Alfalaval AlfaNova 14 User manual

AlfaNova 14–76
Instruction manual
Fusion Plate Heat Exchangers
EN Instruction manual
AlfaNova Fusion Plate Heat Exchangers ...............................1
DE Bedienungshandbuch
Heißgeklebte Plattenwärmeübertrager ................................11
FR Manuel d’instructions
Échangeurs thermiques à plaques soudées par fusion.......21
ES Manual de instrucciones
Intercambiadores de calor de placas fundido ......................31
PT Manual de instruções
Permutadores de calor de placas fundidas..........................41
NL Handleiding
Fusion platenwarmtewisselaars...........................................51
IT Manuale di instruzioni
Scambiatori di calore a piastre
con technologia di fusione....................................................61
SV Bruksanvisning
Fusionssammanfogade plattvärmeväxlare ..........................71
NO Instruksjonshåndbok
Fusjonsplatevarmevekslere..................................................81
DA Instruktionsvejledning
Fusionspladevarmevekslere.................................................91
FI Ohjekirja
Fusion-levylämmönvaihtimet..............................................101
PL Instrukcja obsługi
Lutowane płytowe wymienniki ciepła.................................111
RU Èíñòðóêöèè ïî ýêñïëóàòàöèè
Ïàÿíûå ïëàñòèí÷àòûå òåïëîîáìåííèêè........................121
Part number 34562191-03
0903

Figure 1. AlfaNova main components
Figure 2. Function
Figure 3. Installation requirements
Figure 4. Lifting
Figure 5. Installation as evaporator (A) and
condenser (B)
Figure 6. Operation
Connec-
tion
Cover
plate
Bonded
seal
Support
Bonded
seal
Cover plate
Bonded
corrugated
plates
Protection
against
overheating
Protect the heat
exchanger by
using a heat-sink
(welding paste or
tape) around the
connection
AlfaNova 76 AlfaNova 400
AB
1
2
3
45

Table of contents English 1
AlfaNova 14–76, Part no. 34562191-03
Table of contents
Description .............................................................. 2
Definitions............................................................... 2
Main components ................................................... 2
Name plates ........................................................... 2
Function.................................................................. 5
Installation............................................................... 5
Requirements ......................................................... 5
Installation in general ............................................. 5
Installation as evaporator ....................................... 5
Installation, welding aspects................................... 6
Lifting...................................................................... 6
Operation................................................................. 6
Start-up.................................................................. 6
Unit in operation ..................................................... 6
Shut-down .............................................................. 7
Maintenance ........................................................... 8
General guidelines regarding maintenance........... 8
Cleaning-In-Place (CIP) ........................................ 8
Fault tracing ............................................................ 9
Pressure drop problems ....................................... 10
Heat transfer problems......................................... 10
Except for this Instruction
Manual, the following
document is also included in
this shipment:
• Declaration of Conformity
How to contact Alfa Laval:
Contact details for all
countries are continually
updated on our website.
Please wisit
www.alfalaval.com and
contact your local Alfa
Laval Representative.

2 English Description
AlfaNova 14–76, Part no. 34562191-03
Description
Definitions
Main components
Bear in mind that the AlfaNova Fusion Plate Heat Exchanger
cannot be opened!
See Figure 1.
Name plates
On the name plate, the type of unit, manufacturing number and
manufacturing year can be found. Pressure vessel details in
accordance with the applicable pressure vessel code are also
stated. The name plate is fixed to the frame plate (most
common) or the pressure plate.
Four name plates exist depending on the type of pressure
vessel approval.
AlfaFusion™ One-material process that results in an
all-stainless steel fusion-bonded plate
heat exchanger, gives joints superior to
welded joints
Connection plate Plate used to separate two or more
services in one plate heat exchanger.
The plate pack performing such a
service is called a section.
Fusion plate heat
exchanger
A number of corrugated plates and its
frame bonded to a plate pack at high
temperature.
Figure 1 shows typical components of a
fusion plate heat exchanger.
Heat transfer area The area of the plate which is in contact
with both fluids.
Plate A sheet of 100% stainless steel plate
pressed into a corrugated pattern and
equipped with port holes for media inlet
and outlet.
Plate pack An assembly of plates bonded together
to a unit with internal channels in which
two or more fluids can be handled.
Port Inlet or outlet opening in the plates and
in the cover plates. Most plates have
four ports.
Total heat transfer
area
The total surface area of all the bonded
plates, which are in contact with both
fluids.
WARNING! For each unit, the mechanical design
pressures and temperatures are marked on the
name plate. These must not be exceeded.

Description English 3
AlfaNova 14–76, Part no. 34562191-03
Name plate type 1,
PED Standard
1. Manufacturer's name
2. Article number
3. Type
4. Manufacturing number
5. Date of manufacture
6. Max. allowed operating
temperatures
7. Max. allowed operating
pressures
8. Test pressure
9. Volume of each space
10. Operating area
11. Fluid group
12. Information unique to
the customer
13. Bar code information
14. Space for logotype
15. Locations of
connections for each
fluid
16. Allowed operating
temperatures and
pressures
17. Description of each
space
18. *) Possible locations of connections
19. Space for mark of approval
– CE-409 BHE Manufacturing, Ronneby, Sweden
– CE-036 Alfa Laval (Jiangyin) Manufacturing Co., Ltd,
Jiangyin City, PRC
– CE-0948 Alfa Laval S.p.A. Alonte, Italy
Name plate type 2, PED
Stainless steel,
optional
1. Space for logotype
2. Manufacturer's name
3. Type
4. Serial number
5. Manufacturing year
6. Fluid group.
7. Locations of
connections for each
fluid
8. Volume
9. Max. allowed operating
pressures
10. Max. allowed operating
temperatures
11. Test pressure
12. Max. operating
temperatures and
pressures
13. Date of test pressure
14. Information unique to
the customer
15. Space for mark of approval
– CE-409 BHE Manufacturing, Ronneby, Sweden
– CE-036 Alfa Laval (Jiangyin) Manufacturing Co., Ltd,
Jiangyin City, PRC
– CE-0948 Alfa Laval S.p.A Alonte, Italy
16. *) Possible locations of connections
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15 16
*) Sketch on name plate showing possible locations of connections
depending on heat exchanger execution.

4 English Description
AlfaNova 14–76, Part no. 34562191-03
Name plate type 3,
ASME
1. Space for logotype
2. Space for National
Board stamp and serial
number
3. Manufacturer’s name:
– CE-409 BHE
Manufacturing,
Ronneby, Sweden
– CE-036 Alfa Laval
(Jiangyin)
Manufacturing Co.,
Ltd, Jiangyin City,
PRC
– CE-0948 Alfa Laval
S.p.A. Alonte, Italy
4. Locations of
connections for each
fluid
5. Max. allowed working
pressures at
temperature
6. Max. allowed medium temperature at max. allowed working
pressure
7. Serial number
8. Manufacturing year
9. Test pressure
10. Volume of each space
11. Type
12. Information unique to the customer
13. *) Possible locations of connections
Name plate type 4,
PED Customer
designed, optional
1. Article number
2. Type
3. Manufacturing number
4. Date of manufacture
5. Max. allowed
operating
temperatures
6. Max. allowed
operating pressures
7. Test pressure
8. Volume of each space
9. Fluid group
10. Customer unique
information
11. Customer unique
information
12. Space for logotype
13. Manufacturer's name
14. Locations of
connections for each
fluid
15. Customer unique
information
16. Space for mark of approval
– CE-409 BHE Manufacturing, Ronneby, Sweden
– CE-036 Alfa Laval (Jiangyin) Manufacturing Co., Ltd,
Jiangyin City, PRC
– CE-0948 Alfa Laval S.p.A. Alonte,Italy
1
2
3
4
5
6
7
8
9
10
11
12 13
*) Sketch on name plate showing possible locations of connections depending
on heat exchanger execution.

Installation English 5
AlfaNova 14–76, Part no. 34562191-03
Function
Fusion plate heat exchangers consist of a pack of bonded
corrugated metal plates with ports for the passage of the two
fluids between which heat transfer will take place.
The media in the heat transfer are led into the bonded plate
pack through portholes at the corners and are distributed into
the passages between the bonded, corrugated plates.
The heating surface consists of thin corrugated plates stacked
on top of each other. In the fusion process at high temperature
channels are formed between the plates and corner ports are
arranged so that the two media flow through alternate
channels, always in counter-current flow. The contact points
are also bonded to withstand the pressure of the media
handled. Also see Figure 2.
Installation
Requirements
Note! Unless otherwise specified, product data for normal
refrigerants, i.e. HFC and HCFC, are applicable to refrigeration
applications. The manufacturer must be specifically consulted
before the heat exchanger is used for flammable, toxic or
dangerous liquids (e.g. hydrocarbons). The use must follow the
relevant safety rules for handling such liquids. For further
information, please refer to the supplier's website.
Also see Figure 4.
Installation in general
Note! Before connecting any piping, make sure all foreign
objects have been flushed out of the system.
The installation must be provided with equipment that protects
the heat exchanger against pressures and temperatures
outside the approved minimum and maximum values shown on
the name plate.
For best possible heat transfer performance, the heat
exchanger should be connected so that the media flow through
the heat exchanger in opposite directions (in counter-flow).
Take into account the risk of fire during the installation work, i.e.
bear in mind the distance to flammable substances. Also see
Figure 4.
Installation as evaporator
Note! To avoid damage due to freezing, the medium used
must include an anti-freeze agent at operating conditions
below 5 °C/41 °F and/or when the evaporating temperature is
below 1 °C/34 °F.
Note! In evaporator applications and in applications in which a
phase change of the media occurs, the heat exchanger should
be installed vertically.
WARNING! The heat exchanger must be installed
and operated in such a manner that no risk of injury
to personnel and damage to property will be incurred.
WARNING! Safety valves should be installed
according to pressure vessel regulations.

6 English Operation
AlfaNova 14–76, Part no. 34562191-03
For refrigeration applications – Figure 5A shows the installation
of an evaporator, for which the connections may be either on
the front or on the rear. Figure 5B shows a condenser.
• Use an anti-freeze thermostat and flow monitor to ensure a
constant water flow before, during and 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.
• Use a flow switch and a low-pressure switch.
Installation, welding aspects
Note! Protect the heat exchanger by using a heat-sink
(welding paste or tape) around the connection.
For installation of AlfaNova equipped with welding connections,
the TIG or MIG welding method must be used for installation of
the heat exchanger to minimise heat impact of the heat
exchanger.
Lifting
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, causing liquids to
travel along a pipe as a wave at the speed of sound. This can
cause considerable damage to the equipment.
1. Check that the valve is closed between the pump and the
unit controlling the system flowrate.
2. If there is a valve at the exit, make sure that it is fully
open.
3. Open the vent and start the pump.
4. Open the valve slowly.
5. When all air is expelled, close the vent.
6. Repeat steps 1–5 for the second media. See Figure 6.
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.
WARNING! Never lift by the connections or the
studs around them. Straps should be used when
lifting. Place straps according to Figure 3, Lifting.

Operation English 7
AlfaNova 14–76, Part no. 34562191-03
Protection against freezing
Bear in mind the risk of freezing at low temperatures. 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 at operating conditions
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, consult your nearest representative of
the supplier or look under Product information on the supplier's
web site.
Protection against thermal or/and pressure fatigue
Sudden temperature and pressure changes could cause
fatigue damage to the heat exchanger. Therefore, the following
must be taken into consideration to ensure that the heat
exchanger operates without swinging pressures/temperatures.
• Locate the temperature sensor as close as possible to the
outlet from the heat exchanger.
• Choose valves and regulation equipment which give stable
temperatures/pressures for the heat exchanger.
• To avoid water hammer, quick-closing valves must not be
used, e.g. on/off valves.
• In automated installations, the stopping and starting of
pumps and actuation of valves should be programmed so
that the resulting amplitude and frequency of the pressure
variation will be as low as possible.
Protection against corrosion
All components in contact with media are manufactured in
stainless steel grade AISI 316. Media causing corrosion to AISI
316 must not be exposed to the heat exchanger.
Insulation
Heating and cooling insulations are available as accessories.
Shut-down
Note! If several pumps are included in the system, make sure
you know which one should be stopped first.
1. Slowly reduce the flow rate in order to avoid water
hammer.
2. When the valve is closed, stop the pump.
3. Repeat steps 1–2 for the other medium/media.
4. If the fusion plate heat exchanger is shut down for a
longer period, it should be drained.
Draining should also be done if the process is shut down
and the ambient temperature is below the freezing
temperature of the media.
Depending on the media processed, it is also
recommended to rinse and dry the heat exchanger and its
connections.

8 English Operation
AlfaNova 14–76, Part no. 34562191-03
Maintenance
General guidelines regarding maintenance
Plate Sheet material
Stainless steel can corrode. Chlorine ions are hazardous.
Avoid cooling brines containing chloride salts as NaCI and,
most harmful, CaCI2.
Note! Rinse well!
Note! Under no circumstances should hydrochloric acid be
used with stainless steel plates.
Water of more than 300 ppm Cl ions may not be used for
preparation of cleaning solutions.
Chlorine as a growth inhibitor
Note! Chlorine, commonly used as a growth inhibitor in
cooling water systems, reduces the corrosion resistance of
stainless steels.
Chlorine weakens the protection layer of these steels making
them more susceptible to corrosion attacks than they otherwise
should be. It is a matter of time of exposure and concentration.
In every case where chlorination of the AlfaNova heat
exchanger cannot be avoided, your local representative must
be consulted.
Cleaning-In-Place
The Cleaning-In-Place (CIP) equipment permits cleaning of the
plate heat exchanger.
CIP performs:
• cleaning of fouling and descaling of lime deposits
• passivation of cleaned surfaces to reduce susceptibility to
corrosion
• neutralisation of cleaning liquids before draining.
Follow the instructions of the CIP equipment.
The following CIP models can be used: CIP200L, CIP400L and
CIP800L.
Cleaning
liquid Description
AlfaCaus A strong alkaline liquid, for removing paint, fat,
oil and biological deposits.
AlfaPhos An acid cleaning liquid for removing metallic
oxides, rust, lime and other inorganic scale.
Includes an inhibitor for passivation.
AlfaNeutra A strong alkaline liquid for neutralisation of
AlfaPhos before drainage.
Kalklöser P An acidic cleaning powder with a corrosion
inhibitor particularly effective for removing of
calcium carbonate and other inorganic scale.
Neutra P An alkaline powder for neutralisation of used
Kalklöser P prior to disposal.

Fault tracing English 9
AlfaNova 14–76, Part no. 34562191-03
Fault tracing
Pressure drop problems
AlfaAdd A neutral cleaning strengthener to be used with
AlfaPhos, AlfaCaus and Kalklöser P. Provides
better cleaning results on oily, fatty surfaces
and where biological growth occurs. AlfaAdd
also reduces any foaming.
Alpacon
Descalant An acidic, water based, non-hazardous cleaning agent designed for removal of scale,
magnetite, algae, humus, mussels, shellfish,
lime and rust. Containing BIOGEN ACTIVE, a
biological mixture made from renewable
materials, as an active ingredient.
Alpacon
Degreaser A neutral degreaser to be used with Alpacon Descalant. Effectively removes oil, fat or grease
layers, but also reduces foaming. Containing
BIOGEN ACTIVE, a biological mixture made
from renewable materials, as an active
ingredient.
Action Re-
sult Correction
1 Check that all valves
are open including
non-return valves.
• Measure the
pressure just before
and just after the
heat exchanger, and
the flow rate. For
viscous media a
membrane
manometer with a
diameter of at least
30 mm should be
used.
• Measure or estimate
the flow rate if
possible. A bucket
and a watch showing
seconds may be
sufficient for small
flow rates. For larger
flow rates, some type
of flowmeter is
required.
––
Cleaning
liquid Description

10 English Fault tracing
AlfaNova 14–76, Part no. 34562191-03
Heat transfer problems
The heat transfer capacity is dropping.
2 Compare the
pressure drop
observed with the one
specified for the
actual flow rate (see
data printout). Is the
pressure drop higher
than specified?
YES Check the temperature
program, see step 3.
NO If the pressure drop
corresponds to the
specifications, there is no
need for action.
If the pressure drop is lower
than specified, the pump
capacity is probably too small
or the observation may be
wrong. See pump instruction
manual.
3 Check the
thermometer
readings. Do the
readings correspond
to those specified?
YES The heat transfer surface is
probably clean enough, but
the inlet to the heat
exchanger may be clogged by
some objects. Check the port
area.
NO Heat transfer is obviously
dropping below
specifications, because of
deposits on the heat transfer
surface, which at the same
time also increases the
pressure drop, since the
passage becomes narrower.
If a Cleaning-In-Place (CIP)
system is available, follow the
instructions and use it to
wash out the deposits.
Action Re-
sult Correction
Measure temperatures at
inlets and outlets. Also
measure flow rates on both
media, if possible. At least
on one of the media, both
temperatures and the flow
rate must be measured.
• Check to see if the
transferred amount of
heat energy corresponds
to the specifications.
• If great precision is
important, it will be
necessary to use
laboratory thermometers
with an accuracy of 0.1
°C, and also to use the
best equipment available
for flow measurement.
Has the heat transfer
capacity of the unit dropped
below specified values?
YES Clean the heat transfer
surface. Use the
Cleaning-In-Place (CIP)
system.
NO –