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 email@example.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: firstname.lastname@example.org 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: email@example.com Tranter Service Center 1213 Conrad Sauer Houston, TX 77043 Tel. 1-800-414-6908 • Fax: 713-467-1502 E-mail: firstname.lastname@example.org Tranter International AB Via Ercolano, 24 IT-20052 Monza MI Italy Tel: +39-039 28 282 210 • Fax: +39-039 834 315 E-mail: email@example.com Tranter Midwest Service Center 30241 Frontage Road Farmersville, IL 62533 Tel. 217-227-3470 E-mail: firstname.lastname@example.org 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: email@example.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: firstname.lastname@example.org 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: email@example.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: firstname.lastname@example.org 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: email@example.com Stockholm, Sweden Tel: +46 (0)8 442 49 70 Fax: +46 (0)8 442 49 80 E-mail: firstname.lastname@example.org Pune, India Tel: +91 20-30519300 Fax: +91 20-30519350 E-mail: email@example.com www.tranter.com SC-IOM-11-0107 650531 © 2007 Tranter, Inc.