Alfalaval AQ1 User manual

Gasketed plate-and-frame heat exchangers
AQ line - AQ1, AQ1A, AQ1L, AQ2, AQ2A, AQ2L, AQ2S, AQ2T, AQ3, AQ4, AQ4T
Lit. Code 200000284-1-EN-GB
Instruction Manual

Published by
Alfa Laval Lund AB
Box 74
Visit: Rudeboksvägen 1
226 55 Lund, Sweden
[phone]
[phone]
[email protected]
The original instructions are in English
© Alfa Laval Corporate AB 2019-05
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.

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Contents
1 Preface............................................................................................................................ 7
1.1 Conditions and Requirements................................................................................... 7
1.2 Environmental compliance........................................................................................ 8
2 Safety............................................................................................................................... 9
2.1 Safety considerations................................................................................................ 9
2.2 Definitions of expressions..........................................................................................9
3 Description.................................................................................................................. 11
3.1 Components............................................................................................................ 11
3.2 Name plate.............................................................................................................. 14
3.3 Function...................................................................................................................16
3.4 Multi-pass................................................................................................................ 17
3.5 Identification of plate side........................................................................................17
4 Installation................................................................................................................... 19
4.1 Before installation....................................................................................................19
4.2 Requirements.......................................................................................................... 20
4.3 Lifting.......................................................................................................................22
4.4 Raising.....................................................................................................................24
5 Operation..................................................................................................................... 27
5.1 Start-up....................................................................................................................27
5.2 Unit in operation...................................................................................................... 29
5.3 Shut-down............................................................................................................... 29
6 Maintenance.............................................................................................................. 31
6.1 Cleaning – Non-product side...................................................................................31
6.2 Opening...................................................................................................................33
6.2.1 Bolt configuration....................................................................................... 33
6.2.2 Opening procedure.................................................................................... 34
6.3 Manual cleaning of opened units.............................................................................37
6.3.1 Deposits removable with water and brush.................................................37
6.3.2 Deposits not removable with water and brush...........................................38
6.4 Closing.....................................................................................................................38
6.5 Pressure test after maintenance..............................................................................41
6.6 Regasketing.............................................................................................................42
6.6.1 Clip-on / ClipGrip........................................................................................42
6.6.2 Glued gaskets............................................................................................43

7 Storage of the heat exchanger......................................................................45
7.1 Storage in packing box............................................................................................45
7.2 Taken out of service.................................................................................................46

1 Preface
This manual provides information needed to install, operate and carry out
maintenance of your gasketed plate-and-frame heat exchanger.
The following models are covered in this manual:
• AQ1
• AQ2
• AQ4
• AQ2S
• AQ1A
• AQ2A
• AQ2T
• AQ3
• AQ4T
• AQ1L
• AQ2L
1.1 Conditions and Requirements
Prior knowledge
The heat exchanger shall be operated by persons who have studied the
instructions in this manual and have knowledge of the process. This includes
knowledge of precautions regarding media type, pressures, temperatures in
the heat exchanger as well as specific precautions required by the process.
Maintenance and installation of the heat exchanger shall be done by persons
who have knowledge and authorization according to local regulations. This
may include actions such as piping, welding and other kind of maintenance.
For maintenance actions not described in this manual, contact your Alfa Laval
representative for advice.
PHE drawings
PHE (plate heat exchanger) drawings mentioned in the manual are the
drawings included in the delivery of the heat exchanger.
Warranty conditions
The warranty conditions are usually included in the signed sales contract prior
to the order of the delivered heat exchanger. Alternatively, the warranty
conditions are included in the sales offer documentation or with a reference to
the document specifying the valid conditions. If faults occur during the
specified warranty period, always consult your local Alfa Laval representative
for advice.
Report the date when the heat exchanger was put into operation to the local
Alfa Laval representative.
200000284-1-EN-GB 7
EN

Advice
Always consult your local Alfa Laval representative for advice on:
• New plate pack dimensions if you intend to change the number of plates
• Selection of gasket material if operating temperatures and pressures are
permanently changed, or if another medium is to be processed in the heat
exchanger
1.2 Environmental compliance
Alfa Laval endeavours to perform its own operations as cleanly and efficiently
as possible, and to take environmental aspects into consideration when
developing, designing, manufacturing, servicing and marketing its products.
Unpacking
Packing material consists of wood, plastics, cardboard 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
• All metal parts should be sent for material recycling.
• Oil and all non-metal wear parts must be taken care of in accordance with
local regulations.
Scrapping
At end of use, the equipment shall be recycled according to relevant, local
regulations. Besides the equipment itself, any hazardous residues from the
process liquid must be considered and dealt with in a proper manner. When in
doubt, or in the absence of local regulations, please contact the local Alfa
Laval sales company.
200000284-1-EN-GB8
1 PrefaceEN

2 Safety
2.1 Safety considerations
The heat exchanger shall be used and maintained in accordance with Alfa
Laval’s instructions in this manual. Incorrect handling of the heat exchanger
may result in serious consequences with injuries to persons and/or property
damage. Alfa Laval will not accept responsibility for any damage or injury
resulting from not following the instructions in this manual.
Your heat exchanger should be used in accordance with the specified
configuration of material, media types, temperatures and pressure for your
specific heat exchanger
2.2 Definitions of expressions
WARNING Type of hazard
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION Type of hazard
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous situation which, if not avoided,
may result in property damage.
200000284-1-EN-GB 9
EN
Safety

200000284-1-EN-GB10
2 SafetyEN
Safety

3 Description
3.1 Components
8
7
3
5
6
24
1
Main components
1. Frame plate
Fixed plate with a various number of portholes for the connection of the
piping system. The carrying and guiding bar are attached to the frame
plate.
2. Carrying bar
Carries the plate pack and the pressure plate.
3. Plate pack
Heat is transferred from one media to the other through the plates. The
plate pack consists of channel plates, end plates, gaskets and in some
cases transition plates. The measurement of the plate pack is the A
dimension, i.e the measurement between frame plate and pressure plate.
Refer to the PHE drawing.
4. Pressure plate
Moveable plate that can contain a various number of portholes for the
connection of the piping system.
5. Guiding bar
Keeps the channel plates, connection plates and the pressure plate
aligned at their lower end.
6. Support column
Supports carrying and guiding bars.
For some smaller heat exchanger models no support column is used.
200000284-1-EN-GB 11
EN

7. Tightening bolts
Compress the plate pack between the frame plate and the pressure plate.
There are usually four tightening bolts used, in some cases six, these are
used to open and close the heat exchanger.
Remaining bolts are used as locking bolts.
8. Portholes
Portholes through the frame plate allow the media to enter into or exit from
the heat exchanger.
Different types of connections can be used to connect the piping system to
the apparatus. The portholes may be protected against corrosion by metal
or rubber linings.
Connections
•Pipe connection
The heat exchanger can be equipped with of fixed pipe connection for
different types of attachments such as pipes for welding, threaded pipes or
grooved pipes.
•Stud bolts
Threaded stud bolts around the portholes secure the flange connections to
the apparatus.
•Squared loose flange
The squared loose flange is a special flange supplied by Alfa Laval to be
used with the customers piping and is attached with four stud bolts.
Optional components
•Foot
Gives stability and is used to secure the heat exchanger with bolts to the
foundation.
Feet is an optional feature.
•Protection sheets
Cover the plate pack and protect against leakage of hot or aggressive fluids
and the hot plate pack.
•Bolt protection
Plastic tubes that protect the threads of the tightening bolts.
•Insulation
For applications where the heat exchanger surface will be hot or cold,
insulation can be used.
200000284-1-EN-GB12
3 DescriptionEN

•Earthing lug
An earthing connection is used to eliminate the risk of static electricity
building up in the equipment.
•Nozzle cover
Protection to avoid particles to enter into the heat exchanger during
transportation.
•Drip tray
Depending on the type of fluid in the heat exchanger and the type of
installation, a drip tray (drainage box) may be necessary to avoid injury to
personnel and damage to equipment.
200000284-1-EN-GB 13
Description 3 EN

3.2 Name plate
The type of unit, manufacturing number and manufacturing year can be found
on the name plate. Pressure vessel details in accordance with the applicable
pressure vessel code are also given. The name plate is fixed to the frame
plate, most commonly, or the pressure plate. The name plate can be a steel
plate or a sticker label.
WARNING
The design pressures and temperatures for each unit are marked on the
name plate. These must not be exceeded.
CAUTION
Avoid aggressive chemicals for cleaning the heat exchanger when a
sticker label is used.
The design pressure (11) and the design temperature (10), as given on the
name plate, are the values against which the heat exchanger is approved
according to the pressure vessel code in question. The design temperature
(10) may exceed the maximum operating temperature (8) for which the
gaskets have been selected for. If the operating temperatures as specified on
the PHE drawing are to be changed the supplier should be consulted.
1. Space for logotype
2. Open space
3. Website for service
4. Drawing of possible locations of connections/Location of 3A tag for 3A
units
5. Space for mark of approval
6. Warning, read manual
7. Date of pressure test
8. Maximum operating temperature
9. Manufacturer test pressure (PT)
10. Allowable temperatures Min/Max (TS)
11. Allowable pressures Min/Max (PS)
12. Decisive volume or volume for each fluid (V)
13. Locations of the connections for each fluid
14. Decisive fluid group
15. Year of manufacture
16. Serial number
17. Type
18. Manufacturer’s name
200000284-1-EN-GB14
3 DescriptionEN

1
2
3
4
18
17
16
15
14
13
12
11
10
9
8
7
6
5
1
18
15
13
14
12
8
11
10
9
6
5
4
17
7
3
TS
V
INLET → OUTLET
VOLUME
MIN./MAX.
ALLOWABLE PRESS.
→ →
STATISTICAL BASIS.
MANUFACTURER
FOR SERVICE:
PRESSURE TESTING PERFORMED ON
PRESSURE TESTED
MAX. OP. TEMP.
FLUID GROUP
YEAR OF MANUFACTURING:
MANUFACTURER:
ALLOWABLE TEMP.
MIN./MAX.
TYPE: SERIAL NUMBER:
PT
PS
Service
Year
Manufacturer
Fluid group
Inlet Outlet
Allowable press.
Allowable temp.
Volume V
Manufacturer
Serial No.
Type
Max. op. temp.
Test pressure date
WARNING
Min./Max. PS
Min./Max. TS
PT
16
Figure 1: Example of CE metallic name plate to the left and CE sticker label
name plate to the right
200000284-1-EN-GB 15
Description 3 EN

3.3 Function
The heat exchanger consists of a pack of corrugated metal plates with
portholes for the input and output of the two separate fluids. The heat transfer
between the two fluids takes place through the plates.
The plate pack is assembled between a frame plate and a pressure plate and
compressed by tightening bolts. The plates are fitted with a gasket which seals
the channel and directs the fluids into alternate channels. The plate
corrugation promotes fluid turbulence and supports the plates against
differential pressure.
Figure 2: Example of a single-pass set up.
200000284-1-EN-GB16
3 DescriptionEN

3.4 Multi-pass
Multi-pass sections can be created by using turning plates with 1, 2 or 3
unholed ports. The main purpose is to change the flow direction of one or both
fluids.
An example of where multi-pass can be used is in processes that require
longer heating periods if the media requires slower heating.
331
24
5
Figure 3: Example of a multi-pass set up.
1. End plate I
2. End plate II
3. Channel plates
4. Transition plate
5. Turning plate
3.5 Identification of plate side
The A side of the plates (symmetric pattern) are identified by a stamp with the
letter A and the model name at the top of the plate (refer to image 1 below).
Plates with asymmetric pattern has two possible sides for placement of the
gaskets. The pattern is marked A W for the wide-side image 2 and B N for
normal-side image 3.
R
v
2. 3.
AXXX
1.
AXXX AXXX
200000284-1-EN-GB 17
Description 3 EN

200000284-1-EN-GB18
3 DescriptionEN

4 Installation
4.1 Before installation
CAUTION
During installation or maintenance, precautions must be taken to avoid
damaging the heat exchanger and its components. Damage to
components can adversely affect the performance or serviceability of the
heat exchanger.
To consider before installation
• Before connecting any piping, make sure all foreign objects have been
flushed out of the piping system that should be connected to the heat
exchanger.
• Before connecting any piping, make sure that all the bolts for the feet are
tightened and that the heat exchanger is firmly fixed to the foundation.
• Before start-up, check that all the tightening bolts are firmly tightened and
that the plate pack has the correct measurements. Refer to the PHE
drawing.
• When connecting the piping system, make sure the pipes do not subject
the heat exchanger to stress or strain.
• To avoid water hammer, do not use fast-closing valves.
• Make sure that no air remains inside the heat exchanger.
• Safety valves shall be installed according to current pressure vessel
regulations.
• It is recommended that protection sheets are used to cover the plate pack.
Protect against the leakage of hot or aggressive fluids and the hot plate
pack.
• If the heat exchanger surface temperature is expected to be hot or cold,
take protective actions, such as insulate the heat exchanger, to avoid risk
for personnel injuries. Always ensure that required actions are according to
local regulations.
• Design pressures and temperatures for each model are marked on the
name plate. These shall not be exceeded.
200000284-1-EN-GB 19
EN

4.2 Requirements
4
1
3
2
Space
Please refer to the delivered PHE drawing for actual measurements.
1. Free space is required for lifting plates in and out.
2. Free space is required under the lower tightening/locking bolt for
maintenance.
3. Supports for the guiding bar may be needed.
4. Do not use fixed pipes or other fixed parts like feet, fasteners etc. inside
the shaded area.
Foundation
Install on a flat foundation giving enough support to the frame.
Elbow
To make it easier to disconnect the heat exchanger, an elbow should be fitted
to the connection in the pressure plate, directed upwards or sideways, and
with another flange located just outside the contour of the heat exchanger.
Shut-off valve
To be able to open the heat exchanger, shut-off valves should be provided in
all connections.
Connection
Different types of connections can be used to connect the piping system to the
apparatus.
Avoid excessive loads from the piping system.
Make sure the pipe connections are securely held when working on the
pipings.
200000284-1-EN-GB20
4 InstallationEN