lines. Plate portsthat block flow (not open) are representedby small black rectangles.

Each connection on the plate diagram isidentified and labeled. The connections arealso identified on the dimensioned view orthe isometric view of the plate heatexchanger and the Connection Schedule.

Along the top of this diagram is a listing ofeach plate required, showing the hand ofeach plate (Right or Left), the direction thegaskets face (Head or Follower) and thepunch code (blanking designation). Thepunch code indicates which ports are openand allow flow. Additional codes may belisted indicating plates with drains (D) andvents (V) or plates with end gaskets (K).Other symbols may be used to indicatespecial support pads or gaskets. Thegeneral arrangement drawing includes akey, which illustrates the punch codes. Thepunch codes are also illustrated on thefollowing pages in Figure 11 for verticalflow plates and Figure 12 for diagonal flowplates.


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sknierimFigure 12


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Examples:

Figure 13 shows a typical single passarrangement using diagonal flow plates withall the connections on the head.

Note:

Figure 14 shows a typical three passarrangement using diagonal flow plates withtwo connections on the head and two onthe follower.

PLATES MUST BE ARRANGEDALTERNATELY LEFT AND RIGHT.FOR CONVENIENCE ON THEDRAWING, WHERE BLOCKS OF R1234AND L1234 PLATES OCCUR, THETOTAL NUMBER OF EACH IS GIVEN.


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4.0 INSTALLATION

4.1 Location

The heat exchanger should be installed inan area with adequate clearance aroundthe unit to install or remove plates andperform maintenance.

The unit should also be located withconsideration for the required pipingconnections. Product and service linesshould be designed to minimize pressuredrops and be adequately supported tominimize the loads on the heat exchanger.

4.2 Foundations

The foundation pad for the heat exchangershould be level and sized properly for theoutline of the frame. It must also be ofadequate strength to support the fulloperating weight of the unit. The overalldimensions and operating weight are listedon the general arrangement drawing.

4.3 Space Requirements

On at least one side of the plate heatexchanger there must be sufficientclearance to remove a plate from the topbar. Also, there must be adequate room totighten or remove the tie bars and inspectthe plate heat exchanger (Figure 15). Thefollower must be free to move along the fulllength of the top bar as shown in (Figure16). The general arrangement drawingprovides overall dimensions and plateremoval distance.

4.4 Connections and Piping

The plate heat exchanger must beconnected in accordance with thearrangement shown on the generalarrangement drawing provided with theheat exchanger.

Pipe lines to the follower and connectorgrid(s) must be located to allow the unit tobe easily opened for inspection andmaintenance. These lines must also beflexible to allow for small variations in thetightening dimensions and possible thermalexpansion.


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4.5 Pressure Pulsation and Vibration

Piston pumps, gear pumps, valves etc.must not be able to transfer pressurepulsations or vibrations to the plate heatexchanger as this may cause fatiguefracture in the plates. The use of pressuredampers in the pipeline is recommended tominimize this effect.

4.6 Pressure/Temperature Ratings

The pressure and temperature ratings for aspecific heat exchanger are listed on thegeneral arrangement drawing provided withthe unit. These ratings must not beexceeded at any time during startup oroperation.

Over pressure protection must be providedif it is possible the system may develop ahigher pressure than the maximumallowable working pressure of the heatexchanger.

4.7 Hydraulic Shock

The plate heat exchanger will be damagedby any hydraulic shock that occurs duringstart up or operating changes. To avoiddamage, throttling valves and soft pumpsare recommended.

4.8 Heat Shields

A heat shield may be provided for new orexisting heat exchangers. They are

recommended whenever corrosive liquidsor high temperatures are present. SeeSection 9.0 Accessories for moreinformation.

4.9 Short Term Storage

All heat exchangers and components mustbe stored in a cool environment away fromsunlight. They must also be coveredloosely by a tarp or plastic sheet that allowsair circulation and provides protection fromwater, debris, and sunlight. This procedureis suitable when the storage period is lessthan six months.

4.10 Long Term Storage

Long term storage of APV Plate HeatExchangers requires following ProcedureSP5002 to avoid damage or deterioration.This procedure should be used when a heatexchanger will not be placed in servicewithin six months after shipment from thefactory. Contact the Customer ServiceDepartment listed in Section 8.0 of thismanual for copies of the procedure andassistance.

Warning:

Do not exceed the maximumoperating pressure ortemperature listed on the GeneralArrangement Drawing or damageto the heat exchanger will result.

Caution:

A heat exchanger which has been instorage for more than five (5) yearsshould be inspected by an APVrepresentative prior to preparing it foroperation.


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5.0 ASSEMBLY

5.1 Handling

APV Paraflow Plate Heat Exchangers areshipped fully assembled and skid mountedor, when required, they are shippedunassembled in boxes. In either case,proper handling practices must be followed.The weight of an assembled heatexchanger is listed on the generalarrangement drawing. Weights ofcomponents are listed on the shipping box.The skids and boxes are designed to bemoved by standard lift trucks of propercapacity.

5.2 Lifting

All APV heat exchangers are provided withlifting holes, lugs, or eyebolts to simplifylifting. The general arrangement drawingshows their size and location. When liftingan assembled heat exchanger frame,ensure that the lifting point is approximatelyabove the center of the plate pack. Aspreader beam is recommended for largeor long frames.

5.3 Assembling the Frame

The following steps are recommended tosafely assemble an APV heat exchanger.These instructions refer to the componentsillustrated in Figure 2 in Section 3.0.

When assembling a heat exchanger frame,start by erecting and securing the head.Fasten the bottom guide bar to the head bythe bolts supplied and block it up. Bolt theend support to the bottom guide bar withthe bolts supplied. See Figure 17. Notethat shorter bolts are used at the endsupport.

Position the follower in the frame next to thehead and brace it securely. See Figure 18.

Warning:

All lifting equipment must have theproper capacity and be in goodcondition. Personnel must followsafe rigging practices at all times.

Caution:

All components must be properlysupported during all phases ofassembly.


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Position the top carrying bar between thehead and end support and using the boltsprovided, fasten it securely. See Figure19.

Lift the follower into place and install theroller and axle assembly. See Figure 20.Roll the follower back to the end support toallow plate installation.

5.4 Installation of Plates

Wipe the top carrying strip clean betweenthe head and the end support and apply apetroleum based grease to allow the platesto slide freely.

Install all the plates of the type and quantityspecified on the plate arrangement drawing,starting at the head end of the frame.Check to make sure all plates are orientedproperly, that gaskets are properly seatedin their grooves, and there is no debrisanywhere on the plates or gaskets. Cleanthe sealing surface with a lint free cloth.Push each plate firmly against the previousone. Use special care with plates havingParaclip gaskets (gaskets clipped to theplates) to avoid dislodging them. SeeFigure 21.

Note: The plate arrangement on thegeneral arrangement drawing indicates ifthe gasket side of the plate faces the heador follower.

CAUTION:

During installation, alwaysalternate left and right handplates. For simplification only,whole blocks of identical left orright hand plates are shown onthe plate arrangement drawing.The total number of each isgiven.


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5.5 Installation of Tie Bars

When all plates have been correctlyinstalled, roll the follower up to the end ofthe plate pack. Install the tie bars into theframe holes or key hole slots as specifiedby the tightening instructions below.

Clean the tie bar threads and liberally applyan anti-seize compound along the areawhere the nuts will travel during tightening.Also apply the compound to both sides ofthe plain washer under the tie bar nut. APVrecommends Never-Seez Regular GradeLubricant for carbon steel tie bars andNever-Seez Black Molly Lubricant forstainless steel tie bars. Do not usestandard grease as it may result in galling.Figure 22 shows an assembled frame withtie bars installed.

5.6 Closing Tie Bar Frames

The intent of these instructions is to providea method to evenly and safely tighten aParaflow Plate Heat Exchanger with tiebars. Proper tightening is essential forsatisfactory operation and maximum gasketlife. These instructions should be followedclosely for both initial assembly andwhenever the exchanger is closed afterservice.

1. Confirm that plates are all installedcorrectly to the general arrangementdrawing. Check the quantity andorientation (alternating left and right). Movethe follower toward the fixed head as far asit can go. Install four tie bars as shown inFigure 23.

2. Starting with the top tie bar pair andalternating with the bottom, tighten the tiebars evenly about to 1 at a time, untilthe platage dimension (thickness of theplates) measured at the installed tie bars isequal and the follower is parallel to thehead. This measurement should be about10% over the final plate dimensionspecified on the Paraflow platearrangement drawing. Throughout thisstep, keep the dimension from one side to

CAUTION:

Never-Seez Regular Grade isnot suitable for stainless steel tiebars.


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the other at each pair of tie bars within .Also, always tighten the top pair of tie barsfirst to keep the plates from riding up.

3. Install the rest of the tie bars on thesides of the heat exchanger between theports (if applicable) and tighten them evenlyuntil the plate dimension is the same at allinstalled tie bars.

4. Starting with the top pair of tie bars,continue tightening equally about at atime until the platage dimension measuresabout 5% above the final dimension.

5. Install the remaining tie bars (ifapplicable) above the top ports and belowthe bottom ports of the frame. Starting withthe top pair and working down, tighten eachpair 1/8 at a time. After each tighteningcycle of 1/8, return to the top set of barsand repeat the procedure.

Note: On large heat exchangers using 2,42 mm or 48 mm diameter tie bars, it mayonly be possible to achieve 1/16movement during the final stages oftightening.

6. Tighten the exchanger to the maximumplatage dimension specified on the platearrangement drawing. The dimension mustbe the same at all tie bars. See Figure 24.

Note: Due to o-ring type gasket seal, thefinal closed dimension is determined bydimension, not tie bar torque.

Manufacturing tolerances of the plate mayresult in the actual minimum platagedimension varying. Refer to your platearrangement drawing for actual minimumand maximum dimensions.

7. Pressure test the heat exchanger forleaks by using potable water at the desiredpressure but do not exceed the pressurespecified on the drawing. The test may bedone on each side separately or on bothsides at once. Make sure all air is ventedfrom the heat exchanger before performingthe pressure test.

8. If leaks occur, the heat exchanger maybe further tightened and retested. It issuggested that this be done in steps ofapproximately 0.001 per plate until the leakstops or the minimum dimension specified

WARNING:

Never tighten a Paraflow, which isunder pressure from any source.

Never tighten a Paraflow with pipingconnected to the follower orconnector grids.

WARNING:

Refer to your plate arrangementdrawing for the proper tightening plate

dimension


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on your general arrangement drawing isreached.

9. If the leaks continue, mark themcarefully and open the exchanger inaccordance with Paragraph 5.7. Inspectthe area of the leaks closely for damagedgaskets, plates, sealing surfaces or debris.Replace all suspect plates or gaskets, cleanthe sealing surface with a lint free cloth, andrepeat steps 1 through 7.

5.7 Opening Tie Bar Frames

Tie bar frames may be opened safely byfollowing steps 1 through 6 in paragraph 5.6in reverse order. The tie bars must beloosened in the same sequence andamount as described in each step.

WARNING:

Never open a Paraflow until the unithas been cooled below 100F(38C).Never open a Paraflow which isunder pressure from any source.

Never open a Paraflow with pipingconnected to the follower orconnector grids.


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6.0 STARTUP AND OPERATION

6.1 General

Prior to startup, make sure the unit iscorrectly assembled and the pipingconnected properly. Also, check that theplates have been compressed to the properdimension specified on the generalarrangement drawing. See Figure 24 andrefer to section 5.0.

6.2 Startup

Sudden surges and rapid changes inpressure or temperature must be avoided,as these may damage the plates andgaskets. Throttling valves, flow diversionvalves and shut-off valves must beoperated slowly. Control flows withthrottling valves downstream of the heatexchanger.

Valves located on the outlet side of anyliquid stream must be opened prior tostartup to prevent dead heading of the heatexchanger.

If steam or another condensable vapor isused as a heating media, it must be turnedon after liquid has been introduced on theproduct side.

During initial startup, the exchanger maydevelop minor leaks. If these leaks do notstop when the unit has reached operatingtemperatures, refer to Paragraph 6.5Troubleshooting.

Air in the heat exchanger will normally becarried out by the liquid flow. However, it isgood practice at startup to vent air from thesystem at a high point in the piping. Thiswill insure the system is filled with liquid.

6.3 Operation

During operation, the same precautionsagainst rapid changes of pressure ortemperature during start-up must beobserved. Increasing pressure dropsand/or falling temperature may indicatereduced performance of the heatexchanger. This must be investigated to

Warning:

Proper assembly and tightening arerequired for safe startup andoperation.

Caution:

All pipe lines must be inspectedand flushed clean prior tooperation. Strainers arerecommended to prevent debrisfrom installation from entering theunit.

Caution:

Do not allow the pressure to changemore than 150 psig (10 bar) perminute or the temperature morethan 20F (11C) per minute.Improper startup will cause damageto the heat exchanger frame, platesor gaskets. Follow instructionsclosely.


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determine the cause. See Paragraph 6.5Troubleshooting.

6.4 Shut Down

The heat exchanger must be shut downslowly and allowed to cool naturally to roomtemperature. Inlet valves, if used, shouldbe closed before outlet valves. If steam isbeing used as a heating media, it must beshut off first. In cooling duties, the coolingliquid must be shut down first to avoidfreezing of the product.All liquids must be drained from the heatexchanger after shut down to preventprecipitation of products or scale buildup.

If the heat exchanger will be out of servicefor six months or longer, it must be properlyprepared for storage. See APV StandardProcedure for SP5002 for instructions.Contact the Customer Service Departmentlisted in Section 8.0 of this manual forcopies of the procedure and assistance.

6.5 Troubleshooting

APV plate heat exchangers are designed toprovide trouble-free service over the life ofthe unit. However, conditions or processesmaychange, resulting in reduced performanceor even leakage. The following tableprovides some guidelines for diagnosingcommon problems and suggestedsolutions. This table is intended as ageneral guide only. Assistance in specificcases may be obtained by calling yournearest Service Center listed on the front ofthis manual or the Customer ServiceDepartment listed in Section 8.0.

Warning:

Do not exceed the maximum operatingpressure or temperature listed on thegeneral arrangement drawing ordamage to the heat exchanger willresult.


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Troubleshooting Plate Heat ExchangersProblem Possible Causes Suggested Solutions

1. Reduced Heat Transfer a. The inlet temperatures or flow rates do not correspond to the original design.

b. Plate Surfaces have become fouled on either the product side or service side.

c. Freeze up.

Correct temperatures or flowrates to design conditions.

Open the heat exchanger andclean the plates or clean theplates in place by circulating asuitable cleaning agent SeeSection 7.0

Correct temperatures or flowrates to design conditions.

2. Increased Pressure Drop or Reduced Flow

a. Plate surfaces have become fouled on either the product side or the service side.

b. Debris is blocking the flow channels.

See paragraph 1(b) above.

Open the heat exchanger andclean the plates see Section6.0. Screens or filters must beinstalled to prevent debris fromentering the unit.

3. Visible leakage a. Operating pressure exceeds the rating of the heat exchanger.

Reduce the operating pressureto the rating of the heatexchanger. If the unit continuesto leak after the pressure isreduced, the plates or gasketsare damaged and must bereplaced. see Section 7.0.


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Troubleshooting Plate Heat ExchangersProblem Possible Causes Suggested Solutions

3. Visible leakage (continued)

b. The heat exchanger is not tightened adequately for the operating conditions.

c. Sealing surfaces of plates or gaskets may be damaged or dirty.

d. Chemical attack of the gaskets.

Tighten the heat exchangerfurther in increments of .0001inch per plate, checking forleakage each time. Do nottighten below the minimumdimension shown on the generalarrangement drawing seeParagraph 5.6. If leakscontinue, see paragraph 3(c)below.

Open the heat exchanger andinspect the plates and gaskets.There must not be any cuts,cracks, debris or flat spots onthe gaskets. Paraclip gasketsmust not have any debris underthe gasket. The plates must beclean and free of heavyscratches or dents on bothsides. Replace the defectiveparts.

Identify the source of chemicalattack and correct either byeliminating the corrosive agentor changing the material of thegaskets.

4. Cross contamination a. Cracks in one or more plates. These may be caused by fatigue resulting from pressure fluctuations during operation. Dye penetrant testing may be required to identify cracks in the plates refer to Factory Service, Section 8.0 for assistance.

b. Holes in the plates caused by corrosion.

Open the heat exchanger andinspect the plates. Replace thedefective parts. Identify thesource of pressure fluctuationsand correct.

Identify the source of corrosionand correct either by eliminatingthe corrosive agent or changingthe material of the plates.


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7.0 MAINTENANCE

7.1 Opening the Frame

Opening Tie Bar FramesDrain all fluids from the heat exchanger andallow it to cool. Loosen the tie bars evenlyin reverse order of steps 1 through 6 inParagraph 5.6. Remove the tie bars andpush the follower towards the end support(Figure 25). The plates may now beseparated for cleaning and inspection.

7.2 Inspection

Check the front and back of every plate forcleanliness and freedom from debris.Product build up and scale will reduce theperformance of the heat exchanger andcleaning is required see Paragraph 7.3.

Check each plate for cracks or holes.Some cracks may not be readily visible andwill require dye penetrant inspection tolocate them. Contact your nearest APVService Center listed at the front of thismanual.

Gaskets must be thoroughly checked forcuts, flattening, cracks, brittleness,breakage and proper fit of the gasketgroove. The gasket groove in the platemust be free of distortion or kinks.

The entire gasket and sealing surfaces ofthe plates must be totally free of any debrissince any foreign material will causeleakage and may damage the gasket.When installing clip in gaskets, carefulinspection is required to be sure there is nodebris or glue from previous gaskets underthe installed gasket, which will causeleakage.

7.3 Cleaning

APV offers factory cleaning, testing andregasketing services at Service Centerslocated around the country. A customersplates are thoroughly cleaned, inspectedboth visually and with dye penetrant, andnew Paraclip or glued in gaskets installedas required. Call Factory Service at (800)278-6080 for more information and pricing.

To maintain the performance andresistance to corrosion of the plate heatexchanger, it is essential that the plates bekept clean. Product build up and scalemust be removed either manually or by CIP(Clean in Place) procedures outlined below.

Manual Cleaning

After a heat exchanger has been opened,individual plates can be removed for

WARNING:

Never open a Paraflow until the unithas cooled below 100F (38C).Never open a Paraflow, which isunder pressure from any source.

Never open a Paraflow with pipingconnected to the follower orconnector grids.


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cleaning with a soft brush and a suitabledetergent. In case of thick layers of scaleor organic materials, the plates may be putin a bath of a suitable cleaning solution. Donot use a steel brush, metal scraper orsimilar tool, which will damage the plate orgasket. A high-pressure cleaner can beused with care. However, never clean withsand or other abrasives.

Clean In PlaceCleaning in place is accomplished bycirculating a suitable cleaning solutionthrough the heat exchanger instead ofopening it. This removes deposits ortrapped product on the plates. CIP worksbest in the reverse direction of normal flow.Good results are also possible with thesame direction flow and higher velocities.

Great care must be taken to select propercleaning solutions and cycles to avoiddamaging the plates and gaskets. Due tothe large variety of cleaning needs, eachuser is responsible for determining the bestmethod for his situation. It is recommendedthat a reputable supplier of cleaningmaterials be consulted for assistance.

7.4 Replacement of Plates

Before replacing a plate in a heatexchanger, the new plate must be checkedagainst the plate it is replacing. The newplate must be identical in every way.

The general arrangement drawing providedwith the heat exchanger providesinformation on the material, port punching,gaskets and location of each plate in theheat exchanger.

Note: During the installation, alwaysalternate left and right hand plates. Forsimplification only, whole blocks of identicalleft or right hand plates are shown on theplate arrangement drawing. The totalnumber of each is given. Vertical flowplates may be changed from left hand toright or vice versa by turning the plate over.

7.5 Regasketing

Plate heat exchanger gaskets are attachedto individual plates by one of two methods,glued or clip in. Glued in gaskets areattached by a thermoplastic adhesive whichis heat cured for maximum strength.

The clip in gaskets (Paraclip) are attachedto the plates by small nubs around theperimeter of the gasket which snap intomatching holes.

Removal of old gasketsTo remove Paraclip clip in gaskets, thegasket may be carefully pulled from theplate. If the gasket is to be reused, pullslowly to avoid tearing off the clips orstretching the gasket.

To remove glued in gaskets, the bondbetween the plate and gasket is softenedby using a propane torch to heat the platefrom the nongasketed side directly behindthe gasket. As the adhesive softens, usepliers too pull the gasket from the groove.Continue this process until the entire gaskethas been removed.

Caution:

The heat exchanger must bethoroughly drained and rinsedimmediately following CIP. Residuefrom CIP may cause corrosion if leftin the heat exchanger.

apv paraflow plate hx manual

Documents

heat shields4

plate arrangement drawing4

athin corrugated metal

designthe paraflow

safe andproper installation

safetysafe installation

installation of plates5

maintenance safety2