Superchanger IOM - RW Fernstrum & Company

Installation And
Operation Manual
SUPERCHANGER
®
PLATE & FRAME HEAT EXCHANGER
www.tranter.com
TABLE OF CONTENTS
EQUIPMENT LOG SHEET
2
3
IDENTIFYING YOUR SUPERCHANGER® UNIT
3
PLATE DESCRIPTIONAND CONSTRUCTION
4
Plate Details
Unit Part Numbers
Plate Material and Date of Manufacture Data
Model Nomenclature
Frame Pressure Ratings
Condensed Unit Specifications
Plate Pack Widths
Plate Pack Tightening Dimensions
Plate Designations
Drawings
Element Composition Diagram
Plate Hole Designation for UX, SX, GC and GF Series
5
6
7
8
8
9
10
10
11
12
12
13
PASS AND FLOW ARRANGEMENT
14
Pass Arrangement
Flow Arrangement
Drains
Connecting “C” Frames
14
14
15
17
PLATE STYLES
18
Drawings
Four-Plate Sequence
Multi-Pass Units
19
20
20
GASKET DATA
21
Gaskets—Glued
Gaskets—Glueless
Gasket Storage Procedures
Mixed Gasket Materials
GX Gluing Codes
GX Start and End Plate Explanations
21
22
23
24
26
27
INSTALLATION
28
Tightening the Plate Pack
Tightening Sequences
Precautions Prior to Start-Up
29
30
30
SERVICING
31
Shutting Down the Unit
Disassembly Procedures
Removal of Plates
Replacing Plates
Replacing Gaskets
31
31
31
32
32
Removing Old Gaskets
Installing Continuously Glued Gaskets
Installing Spot-Glued Gaskets
Installing SUPERLOCK® Snap-In Gaskets
Installing Teflon Encapsulated Gaskets and Unit Assembly
Installing Clip-On Gaskets
32
33
34
35
35
36
Steps for Manual Cleaning of Plates
Plate Cleaning Tips
Cleaning-In-Place (CIP)
Back Flushing and Strainers
Cleaning Guidelines
37
38
38
39
39
TROUBLESHOOTING
40
Leakage Between the Plate Pack and the Frame
Leakage Between the Nozzle and the End Frame
Leakage Between the Plates to the
Outside of the Unit
Mixing of Fluids
Increase in Pressure Drop or a Reduction
in Temperature Reading
How to Find a Defective Plate With Through Holes
41
41
STORAGE PROCEDURES
44
MISCELLANEOUS INSTRUCTIONS
45
General Maintenance
Ordering Parts
Returned Material
Damaged Shipments
Additional Information
45
45
45
45
45
AUTHORIZED SERVICE CENTERS
46
42
42
43
43
EQUIPMENT LOG SHEET
You will need the information shown in the table below whenever you contact the factory for service. Upon delivery of your
SUPERCHANGER unit(s), be sure to record the information from the Data Plate on each unit in case the nameplate is destroyed,
lost or becomes illegible.
Equipment Tag #
Serial #*
Drawing #*
Model*
* Tranter must have serial or drawing number to properly identify your equipment.
For PHE parts, service or performance ratings, contact one of Tranter’s authorized Service Centers (see full information for contacting
on page 46).
IDENTIFYING YOUR
SUPERCHANGER® UNIT
If the Customer Tag is missing
on delivery, the SO# is stamped
in the top right corner of the
stationary frame.
R
�
Data Plate
Figure 1
A data plate like the one shown on the picture above is fixed to the stationary frame
of the unit and provides the following information. This information is helpful
when contacting the factory.
3
“S” Frame
PLATE DESCRIPTION
AND CONSTRUCTION
“E” Frame
Upper
Guide Bar
Straight Nozzle
Support
Column
“P” Frame
Plate Pack
Elbow
Nozzle
Optional Shroud
Lower
Guide Bar
Figure 2
SUPERCHANGER plate corrugations are available in four
patterns. Depending on the applications, the GF, UX, SX,
GC and GX Series plates are used to achieve maximum heat
transfer.
UX, SX and GC Series plates: Herringbone (chevron) pattern
is ideally suited for handling aqueous solutions.
GF Series: Wide gap and parallel (washboard) patterns are
designed for applications where there are high viscosity fluids or
fluids containing fibers or coarse particles.
GX Series: An asymmetrical four quadrant plate suited for low
viscosity and close temperature approach applications or processes
involving two vastly different flow rates. It is also well suited for
equal flows and close approach.
Superchanger Frame, Models HP, UP, SP, MP and FP.
All plates are manufactured from die-formed sheet metal in
virtually any material that can be cold worked, such as stainless
steel, titanium, Alloy C-276, Alloy-20, etc. There are grooves
around the circumference of the plates which accept the sealing
gasket and also add reinforcement because of the ribbed edges.
Fluid passage holes are pierced at the corners of each plate. The
number and location of the holes is dependent upon the design
conditions.
Support
Pad
Figure 3
Superchanger Frame, Models HJ, UJ, SJ and MJ.
4
The gaskets are single piece, molded construction, and generally
bonded to the plates with Pliobond 30 adhesive. The gasket
material is selected for compatibility with the fluids being
processed and the operating temperatures.
Each plate also contains flow directors at the top and bottom
of the heat transfer surface in the port hole areas, which evenly
distribute the fluids. Some plates require a hanger, which attaches
the plate to the upper guide bar. For most models, the upper
guide bar is the plate’s sole support member in the frame, while
the lower guide bar serves as an alignment member in all plates
except the UXP-005 and the UXP-001, which are supported by
the lower guide bar. See Figures 4 through 7 and Tables 1a and
2 for specific models.
Plate Details
Nozzle Numbers on
Fixed Frames
*Hanger
1
4
4
Flow
Directors
*Hanger
1
1
4
4
1
Flow
Directors
Plate Gasket
“B” Plate
“A” Plate
Plate Gasket
3
2
3
3
Typical UX, SX or GC Series (herringbone) plate with gasket and hanger. Note
that the chevron angle for the herringbone plate can differ on various models.
Figure 6
4
1
3
2
Typical GX plate with gasket. Note that the chevron angle for the herringbone
plate can differ on various models.
2
3
2
“A” Plate has wider groove in this area at ports #1 and #2
Hanger Slots
Figure 4
“B” Plate
has narrow
gasket
grooves in
this area at
ports #1
and #2
“B” Plate
Corrugated
Surface
2
Chevrons point up on “A” Plate and
down on “B” Plate
“A” Plate
Figure 5
Typical GF Series (washboard) plate with gasket and hanger.
4
1
3
2
Figure 7
Typical GF (wide gap) plate with gasket.
5
Unit Part Numbers
Type Of Plate
Plate Model
Plate Thickness
GXD-042-H-7-UP-102
Flow Direction
Chevron Angle
Frame Type
Number Of Plates
Figure 8
Typical SUPERCHANGER model number, in this case a diagonal flow GX-42 unit
with glued gaskets, 0.7 mm thick high-theta plates, a UP frame and 102 plates.
Figure 8 displays a typical SUPERCHANGER unit part number.
The first entry represents the plate style (two-letter code) and
flow, such as:
GX
GC
GD
GW
GF
GM
GL
Gasketed Ultraflex / Gasket groove in the
neutral plane
Gasketed Conventional / Gasket grove in the
bottom plane
Gasketed Double Wall
Gasketed Semi Welded
Gasketed Free Flow (Wide Gap and Washboard)
Gasketed Mechanical Glue (Snap-In gaskets)
Gasketed Conventional / Gasket groove in the
neutral plane
The second entry (third character) represents the flow; D for
diagonal and P for parallel.
The fourth entry represents the plate profile angle, or theta:
H (high)
L (low)
M (mixed)
A (30°+45° for UXP-960)
Z (45°+60° for UXP-960)
The fifth entry represents the plate thickness:
5 (0.5 mm)
6 (0.6 mm)
7 (0.7 mm)
8 (0.8 mm)
9 (0.9 mm)
0 (1 mm)
The sixth entry shows the frame type (HP, UP, etc.).
The final entry (three-digit code) represents the plate count.
The third entry (three-digit code) represents the plate model or
surface area.
6
Plate Material and Date of
Manufacture Data
All plates are stamped with identifcation numbers. The numbers
are located on both ends of the plates as indicated in the sketches
below. The heat number, material and month and year of
manufacture can be determined from these numbers.
Figure 9
General locations of code stamping for various plate models.
Six-Digit Codes
Table 1
Six-Digit
Heat No. Code
(avail. from
Engineering)
Month
XXX X X X
Material
Year
Five-Digit Codes
Heat No. Code (avail.
from Engineering
Year
X X XXX
Material
P-Prefix Codes
Material
Source Prefix
P 0X X XX
Year (two-digit)
Plate Codes
Heat No. Code (avail.
from Engineering
Five-Digit or P-Prefix
Material
0
Other (Nickel, 317
SS, 317L SS, etc.)
AISI 304
1
304 SS
AISI 316
2
316 SS
AISI 316L
3
Titanium
654 SMO
4
316L SS
254 SMO or other SS
5
Hastelloy-C-276
Titanium Grade 1
6
Incolloy 825
Titanium Grade 2
7
Monel 400
Hastelloy-C-276
8
316 High Moly
9
304L SS
G-30
Other materials
Year Of Manufacture
8 or 08
1998
9 or 09
1999
0 or 00
2000
1 or 01
2001
2 or 02
2002
3 or 03
2003
4 or 04
2004
5 or 05
2005
6 or 06
2006
7 or 07
2007
Month Of Manufacture
1
Jan/Feb
NA
2
Mar/Apr
NA
3
May/June
NA
4
July/Aug
NA
5
Sept/Oct
NA
6
Nov/Dec
NA
7
Model Nomenclature
If your unit was manufactured before July 1, 2002, use Table
1a to determine the current plate style nomenclature for your
Table 1a
unit. Note the port numbering has changed to the new design
(see page 13).
Updated Nomenclature Codes
Old Name
Old Name
New Name
New Name
Glued Gasket Models
Glued Gasket Models
GC-12
GCD-012
UFX-118/GX-118
GXD-118
GC-30
GCD-030
UFX-140/GX-140
GXD-140
GC-48
GCD-048
UFX-145/GX-145
GXD-145
GC-50
GCD-050
UFX-180/GX-180
GXD-180
GC-26
GCP-026
UFX-205/GX-205
GXD-205
GC-28
GCP-028
UFX-265/GX-265
GXD-265
GC-51
GCP-051
UFX-325/GX-325
GXD-325
GC-60
GCP-060
07S
SXP-070
S3
GFP-030
14S
SXP-140
S8
GFP-080
SX41
SXP-400
TW-05
GFP-057
UX-05
UXP-005
TW-10
GFP-097
UX-01
UXP-010
TW-18
GFP-187
06T
UXP-060
TD-10
GCD-010
UX-10
UXP-100
TP-10
GCP-010
11T
UXP-110
GW-81
GWP-081
UX-20
UXP-200
GW-82
GWP-082
UX-40
UXP-400
GW-83
GWP-083
UX-81
UXP-801
WH-040
GWP-400
UX-83
UXP-802
WX-050
GWP-500
UX-90
UXP-900
UFX-6/GX-6
GXD-006
LP-80
UXP-960
GX-7
GXD-007
Snap-In Gaskets
UFX-12/GX-12
GXD-012
GC-26
GMP-026
UFX-18/GX-18
GXD-018
UX-05
UMP-005
UFX-26/GX-26
GXD-026
UX-01
UMP-010
UFX-37/GX-37
GXD-037
UX-20
UMP-200
UFX-42/GX-42
GXD-042
UX-40
UMP-400
UFX-51/GX-51
GXD-051
06T
UMP-060
UFX-60/GX-60
GXD-060
TP-10
GMP-010
UFX-64/GX-64
GXD-064
TD-10
GMD-010
UFX-85/GX-85
GXD-085
Double Wall
UFX-91/GX-91
GXD-091
GX-42
GDD-042
UFX-100/GX-100
GXD-100
UX-01
UDP-010
Frame Pressure Ratings
Table 1b
FRAME TYPE
8
Frame Pressure Ratings
NOMINAL ASME CODE PRESSURE RATINGS
Design Pressure, (psig)
Test Pressure, (psig)
NJ/NP/VJ/VP
Non-code; contact factory
Non-code; contact factory
HJ/HP
100
130
UJ/UP
150
195
SJ/MJ/SP/MP
300
390
FP
350
455
Standard unit pressure ratings are shown. Contact the factory
for higher design pressures, up to 400 psig, depending upon
the application.
Condensed Unit Specifications
Table 2
Condensed Unit Specifications
Nominal Frame Dimensions
Channel Volume Between Plates (gal)
Model
Height (in.)
Width (in.)
Connection (in.)
Max. Flow (gpm)
Wide
Medium
Narrow
GXD-007
37
8-1/4
1
75
NA
0.0423
NA
GXD-012
39
14
2
292
NA
0.0872
NA
GXD-018
48
14
2
292
NA
0.124
NA
GXD-026
54
22
2, 4
1171
NA
0.227
NA
GXD-042
71
22
2, 4
1171
NA
0.351
NA
GXD-051
72
27
4, 6
2264
NA
0.444
NA
GXD-037
60
27
4, 6
2769
NA
0.246
NA
GXD-064
79
27
4, 6
2769
NA
0.423
NA
GXD-091
98
27
4, 6
2769
NA
0.6
NA
GXD-118
117
27
4, 6
2769
NA
0.777
NA
GXD-060
69
38
4, 6, 8
4755
NA
0.502
NA
GXD-100
92
38
4, 6, 8
4755
NA
0.845
NA
GXD-140
115
38
4, 6, 8
4755
NA
1.162
NA
GXD-180
138
38
4, 6, 8
4755
NA
1.479
NA
GXD-085
81
50
10, 12, 14
10471
NA
0.88
NA
GXD-145
104
50
10, 12, 14
10471
NA
1.334
NA
GXD-205
127
50
10, 12, 14
10471
NA
1.788
NA
GXD-265
149
50
10, 12, 14
9183
NA
2.243
NA
GXD-325
172
50
10, 12, 14
9183
NA
2.695
NA
UXP-005
24
12
1, 2
265
NA
0.06
NA
UXP-010
31
12
1, 2
292
NA
0.08
NA
UXP-100
45
17
2, 3
520
NA
0.13
NA
GFP-030
58
22
2, 3, 4
1060
NA
0.4
NA
UXP-200
62
24
2, 3, 4
1060
NA
0.34
NA
UXP-060
74
32
4, 6, 8
3825
NA
0.67
NA
SXP-070
71
36
4, 6, 8
4754
NA
0.52
NA
GFP-080
85
30
4, 6, 8
3450
NA
0.9
NA
UXP-400
85
32
4, 6, 8
3825
NA
0.87
NA
SXP-400
83
36
4, 6, 8
4754
NA
0.63
NA
UXP-110
106
32
4, 6, 8
3825
NA
1.21
NA
SXP-140
103
36
4, 6, 8
4754
NA
0.81
NA
UXP-801
105
54
10, 12, 14
11200
NA
2.40
NA
GCP-010
38
13
1, 2
292
NA
0.1135
NA
GCP-016
39
14
2, 5
292
NA
0.063
NA
GCP-026
54
22
2, 3, 4
1171
NA
0.2642
NA
GCP-028
31
7
1
75
NA
0.4
NA
GCP-051
72
27
4, 6
2324
NA
0.55
NA
GCP-060
69
38
4, 6, 8
4755
NA
0.783
NA
GFP-057
71
35
4, 6, 8
4755
2.36
2
1.63
GFP-097
88
35
4, 6, 8
4755
3.23
2.61
1.99
GFP-187
126
35
4, 6, 8
4755
5.08
3.92
2.76
GLP/GLD-013
39
14
2.5
475
NA
0.087
NA
GL-230
121
66
20
23465
NA
3.33
NA
GL-330
145
66
20
23465
NA
3.78
NA
GL-430
169
66
20
23465
NA
4.65
NA
9
Plate Pack Widths
“A” Dimension for standard thickness materials
Calculating the “A” dimension (Plate Pack Width in Inches) for
various SUPERCHANGER Models can be accomplished by using
the formulas indicated in Table 3. N = Number of Plates.
PLATE DESIGNATION, p
PLATE THICKNESS, t
4
0.015748
5
0.019685
6
0.023622
7
0.027559
8
0.031496
0
0.039370
N = Number of Plates
p = Plate Thickness Designation
t = Plate Thickness in Inches
Please contact Tranter for the “A” Dimension when other plate
thicknesses are involved.
Figure 10
Plate thicknesses.
Plate Pack Tightening Dimensions
Table 3
Plate Pack Tightening Dimensions
Plate Type
A Max.* (in.)
A Min.* (in.)
Plate Type
A Max.* (in.)
A Min.* (in.)
UXP-005
(t + 0.102362) N
(t + 0.094488) N
GXD-026, GXD-042
(t + 0.13441) N
(t + 0.12541) N
UXP-010
(t + 0.102362) N
(t + 0.094488) N
GXD-037, -064, -091, -118
(t + 0.11821) N
(t + 0.11021) N
UXP-100
(t + 0.0944) N
(t + 0.0866) N
GXD-051
(t + 0.13441) N
(t + 0.12541) N
UXP-200
(t + 0.108268) N
(t + 0.102362) N
GXD-060, -100, -140, -180
(t + 0.13441) N
(t + 0.12541) N
UXP-060
(t + 0.141732) N
(t + 0.133858) N
(t + 0.13441) N
(t + 0.12541) N
UXP-400
(t + 0.141732) N
(t + 0.133858) N
GXD-085, -145, -205, -265,
-325
UXP-110
(t + 0.141732) N
(t + 0.133858) N
GFP-057, -097, -187
(t + 0.2965) N
(t + 0.3025) N
SXP-070, SXP-400,
SXP-140
(t + 0.102362) N
(t + 0.094488) N
GCP-010
(t + 0.1378) N
(t + 0.1299) N
GCP-016
(t + 0.07205) N
(t + 0.06969) N
UXP-801
(t + 0.181102) N
(t + 0.173228) N
GCP-026
(t + 0.1633) N
(t + 0.1523) N
UXP-802
(t + 0.181102) N
(t + 0.173228) N
GCP-051
(t + 0.1601) N
(t + 0.1548) N
GFP-030
(0.1881N) + 0.07874
(0.1767N) + 0.07874
GCP-060
(t + 0.1790) N
(t + 0.1676) N
GFP-080
(0.189013N) + 0.07874
(0.1796N) + 0.07874
GCD-012
(t + 0.1000) N
(t + 0.09685) N
GXD-007
(t + 0.10191) N
(t + 0.09491) N
GLD-230, -330, -430
(t + 0.1831) N
(t + 0.1713) N
GXD-012, GXD-018, GL-013
(t + 0.11821) N
(t + 0.11021) N
*Applicable to units with elastomeric gaskets, round off to the
nearest 1/32 in. Units with teflon encapsulated gaskets should
be tightened to the “A Max.” formula.
The single digit of the model number given just before the frame
designation indicates the plate thickness in tenths of a millimeter.
The only exception is the zero (0) designation, which indicates a
1.0 mm plate thickness.
10
HOW TO USE TABLE 3:
EXAMPLE: Given a model UXP-100-L-6-MP-32, go to thePlate
Pack Width chart above and select Plate Designation 6, the Plate
Designation for a model UXP-100. The corresponding Plate
Thickness is 0.023622 in. Now find the Plate Type row showing
UXP-100 in Table 3. The “A Max.” dimension is calculated by:
(t+.0.0944)N = (0.023622+0.0944)32 = 3.78 in. The “A Min.”
dimension is calculated in a similar manner. Round off calculated
number to nearest 1/32 in.
CAUTION: On units operating in excess of 200 psig, the tightening dimension is to equal or approach the minimum dimension.
Plate Designations
SUPERCHANGER units are designed so that a fluid which
enters the “A” plate circuit (nozzles S1, S2, M1 or M2) always
flows in the “A” circuit only. Fluid which enters the “B” plate
circuit (nozzles S3, S4, M3 or M4) always flows in the “B” circuit
only. Facing the stationary frame, the right side is always the
“A” side, while the left side is always the “B” side. The “A” and
“B” term refers to the gasket orientation. When looking at the
gasketed side of the plate, an “A” plate becomes a “B” plate when
reversed (turned upside down). If the flow comes in and out on
the left side, it is a “B” orientation.
NOTE: Every other plate has to be rotated 180° A-B-A-B in order
to prevent mixing. The first plate in the unit is called a “D” plate
and has a special gasket arrangement. This arrangement keeps
the flow from contacting the stationary frame. The last is called
the “E” plate and is gasketed normally.
4
1
Movable end frame side
B side
To and from
additional
plates
A side
1
4
3
2
Stationary end frame side
3
2
Items 1–4 indicate nozzle locations
Figure 11
Plate orientation for the UX, SX, GC and GF Series.
“B” plate
“A” plate
Figure 12
Gasket orientation.
11
Drawings
SUPERCHANGER units are custom designed for each application. A drawing is supplied with each unit depicting all required
dimensional data, equipment specifications, unit performance, nozzle locations and sequence of plates in the heat exchanger. Most
information contained on the drawing is self-explanatory. However, sections illustrating the internal functions of a plate and frame
heat exchanger are sometimes difficult to interpret. The following diagrams are aids for understanding the equipment.
Element Composition Diagram
Figure 13 shows an “S” frame (stationary member), “E” frame
(moveable member) and plates of the plate heat exchanger
depicted in an element composition diagram. In an element
composition diagram, “B” plates are located at the upper part of
the drawing and “A” plates are shown on the lower side.
Plate location
symbol plate
B side
Plate hole
designation box
A plate is indicated by the line centrally located within a
rectangular compartment between the “S” and “E” frames.
The designation of plate holes is written in the hole designation
box formed by extending the vertical plate lines above the center
line for “B” plates and below the center line for “A” plates. The
plate sequence number is written in a box above and below the
plate hole number, respectively, for “B” and “A” plates.
A side
Plate sequence no.
Figure 13
Element composition diagram.
12
Plate Hole Designation for UX, SX,
GC and GF Series
As shown in Figure 14, the pierced holes at the corners of the
plate are designated as: 1 for upper right, 2 for lower right, 3 for
lower left and 4 for upper left when facing the gasketed side of
the plate. Plates 1 and 2 in Figure 14 are represented as A1234
and B1234 respectively. Plates with all four holes pierced can also
be designated with a blank space or an *. Unpierced ports will
be represented as a zero (0). For example, Plate 3 is represented
by a A1004 since there are no holes at position 2 and 3. Table
8 shows A and B equivalents when an “A” plate is rotated to
become a “B” plate.
Make sure the gaskets are installed correctly in relation to the
flow directors. (See Figures 15 and 16.)
Table 4
“A” and “B” Equivalents
“A” Plate
“B” Plate
“A” Plate
“B” Plate
1234
1234
0204
0204
1034
1230
0034
1200
1204
0234
1200
0034
0234
1204
0004
0200
1230
1034
1000
0030
1004
0230
0030
1000
0230
1004
0200
0004
1030
1030
0000
0000
Porthole designations shown apply to all units purchased
after June 1, 2002. Refer to unit drawing or previous
IOM (SC-10M-9) for older UX, SX, S, GF or TW Series.
NOTE: Flow
directors as related
to “A” and “B”
plates
“A” Plate
Correct gasket location.
Hole designations.
NOTE: Flow
directors as related
to “A” and “B”
plates
“A” Plate
“B” Plate
Chevrons point
up on “A” plates
and down on
“B” plates
Figure 15
Figure 14
“B” Plate
Chevrons point
up on “A” plates
and down on
“B” plates
Figure 16
Incorrect gasket location.
13
PASS AND FLOW ARRANGEMENT
Pass Arrangement
Positions 1 and 4, as shown above in Figure 17, are upper
connections, right and left respectively, and positions 2 and 3 are
lower connections, right and left respectively. Each vertical line
in between the “S” and “E” members represents a heat transfer
plate while the arrows show the directions of flow in the channels
between two plates and in the port holes.
In the element composition diagram (Figure 17), plate numbers
are shown in boxes as:
The position of a plate hole is indicated by the intersection
between a vertical line representing the plate and a horizontal
line indicating the flow direction and passage. Holes for passage
of fluid flowing on the surface of a “B” plate are always located
on the left side (Holes 3 and 4), and holes for passage of liquid
flowing on the surface of an “A” plate are always found on the
right side (Holes 1 and 2).
“D” in D1004 represents the plate adjacent to the “S” frame.
“D” also denotes that no fluid runs on the heating surface.
1 D1004
1034
(“A” side)
2 (“B” side”)
A box with no port hole numbers, 11
, in Figure
17 means 11 1234 . This is done for simplicity as most plates
in a unit have four holes.
B side
Flow Down
Plate
Flow Up
Plate
A side
*No number indicates that fluid passes through
all four holes in the plate.
Figure 17
Element composition diagram.
Flow Arrangement
Figure 18 shows the plate arrangement in which “B” side is
arranged in two parallel channels with three passes in series
and “A” side is arranged in three parallel channels with two
passes in series. In two parallel channels with three passes in
series, the fluid flow Q1 flows on the heating surfaces of two
plates separately (Q1/2) and gathers again in the port hole. This
operation is repeated three times. In the case of three parallel
channels, with two passes in series, flow Q2 similarly flows on
the three heating surfaces separately (Q2/3), gathering once again
in the port hole.
14
The product of the number of channels in parallel, times the
number of passes in series, is always equal or different from each
other by one plate when comparing “A” side with “B” side. The
total number of plates can be obtained by adding the number of
“D” plates to the number gained by adding the products of “A”
side and “B” side. In Figure 18 (2 x 3) + (3 x 2) + 1 = 13.
B side
Q1
Q1
Q2
Q2
Q1/2
A side
Q2/3
*No number indicates that fluid passes through
all four holes in the plate.
Figure 18
Flow arrangement.
Drains
There are three methods used for draining
SUPERCHANGER units:
1.
One pass/one pass (also two pass/two pass with all lower
nozzles, but not shown) units can be drained by opening
the piping to the lower nozzles or by opening drain valves
that can be provided in the field in the connecting piping.
See Figure 19.
2. Multi-pass units may require factory installed drains, i.e., an
additional nozzle in the end frame. These must be factory
installed. See Figure 19.
3. If the number of passes is greater than four as in Figure 20,
the above options require the addition of small holes in
plate corner sections as shown in Figure 22. The amount
of by-pass through these holes is negligible and there is
no possibility of fluid intermix. These drain holes in the
element composition diagram (Figure 21) are noted by ,
as the small hole is always placed in the corner without a
passage hole. For example, 1204 is changed to 12 4 if
a drain hole is present. The size and position of the drain
hole is separately specified.
•
•
NOTE: On multi-pass units that are sized for a close temperature approach, these drain holes are not provided due to the small amount of
bypassing that occurs. Check the drawing to determine whether drains are present.
Plate sequence no.
B side
A side
Plate sequence no.
Factory installed drains
through frame
Field supplied drain
Figure 19
One pass—one pass.
15
Cannot drain out
Plate sequence no.
B side
A side
Plate sequence no.
Figure 20
Five-pass unit with 2 passes that are not drainable.
Plate sequence no.
B side
A side
Plate sequence no.
Figure 21
Five-pass with pass 3 and 4 as drainable. (Plates 8 and 9 have small drain holes.)
Drain
Figure 22
Small hole in Plates 8 and 9
Showing first 12 of the 21 plates in Figure 21 with drains in plates 8 and 9.
16
Connecting “C” Frames
SUPERCHANGER units can be partitioned into multiple
sections by employing the required number of connecting “C”
frames when more than one heat exchange operation is required.
Connecting frames allow several liquids to be processed at the
same time or allow the same liquid to run through several stages
of heat transfer. The flow arrangement with use of a connecting
frame is illustrated in Figure 23 isometrically and in Figure 24
in an element composition diagram.
“C” Frame
Brine
Liquid
Liquid
Water
Brine
Water
Figure 23
Connecting “C” frame—flow diagram.
“C” Frame
Plate sequence no.
Liquid inlet
B side
Water outlet
A side
Liquid outlet
Brine inlet
Plate sequence no.
“S” Frame
Water inlet
“M” Frame
Brine outlet
Figure 24
Connecting “C” frame—element composition diagram.
17
PLATE STYLES
Unlike all other SUPERCHANGER models, the GX series of
plates is based on a diagonal flow pattern. On a typical one-byone pass unit, nozzle numbers 1 and 3 will be the hot inlet and
hot outlet connections. Nozzle numbers 2 and 4 are the cold inlet
and cold outlet located lower right and upper left, respectively.
Unlike other plates, GX series can also be designed for parallel
flow. The flow direction is always designated in the model number
by a “P” (parallel) or “D” (diagonal) after the letters “GX.”
ULTRAFLEX (GX) and WIDE-GAP (GF) plates differ from
conventional plates in another aspect. Because the gasket groove
lies in the plate’s neutral plane, additional configurations are
possible with a given plate. This feature allows the heat exchanger
to be more precisely designed for each application.
Figure 25
Figure 26
Figure 27
Figure 28
ULTRAFLEX (GX) plate design.
GX type “L” plate.
18
GX type “H” plate.
GF-type plate.
Drawings
The bottom left hand corner of each GF and GX unit drawing has
a plate specification chart and plate arrangement/assembly listing
to assist in determining the proper sequence and orientation of
the plates in the unit. You will note that the gaskets used between
the first and last plate of the plate pack and the respective frames
are half thickness.
Due to the number of combinations achievable with GX and GF
technology, we have simplified the assembly process by assigning
a code letter to each corner of the plate. The plate is installed
correctly when the letter is readable from the upper right corner
when facing the front of the unit.
The following examples will help you understand the plate
designations:
Quantity
Gasket Material
Theta/Piercing
Gluing
1
NBR
H 1234
RC Start
134
NBR
H 1234
LG
133
NBR
H 1234
RC
1
NBR
H 0000
RC End
Figure 29
Ultraflex plate gluing assembly.
WIDE-GAP PLATE ASSEMBLY
In the Wide-Gap (GF) series of plates, three different channel
geometries can be created with each model: wide, medium
or narrow. All units will be wide-narrow, narrow-wide or
medium-medium configuration. The code letter in the top right
hand corner of the plates is used to create the various channel
geometries as shown below.
GAP
FLOW ON SIDE
CODE
Wide
A
R+L
Wide
B
S+K
Medium
A
K + L or R + S
Medium
B
L + K or S + R
Narrow
A
K+S
Narrow
B
L+R
19
Four-Plate Sequence
In some instances, the arrangement in a GX model will follow a
repeating four-plate sequence. An example is shown below:
Plate
208
209
210
211
212
213
214
215
S
C
R
B
S
C
R
B
Plate 208
Plate 209
Plate 210
Plate 211
Figure 30
Four-plate ULTRAFLEX sequence.
Table 5
Plate Hanging Assembly–Four-Plate Sequence
Plate Sequence
Gasket Material
Piercing
Gluing
Hanging
1
NBR
H 1234
RC Start
B
2, 4....206
NBR
L 1234
LS
R
3, 5....207
NBR
H 1234
RC
B
208, 210....266
NBR
L 1234
LS
S, R
209, 211....267
NBR
H 1234
RC
C, B
268
NBR
L 1234
LS
S
269
NBR
H 0000
RC End
C
Multi-Pass Units
Table 6 provides an example of plate arrangement and
specifications for a multi-pass unit.
Table 6
20
Plate Hanging Assembly–Multi-Pass Units
Plate Sequence
Gasket Material
Piercing
Gluing
Hanging
1
NBR
H 0234
RC Start
B
2, 4....22
NBR
L 1234
LS
R
3, 5....23
NBR
H 1234
RC
B
24
NBR
L 1234
LS
R
25
NBR
H 1004
RC
B
26, 28....46
NBR
L 1234
LS
R
27, 29....47
NBR
H 1234
RC
B
48
NBR
L 1234
LS
R
49
NBR
H 0230
RC End
B
GASKET DATA
Table 7
Temperature Ratings
Gasket Material
Max. Temp.
(oF)
Color Code
Gasket Material
Max. Temp.
(oF)
Color Code
EPDM (Full FDA Approved)
300
1 Grey + 1 Red
NBR (Industrial Grade)
270
3 Blue
EPDM (Industrial Grade)
338
1 Grey
NBR (Partial FDA Approved)
270
1 Blue
EPDM (Partial FDA Approved)
338
3 Grey
NBR LH (Low Hard)
1 Blue + 1 Green
EPDM(IR)
1 Grey + 1Green
NBR LT (Low Temp)
1 Blue + 1 Yellow
EPDM(P) Soft
2 Grey + 1 Green
NBR(P)
1 Blue or (1 Blue + 1 White)
EPDM(S)
2 Grey
NBR(S)
No marking
EPDM-XH
4 Grey
NBR(S) 14-920
Fluoroelastomer (Viton) A & G
350
1 Purple
Neoprene (CR)
Fluoroelastomer (Viton) B
35
2 Purple
PTFE encapsulated EPDM
Fluoroelastomer (Viton) FDA Full
Fluoroelastomer (Viton) GF
1 Purple + 1 Red
350
3 Purple
PTFE encapsulated NBR
1 Blue + 1 Brown
255
1 Green
Nothing on the outside (core
EPDM is marked with 1 Grey)
270
Nothing on the outside (core NBR
is marked with 3 Blue)
Fluoroelastomer (Viton) GF 04-312
1 Purple + 1 White
R.C. Butyl
1 Yellow
Steam grade fluoroelastomer for GE
test units
4 Purple
Silastic (Dow)
None
Silicone
1 Orange (only if the rubber color
is black)
Hypalon (CSM)
158
1 Red
NBR (Full FDA Approved)
270
1 Blue + 1 Red
NBR (Hydrogenated)
302
2 Blue
*This gasket requires the use of .8 mm (.032 in.) thick plate and a special double side tape
instead of Pliobond.
DO NOT OVER TIGHTEN!
The above temperatures are the maximum allowable regardless of applications. In some cases, the upper limit may be lower depending
on the fluids being handled and on the unit design pressure.
Gaskets—Glued
Each plate has a molded one piece boundary gasket which is
glued into the continuous gasket groove in each plate. The liquid
flowing on the surface of each plate flows on the inside of each
boundary gasket.
Every port hole gasket contains four bleed passages. (See Figure
32.) If one of the liquids should leak beyond a boundary gasket,
it will flow to the outside of the unit, thus preventing any possible
intermix. (See Figures 31 and 33.)
Bleed ports typical
four places
Figure 31
Flow to exterior from damaged boundary gasket.
Gasket code
number
Gasket
Figure 32
Four bleed passages.
Plate
Figure 33
Flow to exterior from damaged boundary gasket.
21
Gaskets—Glueless
SUPERLOCK®
Clip-On
Functionally, Tranter’s patented SUPERLOCK glueless gaskets
perform in the same manner as glued gaskets (see Figures 30, 31
and 32). SUPERLOCK’s unique lock-in design allows simple
installation and removal without glue. The gasket has tabs that
press easily into the holes in the plate. Please note that the
differences between glueless gasket plate assemblies and glued
gasket plate assemblies do not allow for the use of a glued gasket
on a SUPERLOCK style plate. The use of a glueless gasket on
a plate requiring a glued gasket is also incorrect. (NOTE: the
D, E and any special turning plates will be standard spot-glued
gasketed.) The SUPERLOCK design is indicated by replacing
the “X” in the model number with an “M” for a mechanically
attached gasket. It is available in the following models: UMP005, UMP-010, UMP-060, UMP-200, UMP-400, GMP-026
and GM-010.
®
Table 8
Tranter’s Clip-On glueless gaskets also perform in the same
manner as glued gaskets.The unique design allows easy and
fast clip-on installation without glue or tools, as well as simple
removal. Positive gasket seating and lock-in eliminates assembly
uncertainties. After inspection, undamaged gaskets can be
reused.
The Clip-On gasket system is available in NBR and EPDM, both
industrial and FDA ratings. The Clip-On design is available in
the following models: GMP-026, GC-8, GC-026, GX-26, GX42 and GL-13. Four of these models—GC-8, GX-26, GX-42
and GL-13—are interchangeable plates, and can be used with
either glued or Clip-On gaskets.
Typical Clip-On Gasket Installation
PLATE NO.
GASKET
PLATE
CLIPPING
HANGING
1
NBR (S)
H0230
RC START
B
2, 4, 6, 8, 10
NBR (S)
H1234
LG
E
3, 5, 7, 9, 11
NBR (S)
H1234
RC
B
12, 14, 16, 18
NBR (S)
H1234
LG
GE
13, 15, 17, 19
NBR (S)
H1234
RC
CB
20
NBR (S)
H1234
LG
G
21
NBR (S)
H1004
RC END
C
22
NBR (S)
H1004
23
NBR (S)
H1004
RC START
B
24, 26, 28, 30, 32
NBR (S)
H1234
LG
E
25, 27, 29, 31, 33
NBR (S)
H1234
RC
B
34, 36, 38, 40
NBR (S)
H1234
LG
GE
35, 37, 39, 41
NBR (S)
H1234
RC
CB
42
NBR (S)
H1234
LG
G
43
NBR (S)
H0230
RC END
C
PARTITION
Model: GXD-042; Plate Material: 304 SS; Plate Thickness: 0.5 mm.
Plate No.: Indicates plate number if single number is given.
Indicates a numerical sequence pattern if multiple numbers are
given. If multiple letter codes are given in the Hanging column, an
alternating sequence between the two letters should be followed
as indicated in the Plate No. column.
Gasket: Defines the gasket material.
Plate: A five-digit identifier, which describes plate theta as being
“H” high or “L” low, is followed by four integers. These four
integers indicate which ports are pierced. A zero (0) denotes NO
piercing at this port location.
22
Clipping: An eight-character field describing how the gasket is
to be clipped to the plate. The first letter describes whether the
closed port (ringed gasket corner) is in the Lower Right or Lower
Left. Therefore, “R” is Right and “L” is Left. The second letter
denotes the plate letter code. Both of these descriptions apply
when the plate is viewed upright with the designated letter code
being read left-to-right in the upper right hand quadrant of the
plate. Gaskets will be clipped to the front of plate as viewed in
their installed orientation from front-to-back of the assembled
unit. “Start” or “End” can be added to the first two-letters with
a space between to denote special gasketing instructions for the
first and last plates between end-frames and/or partition plates.
Hanging: Indicates the letter code by which a plate is to be hung
in the unit. This letter should be located in the upper right of
the plate and read from left-to-right. The plate should be viewed
as if from looking from the front of the unit.
Start Plate
Gasket Storage Procedures
End Plate
When SUPERCHANGER heat exchanger plate gaskets are
maintained as spare parts, it is important that certain storage
procedures be followed to assure that the elastomeric compounds
making up the gaskets do not deteriorate and the useful life of
the gaskets is preserved.
1. Store in an area where the temperature does not exceed 70°F.
The ideal storage temperature is 60°F. NOTE: Never store in
an area where the temperature may fall to or below 32°F.
2. Maintain a maximum of 70% relative humidity.
Clip-On, Channel
A, Half Gasket
Front, All (4)
Ports)
Channel A Gasket
Front, Half
Thickness, Gasket
Rear, Channel B,
All (4) Ports)
Figure 34
GX Clip-On codes (diagonal flow).
3. Store in a darkened room. Ultraviolet light must be avoided.
4. Store gaskets so they are free from tension. Do not store in
a stretched or severely bent condition.
5. All potential sources of Ozone, such as operating electric
motors or welding equipment, must be removed from the
storage area.
6. Organic solvents, acids, etc. must not be kept in the storage area.
7. Do not store near heating system radiators.
8. Cover or keep the gaskets in bags or boxes to minimize
exposure to air circulation.
9. Keep gaskets free from dust and particulates.
Right B
RB
Channel A
Left E
LE
Channel B
Right C
RC
Channel A
Left G
LG
Channel B
Figure 35
GX Start and End plate explanations.
23
Mixed Gasket Materials
Most SUPERCHANGER units are equipped with gaskets made
of one material. However, there are two conditions that dictate
the use of different material on a plate.
The first is gasket/fluid compatibility. In this case, one material
is not suitable for both fluids in the heat exchanger. An example
is heating quench oil with 285°F steam. Quench oil dictates the
use of nitrile rubber gaskets, while steam temperature requires
EPDM gaskets.
The second reason for using two gasket materials on a single plate
is cost. This is encountered when an expensive material (usually
viton) is required on only one side of the SUPERCHANGER
unit. A significant savings can be realized by using a less expensive
gasket material on the other side.
As an example: Cooling 180°F sulfuric acid with tower water
requires viton on the acid side, but nitrile is sufficient on the
water side.
Each plate has contact with both fluids in a SUPERCHANGER
unit. One fluid travels across the plate while the other fluid
passes through the gasketed port holes. In a mixed gasket unit,
each plate will have two materials. The fluid traveling across the
“A” plate requires gasket material 1. The fluid on the “B” plate
requires gasket material 2.
In the case of a UX, SX, GF or GC series model, the “A” plate
will have material 1 on the perimeter while port holes 3 and 4 are
material 2. The “B” plate will have material 2 on the perimeter
with port holes 1 and 2 of material 1. GX models with mixed
gaskets would be similar. However, flow is diagonal so diagonally
opposed ports would have the same gasket material.
All SUPERCHANGER gaskets are purchased as one piecemolded items. To physically accomplish mixing gaskets on a
plate, the port holes are cut from both gaskets. Subsequently,
the port holes of material 1 are matched with the perimeter of
material 2 and vice versa. (See Figure 36.)
The following illustrates the above in a typical UX Series plate.
= Gasket Material 1
= Gasket Material 2
Fluid on “A” plate uses port
holes 1 and 2.
Fluid on “B” plate uses port
holes 3 and 4.
NOTE: Chevron orientation as related to
“A” & “B” plates.
Porthole designations shown apply to all
units purchased after June 1, 2002. Refer to
unit drawing or previous IOM (SC-IOM-9) for
older UX, SX, S, GC or TW series.
Figure 36
Multiple gasket materials on a UX Series plate.
24
“A” plate
“B” plate
Typical Hanging Specification
Table 9
PLATE NO.
GASKET
PLATE
GLUING
HANGING
1
NBR (S)
H0230
RC START
B
2, 4, 6, 8, 10
NBR (S)
H1234
LG
E
3, 5, 7, 9, 11
NBR (S)
H1234
RC
B
12, 14, 16, 18
NBR (S)
H1234
LG
G, E
13, 15, 17, 19
NBR (S)
H1234
RC
C, B
20
NBR (S)
H1234
LG
G
21
NBR (S)
H1004
RC END
C
22
—
H1004
23
NBR (S)
H1004
RC START
B
24, 26, 28, 30, 32
NBR (S)
H1234
LG
E
25, 27, 29, 31, 33
NBR (S)
H1234
RC
B
34, 36, 38, 40
NBR (S)
H1234
LG
G, E
35, 37, 39, 41
NBR (S)
H1234
RC
C, B
42
NBR (S)
H1234
LG
G
43
NBR (S)
H0230
RC END
C
PARTITION
Model: GXD-060; Plate Material: 304 SS; Plate Thickness: 0.5 mm.
Plate No.: Indicates plate number if single number is given.
Indicates a numerical sequence pattern if multiple numbers
are given. If multiple letter codes are given in the Hanging
column, an alternating sequence between the two letters should
be followed as indicated in the Plate No. column.
Gasket: Defines the gasket material.
Plate: A five-digit identifier, which describes plate theta as being
“H” high or “L” low, is followed by four integers. These four
integers indicate which ports are pierced. A zero (0) denotes NO
piercing at this port location.
Gluing: An eight-character field describing how the gasket is
to be glued to the plate. The first letter describes whether the
closed port (ringed gasket corner) is in the Lower Right or Lower
Left. Therefore, “R” is Right and “L” is Left. The second letter
denotes the plate letter code. Both of these descriptions apply
when the plate is viewed upright with the designated letter code
being read left-to-right in the upper right hand quadrant of the
plate. Gaskets will be glued to the front of plate as viewed in their
installed orientation from front-to-back of the assembled unit.
“Start” or “End” can be added to the first two-letters with a space
between to denote special gasketing instructions for the first and
last plates between end-frames and/or partition plates.
Hanging: Indicates the letter code by which a plate is to be hung
in the unit. This letter should be located in the upper right of
the plate and read from left-to-right. The plate should be viewed
as if from looking from the front of the unit.
25
GX Gluing Codes
Diagonal Flow Plates:
Right C
RC
Left G
LG
Right L
RL
Left S
LS
Parallel Flow Plates:
Figure 37
Left C
LC
Right G
RG
Left L
LL
Right S
RS
Left B
LB
Right E
RE
Left K
LK
Right R
RR
These drawings depict how GX plates are to be glued. Note that gluing instructions for diagonal flow GX plates can be reduced to four combinations
while parallel flow GX plates require eight.
26
GX Start and End Plate Explanations
Moveable
Frame Side
Stationary
Frame Side
Looking from the
stationary frame to
the moveable frame
Start Plate—ALL
front side ports
gasketed.*
Start Plate—back
side has NO
gasket.
Moveable
Frame Side
Stationary
Frame Side
Looking from the
stationary frame to
the moveable frame
End Plate—front
side of end plate has
a normal gasket with
two ports gasketed.**
End Plate—all
back side ports
gasketed.*
Figure 38
* These gaskets are half thickness and may be pieced together in various ways depending upon specific model. Flow direction
(i.e., Diagonal/Parallel) is not a factor for these gaskets.
** This gasket will be the same as all non-Start/End plate gaskets. It will have two ports closed by the gasket. Which ports will
be determined by the flow direction (Diagonal/Parallel). Diagonal flow is shown in these illustrations.
27
INSTALLATION
Unpacking
SUPERCHANGER units (with optional shroud) are bolted
to and shipped assembled on a skid. Other optional items, if
supplied, are packed separately. All items should be checked
against packing lists.
SHOULD ANY PARTS BE MISSING OR DAMAGED,
IMMEDIATELY NOTIFY:
Tranter, Inc.
P.O. Box 2289
Wichita Falls, TX 76307
940-723-7125
Recommended Procedures
All frame models are provided with special lifting eyeholes for
transportation and installation by crane. Rigidly set all models on
the floor by means of foundation bolts. The following installation
tips are also recommended:
11. Do not apply valve and piping loads to the nozzles. Use
pipe supports.
1. Level the unit.
13. Place vent valves for draining at the highest possible point.
2. Locate the unit in an area that is not congested with piping
and other equipment. For units with nozzles on the movable
frame, refer to Figures 39 and 40 on page 29.
14. Provide pumps sending liquid into the SUPERCHANGER
with throttling valves.
3. Provide three feet of working area around the unit.
15. Install a safety relief valve if the maximum pressure output
of the pump is greater than that of the heat exchanger.
4. The piping system must allow for thermal expansion. This
can be accomplished inherently within the piping layout or
by flexible connections.
16. When a pressure control valve is installed, place it at the
inlet of the heat exchanger, even if a pressure control switch
is provided.
5. Debris can cause damage to the gaskets. The gasket areas
must be free from sand, gravel, pieces of iron, etc. before the
unit is closed.
6. Lubricate the tie bolts.
7. Tighten all tie rod nuts. Tighten the unit to plate pack
dimension per assembly drawings prior to making any
assembly connections.
8. Uniformly tighten the plate pack. (See tightening instructions
following.)
9. Flush connecting piping of all debris prior to “hook-up” with
the heat exchanger.
10. Correctly center gaskets inserted between pipe flanges.
28
12. Install shutoff valves at all nozzle locations.
CAUTION: Do
not expose plate and frame heat
exchangers to continuous vibration and/or high
frequency cyclic on/off operation since damage
from fatigue may occur. Do not use metering and
pulsating type pumps. If the SUPERCHANGER
unit is used in cyclic operation, the equipment
should be tightened to the minimum dimension
(see Table 3) to prevent fretting failure. Contact the
factory for assistance.
Tightening the Plate Pack
The plate pack tightening length (distance between the facing
surfaces of the “S” and “E” frames) is given on the assembly
drawing and on the unit data plate. The tightening dimension
is identified as “A Max.” and “A Min.” The unit is normally
tightened at the factory to the average dimension between “A
Max.” and “A Min.” “A Min.” is a minimum length. Consult the
SUPERCHANGER Engineering Department before tightening
the unit to a smaller dimension. CAUTION: On units
operating in excess of 200 psig, the tightening dimension is
to equal or approach the minimum dimension. The wrench
size required for the various SUPERCHANGER tightening bolt
diameters is shown below. Refer to the SUPERCHANGER
drawing for the actual bolt diameter.
BOLT DIAMETER (in.)
Due to manufacturing tolerances, a unit is sometimes shipped
with a plate pack dimension greater than the minimum
dimension stated on the drawing. If leakage occurs, after a
period of time, tighten the unit to the minimum length. If the
plate pack length is shorter than the minimum length, damage
to the plates at contact points may result. If leakage occurs at the
minimum length, contact the SUPERCHANGER Engineering
Department for recommendations regarding gasket replacement
or additional tightening.
WRENCH SIZE (Across Flats) (in.)
3/4
1 1/4
1
1 5/8
1 1/4
2
1 1/2
2 3/8
1 3/4
2 3/4
2
3 1/8
2 1/4
3 1/2
2 1/2
3 7/8
A
The end frame is
immovable with this
piping arrangement
B
Figure 39
Correct piping installation—disconnecting A and B connections will permit
movement of the end frame (top view).
Figure 40
Incorrect piping installation—the end frame is immovable (side view).
An EZCHANGER Hydraulic Closing Device is available for assembly/disassembly of larger units. See page 45 for details.
29
Tightening Sequences
Figure 41 gives the tightening sequence for all units. When
facing the stationary frame, tighten using the 1, 2, 3 and 4 bolts
in sequence as far as possible before installing the remaining bolts.
Be careful to tighten uniformly so that the moveable frame is
kept parallel with the fixed frame within 1/4 in. Check the plate
pack length on both sides of the plate pack at all tightening bolt
locations. Tighten the unit, according to this procedure, to the
plate pack dimension stated on the assembly drawing or unit data
plate. Measure the dimension with a metal tape and tighten all
bolts within 1/32 in. of the “A” dimension. (See Table 3.)
4 bolt unit
6 bolt unit
8 bolt unit
10 bolt unit
Do not tighten the plate heat exchanger
when it is holding liquid, under pressure or
operating. Rupture of the gaskets and exposure to
physical injury may occur. Always cool and drain the
heat exchanger before tightening.
WARNING:
12 bolt unit
14 bolt unit
16 bolt unit
18 bolt unit
20 bolt unit
Figure 41
Tightening sequence for all units.
START-UP PROCEDURES
Precautions Prior to Start-Up
1.
If there is particulate matter in the process streams, contact
your Tranter sales/service office to determine if a pipeline or
in-port strainer should be used before operating the unit.
2.
Confirm that the plate pack length is correct.
3.
Open all outlet valves completely.
4.
Completely close the pump discharge valves to the heat
exchanger.
5.
Provide venting on both sides of the heat exchanger to
facilitate the removal of air from the system.
6.
30
Start pumps and increase the pressure by opening the pump
discharge valve slowly.
7.
When all air is out, liquid will flow out of the vent. Close
the vent.
8.
Slowly and simultaneously open the inlet valves for both fluids
to avoid extreme over-pressure due to hydraulic shock.
9.
Control the amount of heating or cooling by using throttling
valves and product thermometers in conjunction.
CAUTION: To reduce the possibility of water hammer,
do not use fast opening and closing valves. The
pressure surge caused by a sudden change in the fluid
velocity can be several times higher than the normal
operating pressure of the system.
SERVICING
Shutting Down the Unit
Disassembly Procedures
1.
Gradually decrease the pressure of both fluids simultaneously
until all pressure is relieved.
2.
Never open a superchanger unit when it is hot. Cool the
unit to a warm temperature before opening to prevent
personal injury and gasket loosening.
To open the exchanger, it is necessary to disconnect all
connections (if any) to the “E” moveable frame. Lubricate all
bolts prior to disassembly. Then completely loosen and remove
all bolts except those indicated by a “filled circle” in the sketch
below for the size unit involved. The four remaining bolts can
then be loosened in any left-right sequence at 1/4 in. increments
until they can be lifted out.
3.
Completely drain fluids from the unit.
4 bolt unit
6 bolt unit
8 bolt unit
10 bolt unit
12 bolt unit
14 bolt unit
16 bolt unit
18 bolt unit
20 bolt unit
Figure 42
Loosening sequence.
Removal of Plates
3.
Exercise care when handling plates. The
edges are sharp. Leather gloves must be worn.
CAUTION:
1.
Remove the plates one by one from the frame.
2.
Clean and/or inspect the plates hanging in the frame by
removing them one at a time.
To remove a plate from the frame:
(a) For UXP-005, UXP-010, UXP-100, SXP-070, SXP-400,
SXP-140, GC, GX and GFP-050, GFP-100 and GFP-150
Series, tilt the plate and remove it.
(b) GFP-030, GFP-080, UXP-200, UXP-060, UXP-400
and UXP-110 Series, lift the plate, push down on the hanger
to release it, tilt the plate and remove it.
(c) UXP-801 and UXP-802 Series, remove the sectional
guide bar track, which is bolted into the bottom of the upper
I beam near the moveable end. Tilt the plates and remove
them one at a time. (There are three of the removable
track sections along the guide bar length to facilitate plate
removal.)
31
Replacing Plates
A faulty plate can easily be removed and replaced by a spare plate.
Check that the new plate has the holes and gaskets arranged in the
same way as the faulty one, and that the hangers are arranged in
the same direction as the original installation. When the plates are
properly assembled, the edges form a “honeycomb” configuration
as seen in Figure 43.
If a four-hole plate is defective and no spare plate is available, the
defective plate and one adjacent four-hole plate can be removed.
The capacity of the plate heat exchanger is then reduced, but
usually only slightly. When plates are removed calculate new
“A” tightening dimensions from Table 3.
Figure 43
Plate assembly.
Replacing Gaskets
See Figures 4, 5, 6, 7 and 36.
Removing Old Gaskets
When a gasket requires replacement, steps A1, A2 and A3 may
be followed or alternately steps B1, B2 and B3 may be used if
facilities are available.
A1. Remove the plate from the frame and lay it on a clean,
flat, horizontal surface. Examine and note exactly how the
gasket is positioned on the plate, particularly what grooves
the gasket does and does not occupy.
A2. Insert a pointed tool (screw driver) under the gasket until
a finger can be inserted. Then pull slowly until the gasket
is removed.
A3. Clean the gasket groove. Adhesive residue, oil, grease and
other foreign matter can be removed by applying a solvent
such as Methyl Ethyl Ketone (MEK), Acetone or other
Ketones with a nylon or stainless steel brush. Commercial
paint stripping compounds are also effective in removing
the gasket adhesive. Dry/wipe the gasket groove. (NOTE:
Use all solvents at room temperature (70°F) and in a well
ventilated area not exposed to open flame, electric motors,
etc.) Torches, grinding wheels and powered steel wire
brushes are not to be used to remove adhesive residue since
such tools will damage the plates.
B1. When a gasket requires replacement, remove the plate from
the frame and lay it on a clean, flat, horizontal surface.
Examine and note exactly how the gasket is positioned
32
on the plate, the orientation of the bleed grooves and
particularly what grooves the gasket occupies.
B2. For gasket removal, immerse the plate assemblies in a
10% to 15% caustic bath solution at 140°F to 180°F for
approximately 8 hr. The caustic will soften the glue and
the gaskets can be removed. Brushing with a nylon brush
will help remove the softened residual glue. (NOTE: Soak
time will vary depending on the type of service and the
length of exposure that the plates have seen.)
B3. The caustic solution will normally remove most of the
residue scale buildup on the heat transfer surface. Brushing
with a nylon brush will help remove excess residue. Always
rinse thoroughly.
To remove spot-glued gaskets, follow steps A1, A2 and, if
necessary, step A3.
Remove scale deposits, such as calcium compounds, by immersing
the plates in a 5% to 10% nitric acid solution at room temperature
(70°F). This procedure must be followed by a thorough rinsing.
See “Plate Cleaning Tips” on page 38.
Installing Continuously Glued Gaskets
1. Make sure the gasket groove area is clean and dry prior to
regasketing.
2.
Apply a uniform layer of adhesive in the appropriate
gasket grooves. (A plastic bottle makes an ideal applicator,
provided the tip of the applicator is designed to provide a
bead that is approximately 1/8 in. wide.) Do not apply
adhesive in amounts that will allow it to ooze out when the
gasket is pressed into the groove. Apply adhesive at room
temperature (70°F). After the glue is applied to the plate,
it should be allowed to set for a minimum of 30 sec before
the gasket is set in place. Work on pairs of plates to allow
for this curing time.
The recommended adhesive for all elastomeric gaskets is
Pliobond 30. Pliobond 20 and 3M 1347 can also be used,
if Pliobond 30 is not available. Hardening adhesives are not
to be used. The number of gaskets that can be glued from
one pint bottle of Pliobond 30 glue may be approximated
as in Table 10.
3. Position the gasket on the plate making sure that the
recess in the gasket at the bleed passage location is up. Also,
when the proper side is up, the gasket code number will be
visible in the bleed passage area. Proper groove fit and flow
diverter access is dependent on end-to-end positioning. (See
Figures 15 and 32.)
4. Using finger pressure, firmly press the gasket into the same
grooves from which the original gasket was removed.
5. Compress the gasket by placing the plate under a weighted
Table 10
sheet of wood. The longer the compression time, the better
the bond. Twelve hours cure time at room temperature (70°F)
should be allowed to assure minimum required adhesion
of the gasket to the plate for all elastomers except EPDM.
EPDM gaskets require a minimum of 24 hr cure time at
room temperature (70°F) to assure an adequate bond. (When
several plates are being gasketed, they can be stacked on top
of each other with the weighted wood sheet placed on the
top plate of the stack.)
6. After compression time (step 5), use solvent to remove any
excess adhesive that may have seeped out past the edges of
the gasket.
7. Reinstall plate(s) in the unit insuring that the gasket surface
and the sealing surface of the plate ahead are wiped clean to
provide a positive seal.
NOTE:
Refer to page 24 when using mixed gaskets.
8. Note that the “D” plate (always the plate next to the fixed
frame end) requires different gaskets. The purpose of the
“D” plate is to prevent fluid from flowing across the fixed
end frame. The only sealing surface on the “D” plate is the
port hole gaskets. “D” plate gaskets for the UX series consist
of two half gaskets. “D” plate gaskets for the GFP-030 and
GFP-080 plates consist of four port hole gaskets and straight
strips, which fit in the gasket groove around the periphery of
the plate. The wide port gasket fits the widest groove, and
the narrow port hole gasket fits the narrow groove.
Glue Requirements
MODEL
MODEL
NUMBER OF GASKETS/PINT
NUMBER OF GASKETS/PINT
XP-005
122
GXD-037
30
UXP-010
100
GXD-064
18
UXP-100
85
GXD-091
15
UXP-200
60
GXD-118
13
GFP-030
50
GXD-060, GCP-060
20
UXP-060, SXP-070
35
GXD-100
18
UXP-400
30
GXD-140
14
UXP-110
30
GXD-180
15
SXP-400, SXP-140
30
GXD-085
16
GFP-080
25
GXD-145
14
UXP-801, UXP-802
10
GXD-205
12
GXD-006
50
GXD-265
10
GXD-012, GL-013, GC-016
50
GXD-325
8
GXD-018, GCP-010
35
GFP-057
19
GXD-026, GCP-026
30
GFP-097
18
GXD-042
20
GFP-187
15
GXD-051, GCP-051
17
GL-230, GL-330, GL-430
8, 7, 6
33
Installing Spot-Glued Gaskets
Spot gluing of Elastomeric gaskets is covered under
Tranter’s U.S. Patent #5070939.
In the following procedure, after the glue is applied to the plate
at the appropriate spots, allow it to set for a minimum of 30 sec
before the gasket is mounted. Work on pairs of plates to allow
for this curing time. Work in a well-ventilated area.
1. Clean the gasket groove in one plate with a rag moistened
with Methyl Ethyl Ketone (MEK).
Circled areas show
the 14 “T” joints
2. Apply a 1/8 in. diameter spot of Pliobond 30 approximately
every 4 in. centered in the gasket groove of the plate just
cleaned.
a) Apply the glue so there are no thin spots.
b) Apply spots of glue at the “T” joints (see Figure 44).
3. Clean the groove of a second plate, as in step 1.
4. Apply adhesive to the second plate, as in step 2.
5. Install the gasket on the first plate. Make sure the gasket is
oriented as shown in Figures 15 and 32.
6. Install the gasket on the second plate, as in step 5.
The purpose of working with two plates
simultaneously is to allow the adhesive to set for
a minimum of 30 sec before the gasket is applied.
When working with small plates, a third plate can be
incorporated into the above procedure to obtain set
time. The curing time must not exceed 3 min.
NOTE:
7. Compress the gasket by placing the plate under a weighted
sheet of wood. The longer the compression time, the better
the bond. Twelve hours cure time at room temperature
(70°F) should be allowed to assure maximum adhesion of the
gasket to the plate for all elastomers except EPDM. EPDM
gaskets require a minimum of 24 hr cure time at room
temperature (70°F) to assure an adequate bond. (When
several plates are being gasketed, they can be stacked on top
of each other with the weighted wood sheet placed on the
top plate of the stack.)
34
Figure 44
Locations at “T” joints where glue must be applied.
NOTE:
Refer to page 24 when using mixed gaskets.
8. After adequate compression time, use solvent to remove any
excess adhesive that may have seeped-out past the edges of
the gasket.
9. Reinstall plate(s) in unit insuring that the gasket surface
and the sealing surface of the plate ahead are wiped clean to
provide a positive seal.
Installing SUPERLOCK® Snap-In Gaskets
SUPERLOCK gaskets are covered under Tranter’s
U.S. Patent #4995455.
1. Position the gasket on the plate making sure that the recess
in the gasket at the bleed passage location is up. When the
proper side is up, the gasket code number will be visible in
the bleed passage area. Correct end-to-end position is also
important for a proper groove fit and fluid access to the flow
diverter. (See Figures 15 & 32.)
2. Make sure that the tabs of the SUPERLOCK gaskets are
lined up with the slots in the gasket groove of the plate.
3. Insert each tab inside its corresponding slot and push firmly
until the tab locks into the slot. Make sure that each of the
porthole tabs (located in the bleed port area towards the
middle of the plate) is also snapped into its slot.
NOTE:
Refer to page 24 when using mixed gaskets.
Installing Teflon Encapsulated Gaskets and Unit Assembly
On units operating in excess of 200 psig,
the tightening dimension is to equal or approach the
minimum dimension.
CAUTION:
10. Single side hydrostatic test to design pressure shown on
assembly drawing.
11. Double side hydrostatic test to test pressure shown on
assembly drawing.
1. Install double-sided tape in the center of the gasket
groove. Use continuous strips. Do not contaminate the
tape surface.
12. If unit leaks during either of the above tests, run 150°F to
170°F hot water for one hour. Let the unit cool and tighten
to average dimension as shown on assembly drawing using
same increments as in step 8.
2. Do not overlap tape strips as this will cause leakage in
that area.
13. Re-conduct the hydrostatic test.
3. Install Teflon such that bleed ports (notches) in each section
in rubber core are installed in the up position.
4. Install plates per the assembly drawing that is received with
the unit.
5. Check top surface of Teflon and gasket seal surface for
cleanliness.
6. Install all bolts and tighten the unit (snug tight only).
7. Refer to page 30 for tightening sequence.
8. Tighten unit in 1/16 in. increments to ensure even
compression of gaskets.
9. Ti g h t e n t o m a x i m u m d i m e n s i o n a s s h ow n o n
assembly drawing.
14. If unit still leaks, mark plate and area of leakage.
15. Disassemble unit and check gasket and seal surface for
defects, especially at the leakage sites. If no apparent defect is
found, apply an even thin layer of “Teflon TFE Pipe Thread
Sealer,” furnished by McMaster Carr (www.mcmaster.com,
part #4538K1), to Teflon gasket at leakage site.
16. Retighten unit using same procedure as listed above.
17. Re-conduct the hydrostatic test.
18. Unit should not seal. If unit is still leaking, contact
the factory.
NOTE:
Refer to page 24 when using mixed gaskets.
35
Installing Clip-On Gaskets
There is one kind of channel arrangement. The first, uneven and
last channel will always be S2/S4. The even channels will always
be S1/S3. The Tranter standard connection location is hot in/out
S1/S3. Therefore, it will start and end with a cold channel. If a
hot in/out in S2/S4 is required, the first and last channels will
subsequently be hot.
1. Attach half-A gasket to the start plate in the RORU
orientation, as in Figure 46. Hang by the ORU orientation,
as shown in Figure 45.
2. Attach B gaskets to even plates by the LOLU orientation. (See
Figure 46.) Hang by the ORD orientation, so the “O” is in
the lower right corner. (See Figure 45.) This is equivalent to
Channel B.
ORU
ORD
Figure 45
Plate hanging orientation.
3. Attach A gaskets to odd plates by the RORU orientation,
as shown in Figure 46. Hang by the ORU orientation, as in
Figure 45. This forms a Channel A.
4. Attach B gasket to end plate by the LOLU orientation, and
attach half-A gasket to the backside of the end plate by the
RORU orientation. (See Figure 46.) Hang by the ORD
orientation with B gasket facing inside. (See Figure 45.) This
completes the plate pack.
The following is an example of the above in a GLD-013 heat
exchanger:
Start plate
RORU
Plate Hanging Assembly
PLATE SEQUENCE
ATTACHING
HANGING
1
RORU Start
ORU
2, 4..54, 56
LOLU
ORD
3, 5..55, 57
RORU
ORU
58, 60..70, 72
LOLU
ORD
59, 61..71, 73
RORU
ORU
74
LOLU End
ORD
Gasket Attaching Assembly
QUANTITY
Even plates
LOLU
Odd plates
RORU
End plate
LOLU
End plate
RORU
ATTACHING
1
RORU Start
28
LOLU
36
RORU
8
LOLU
1
LOLU End
Figure 46
Gasket attaching orientation.
36
CLEANING
SUPERCHANGER plate and frame type heat exchangers
are designed for both manual cleaning and cleaning-in-place
operations. Where possible, utilize a cleaning-in-place system
that will allow pumping water or cleaning solutions into the
unit without disassembling. A CIP system may be purchased
through Tranter. If this is not feasible, use the manual method.
Descriptions of the two cleaning procedures follow.
Steps for Manual Cleaning of Plates
1. Open the unit in accordance with disassembly procedures
on page 31.
2. Clean each plate separately. Depending upon the amount
of cleaning to be performed, the plate can be cleaned while
still hanging in the unit or removed, placed on a flat surface
and cleaned.
3. Never use a steel brush or steel wool on the plates. If a
brush is required, use one with bristles that are softer than
the plate material. If iron is forcibly rubbed on a stainless
steel surface, it is impossible to remove all imbedded particles
and will result in accelerated rusting and/or corrosion. If it
is absolutely necessary that a metal brush be used, the brush
material must be compatible with the plate material.
9. The lower portion of each plate as hung in the unit should
be inspected carefully and cleaned appropriately as this
is the primary area where residual solid material tends to
accumulate.
10. Wipe off the mating surface, i.e., the rear of the plate where
the gasket seats.
11. Upon completing the cleaning, inspection and installation of
each plate, the unit may be closed, tightened per the assembly
drawing and the tightening instructions (page 30), and placed
into operation.
Do not use chlorine or chlorinated water
to clean stainless steel, Hastelloy, Incolloy, Inconel
and 254SMO. Chlorine is commonly used to inhibit
bacteria growth in cooling water systems. It reduces
the corrosion resistance of stainless steel, Hastelloy,
Incolloy, Inconel and 254SMO. The “protection layer”
of these steels is weakened by chlorine and makes
them more susceptible to corrosion. This increase
in susceptibility to corrosion is a function of time
and the chlorine concentration. For any applications
where chlorination must be used with non-titanium
equipment, please contact the factory.
CAUTION:
4. Be careful not to scratch the gasket surfaces.
5. After brushing, each plate should be rinsed with clean water.
6. Use high pressure rinse when cleaning continuously glued
plate assemblies.
7. See “Plate Cleaning Tips” on page 38 for specific types
of deposits.
8. The gaskets must be wiped dry with a cloth. Solid particles
adhering to the gaskets cause damage and result in leakage
when the unit is put back in operation.
37
Plate Cleaning Tips
1.
2.
3.
Do not use hydrochloric acids, or water containing in excess
of 300 ppm chlorides, with stainless steel.
Do not use phosphoric or sulfamic acid for cleaning
titanium plates.
Limit cleaning solution concentration to 4% in strength, with
temperatures not exceeding 140°F unless otherwise specified.
General guidelines for cleaning are tabulated below. (Please refer
to steps 1 through 3 above for precautions.)
TYPE OF FOULING
SUGGESTED CLEANERS
Calcium Sulphate, Silicates
Citric, Nitric, Phosphoric or Sulfamic Acid
Calcium Carbonate
10% Nitric Acid (1 volume concentrated
Nitric Acid with specific gravity 1.41 to 9
volumes of water), Oakite 131
Alumina, Metal Oxides, Silt
Citric, Nitric, Phosphoric, or Sulfamic Acid
(To improve cleaning, add detergent to acid.)
Barnacles, Mussels, Seaweed, Wood Chips
Back flush per cleaning-in-place procedure
below and Figure 48
Biological Growth
Sodium carbonate or sodium hydroxide
Return
Process
supply
pH probe
to monitor
cleaning
procedure
Self-priming
pump
CIP cleaning
solution tank
Figure 47
Cleaning-in-place flow chart.
Figure 48
Piping using brine (top view).
Cleaning-In-Place (CIP)
Cleaning-in-place is the preferred cleaning method when
especially corrosive liquids are processed in a SUPERCHANGER
unit. Install drain piping to avoid corrosion of the plates due
to residual liquids left in the unit after an operation cycle. (See
Figure 47.)
To prepare the unit for cleaning, follow the procedures listed
below:
1. Drain both sides of the unit. If it is not possible to drain,
force liquids out of the unit with flush water.
2. Flush the unit on both sides with warm water at
approximately 110°F until the effluent water is clear and
free of the process fluid.
3. Drain the flush water from the unit and connect CIP pump.
(See “Plate Cleaning Tips” above for suggested cleaners.)
4. For thorough cleaning, it is necessary to flow CIP
solution bottom to top to insure wetting of all surfaces
with cleaning solution. When cleaning multiple pass units,
38
it will be necessary to reverse flow for at least 1/2 the cleaning
time to wet all surfaces.
5. For optimum cleaning, use the maximum flow rate of water,
rinse, or CIP solution that the CIP nozzle size will allow (2
in. @ 260 gpm, 1 in. @ 67 gpm.) A CIP operation will be
most effective if performed on a regularly scheduled basis
and before the unit is completely fouled.
6. Flush thoroughly with clean water after CIP cleaning.
If brine is used as a cooling medium,
completely drain the fluid from the unit and flush the
unit with cold water prior to any cleaning operation.
Corrosion will be kept at a minimum if all traces of
brine are eliminated before using hot cip solutions
on either side of the heat exchanger.
CAUTION:
Back Flushing and Strainers
Often, when fibers or large particulates are present, back flushing of the unit proves to be very beneficial. This is accomplished by either of the following methods:
1.
Flush the unit with clean water in reverse flow pattern to
the normal operating direction.
2.
Arrange piping and valves so the unit may be operated in
reverse flow mode on the product side for fixed periods of
time. This method is particularly well suited for steam-toproduct units.
3.
The use of strainers are recommended in supply lines
ahead of the exchanger when the streams contain significant
solids or fibers. This will reduce the requirements for
back flushing.
Cleaning Guidelines
1.
Never open the unit when hot, under pressure, holding
liquid or operating.
2.
Never clean the plates with a steel brush or steel wool.
3.
Always wipe the gaskets clean before closing the
unit to prevent damage resulting from adhering
particulate matter.
4.
Always use clean water (free from salt, sulphur,
chlorine or high iron concentrations) for flushing and
rinsing operations.
5.
If steam is used as a sterilizing medium, do not exceed
270°F steam temperature with nitrile gaskets and 350°F
with EPDM gaskets.
6.
If chlorinated solutions are used as the cleaning media,
employ a minimum concentration at the lowest temperature
possible. Minimize the plate exposure time. The chlorine
concentration must be less than 100 ppm and temperatures
must be under 100°F with a maximum plate exposure
time of 10 min. Follow the cleaning recommendations
of suppliers, relative to concentration, temperature and
treatment time.
7.
Always add concentrated cleaning solutions to water before
circulating through the unit. Never inject these solutions
while the water is circulating.
8.
Remove rusted or pitted areas that appear on the plates with
commercial scouring powder. Follow this by flushing with
clean water.
9.
Cleaning solutions should always be circulated with a
centrifugal pump.
10. Do not use hydrochloric (muriatic) acid for cleaning plates.
11. Thoroughly rinse the plates with clean water following any
type of chemical cleaning.
39
TROUBLESHOOTING
2
1
3
Figure 49
Troubleshooting sources of leaks.
40
Leakage Between the Plate Pack and the Frame
(See Figure 49, Item 1)
PROCEDURES AND OBSERVATIONS
1.
SOLUTIONS
Use a felt tip marker to identify the area where the leakage
seems to be occurring and then open the plate pack.
2. If the leakage occurs in the area of a nozzle, then observe the
gasket condition of the “D” plate or “E” nozzle “O” ring.
Foreign matter, scars, other damage to the gasket surfaces
and any gasket dislocation may be the problem.
Remove all foreign matter, relocate the gasket, or replace the
damaged gasket.
3. Check the end frame for foreign objects, surface unevenness,
or any other condition which might interfere with the seal
between the gasket and the adjacent surface.
Remove any interference between the gasket and the surface
of the end frame.
4.
If a plate has perforation, it must be replaced.
Check the plate for cracks or holes.
Leakage Between the Nozzle and the End Frame
(See Figure 49, Item 2)
PROCEDURES AND OBSERVATIONS
SOLUTIONS
1. Fluid is flowing from the area between the nozzle and the
end frame (point A on Figure 50) and/or the interior of the
end frame and the seal plate (point B on Figure 50).
A
B
Check the integrity of the continuous pressure weld between
the stub end and the seal point (point C on Figure 50). Dyecheck for small cracks. If the dye-check reveals any linear
indication, the area needs to be ground down and re-welded
using TIG welding, and the appropriate welding wire. If the
weld damage occurred due to a blow to the nozzle, some of
the plate assemblies may be damaged. Damaged plates should
be replaced.
C
Figure 50
Troubleshooting nozzle/end frame leaks.
41
Leakage Between the Plates to the Outside of the Unit
(See Figure 49, Item 3)
PROCEDURES AND OBSERVATIONS
1.
SOLUTIONS
Mark the area of the leak with a felt tip marker.
2. Check the plate pack dimensions to insure they agree with
Table 3. Overtightening may cause plate damage.
Depressurize unit and adjust the plate pack as necessary.
Disassemble unit per procedure on page 31.
3.
Look for mislocated, loose or damaged gaskets.
Relocate gaskets, reglue loose gaskets and replace damaged
gaskets.
4.
Check for plate damage in the area.
A damaged plate usually must be replaced. For temporary
duty, if the damaged plate has four holes and an adjacent plate
(front or back) has four holes, remove both plates and retighten
the plate pack according to Table 3. Contact the factory if
temporary operating characteristics need to be developed for
a smaller number of plates. See “How to Find a Defective
Plate” on page 43.
5.
Make sure the plate pack sequence is A-B-A-B-etc., see
Figure 15.
Inspect the plate pack for damage and place the plate assemblies
in the correct order.
Mixing of Fluids
PROCEDURES AND OBSERVATIONS
42
SOLUTIONS
1. Make sure the piping is connected to the correct locations
on the heat exchanger.
Relocate piping to the correct connections.
2. Make sure the plates are properly arranged on each adjacent
plate according to the assembly drawing (A-B-A-B...
arrangement).
Open the plate pack and replace the plate gasket assembly.
3. Make sure the gaskets are correctly oriented on the plates
with the “bleed port” of each gasket facing away from the
plate surface. See Figures 32 through 34.
Replace gaskets correctly.
4.
Remove and replace as discussed on page 33. Inspect the
plate pack for damage and place the plate assemblies in the
correct order.
Follow the steps described in “How to Find a Defective
Plate” on page 43. If a leak is found, use a felt tip marker
to locate the place.
Increase in Pressure Drop or a Reduction in Temperature Reading
PROCEDURES AND OBSERVATIONS
SOLUTIONS
1. The pressure drop from the inlet to the outlet on one or
both sides of the unit is too high compared to the original
specified pressure change.
Try cleaning-in-place (CIP) as described in Figures 47 and
48. Check the accuracy of the instrumentation. Pressure
taps should be installed 10 and 5 pipe diameters upstream
and downstream, respectively, from flow disturbing source,
i.e., elbow, valve, reducer, etc.
2. The temperature readings are correct for the process;
however, the pressure drop is high.
The plate surfaces are clean enough, however, the inlet of the
unit could be clogged. Back flushing the equipment or CIP
may solve the problem.
3. The temperature readings do not correspond to the original
temperature settings or specifications.
The pressure drop is probably also increasing. The change
in the temperature readings indicates that there is a buildup
of deposits on the plate surfaces. If CIP or back flushing the
equipment does not work, the unit will need to be opened and
the plates cleaned.
4. The pressure drop is too low, and the unit is known to
be clean.
The pump capacity may be too small. Check the pump manual.
How to Find a Defective Plate With Through Holes
Severe corrosion may cause defect to occur. The following
method is recommended to determine the location of the
defective plate or plates:
8.
1.
Open the unit, remove all fouling from surfaces and dry the
plates after cleaning. Make sure the bleed port areas (see
Figure 32) are clear.
9.
2.
After completely drying the plates, reassemble the unit.
3.
Supply water to one side (“A” side) and raise the water
pressure to approximately 50 psig.
4.
Open the drain valve at the lowest point or break the
flange on “B” side. By removing the flange and fittings, it
is possible to look into the nozzle and measure to the exact
leaking plate.
5.
Stop the test if water flows out of the drain valve or flange
on “B” side.
6.
Open all valves and empty the unit of all water.
7.
Open the unit promptly and find which plate is wet on
“B” side. This plate and the preceding plates may have
defects.
The defect can be found by placing a lamp on the rear side of
the plate and by observing the light that passes through.
If the defect is small, the use of dye penetrant may be required
to locate the defect. Because of the metal to metal contact
of the plates, the defect can be larger when the plate pack is
compressed than when it is in the free state.
A unit with multiple pass circuits that does
not allow the fluid to drain out of each channel
on one side cannot be tested in this way unless the
special center plates are first removed. See Figure
20 as an example.
NOTE:
43
STORAGE PROCEDURES
When a SUPERCHANGER plate and frame heat exchanger is
to be placed in storage for six months or longer, the procedures
listed below must be followed:
1. If the unit has been recently shipped from our factory and
is unused, disregard steps 2, 3 and 4; follow steps 5 through
10.
2. If the unit has been used and long-term storage is required,
it must be completely drained. Prior to draining remove the
optional shroud, if provided, and let the unit cool to ambient
temperature. Units with plate packs arranged with one pass
on each side (all nozzles on the stationary end frame) are
self-draining. Simply vent at the upper nozzle location and
drain from the lower nozzle for each side individually. A two
pass/two pass or one pass/two pass plate arrangement is also
self-draining, provided all two pass side nozzles are at the
lower elevations (numbers S2, S3, M2 and M3). Other units
may be self-draining if they have been fitted with separate
drain and vent nozzles, or with vents and drain holes. Units
that are not self draining must have the plate pack completely
loosened to drain all liquids. Before opening the plate pack,
wipe off the exterior surfaces to make sure no fluids or debris
fall onto the plate pack.
3. Open the plate pack and thoroughly clean the unit internally
and externally. Dry the unit. (Blowing dry, hot air at
approximately 150°F on all areas is an excellent method.)
4. Install blind flanges with gaskets on all nozzles. Plug all
other openings.
5. Coat all unpainted carbon steel component surfaces with
light grease, SAE 30 oil or other rust inhibiting products.
44
6. Coat all bolt threads with light grease.
7. Loosening of the plate pack is not recommended. However,
it is advisable that to avoid any compression set of the
gaskets, the plate pack length dimension be adjusted.
This should be greater than the unit’s stated minimum
tightening dimension (T.D.).
8. Protect the unit from direct sunlight, intense heat radiation
or ultraviolet radiation by loosely covering the unit with an
opaque, reflecting type plastic film or similar material. Make
sure air is allowed to circulate around the unit.
9. It is preferable to store the unit indoors, well protected from
the weather. The temperature in the storage area should
ideally be 60°F to 70°F with a relative humidity of 70%
or lower.
Never store the unit in an area where the
temperature is at 32°F or lower.
CAUTION:
10. All potential sources of Ozone, such as operating electric
motors or welding equipment, should be removed from the
storage area to preclude Ozone attack on gaskets. Gaskets
should not be exposed to direct sunlight (ultraviolet
radiation) and should be stored in dark plastic bags. Under
proper storage conditions, gaskets generally have a shelf life
of approximately four years.
MISCELLANEOUS INSTRUCTIONS
General Maintenance
It is recommended that tightening bolts and tightening nuts be
lubricated periodically in order that they can be easily loosened
at time of disassembly. The upper guide bars where the plates
slide should be coated with a lubricant to avoid corrosion and
to enable the plates to slide smoothly. Rollers in the moveable
end frame and connecting frames should be lubricated with oil
periodically.
EZCHANGER Hydraulic
Closing Device
Disassembly and reassembly of your SUPERCHANGER plate
and frame heat exchanger during maintenance operations
using standard tools can be challenging and time consuming,
particularly with larger units. The EZCHANGER Hydraulic
Closing Device can easily cut your assembly/disassembly
time by 50% or more. Call Tranter or your nearest Tranter
representative for immediate pricing and delivery information.
Ordering Parts
When ordering parts or requesting information, always give the
Model and Serial Number of the unit.
Refer to the parts list on your assembly drawing for correct
nomenclature and numbers.
Additional Information
For any additional information concerning the operation, care
or maintenance of your SUPERCHANGER, feel free to contact
our SUPERCHANGER technical specialists at one of our
manufacturing locations. Visit our web site for parts quotations
at www.tranter.com, or e-mail us directly at sales@tranter.com.
Tranter, Inc.
1900 Old Burk Highway
Wichita Falls, TX 76306
Tel. 1-800-414-6908 • Fax: 940-723-5131
Tranter International AB
Wakefield Factory
Tranter Ltd, Unit 50
Monckton Road Industrial Estate
Wakefield WF2 7AL England
Tel. +44-1924 298 393 • Fax: +44-1924 219 596
Tranter International AB
Regementsgatan 32
PO Box 1325
SE-462 28 Vänersborg Sweden
Tel. +46 521 799 800 • Fax: +46 521 799 822
Tranter India Pvt. Ltd.
Gat. No. 985, Sanaswadi Tal. Shirur
Dist.Pune -412 208 (India)
Tel. +91-2137 392 300 • Fax: +91 2137 252 612
Returned Material
Units or parts are not to be returned without first sending prenotification to the factory. Parts accepted for credit are subject
to a service charge plus all transportation charges. Any items
authorized for return must be adequately packed to reach Tranter
at the address shown below without damage.
Damaged Shipments
Tranter’s equipment is carefully packaged at the factory to protect
it against the normal hazards of shipment. If Tranter equipment
should arrive in a damaged condition, the customer must file a
damage report with the carrier. A copy of this claim should be
sent to:
Tranter, Inc.
1900 Old Burk Highway
Wichita Falls, TX 76306
45
Authorized Service Centers
To obtain additional information on operation and maintenance,
contact your local Tranter, Inc., representative or the nearest
Tranter, Inc., factory-authorized Service Center.
Tranter, Inc.
Factory/Sales/Engineering Office
1900 Old Burk Highway
Wichita Falls, TX 76306
Tel. 1-800-414-6908 • Fax: 940-723-5131
E-mail: aftermarket@tranter.com
Tranter International AB
Käthe-Paulus-Strasse 9
Postfach 10 12 14
DE-31137 Hildesheim Germany
Tel. +49-512 175 2077 • Fax: +49-512 188 8561
E-mail: aftermarket@tranter.com
Tranter Service Center
1213 Conrad Sauer
Houston, TX 77043
Tel. 1-800-414-6908 • Fax: 713-467-1502
E-mail: aftermarket@tranter.com
Tranter International AB
Via Ercolano, 24
IT-20052 Monza MI Italy
Tel: +39-039 28 282 210 • Fax: +39-039 834 315
E-mail: aftermarket@tranter.com
Tranter Midwest Service Center
30241 Frontage Road
Farmersville, IL 62533
Tel. 217-227-3470
E-mail: aftermarket@tranter.com
Tranter Ind e Com de Equipamentos Ltda
Av. Leonil Cre Bortolosso, 88 Galpão 1 -Vila Quitaúna
06194-971 Osasco, SP Brazil
Tel. +55 11 3608-4154
E-mail: aftermarket@tranter.com
Tranter International AB
Wakefield Factory
Tranter Ltd, Unit 50
Monckton Road Industrial Estate
Wakefield WF2 7AL England
Tel. +44-1924 298 393 • Fax: +44-1924 219 596
E-mail: aftermarket@tranter.com
Tranter India Pvt. Ltd.
Gat. No. 985, Sanaswadi Tal. Shirur
Dist.Pune -412 208 (India)
Tel. +91-2137 392 300 • Fax: +91 2137 252 612
E-mail: aftermarket@tranter.com
Tranter International AB
Regementsgatan 32
PO Box 1325
SE-462 28 Vänersborg Sweden
Tel. +46 521 799 800 • Fax: +46 521 799 822
E-mail: aftermarket@tranter.com
SUPERCHANGER
SUPERCHANGER units are plate and frame type heat
exchangers consisting of corrugated heat transfer plates, frames,
nozzles and tightening bolts. The corrugated plates are held in
between the stationary and moveable frames and are compressed
by tightening bolts. Optional shrouds are available on request.
The plates are equipped with elastomeric gaskets and have port
holes pierced in the corners. When the unit is tightened, the
gaskets seal the structure and, in conjunction with the port
holes, allow fluids to flow in alternate channels and almost always
flow counter-currently. The thin fluid interspace coupled with
the corrugated plate design induces turbulence that produces
extremely high heat transfer coefficients.
Plates are manufactured in standard sizes in virtually any material
that can be cold worked. The size, number and arrangement of the
plates is contingent upon the duty to be performed. Accordingly,
the units are custom designed for each application.
46
SUPERCHANGER frames are provided in two basic designs,
differing primarily in their support systems. One type uses an
external support column (Models HP, UP, SP, MP and FP) while
the other type uses a self-contained supporting pad (Models HJ,
UJ, SJ and MJ). The “J” Models conserve more space, but have
a limited plate capacity while the “P” Models can contain up to
700 plates in a single frame. (See Figures 1 and 2.)
Information in this brochure is subject to
change without notice. The manufacturer reserves
the right to change specifications at any time.
NOTE:
NOTES
47
At the forefront of heat exchanger
technology for more than 70 years
Tranter top quality, high-performance, proprietary
products are on the job in demanding industrial and
commercial installations around the world. Backed by
our comprehensive experience and worldwide presence,
Tranter offers you exceptional system performance, applications assistance and local service. Tranter is close
to its customers, with subsidiary companies, agents,
distributors and representatives located worldwide.
Contact us for a qualified discussion of your needs.
North/South America
Europe
Middle East/Asia
Tranter, Inc.
Tranter International AB
Tranter India Pvt. Ltd
Wichita Falls, TX USA
Tel: (940) 723-7125
Fax: (940) 723-5131
E-mail: sales@tranter.com
Stockholm, Sweden
Tel: +46 (0)8 442 49 70
Fax: +46 (0)8 442 49 80
E-mail: info@se.tranter.com
Pune, India
Tel: +91 20-30519300
Fax: +91 20-30519350
E-mail: sales@in.tranterphe.com
www.tranter.com
SC-IOM-11-0107
650531
© 2007 Tranter, Inc.