Alfalaval AlfaNova 76 User manual

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Instruction Manual
Fusion Plate Heat Exchangers
AlfaNova 76
AlfaNova 400
Part number 34562191-01
0903

Table of contents English
Fusion Plate Heat Exchanger EN
EN
Table of contents
Description ........................................................................................ 1
Definitions .................................................................................. 1
Main components ...................................................................... 2
Name plate ................................................................................ 3
Function ..................................................................................... 5
AlfaFusion technology ............................................................... 6
Installation ......................................................................................... 7
Requirements ............................................................................ 7
Installation as evaporator........................................................... 8
Installation, welding aspects ...................................................... 8
Lifting ......................................................................................... 9
Operation ......................................................................................... 10
Start-up .................................................................................... 10
Unit in operation....................................................................... 11
Shut-down................................................................................ 12
Maintenance .................................................................................... 13
General guidelines regarding maintenance ............................. 13
Cleaning-In-Place (CIP)........................................................... 14
Fault-tracing .................................................................................... 15
Pressure drop problems .......................................................... 15
Heat transfer problems ............................................................ 16
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 visit www.alfalaval.com
and contact your local Alfa Laval
Representative.

English Environmental compliance
Fusion Plate Heat Exchanger
EN
EN
Environmental compliance
AlfaLaval endeavours to perform its own oper-
ations as cleanly and efficiently as possible,
and to take environmental aspects into con-
siderattion when developing, designing, manu-
facturing, servicing and marketing its
products.
Unpacking
Packing material consists of wood, plastics, card-
board boxes and in some cases metal straps.
• Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
• Plastics should be recycled or burnt at a
licensed waste incineration plant.
• Metal straps should be sent for material
recycling.
Maintenance
During maintenance oil and wear parts in the ma-
chine are replaced.
• All metal parts should be sent for material recy-
cling.
• Worn out or defective electronic parts should
be sent to a licensed handler for material recy-
cling.
• Oil and all non metal wear parts must be taken
care of in agreement with local regulations.
Scrapping
At end of use, the equipment shall be recycleed
according to relevant, local regulations. Beside the
equipmnet itself, any hazardous residues from the
process liquid must be considered and dealt with in
a proper manner. When in doubt, or in absence of
local regulations, please contact the local Alfa
Laval sales company.

Description English
Plate Heat Exchanger 1
EN
EN
Description
Definitions
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 on page 2 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 an unit having internal chan-
nels 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.

English Description
2 Plate Heat Exchanger
EN
EN
Main components
WARNING!
The fusion PHE must
not be opened.
Support
Can as an option be
equipped with earth-
ing lugs.
Connections
Equipped with carbon
steel or stainless steel
fittings, permitting the
media to enter into the
heat exchanger.
Bonded seal
Keeping the media
within the unit
Lifting device
For correct and safe lifts during
transportation and installation
Cover plates
Front and rear
cover plates to
protect the chan-
nel plates and in-
crease the design
pressure.

Description English
Plate Heat Exchanger 3
EN
EN
Name plate
On the name plate the type of unit, manufacturing
number and manufacturing year can be found. Pres-
sure 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 nameplates, type 1–4, exist depending on the
type of pressure vessel approval.
Nameplate 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. Customer unique information.
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.
Nameplate 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 of each space.
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.
*) Sketch on nameplate showing possible locations of
connections depending on heat exchanger performance.
Warning!
For each unit, the mechanical design pres-
sures and temperatures are marked on the
name plate. These must not be exceeded.
14
1
2
3
415
6
7
8
916
10
17
11
12 18
13
5
19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

English Description
4 Plate Heat Exchanger
EN
EN
Nameplate type 3, ASME
1. Space for logotype.
2. Space for National Board stamp and serial number
3. Space for 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 work-
ing 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.
Nameplate 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.
*) Sketch on nameplate showing possible locations of
connections depending on heat exchanger execution.
1
2
3
4
5
6
7
8
9
10
11
12 13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Description English
Plate Heat Exchanger 5
EN
EN
Function
The 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 trans-
fer will take place.
The media in the heat transfer are led into the bond-
ed plate pack through portholes at the corners and
are distributed into the passages between the bond-
ed, 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 chan-
nels, always in counter-current flow. The contact
points are also bonded to withstand the pressure
of the media handled.
The fusion plate heat exchanger is typically
used for heating or cooling media with low to
medium viscosity. A specific fusion plate heat
exchanger is dimensioned for a specific duty,
set out in the product documentation, and
should not be used in any other way without
consulting the supplier.
Bonded seal
Keeping the media
within the unit.
Bonded corrugated
plates for media flow in
alternate channels.
Cover plates
Front and rear cover plates to
protect the channel plates and
increase the design pressure.

English Description
6 Plate Heat Exchanger
EN
EN
AlfaFusion technology
Fusion-bonded plate heat exchangers represent a
new class of plate heat exchangers made of
100 % stainless steel.
AlfaNova comprises a number of thin corrugated
stainless steel plates. The process uses a stain-
less steel filler as activator to bond the plates to-
gether in a high temperature furnace. At contact
points between the corrugated plates the filler re-
acts with the plate surface. The filler has a very
good capability to wet surfaces and fill crevices.
It has almost full interaction with the plates and a fu-
sion zone is created. This zone is in consequence
also of stainless steel and has similar properties to
the plates in terms of corrosion resistance and dura-
bility.
AlfaFusion technology enables the production of reli-
able heat plate exchangers with higher mechanical
and termal resistance than those of conventional
technology.
Cover plate
Corrugated plates
bonded together
with stainless steel
filler forming chan-
nels between the
plates.
Cover plate

Installation English
Plate Heat Exchanger 7
EN
EN
Installation
Requirements
WARNING!
The fusion PHE must
not be opened.
Installation in general
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 nameplate.
For best possible heat transfer performance, the
heat exchanger should be connected so that the me
-
dia flow through the heat exchanger in opposite di-
rections (in counter-flow). Take into account the risk
of fire during the installation work, i.e. bear in mind
the distance to flammable substances.
Warning!
The heat exchanger must be installed and
operated in such a manner that no risk of
injury to personnel and damage to proper-
ty will be incurred.
Note!
Unless otherwise specified, product data
for normal refrigerants, i.e. HFC and HCFC,
are applicable to refrigeration applications.
The manufacturer must be specifically con-
sulted 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 Internet site of the supplier.
Warning!
Safety valves should be installed according
to pressure vessel regulations.
Note!
Before connecting any piping, make sure all
foreign objects have been flushed out of the
system.
Foundation
Install on a flat foun-
dation giving enough
support to the unit.
Protection against
pipe forces
Fit the pipes so that no
tension is transferred to
the heat exchanger.
Protection against
overheating
Protect the heat ex-
changer by using a
heat-sink (welding
paste or tape) around
the connection before
welding operation.

English Installation
8 Plate Heat Exchanger
EN
EN
Installation as evaporator
For refrigeration applications – figure A below
shows the installation of an evaporator, for which
the connections may be either on the front or on
the rear. In evaporator applications and in applica-
tions in which a phase change of media occurs,
the heat exchanger should be installed vertically.
Figure B 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 evapora-
tor 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
For installation of AlfaNova equipped with welding
connections, TIG or MIG welding method must be
used for installation of the heat exchanger to min-
imize heat impact of the heat exchanger.
A
B
Note!
To avoid damage due to freezing, the
medium used must include an anti-
freeze agent at operating conditions be-
low 5 °C/41 °F and/or when the evapo-
rating temperature is below 1 °C/34 °F.
Note!
Protect the heat exchanger by using a
heat-sink (welding paste or tape) around
the connection before welding opera-
tion.

Installation English
Plate Heat Exchanger 9
EN
EN
Lifting
W
arn
i
ng
!
Never lift by the connections or the studs
around them. Straps should be used when
lifting. Place straps according to picture.
AlfaNova 76
AlfaNova 400

English Operation
10 Plate Heat Exchanger
EN
EN
Operation
Start-up
Check that the valve is closed between the
pump and the unit controlling the system
flow rate.
If there is a valve at the exit make sure that
it is fully open.
Open the vent and start the pump.
Open the valve slowly.
When all air is expelled, close the vent.
Repeat steps 1–5 for the second medium.
Note!
If several pumps are included in the sys-
tem, 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 pres-
sure 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
Closed
Open
Closed
Open Closed
2
3
Open
4
Open
slowly
5
Close
6

Operation English
Plate Heat Exchanger 11
EN
EN
Unit in operation
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 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 risk of
freezing.
Protection against clogging
Use a filter as protection against the possible occur-
rence of foreign particles. If you have any doubt con-
cerning the maximum particle size, consult your
nearest representative of the supplier or look under
Product information at the supplier's Internet site.
Protection against thermal or/and pressure
fatigue
Sudden temperature and pressure changes could
cause fatigue damage to the heat exchanger. There-
fore, following must be taken into consideration to
ensure that the heat exchanger operates without
swinging pressures/temperatures.
• Locate the temperature sensor as close as possi-
ble 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 start-
ing 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 manufac-
tured in stainless steel grade AISI 316.
Media causing corrosion to AISI 316 must not be ex-
posed to the heat exchanger.
Insulation
Heating and cooling insulations are available as ac-
cessories.
Note!
Adjustments of flow rates should be made
slowly in order to protect the system against
sudden and extreme variations of tempera-
ture and pressure.
Note!
To avoid damage due to freezing, the
medium used must include an anti-
freeze agent at operating conditions be-
low 5 °C/41 °F and/or when the evapo-
rating temperature is below 1 °C/34 °F.

English Operation
12 Plate Heat Exchanger
EN
EN
Shut-down
Slowly reduce the flow rate in order to
avoid water hammer.
When the valve is closed, stop the pump.
Repeat steps 1–2 for the other medium/
media.
If the fusion plate heat exchanger is shut
down for a longer period, it should be
drained.
Draining should also be done if the pro-
cess is shut down and the ambient
temperature is below freezing temperature
of the media.
Depending on the media processed, it is
also recommended to rinse and dry the
heat exchanger and its connections.
Note!
If several pumps are included in the sys-
tem, make sure you know which one
should be stopped first.
1
2
3
4

Maintenance English
Plate Heat Exchanger 13
EN
EN
Maintenance
General guidelines regarding
maintenance
Plate Sheet material
Also stainless steel can corrode. Chlorine ions are
hazardous.
Avoid cooling brines containing chloride salts as
NaCI and, most harmful, CaCI2.
Chlorine as a growth inhibitor
In every case where chlorination of AlfaNova heat
exchanger cannot be avoided, your local representa-
tive must be consulted.
Note!
Rinse well!
Note!
Under no circumstances should Hydrochlo-
ric acid be used with stainless steel plates.
Water of more than 300 ppm Cl ions may
not be used for preparation of cleaning
solutions.
Note!
Chlorine, commonly used as growth inhibi-
tor 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.

English Maintenance
14 Plate Heat Exchanger
EN
EN
Cleaning-In-Place (CIP)
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 sus-
ceptibility to corrosion
• neutralization of cleaning liquids before drain-
ing.
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 depos-
its.
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 neutralization 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 neutralization of used Kalklöser P prior to dis-
posal.
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.

Fault-tracing English
Plate Heat Exchanger 15
EN
EN
Fault-tracing
Pressure drop problems
The pressure drop has increased.
Action Result 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 possi-
ble. A bucket and a watch showing seconds
may be sufficient for small flow rates. For
larger flow rates, some type of flowmeter is
required.
––
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 is corresponding
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 read-
ings 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.

English Fault-tracing
16 Plate Heat Exchanger
EN
EN
Heat transfer problems
The heat transfer capacity is dropping.
Action Result 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 specifica-
tions.
• 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 –