Alfalaval AC Series User manual

Instruction Manual -
Brazed plate heat exchangers
AC, AXP, CB, CD, DOC
EN
3450021401-EN 2017-06
Original manual

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Table of contents
Description ............................................ 11
Function ............................................... 11
Nameplates .......................................... 11
Installation ............................................. 12
Unpacking ............................................. 12
Lifting .................................................. 12
Requirements ......................................... 13
Mounting .............................................. 15
Installation in general ................................. 16
Installation as evaporator or condenser ............. 17
Leaktest .............................................. 18
Operation .............................................. 19
Start-up ............................................... 19
Unit in operation ...................................... 20
Shut-down ............................................ 22
Maintenance .......................................... 23
General guidelines regarding maintenance .......... 23
Cleaning-In-Place ..................................... 23
Faulttracing ........................................... 25
Pressuredropproblems .............................. 25
Heattransferproblems ............................... 26
How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected
by laws governing intellectual property and thereto related rights. It is the
responsibility of the user of this document to comply with all applicable intellectual
property laws. Without limiting any rights related to this document, no part of this
document may be copied, reproduced or transmitted in any form or by any means
(electronic, mechanical, photocopying, recording, or otherwise), or for any purpose,
without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate
AB will enforce its rights related to this document to the fullest extent of the law,
including the seeking of criminal prosecution.
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3450021401 EN 2017-06 Instruction Manual -
Brazed plate heat exchangers 7
EN

Preface
Preface
This manual provides information needed to install, operate
and carry out the maintenance of the plate heat exchanger.
Intended use
The plate heat exchanger has been designed to meet the
requirement for a wide range of heat transfer applications such
as refrigeration, comfort heating, industrial heating and cooling,
and the process industry.
Safety considerations
The plate heat exchanger must be used and maintained
in accordance with the instructions in this manual. Faulty
handling of the plate heat exchanger may result in serious with
injuries and/or property damage. Alfa Laval will not accept
responsibility for any damage or injury caused as a result of
not following the instructions in this manual.
The plate heat exchanger must be used in accordance with the
specified configuration of material, media, temperatures and
pressure for the specific plate heat exchangers.
Prior knowledge
The plate heat exchanger must be operated by individuals
who have studied the instructions in this manual and have
knowledge of the process. This includes knowledge of the
precautions regarding media, pressures, the temperatures
in the plate heat exchanger as well as specific precautions
required for the process.
Maintenance and installation of the plate heat exchanger
must be performed by individuals who have knowledge and
authorization according to the local regulations. This includes
performance work such as piping, welding and maintenance.
For maintenance work not described in this manual, please
contact an Alfa Laval Representative for advice.
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Preface
Definitions of expressions
Warning!
Type of hazard
WARNING indicates a potentially hazardous situation
that, if not avoided, may result in death or serious
injury.
Caution!
Type of hazard
CAUTION indicates a potentially hazardous situation
that, if not avoided, may result in minor or moderate
injury.
Note!
NOTE indicates a potentially hazardous situation that,
if not avoided, may result in property damage.
Warranty conditions
Unless altered by written agreement, Alfa Laval standard
warranty applies.
Storage of the plate heat exchangers
Alfa Laval delivers the plate heat exchanger ready for
operation, unless agreed otherwise. Keep the plate heat
exchanger in the packing box until it is ready to be installed.
If there is any uncertainty with regard to the storage of the plate
heat exchanger, please consult an Alfa Laval Representative.
For longer storage periods, keep the heat exchanger in a
protective environment away from corrosive substances and
dust which may affects its performance.
Keep the plastic plugs or caps for the connections in place
during storage.
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Preface
Environmental compliance
Alfa Laval endeavours to perform its own operations as cleanly
and efficiently as possible. Environmental aspects are taken
into consideration when developing, designing, manufacturing,
servicing and marketing the company’s products.
Brazed Plate Heat Exchangers (BHE) consist of stainless steel
channel plates and frame elements and bonded stainless steel
or carbon steel connections. Bolts, which are stainless steel
or carbon steel with different surface treatments, are usually
welded onto the product. Additionally, feet and lifting lugs can
be mounted on demand.
Unpacking
Packing material consists of wood, plastics, cardboard boxes
and, in some cases, metal straps.
Packing materials can be reused, recycled or used for energy
recovery, according to local legislations.
Disposal
Heat exchangers must be recycled according to relevant, local
regulations. Any hazardous residues from the process liquid
must be considered and dealt with in a properly. When in
doubt, or in absence of local regulations, please contact the
local Alfa Laval representative.
Restricted substances
All plate heat exchangers are in compliance with REACH
(Registration, Evaluation, Authorization and Restriction of
Chemicals) and RoHS Directive.
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Description
Description
Function
Plate heat exchangers consist of a pack of corrugated metal
plates with ports for the passage of the two fluids between
which the heat transfer will take place.
The media in the heat transfer are led into the plate pack
through portholes at the corners and are distributed into the
passages between the corrugated plates.
1
2
3
4
Figure 1. Function: Cover plate (1), corrugated plates (2), seal
(3) and ports (4).
Warning!
The heat exchanger must not be opened.
Name plates
Warning!
The mechanical design pressures and temperatures
are marked on the name plate. These must not be
exceeded.
The unit type, manufacturing number and year along with the
pressure vessel details in accordance with applicable pressure
vessel code can be found on the name plate. The name plate
is fixed to the cover plate (usually on the same side as the
connections).
Name plate differs depending on the type of pressure vessel
approval.
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Installation
Installation
Unpacking
Carefully open the package containing the plate heat
exchanger. Check that all items are included according to the
specifications and that all parts are undamaged.
Before installing the plate heat exchanger, remove the plastic
plugs or caps in the connections.
Lifting
Warning!
Never lift only by the connections or anyb of the studs.
Use straps when lifting and place them according to
the figure below.
Figure 2. Examples of lifting.
Note!
When using lifting lugs, keep the angle of the straps
as close as possible to 90° but never less than 60°.
Warning!
Be careful and keep clear of the heat exchanger
during lifting to avoid personal injuries.
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Installation
Warning!
Plate heat exchangers with large plate packs may be
difficult to lift without lifting lugs because the center of
gravity may cause the plate heat exchanger lean too
much. If in doubt, use lifting lugs.
Requirements
Warning!
The plate heat exchanger must be installed and
operated so that no risk of injury to personnel or
damage to property.
Caution!
Protective gloves should always be worn when
handling the plate heat exchanger to avoid hand
injuries caused by sharp edges.
Note!
Unless otherwise specified, product data for normal
refrigerants, i.e. HFC and HCFC, are applicable
to refrigeration applications. The manufacturer
must be consulted before the heat exchanger is
used for flammable, toxic or dangerous liquids
(e.g. hydrocarbons). Relevant safety rules must
be followed for handling such liquids. For further
information, please refer to the supplier’s website.
Protection against loads on connections during operation
The piping must be well supported so that no loads are
transferred to the heat exchanger during operation. Also refer
to “Mounting” on page 15.
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Installation
Connection loads at installation
Fs
Ft
Mt
Mb
Figure 3. Connection loads.
Withreferencetodefinitions in figure, the loads during
installation should not exceed the limits specified in table below.
Maximum recommended connection loads during
installation
D
Figure 4. Outer diameter of the connection (D).
Tension
force Bending moment Shear
force1Torque
Outer diameter
mm (inch) Ft
kN (lbf) Mb Nm
(lbf*ft)
Fs
kN (lbf) Mt Nm
(lbf*ft)
15 -28
(0.6 - 1.1”) 2.4 (539) 14 (10.3) 0.7 (157) 38 (28.0)
29 - 35
(1.1 - 1.4”) 4.0 (899) 45 (33.2) 1.2 (269) 120 (88.5)
36 - 45
(1.4 - 1.8”) 6.5 (1461) 110 (81.1) 2.5 (562) 240 (177.0)
46 - 55
(1.8 - 2.2”) 7.0 (1573) 120 (88.5) 4.8 (1079) 440 (324.5)
56 - 76
(2.2 - 3.0”) 12.0 (2697) 250 (184.4) 5.2 (1169) 600 (442.5)
77 - 99
(3.0 - 3.9”) 13.0 (2922) 310 (228.6) 5.8 (1303) 1200 (885.0)
100 -
(3.9” - ) 28.0 (6294) 800 (590) 5.8 (1303) 2500 (1843)
1. Shear force (Fs) is calculated assuming that the force is
applied at the end of the longest standard connection.
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Installation
Mounting
It is recommended to mount the plate heat exchanger on the
floor, on feet or on the wall.
Larger heat exchangers should be secured with support
mountings (ordered as accessory) intended for a specific heat
exchanger, or be secured with straps or by means of mounting
bolts.
Note!
Regardless of the mounting method minimize the
pipe loads at installation.
Maximum tightening torques for the mounting bolts according
to table below.
Bolt dimension Torque
Nm lbf*ft
M5 2.3 1.7
M6 3.8 2.8
M8 9.5 7.0
M8 (Extra small units) 8.0 5.9
M10 19.0 14.0
M12 33.0 24.3
UNC 1/4” 3.8 2.8
UNC 5/16” 8.6 6.4
UNC 3/8” 15.6 11.5
In a rigid pipe system, small heat exchangers can be
suspended directly in the pipework. To avoid vibrations, use
anti-vibration mounting according to picture below.
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Installation
Installation in general
Warning!
Safety valves must be installed according to pressure
vessel regulations.
Note!
Before connecting any piping, make sure all foreign
objects have been flushed out of the system.
The installation must be installed with equipment that protects
it against pressures and temperatures outside the approved
minimum and maximum values shown on the name plate.
For vibration risks, install anti-vibration mountings as shown in
picture for rigid pipe system in section Mounting at page 15.
Normally the plate heat exchanger is connected so that the
media flows through the plate heat exchanger in opposite
directions (in counter-current flow) and in most cases this
provides the best heat transfer performance.
S4 S1
S3 S2
Take into account the risk of fire during installation, i.e. bear in
mind the distance from flammable substances.
Connections
Threaded connections – Use a torque wrench when
connecting the pipe and observe the specified limits. Refer to
table on page 14.
Brazed connections – Clean by rubbing down and degreasing
the various surfaces. Use the correct brazing temperature and
brazing metal grade.
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Installation
Welded connections – To minimize the heat impact of the
heat exchanger it is recommended to use TIG or MIG welding
methods. Preparation for welding: Grind inside and outside
of the pipe and, if bevelled, also the bevelled edge at least
25 mm from the pipe edge and inward. This should be done
to avoid contamination of copper in the welded area, which
might cause the weld to crack.
Note!
Before connecting the heat exchanger to the system
consider valve set-up and access points for example
to be prepared to perform cleaning.
Note!
Protect the heat exchanger from overheating by
wrapping a piece of wet cloth around the connection
while soldering or welding. Excessive heating could
melt the internal soldering metal inside the heat
exchanger.
Installation as evaporator or condenser
In applications where a phase change of media occurs, the
heat exchanger must be installed vertically.
For refrigeration applications – Figure A shows the installation
of an evaporator, which the connections may be either on the
front or on the rear. Figure B shows a condenser.
• Use an anti-freeze thermostat and flow monitor to ensure a
constant water flow before, during, and at least two minutes
after the compressor has been running.
• Avoid “pump-down”, i.e. emptying the evaporator by
running the compressor after shut-down until a preset
refrigerant pressure is reached. The temperature could then
drop below the brine freezing point, which could damage
the evaporator.
•Useaflow switch and a low-pressure switch.
• Make sure only media from the heat exchanger can pass
the flow switch. The low-pressure switch should assure a
minimum pressure drop of 5 - 10 kPa (0.73 - 1.45 PSI).
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Installation
Heat exchanger with a refrigerant distribution system should
be mounted with the distributor at the bottom.
Typical installation of single circuit:
S4 S1
S3 S2
S4 S1
S3 S2
AB
3
4
2
1
4
3
1
2
Figure 5. Single circuit: A evaporator; B condensor.
1.Refrigerant inlet 2.Refrigerant outlet
3.Water/Brine inlet 4.Water/Brine outlet
For an evaporator, the pipe should be straight (at least 150 mm
/ 5.9 inch length) between the expansion valve and refrigerant
inlet. Avoid using pipe elbows between the expansion valve
and the refrigerant inlet.
The heat exchanger could be of single or dual circuit type.
Flow direction of a single circuit heat exchanger is normally
parallel, while on dual circuit heat exchanger could be diagonal
or parallel. Make sure that the heat exchanger is installed
correctly according to the current flow direction for the heat
exchanger. For detailed information about flow direction see
the name plate.
Connections can be placed in the front or rear of the heat
exchanger. Typical installation of a dual circuit heat exchanger
as an evaporator:
S1
S2
S4.2 S4.1
S3.1 S3.2
S1
S2
S4.2 S4.1
S3.1 S3.2
AB
2
11
2
Figure 6. Dual circuit: A is parallel flow; B is diagonal flow.
1.Refrigerant inlet 2.Refrigerant outlet
Water/Brine inlet and outlet are typically positioned on the
rear side.
Leak test
Perform leakage test before placing the plate heat exchanger
in operation.
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Operation
Operation
Start-up
Note!
If several pumps are included in the system, make
sure you know which one should be activated first.
Note!
Adjustments of flow rates should be made slowly in
order to avoid the risk of water hammer.
Water hammer is a short-lasting pressure peak that
can appear during start-up or shut-down of a system,
which causing liquids to travel along a pipe as a wave
at the speed of sound. This can cause considerable
damage to the equipment.
Step 1
Check that the inlet valve (2) is closed between the pump and
the unit controlling the system flow rate.
Inlet valve (2, 3) for both fluids should be closed, the outlet
valves (1, 4) opened and the vent valve (5, 6) closed.
1
3
2
4
65
Step 2
If there is a outlet valve (4), make sure that it is fully open.
Step 3
Open the vent valve (5) and start the pump.
Step 4
Open the inlet valve (2) slowly.
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Operation
Step 5
When all air is expelled, close the vent valve (5).
Step 6
Repeat steps 1–5 for the second media.
Unit in operation
Note!
Adjustments of flow rates should be made slowly
in order to protect the system against sudden and
extreme variations of temperature and pressure.
During operation, check that:
• media temperatures and pressures are within the limits
stated on the name plate
• no leakages appear due to faulty tightening of the
connections.
Protection against connection loads
Make sure that the heat exchanger is fastened to avoid or
minimize connection loads during operation.
Protection against freezing
Bear in mind the risk of freezing at low temperatures. Plate
heat exchangers that are not in operation should be emptied
and blown dry whenever there is a risk of freezing.
Note!
To avoid damage due to freezing, the medium used
must include an anti-freeze agent when operating
conditions are below 5 °C (41 °F) and/or when the
evaporating temperature is below 1 °C (34 °F).
Protection against clogging
Use a filter as protection against the possible occurrence
of foreign particles. If you have any doubt concerning
the maximum particle size, please consult your Alfa Laval
Representative.
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