Alfalaval COMPABLOC CP15 User manual

COMPABLOC
Installation, Operation and Maintenance Manual
IMCP0002 Rev. J / ENGLISH

Visit our website at www.alfalaval.com
Original Instructions:
Alfa Laval reserves the right to change specifications without prior notification.
This publication or any part thereof may not be reproduced or transmitted by any process ormeans
without the prior written permission of Alfa Laval.

IMCP0002 Rev.J 1
This Instruction Manual IMCP0002 revision J is a revision of IMCP0002 revision I.
This document is English version.
Scope of application:
•CP15, CP20, CP30, CP40, CP50, CP75 and CP120
•CPH15, CPH20 and CPH30
•CPF15, CPF20 and CPF30
IMPORTANT: All other specific information on the general arrangement drawing or other specific
documents provided by Alfa Laval with the equipment takes precedence over information in this
document.
If there is a QR Code on the nameplate of the Compabloc, scan it to access this Instruction Manual
and to Troubleshooting assistant.
Editions & Revisions:
J
01/10/2021
M.BLANCHARD
A. BAYMONT
A. MACIVER
See whereindicated
I
01/02/2020
M.BLANCHARD
A. BAYMONT
A. MACIVER
See whereindicated
H
07/11/2016
M.BLANCHARD
A. BAYMONT
A. MACIVER
See whereindicated
G
21/11/2014
M. CARVALHO
S. PELENC
A. MACIVER
PTFEgaskets torquevalues
F
22/10/12
M.BLANCHARD
S. PELENC
A. MACIVER
Sixth edition
…
…
…
…
…
…
A
15/02/02
M. LAVANCHY
C. ROUSSEL
R. CONSONNI
FirstEdition
REV
DATE
NAME
VISA
NAME
VISA
NAME
VISA
EDITEDBY
VERIFICATION
APPROVAL
OBSERVATIONS
This is an electronic versionof the IOM Manual in pdf format. Only the official paperversion is signed and registered as per
our QA system and copy can be obtained upon request.
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TABLE OF CONTENTS
1 -Description ............................................................................................................................................3
1.1 - General description............................................................................................................................3
1.2 - Function & duty..................................................................................................................................4
1.3 - PED/Risk Analysis .............................................................................................................................4
2 -Installation.............................................................................................................................................5
2.1 - General requirements & precautions ...................................................................................................5
2.2 –Installation ........................................................................................................................................5
2.4 –Lifting .............................................................................................................................................10
2.5 –Storage...........................................................................................................................................11
3 -Operation.............................................................................................................................................12
3.1 - Before start-up (& before eventual insulation).....................................................................................12
3.2 - Start up ...........................................................................................................................................12
3.3 - Unit in operation...............................................................................................................................13
3.4 - Shut down .......................................................................................................................................13
4 -Maintenance ........................................................................................................................................15
4.1 - Chemical cleaning............................................................................................................................16
4.2 - Mechanical cleaning.........................................................................................................................17
4.3 - Panels dismantling & re-assembly procedure.....................................................................................17
5 -Trouble shooting .................................................................................................................................25
6 -Duty summary for Compabloc.............................................................................................................26
7 -Waste management and scrapping .....................................................................................................27
Appendix 1: Panel weights (kg (lbs)) ..........................................................................................................28
Appendix 2: Nominal tightening forces of threaded panels (Nm) ...............................................................32
Appendix 3: Compabloc Name Plate ..........................................................................................................33
Appendix 4: Compabloc Troubleshooting questionnaire ...........................................................................35

IMCP0002 Rev.J 3
1 - Description
1.1 - General description
Compablocisa welded plate heat exchanger without interplate gasketsallowing a large heat transferarea within a very
compact space(low footprint). It is madefrom stacks of welded plate packs inserted in a rigid rectangular bolted frame
formechanical strength and the separation of the various circuits. Each circuit can be fitted with a detachable baffle
plate assembly. Only 4 panel gaskets are installed, as indicated on the exploded viewFigure 1.
Compabloc is designed and manufactured in accordance with a Pressure Vessel Code (ASME, EN-13445, etc.) and
for defined working conditions. The Design & Manufacture of the Compabloc is made per a Quality System
Management according to ISO 9001.
Figure 1: Compabloc exploded view
Four carbon-steel panels fitted with nozzles enable the connection of the pipework. Optionally, these panels can be
lined with the same material as the plates themselves. The plates, baffle plates, nozzles and panels linings can be
made from stainless steel 316L, Titanium, 254 SMO, Hastelloy, or other pressable and weldable material. The flowcan
be directed using baffles (number of passes chosen to maximize heat transfer and minimize fouling).
The bolts of panels are put in place with high temperature lubricant.
Figure 2: flow through Compabloc and cross-section in plate pack

4 IMCP0002 Rev.J
1.2 - Function & duty
The Compabloc is a heat exchanger used for heating or cooling (with or without heat recovery), steam heater,
condenser, 2-pass process condenser, reflux condenser, reboiler, gas cooler, etc...
Each of those duties requires a specific installation and the installation must be in conformity with the thermal data
sheet and the general assembly drawing of the unit.
•Pressure and temperature limits
Never run the Compabloc at lower/higher pressures and/or lower/higher temperatures than those indicated on
the name plate.
•Continuous & cyclical duty
Compabloc has been designed for continuous and stable operating conditions. Compabloc is not suitable for
cyclical operating conditions, especially when sudden temperature changes with high amplitude could occur.
High cyclical duty (temperature and/or pressure) may create fatigueleading to a reduced lifetimeof theunit.
•Operating pressures
It is recommended that the Compabloc always have a differential pressurebetween the two circuits. An identical
operating pressure on both circuits could make the plate pack behave like an accordion because of pressure
inversion, creating fatigue, with the risk of a decreased lifetime.
In case of a maximal differential pressure is indicated on the nameplate (see Appendix 3), make sure that the
differenceof pressure between bothsidesnever exceeds this value because itcouldseriously damage the plate-
pack.
•Duty
In order to ensure optimal efficiency, it is strongly recommended to run your Compabloc as close as possible to
the conditions used for initially designing the heat exchanger.
•Corrosion risk
The material of the parts in contact with the used medium has been specified or chosenbased on data supplied
by the customer (fluid, composition, temperature, etc.). If the media passing through the unit and operating
temperatures is different from those specified in the data sheet, the Customer is responsible for ensuring that
the corrosion resistance is suitable.
Special attention shall be givento the chloride content of thestreams, as this is a frequent cause of corrosion of
stainless-steel materials.
Responsibility regarding the duty or cleaning medium and checking its compatibility with the materials used in
the heat exchanger is with the customer or contractor, if otherwise not agreed with Alfa Laval. The quality of
medium, can considerably affect the operation and lifetime of the heat exchanger.
1.3 - PED/Risk Analysis
All units delivered in the EEC follow the PED (Pressure Equipment Directive) with a level of risk depending on
parameters such as nature of the fluid (gas, liquid, steam, fluid vapour pressure), and the danger level of the fluid,
Design Pressure, Volume of each circuit or Design temperature.
These parameters will determine a PED Category to which is linked a risk analysis as per the PED.
Make sure that the category of yourunit matches your operating conditions.
It is recommended that, in situations where sudden full vacuum or sudden increase of
pressure could occur, that a relief valve be installed in the piping to protect the
Compabloc.

IMCP0002 Rev.J 5
2 - Installation
2.1 - General requirements & precautions
•To allow maintenance and inspection, we recommend leaving a 50 to 120 cm (19 to 48") wide space all around
the Compabloc unit to facilitate panel dismantling.
At the top of the exchanger, it is necessary to have a 100cm (40”) f ree space to allow the possible setting of a
panel-lifting device.
•It is strongly recommended to install the Compabloc on a foundation. Please pay attention in foundation design:
make sure that you have enough space (at least 30 cm) under the bottom bolting of each panel to use tightening
tools incase of maintenance or cleaning. Notice that the panel bolts placed behind flanges may be unaccessible
if the foundation is too close. Pleasereferto the General Arrangement Drawing when designing foundation.
•Follow good engineering practice bothin the design and operationof the plant. Take appropriate precautions to
avoid hydraulic shocks (water hammer), which could damage Compabloc (see Start up section 3.2).
•The connecting pipework should be provided with valves in order to isolatethe unit. Valves are essential between
any pump and the Compabloc.
•All valves should have a slow valve action. Flowrates should be increased slowly and gradually during start up
and reduced gradually during shut down.
•Centrifugal pumps are recommended.Do not use piston-type pumps in line with the Compabloc (these generate
repetitive pulsations in flowrate which may cause serious damage to the platepack).
•Preferably pumps should be installed on the outlet instead of inlet to limit stress on the plate pack when pump
load varies.
•When specifying pumps and heat exchangers, allow ample margins for pressure drop increases above stated
design values. These can be the result of possible variations in fluid properties, flow rates, scaling or deposits on
the heat transfer surfaces.
•When using live steam as heating medium, install a steam trap on the condensate outlet pipe, preferably with
automatic venting of non-condensables.
•Make a check of the torques of the panel bolting before insulating the unit (see para 3.1 for more details) and
piping it.
•When provided with the unit, place the shearing pins in position before fastening the feet on the Compabloc.
•Detach any label fastened to vent and/ordrain beforeconnecting.
2.2 –Installation
•Pipework
No specific precaution needs to be taken when connecting the Compabloc. However, if the connection pipework
includes long, straight runs, it is essential to insert correct bends, or expansion devices. Alfa Laval suggests
placing the pipe supports at a maximum of 2 meters (72 in) distance from the unit.
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6 IMCP0002 Rev.J
•By-pass
The connecting pipework should be provided with valves in order to isolate the unit and with by-pass valve for
start-up and shutdown oneach side.
The isolationvalves forthe process circuits should be positioned in such a way as to enable the panels to be
dismantled without having to remove the valves.
Valves must be kept in good working order. The use of globeor butterfly valves is recommended.
This by-pass line must be used forflushing theline beforestart-up of theCompabloc.
•Venting & draining
CP15, CP20, CP30 and CP40 are provided with nozzles located as low and high as possible acting as vents and
drains, thus allowing a completedraining and venting of theunits. They are self -venting and self-draining.
For CP50, CP75 & CP120 range, which have separate vent and drain connections, there is a need to provide,
as a minimum, a permanent venting of the cold circuit (the one which is heated up) in order to allow propergas
release, preventing the gas released being trapped inside the unit.
Connection of the nozzles with the drain and vent circuits should be donewith isolation valves provided by the
end customer or contractor.
Venting is mandatory on both sides during start-up to remove any presence of vapor/gas pocket in the upper
section of the exchanger.
A typical way to vent a CP50, CP75 or CP120 is shown in Figure 3 (liquid/liquid).
The vent valve must be open on hot and cold side during start-up.
In operation, we recommend that you connect and keep open the cold side vent to allow continuous and
permanent self-venting of Compabloc as the working cold medium stream generates gases. This is the case in
most heat recovery systems - “feed / pumpdown” where the cold stream generally releases a lot of trapped gas
or air.
Figure 3: typical Vertical Compabloc installation

IMCP0002 Rev.J 7
•Case of condensers
For unit operating in the mode of condenser, it is recommended that the valve at the drain nozzle be open as
much as possible in order to prevent condensate accumulation.
•Filters
If the service conditions require it, or if the fluid is loaded with particles, install a filter with maximum mesh of 3
mm (1/8") for all Compablocs, except the CP15 which shall have a maximum filter mesh of 2 mm (1/12"),
upstream of the exchanger.
•Connections/nozzles
All connections/nozzles are marked and should be piped accordingly. In case of doubt, check with the
arrangement drawing. Standard nozzle load limits are indicated on the General Arrangement drawing. For piping
connections, Alfa Laval strongly recommends using a gasket with a gasket factor = 2.5 and a seating load = 21
MPa and SA193B7M bolting to comply with the calculation hypothesis regarding nozzle. Specific allowable
nozzle loads, and moments can be calculated onrequest.
•Other external loads
Compabloc is designed without any otherexternal loads, except if specifically required by customer. In this case,
please refer to the General Drawing and Calculations Note.
•Controls and adjustments
To prevent water hammer and shock, all valves must be opened gradually.
The adjustments and controls, as well as the process used in the circuit, must be studied with care to avoid any
thermal or mechanical stress during the start up and transient operating conditions.
•Earthing lugs
The connection of the Compabloc to Earth is mandatory prior to operation start-up. Please use earthing lugs
provided for this purpose
Always use control valves with a PID system, set for the maximum
proportional range. Avoid operating conditions with only one circuit in
operation.
Depending on the properties of the fluid, install Compabloc within a spill
containment tray to avoid any pollution due to potential leakage.
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8 IMCP0002 Rev.J
2.3 - Control system
•Control system for liquid/liquid applications
A classical system where the outlet process temperature drives the control valve at the service inlet is good as
long it is an automatic control such as a PI orPID system and the control valve is correctly sized.
An oversized control valve creates the risk of ON/OFF operation which is not good, thereby causing fatigue and
stress.
•Control system for steam heaters
It is generally a continuous process with the purpose of heating a fluid by condensing live orsecondary steam
(while with process condensers the purpose is to condense the vapours, not to heat the cooling medium).
To avoid a suddenvacuum inside the unit, due for example to an emergency shut down and a sudden closure
of the steam inlet valve, it is strongly recommended to install a vacuum breaker valve (safety valve) on the
steam inlet line near the Compabloc steam inlet. If the steam inlet valve is closed suddenly, air will be admitted
in the steam inlet line tol avoid vacuum inside the heat exchanger.
✓Steady flowrate of the media to be heated:
It is mandatory that a control system as indicated belowis installed. We recommend a control system
based on a condensatelevel control. The temperature relay (TIC) starts up the condensate control
valve located afterthe steam trap. The steam trap is essential as it will allow only the condensate to
pass.
The condensate control valve must not be oversized! It should typically be sized to handle the maximum,
normal, and the minimum duty of theexchanger. Typically, this translates into the control valve operating
being between 60-80 % openat maximum loadand not less than 20 % open at minimum load.It will avoid
ON/OFF behavior.
The controllerwill act by increasing or decreasing the liquid level in the heat exchanger, allowing smooth
control.
Check the design so that the velocity of thecondensate is below approximately0.5 m/s so the condensate
outlet will be self-venting. Higher speeds can lead to flooding of the connections by accumulation of
condensate.
In case of steam pressure control, it is essential to considerthe different operating loads to properly size
the control valve. (fig.25)
✓Unsteady flowrate of the media to be heated:
If the liquid flowrate is expected to vary a lot, it may generate fatigue leading to reduced lifetime of the
equipment.
Figure25 :
Steam heater –steamcontrol
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IMCP0002 Rev.J 9
•Control system on Process condensers
To avoid a suddenvacuum inside the echanger, due forexample to an emergency shut down, it is strongly
recommended to install a vacuum breaker valve (safety valve) on the vapourinlet line near the Compabloc inlet.
•Control system on low pressure feed-water heater
For low pressure feed-water heaters, it is highly recommended to use a level control for the condensatewith
high and low level. The outlet valve located on the condensate outlet pipeis opening in order to prevent the
condensate level to go higher than the high limit.
This system prevents any contact between steam and condensate.
Ventilation
Air removal
Feed water from
Condenser
LC
1st LPH
Extr. steam
Condensate
FW
In
FW
Out
Restrictor
Closing
valve
Level
Control
Closing
Flap
Heater
bypass
Feed Water to
next LP Heater or
to Feed Water Tank
MCondensate to
-Next preheater or
-Condenser (or other tank)
Heating Steam from
Steam Turbine (or other steam source)
Pneumatic
Assisted
Closing
Device
Solenoid
Operated
Closing
Device P
S
P
Safety
Valves
(Condensate from
Warmer LP Heater)
Make sure a vacuum relief valve is installed in order to avoid sudden vacuum when
shutting down the unit.
Figure 27:
P&I Diagram for LPFW Heater

10 IMCP0002 Rev.J
2.4 –Lifting
The handling of heat exchangers Compabloc should be done by using certified straps, slings and shackles, and also
by appropriatelifting means (jib or bridge crane).
•ertical Compabloc
Lifting rings and lugs are located on the top of the unit.
Lifting rings cannot be used at less than -20°C (-4°F).
Figure 4: lifting of Vertical Compabloc
The nozzles must never be used for handling purposes.
Do not use the welded or screwed lifting lugs located on the panels for
lifting of the complete unit, these are for lifting individual panels only!
It is very important to check that the capacity of the lifting means correspond to the
lift weight.
In general, it is not recommended to handle the Compabloc by using a forklift truck.
For safety reasons, never stand or work under suspended loads.

IMCP0002 Rev.J 11
Remark: For safety reasons during transportation, many big units are delivered in horizontal position. If needed,
handling & tilting procedures are available:
- forCP50 & CP75, please refer to procedureCLIB1001
- forCP120, please refer to procedureCPPB1103
You can obtain these procedures by scanning the QR
code available on the equipment or by scanning now the
QR codes which are on this page.
•Horizontal Compabloc
CP15-CP20-CP30-CP40:lift the exchanger using two soft slings fixed on the lifting lugs.
CP50, CP75 and CP120 range : use the lugs located on the end heads.
For a CP75 unit fitted withmore than 200 plates or any CP120, a lifting-beam must be used.
2.5 –Storage
Compabloc must be stored, rinsed, drained and dried to avoid corrosion. Connections must be closed with blind
flanges, wooden covers or plastic tape.
It is strongly recommended not to storeCompabloc outdoor.
If spare parts are delivered with the unit (we strongly recommend to always keep as spare parts a set of gaskets and
10% of bolting forpreventivemaintenance), they can be stored without time limitation in their original packing and in a
dry area (no outdoorstorage). Gaskets must be stored in horizontal position.
Figure 5: lifting of Horizontal Compabloc
CP120
CP50-CP75

12 IMCP0002 Rev.J
3 - Operation
3.1 - Before start-up (& before eventual insulation)
•Check of panel bolt torques
Before start-up, make sure the unit is correctly installed and make a check of the tightening
torques of the panel bolts as per the values in appendix 2. Values must be at least equal to nominal tightening
forces. The retightening of bolts can be realized one panel after the other, taking one bolt next to the other,
turning around the panel and starting at one bolt randomly.
Panel loosening (with loose bolts consequently) may occur during transportation or storage. In case where the
torque values are below the recommended ones, it is necessary to retighten the bolting with an appropriate
torque wrench beforestarting up the unit.
•Maximal differential pressure
Check if a maximal differential pressure is indicated on the nameplate (see Appendix 3). If it is the case and if
the operating pressure of the cold side is higher than this maximal allowable pressure, start-up process as
described in chapter 3.2 is not applicable.
•Individual precautions
The heat exchanger operates with high temperatures, high pressure and aggressive media: it is necessary to
provide personnel protection measures, in accordance with the applicable safety regulations and work safety
codes at the customer site.
•Personal protection
Make sure the unit has personal protection(a protectionscreen or a cover is generally enough) or the appropriate
insulation so that nobody canbe hurt or burnt by touching the panel surfaces.
3.2 - Start up
In orderto extend lifetimeof theunit, start up must be gradual and smooth.Flowrate adjustments shouldbe doneslowly
in order to avoid the risk of water hammer.
•Check that the Compabloc is correctly installed, with the cold circuit flowing upward (in case of gas/air release).
•Generally speaking, unless specifically recommended, the cold circuit must be filled and started first.
•Open the air vent (it concerns only models CP50, CP75 and CP120, other models are self venting).
•Open the outlet valve on the cold circuit.
•Start the pump forthis circuit with the exchanger inlet valve still closed.
•Slowly open the inlet valve at the heat exchanger.
•When all the air is out, the vent can be closed (CP50, CP75 and CP120 only).
Note: vent can remain open ifconnected to the pipeline.
•Once the cold circuit is running, apply forhot circuit the same procedure as per the cold circuit.
Water hammer is a short pressure peak that can occur during start up or shut down
of a system, causing liquid to travel along the pipe as a wave at the speed of sound.
This may cause considerable damage to the equipment.
Leaks due to not properly tightened panels is not covered by warranty.
If the operating pressure of the cold side is higher than the max allowed differential
pressure (refer to the nameplate –Appendix 3), then both circuits must be started-up
SIMULTANEOUSLY. Differential pressure must never exceed the max allowed differential
pressure indicated on the nameplate.

IMCP0002 Rev.J 13
3.3 - Unit in operation
General technical equipment operating rules should be observed. During operation, the following shall be checked:
•There is no leakage from the gaskets. Normally no retightening should be necessary. Nevertheless, should a
leak be observed, do not hesitate to retighten the panels as per the torque indicated in appendix 2. Cold
retightening is mandatory. The pressure must be released.
•The operating pressures and temperatures must not exceed the maximum design values stated on the name
plate. Operating temperature must never go belowthe minimum designtemperature specifiedonthename plate.
•Differential pressuremust never exceed the max allowed differential pressure indicated on the nameplate (when
indicated).
•Bolts and nuts are kept clean and greased (except if PTFE coating). Prevent damage on coating of bolts & nuts
if they are coated.
•Avoid suddenchanges influid flowrates, pressure and/or temperatures in orderto reduce hydraulic shock and/or
fatigueeffects caused by thermal expansion and contraction.
•Maintain flow rates at the designed values as much as possible. Lower velocities reduce pressure drop and
thermal efficiency. Flow rates much lower than design values may also result in accelerated fouling.
•For fluids containing solids, thetendency of settling and clogging increases if theflow rate is reduced.
•In installations with multiple units in parallel, variations in capacity are best handled by varying the number of
units in operation rather than by majorvariations in flowper unit.
3.4 - Shut down
In case of the warning just above is not applicable, then it is the reverse procedure of start up, with generally the hot
circuit being closed first and the cold circuit still running.
•Slowly close the valve controlling the flowrate of the pump you are about to stop.
•When the valve is closed, stop thepump.
Start-up must be gradual and heat rate shall not exceed 60°C per
hour to avoid thermal shocks or unnecessary stress on the unit.
Pressure buildup rate must not exceed 1 bar/min.
If the operating pressure of the cold side is higher than the max allowed differential pressure
(refer to the nameplate –Appendix 3), then both circuits must be shutdown SIMULTANEOUSLY.
Differential pressure must never exceed the max allowed differential pressure indicated on the
nameplate.
Never tighten or loosen panels under pressure and as long as their
temperature is not at ambient temperature!
In order to prevent possible injury to operators, never touch the unit as long as its
external temperature is not ambient temperature!

14 IMCP0002 Rev.J
•If the Compabloc is shut downforseveral days, it must be drained.
Draining must also be doneif the process is shut down and the ambient temperature is below freezing
temperature of the media. Draining is a simple operationbecause the lower nozzles allow a self draining forthe
CP15 to CP40, while for CP50 to CP120 models, flanged drains have to be used. They should be piped to the
drain circuit or connected to an evacuation system.
•Depending on the process fluids used, it is also recommended to rinse and dry the unit if the shutdown is of
longer duration.
After a long shut down (several months), check the tightening torque of all bolts and
nuts, before re-starting.
Make sure toxic, hazardous, lethal vapors or liquids are NOT released to the
atmosphere or to the ground. These could cause injury to people and/or damage to
the environment.
If fluids are hot, allow the unit to cool down to ambient temperature before draining to
prevent possible injury to operators.

IMCP0002 Rev.J 15
4 - Maintenance
Please find below the preventive maintenance program recommended by AlfaLaval.
It is strongly recommended to always keep as spare parts a set of gaskets and 10% of bolting for preventive
maintenance.
№
Recommended
periodicity
Type of operation
Notes
1
Daily
Not less than
once a week
Supervision of key process
parameters including temperature,
pressure drop and media
composition
If a contamination of media is observed, it is necessary to carry
out a detailed analysis to check forpossible internal leakage in
the plate pack
Follow-up of pressuredrop variation permits to anticipate a loss
of performance (clean the heat exchanger to remove fouling)
2
External visual check
- state of flange connections
- absence of external leak of the Compabloc
- absence of leakage of installed valves
- state of fixing elements and grounding
- state of control and measuring devices
- absence of vibration or pulsation in the pipelines
- absence of abnormal sound or noise inside the unit
3
Once per 3 years
up to
once per 6 years
(during
scheduled shut-
down)
External and internal visual
control
External control concerns external elements of theheat
exchanger, including panels, heads, girders, connections and
bolting (deformation, corrosion), all welds (crack, defects,
corrosion...) and painting (local absence of coating, blister…)
Customer can decide to proceed an internal examination
(depending of criticity of equipment or in case of suspicion of
possible issue). Then, it is necessary to:
- estimate state of internal elements of theheat exchanger,
including baffles, panel lining (check lack of deformations,
cracks, defects in welds and corrosion)
- estimate state of the heat exchanger plate pack –check welds,
lack of deformation of plate pack, erosion-corrosion penetration
damages.
Internal examination requires the disassembly of the panels
(chapter 4.3). Alfa Laval can support you - contact yourAlfa
Laval representative
4
Mechanical and/or chemical
cleaning
Procedure of cleaning according to chapter 4.
Delaying cleaning makes the recovery of initial heat transfer
performances more difficult.
5
Leak tests
Test pressure = design pressure (as indicated on the nameplate)
If a default is detected, necessary actions must be taken as soonas possible to fix theissue.
Alfa Laval is on your side to provide you a large offer of services related to the Maintenance of the Compabloc.
Please contact your Alfa Laval representative.

16 IMCP0002 Rev.J
4.1 - Chemical cleaning
Chemical cleaning is the most efficient way to clean the unit. In general, inorganic deposits are cleaned with acidic
cleaning solutions and organic deposits with alkaline cleaning solutions.
Proprietary cleaning agents should be used in accordance with the manufacturer’s instructions. In this way, the
compatibilitywiththe materials of construction(metal and gaskets)is secured and warranties apply.The whole cleaning
protocol (choice of cleaning agent, its concentration, temperature and time) must be related to the composition of the
fouling species. Some guidelines are given in the Table below to clean various common fouling species.
Cleaning agents - Fouling
Type of deposit
Cleaning agent
Typical conditions
Organic (microbiological growth,
algae, slime, proteins, grease…)
AlfaCaus
10 vol.%, 60oC
Oil-related
Alpacon Multi CIP II
AlfaCaus
Alpacon Degreaser II
10 vol.%, 60oC
Asphaltic, tar,
hydrocarbon-based
Paraffin or naphtha-based
solvents followed by AlfaCaus
Calcium carbonate
Calcium phosphate
Alpacon Descalent II
10 vol.%, 60oC
Iron oxides
AlfaPhos
10-20 vol.%, 60oC
For optimal results, the flow direction should be in the opposite direction of normal flow (“back f lushing” mode). The
circulation of the cleaning solution must be upstream, if possible, with a flow of 50 % of the nominal flow.
It is strongly recommended to monitor thepressure drop through the unit and to carry out chemical cleaning once a set
maximum pressure drop value has been reached.
After every chemical cleaning, rinse the exchanger thoroughly with hot water and drain it.
For additional information on cleaning protocols, please contact your nearest Alfa Laval representative.
Never use hydrochloric acid or other cleaning substances containing
chlorides as their presence will inevitably lead to corrosion of stainless-steel
alloy components.
Always use the appropriate waste container to recover the spent cleaning solution.
Chemical cleaning must be carried out by authorized and qualified personnel.
Take all necessary protection & precautions for health, safety and
environment regarding chemicals.
Check suitability of the cleaning protocol with the materials of your Compabloc.

IMCP0002 Rev.J 17
4.2 - Mechanical cleaning
If chemicals cannot be used for cleaning, the panels and possibly thebaffle cage can be removed to permit access to
the heat transfer surfaces.
Follow instruction as per chapter 4.3 foropening yourCompabloc.
In most cases, it is not necessary to remove the baffle cage forcleaning the plate pack.
If needed, please follow instruction as per chapter 4.3.5.
Clean with high pressure water - High pressure water hydroblasting canbe made up to 1000 barg (14500 psig).
Do not go above 1000 barg (14500 psig)!
As the corrugations are oriented at 45°, it is possible to have good access to the heat exchange surface by orienting
the cleaning device at 45° (hydroblast gun or cleaning bar).
4.3 - Panels dismantling & re-assembly procedure
Panels need to be dismantled in case of mechanical cleaning and/or inspection of plate pack and/or panel linings.
•First, drain completely the 2 circuits.
•Mark the panels with identification symbols (to clarify for which circuit) prior to dismantling (so that they can be
correctly re-installed later).
•Check that none of thetwo circuits are pressurized (and that drains are open).
•Check that the panel being dismantled is firmly secured and cannot fall once unscrewed (see panel weight
Appendix1).
4.3.1 - Dismantling procedure for one panel
Refer to Figure 6.
In order to avoid any twisting of the girder columns, first it is necessary to relax the nuts (marked 4) and then
progressively loosen the bolts of the panel being dismantled, starting with the nuts of the girder (marked 3) then the
nuts of the top and bottom heads (marked 1 & 2).
Use the welded orscrewed lifting lugs located on thepanels to lift thepanels in a safeway.
Before opening a Compabloc, make sure it is empty.
Collect the remaining fluid to avoid any pollution of the environment.
In order to avoid that the Compabloc tilts as long as all panels are not in
place, make sure that the Compabloc is fixed to the floor during panels
dismantling & re-assembly.
If not possible to fix Compabloc to the floor, use a crane to maintain the
Compabloc in case of tilting during dismantling & re-assemblying panels.
It is forbidden to make any marking damaging the surface of the plate pack or the lining.
Girders and heads are fixed items and must never be disassembled from platepack.

18 IMCP0002 Rev.J
4.3.2 - Dismantling procedure for the 4 panels
Progressively loosen the nuts, one girder after the other. When all the nuts of the girders are relaxed, loosen the nuts
of the bottom, one panel after the other.
Please find details of thepanel weights in Appendix 1.
Use the welded orscrewed lifting lugs located on thepanels to lift thepanels in a safe way.
Figure 6
For models CP15/CP20/CP30/CP40, never unscrew the stud bolts used for the
girder assembling to the top and bottom heads.
For CP50/CP75/CP120, never unscrew nuts used for assembling the girder column
to the top and bottom heads.
In order to avoid that the Compabloc tilts during disassembly, always remove first
the panel with the highest weight and finish with the panel with the lowest weight.