Alfalaval Port filter User manual

Port filter
Instruction for Port Filters for Gasketed plate heat exchanger
Introduction
This manual provides information needed to install, operate and carry out
maintenance of the port filter used for gasketed plate heat exchanger with port
size 200 mm or larger.
Intended use
The intended use of this equipment is to prevent foreign objects from entering
and causing clogging in gasketed plate heat exchangers.
All other use is prohibited. Alfa Laval will not be held responsible for injury or
damage if the equipment is used for any other purpose than the intended use
described above.
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.
Waste management
Separate, recycle, or dispose of all material and components in a safe, and
environmentally responsible way, or according to national legislation or local
regulations. If there is any uncertainty regarding what material a component is
made of, contact the local Alfa Laval sales company. Use a certified (ISO
14001 or similar) scrapping or waste handling company.
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.
200001927-2-EN-GB
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.
© Alfa Laval Corporate AB
How to contact Alfa Laval
Up-to-date Alfa Laval contact details for all countries are always available on our website at www.alfalaval.com
Instruction Manual

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.
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Safety
Safety considerations
The port filters shall be used and maintained in accordance with Alfa Laval’s
instructions in this manual. Incorrect handling of the port filters 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.
The port filters shall be used in accordance with the specified configuration of
material, media types, temperatures and pressure for the specific plate heat
exchanger were the port filter are used.
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.
Personal protective equipment
Protective shoes
A shoe with a reinforced toe cap to minimize foot injuries caused by dropped
articles.
Protective helmet
Any helmet designed to protect the head from accidental injury.
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Protective goggles
A pair of tight-fitting eyeglasses worn to protect the eyes from hazards.
Protective gloves
Gloves that protects the hand from hazards.
Working at height
If the installation requires working at a height of two meters or higher, safety
arrangements must be taken in consideration.
WARNING Risk of falling.
For any kind of work at height, always ensure that safe means of access
is available and used. Follow local work at height regulations and
guidelines. Use scaffolds or a mobile work platform and a safety harness.
Create a safety perimeter around the working area and secure tools or
other objects from falling.
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Description
Components
The port filter consists of a cylindrical meshed tube with a flange in one end.
The length of the filter tube is adapted for the total length of the plate pack
including the thickness of the frame and pressure plate. The conical guide ring
is inserted at the opposite port and keep the filter tube centered after
installation. The welded rings in both ports provide a flat surface for flange
gasket sealing against pipework and inspection cover.
NOTE
The port filter length is precisely adapted to the specific plate heat
exchanger. Modifications to the plate heat exchanger may make the port
filter not fit the dimensions of the plate heat exchanger anymore.
Following parts are required to install port filter.
2
3
1
1. Port filter
2. Conical guide ring
3. Flange gasket (4 pieces per port filter)
Function
The port filter is used to ensure high thermal efficiency of the plate heat
exchanger by preventing foreign objects from entering and causing clogging of
the plate pack. The port filter is designed to operate in conditions involving sea
water, process water, cooling tower water or any kind of liquid containing
particles with potential risk of disrupting the performance of the system.
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Installation
Unpacking
Follow the instruction below to unpack the components of the port filter
WARNING Risk of personal injury.
There can be sharp edges, splinters, and nails on the crate and the equipment.
Wear personal protective equipment when handling the equipment during unpacking and
installation. Handle the equipment with precaution. See Section Personal protective equipment in
Chapter Safety
1Prepare an area with required space for
unpacking.
2Open the transport enclosure.
3Check your shipment immediately upon
arrival and make sure that the port filter
received is in accordance with the order
specification. In the event of damage, defects
or deficiency, immediately report the problem
to the transport company and Alfa Laval.
4Remove all additional components such as
conical guide ring or other delivered parts
from the transport enclosur.
5Lift the port filter from the transport enclosure.
Use lifting equipment with straps attached
according to picture or by hand for smaller
port filters.
CAUTION
Risk of damage to equipment.
Handle the port filter with care to avoid
any damage of it. Avoid to expose the
port filter for bending forces as risk of
collapsing the filter tube increases.
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Before installation
Preparation of the plate heat exchanger before installation of the port filter.
1. Prepare the installation area around the plate heat exchanger and ensure
that required space is available.
2. Installing port filter into an existing plate heat exchanger require
preparation to ensure that correct port arrangement is in place for the
installation. Consult Alfa Laval representative if any hesitation.
3. Shut down, isolate and drain the plate heat exchanger by following the
instruction in section Shut-down
4. Install port filter according to the section Installation of port filter
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Shut-down
NOTE
If several pumps are included in the system, make sure you know which one should be stopped
first.
1Slowly close the valve controlling the flow
rate of the pump you are about to stop.
2When the valve is closed, stop the pump.
3Repeat the two steps for the other side for the
second media.
4If the plate heat exchanger is shut down for
several days or longer, 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 plate heat
exchanger plates and connections.
NOTE
Avoid vacuum in the plate heat
exchanger by opening vent valves.
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Installation of port filter
Installation of the port filter can be done when all preparation has been performed with shut-down and
isolating the plates heat exchanger.
NOTE
The port filter length is precisely adapted to the specific plate heat exchanger. Modifications to the
plate heat exchanger may make the port filter not fit the dimensions of the plate heat exchanger
anymore.
5
1
4
3
66
2
1. Pressure plate
2. Frame plate
3. Inspection cover
4. Port filter
5. Conical guide ring
6. Flange gasket
CAUTION Risk of falling.
If the port filter is installed at upper ports take precaution action, see Section Working at height in
Chapter Introduction.
WARNING Risk of personal injury
The edges of the port filter can be sharp.
Wear personal protective equipment when handling the equipment during installation. Handle the
equipment with precaution. See Section Personal protective equipment in Chapter Safety
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1Remove the connection flange pipe on the
frame plate by loosening all nuts.
CAUTION
Risk of personal injury.
The connection flange pipe is heavy and
it is required to use lifting equipment.
Follow the lifting instructions from the
manufacturer of the connection flange
pipe.
2Attach one flange gasket at the port in the
frame plate if not already in place.
3Insert the conical guide ring into the port of
the inlet flow (frame plate).
4Attach one flange gasket to the outside of the
conical guide ring flange.
5Remove the inspection cover from the
pressure plate by loosening all nuts. Use
lifting equipment with straps attached
according to picture.
CAUTION
Risk of personal injury.
The inspection cover is heavy and lifting
equipment is required. Attach the straps
to the lifting eye on the inspection cover.
a) Lower port: Arrange straps and chain
pulley according to picture. Protect the
threads of the tightening bolts by sliding a
metal tube over the tightening bolt.
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b) Upper port: Arrange straps and chain
pulley according to picture. Protect the
threads of the tightening bolts by sliding a
metal tube over the tightening bolt.
6Attach one flange gasket at the port in the
pressure plate if not already in place.
7Insert the port filter into the port in the
pressure plate.
a) For large port filter use lifting equipment.
CAUTION
Risk of damage to equipment.
Handle the port filter with care to
avoid any damage. Avoid exposure of
bending forces as risk of collapsing
the filter tube increases.
b) Installation in lower port: Arrange straps
and chain pulley according to picture for
installation in ports. Protect the threads of
the tightening bolts by sliding a metal tube
over the tightening bolt.
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c) Installation in upper port: Arrange straps
and chain pulley according to picture for
installation in ports. Protect the threads of
the tightening bolts by sliding a metal tube
over the tightening bolt.
8Thread the port filter tube over the cone at
the opposite port by pushing the lower part of
flange against the port and pull the upper part
to guide the tube over the cone. Then push
the port filter until the flange reach the lining
of the port.
9Attach the flange gasket to the outside of the
port filter flange if not already in place.
10 Put the inspection cover back in place and
fasten the nuts. Use lifting equipment with
straps arranged in the same way as in the
step of removing the inspection cover earlier
in this instruction.
CAUTION
Risk of personal injury.
The inspection cover is heavy and lifting
equipment is required. Attach the straps
to the lifting eye on the inspection cover.
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11 Attach the flange connection and fasten the
nuts.
NOTE
Adjusting of pipings
Be aware that minor adjustment of the
piping may be necessary as the
thickness of the flange gasket and the
flange of the port filter are added to the
installation.
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Operation
Start-up
During the start-up, check that there are no visible leakages from the plate pack, valves or piping
system.
CAUTION Risk of leakage.
If the temperature of the plate heat exchanger is below the minimum temperature for the gaskets
prior to the service, it is recommended to heat the plate heat exchanger above this limit to avoid
cold leakage.
NOTE
If several pumps are included in the system, make sure you know which one should be activated
first.
Centrifugal pumps must be started with valves closed and the valves must be operated as smoothly
as possible.
Do not run pumps temporarily empty on the suction side.
NOTE
Adjustments of flow rates should be made slowly in order to avoid the risk of pressure surge
(water hammer).
Water hammer is a short lasting pressure peak that can appear during the 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.
1Check that the valve is closed between the
pump and the unit controlling the system flow
rate to avoid pressure surge.
2If there is a vent valve installed at the exit,
make sure it is fully open.
3Increase the flow rate slowly.
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4Open the air vent and start the pump.
A
5Open the valve slowly.
NOTE
Avoid rapid temperature changes in the
plate heat exchanger. With media
temperatures over 100 °C, slowly
increase the temperature, preferably at
least for one hour.
6When all the air is expelled, close the air
vent.
7Repeat the procedure for the second media.
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Maintenance
To keep a high performance of the plate heat exchanger the port filter needs to
be cleaned at regular intervals. The frequency depends on volume of clogging
or impurities in the media.
Indicators of clogging filters can be pressure drop over the plate heat
exchanger or difficulties to reach design temperature.
Cleaning of port filters can be done by manual cleaning of port filter, see
instruction Manual cleaning of the port filter
CAUTION Risk of damage to equipment.
Backflush (reverse flow) is not allowed with port filter installed. Risk of
collapsing the port filter.
OUT
Backflush
IN
Backflush
Manual cleaning of the port filter
WARNING Risk of falling.
For any kind of work at height, always ensure that safe means of access is available and used.
Follow local work at height regulations and guidelines. Use scaffolds or a mobile work platform
and a safety harness. Create a safety perimeter around the working area and secure tools or
other objects from falling.
1Shut-down the plate heat exchanger
according to the instruction Shut-down.
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2Close the valves and isolate the plate heat
exchanger from the rest of the system.
NOTE
The plate heat exchanger must be
pressureless before disconnecting it.
WARNING
Risk of personal injury.
The plate heat exchanger can be hot.
Wait until the plate heat exchanger has
cooled down to about 40 °C (104 °F).
WARNING
Risk of personal injury
Depending on type of media take
precaution action.
Wear personal protective equipment
when handling the equipment during
installation. Handle the equipment with
precaution. See Section Personal
protective equipment in Chapter Safety
3Remove the inspection cover on the pressure
plate by loosening all nuts. Use lifting
equipment and arrange it according to
instruction in Installation of port filter.
CAUTION
Risk of personal injury.
The inspection cover is heavy and lifting
equipment is required. Attach the straps
to the lifting eye on the inspection cover.
4Remove flange gasket
5Grip around the port filter flange and pull out
the port filter. If stuck, use a sharp tool to
loosen it from the gasket. Use lifting
equipment and arrange it according to
instruction in Installation of port filter.
6Flush the port filter with water and brush to
remove all clogging.
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7If clogging is present in the plate pack follow
instruction in the Instruction Manual for the
plate heat exchanger.
8Re-insert the port filter, follow instruction in
Installation of port filter.
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