BSS Audio BOSS I Series User manual

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BOSS™I-series Plate Heat Exchangers
Instruction Manual
Installation • Function and Operation • Opening & Closing• Dimension A •
Maintenance & Cleaning

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BOSS™I-series Plate Heat Exchangers

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Contents
1. Installation ................................................................................................................................................................ 4
2. Function and Operation ............................................................................................................................................ 6
2.1 Plate pack assembly .......................................................................................................................................... 6
2.2 Start-up ............................................................................................................................................................. 7
2.3 Unit in operation............................................................................................................................................... 8
2.4 Shut-down......................................................................................................................................................... 8
2.5 The risks of not complying with the start-up and shut-down procedures ..................................................... 10
3. Opening and Closing ............................................................................................................................................... 11
3.1 A Opening I30, I60 or I100 .............................................................................................................................. 11
3.2 A Closing I30, I60 or I100 ................................................................................................................................ 12
4. Maintenance and Cleaning ..................................................................................................................................... 14
4.1 Routine maintenance...................................................................................................................................... 14
4.2 Extraordinary maintenance ............................................................................................................................ 15

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1. Installation
It is suggested the heat exchanger is installed on a level foundation
giving enough support to the frame. No special anchorage for the
foundation is required, but minimum free space around the heat
exchanger is needed.
It is necessary to leave enough free space around the heat exchanger
to make future service possible.
Straps should be used when lifting whole I60 or I100 units. Straps to be
placed on unit as shown in picture.
Note! Never lift by the connections or the studs around them. Before connecting any piping, make sure all foreign
objects have been flushed out of the system.
Piping
When connecting the pipe system ensure the pipes do not subject
the plate heat exchanger to undue stress or strain.
Shut-off valves
To be able to open the heat exchanger, shut-off valves should be
provided on all connections.

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Typical operation mode of plate heat exchanger
with parallel and counter current flows
A = Cold
B = Hot

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2. Function and Operation
2.1 Plate pack assembly
The plate pack of a heat exchanger consists of single plates.
Plates are always assembled with the gaskets facing the frame
plate.
Normally there are three kinds of plate in a plate pack.
1. The first plate or End plate II
This plate is used to keep the relative position of the plate
pack within the frame, it is the first plate in contact with the
pipe connections and its gasket has 4 rings to seal off all 4
ports. The gasket is made by affixing two normal field
gaskets together as the figure below shows.
2. Channel plates
Channel plates come into contact with the first plate and are
4 holed. They dominate the plate pack with the chevron
pointing upwards and downwards as per the design
configuration.
3. The last plate or End plate I
Normally has no holes and is assembled after the channel
plates and is in contact with the pressure plate.

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2.2 Start-up
1. Make sure the plate pack is compressed to
the correct ‘A’ measurement before starting
up for the first time or after a long period of
shut down.
It is very important that the system to which
the heat exchanger is connected is protected
against sudden and extreme variations of
temperature and pressure. This is not only for
the heat exchanger but also for the pipe
system itself and thus every piece of
equipment included in it.
This should be kept in mind whenever an
action is to be carried out in the system,
including for example starting up the pumps.
2. Before starting any pump, check whether
instructions exist, telling you which pump
should be started first.
3. Check that the valve is closed between the
pump and the unit controlling the system flow
rate.
4. If there is a valve at the outlet, make sure it is
fully open.
5. Open the vent.
6. Start the pump.
7. Open the valves at inlet slowly.
8. When all air has been purged close the vent.
9. Repeat the above steps for the secondary side.

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2.3 Unit in operation
Adjustments of the flow rates should be made slowly
in order to protect the system against sudden and
extreme variation of temperature and pressure.
Problems in performance of the heat exchanger may
be caused by a change of some of temperature
conditions, the heat load or by fouling.
As long as the heat exchanger is operating
satisfactorily, no further action is required.
It is not necessary to monitor the unit continuously
while operating, but periodically check that
Media pressures are within the correct limits.
Media temperatures are within the correct limits.
No leakage appears due to faulty tightening of the
plate pack or to defective or damaged gaskets.
The bolts are kept clean and greased.
2.4 Shut-down
If the heat exchanger is going to be shut down –or for any reason at all the pump to be stopped - the following
procedure should be followed.

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1. First establish whether instructions exist as to
which side should be stopped first.
2. Slowly close the valve controlling the flow-rate of
the pump you are about to stop.
3. When the valve is closed, stop the pump.
4. Repeat the procedure for the other side.
5. If for any reason the heat exchanger is shut down
for a long periods (more than a number of days), it
should be drained, and depending on the media
processed, it is recommendable to flush and dry it.

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2.5 The risks of not complying with the start-up and shut-down procedures
A liquid in motion in a pipe system represents a lot of energy, and it must be very carefully dealt with.
When the liquid flow is stopped it is imperative that this is done smoothly.
Note! For this reason fast-closing valves should not be used unless the pipes of the system are very short.
Valves must be operated gradually. The longer the pipes and the higher the flow rate, the more important this
becomes.
Note! WATER HAMMER is the name given to short-lasting pressure peaks, travelling along the pipe as a wave at the
speed of sound, and resulting from a sudden deceleration of the motion of the liquid in a closed system.
Thus, it is usually related to shutting down of a system. However, when starting up a system with open valves and
empty pipes, the fluid may encounter an obstacle, like a fine-mesh strainer, a flow meter or heat exchanger, causing
a sudden reduction of flow velocity –if not a complete halt –, and so we may have the condition of a Water
Hammer.
In the worst case, the pressure surge caused by such a sudden stop of the motion of a fluid can be several times the
normal pressure of the system.
Therefore it is very important for the protection of the whole installation that start-ups and shut-downs are carried
out with great care.

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3. Opening and Closing
Warning! If the heat exchanger is hot, wait until it has
cooled down to about 40°C.
Drain the plate heat exchanger.
3.1 A Opening I30, I60 or I100
1. Disconnect the heat exchanger from the
piping system, and place it on timber beams
with its connections facing the floor.
2. Measure and note down the ‘A’ dimension.
3. Lubricate the bolt threads with a thin layer of
grease, e.g. Gleitmo 800 or equivalent.
4. Loosen then remove the two nuts of the end
bolts on the top and bottom of the heat
exchanger, and remove the two plastic end
tubes, then mark the plastic end tubes.
5. Loosen the tightening bolts alternatively and
diagonally in the sequence shown (1-6 for I30,
1-8 for I60 & I100, page 12).

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3.2 A Closing I30, I60 or I100
1. Check that all the sealing surfaces are clean.
2. Brush the threads of the bolts clean, using a steel
wire brush.
3. Attach gaskets to the plates or check that all the
gaskets are properly attached.
Note! If the gasket is wrongly positioned, it will show
by the fact that it rises out of the gasket groove or
that it is positioned outside of the groove.
4. Place the plastic tubes in the right order (marked
plastic end tubes are assembled last and mate
with front tubes). Lock with nuts.
5. Insert the plates with the herring bone pattern
positioned in alternate directions and with the
gaskets turned towards the frame plate.
Note! Check and make sure all the plates are in the
correct order and aligned.
Step
Bolt No.
To dimension
1
1-2 or 3-4
1.10A
2
1-6 (I30) or
1-8 (I60 & I100)
A
6. Place the pressure plate on the plate package.
7. Lubricate the bolt threads with a thin layer of
grease, e.g. Gleitmo 800 or equivalent.
8. Tighten the tightening bolts alternatively and
diagonally in the sequence shown (1-2-3-4) to
1.10A. Be careful so that the frame plate and the
pressure plate are always in parallel, check and
make sure the measurements between them at
positions of bolts are 1.10xA during tightening.
Note! Check again and make sure all the plates are
aligned.

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9. Dismantle the two plastic end tubes from end
bolts and lubricate the bolt threads with a thin
layer of grease, e.g. Gleitmo 800 or equivalent.
10. Tighten the tightening bolts alternatively and
diagonally in the sequence shown (1-6 for I30, 1-
8 for I60 & I100) to ‘A’ dimension.
Note! The dimension measured for ‘A’ should not be
smaller than the specified A.
Make sure all the plates are aligned after tightening.
11. Put the 2 end plastic tubes back through on the
end bolts and lock them.
12. If the plates are correctly assembled, the edges
form a “honeycomb”pattern shown in the
picture. If the plate pack has been marked on the
outside, check that the plates have been
assembled in the correct order.

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4. Maintenance and Cleaning
It is suggested to do routine maintenance and extraordinary maintenance for every heat exchanger, the
maintenance period depends on physical and chemical properties of the media and the heat load.
4.1 Routine maintenance
It is not necessary to open heat exchanger for routine maintenance, unless a reduction in performance is noted. If
this occurs please open the heat exchanger and check the surface of the heat transfer plates. If a leak occurs please
open the heat exchanger and check for gasket degradation or damage.
Alfa Laval can supply Cleaning-In-Place equipment to clean plate heat exchangers.
The Cleaning-In-Place (CIP) equipment permits cleaning of the plate heat exchanger without opening (see following
picture).
It is suggested to install additional valves to the piping system as shown in the following picture.
Cleaning-In Place equipment can clean fouling on plates.
Cleaning liquids:
ALFA CAUS; A strong alkaline liquid, for
removing biological deposits.
ALFA PHOS; For removal of inorganic scale.
ALFA CARBON; For removal of calcium
carbonate.
ALFA PASS; For rinsing and passivation
(inhibition of corrosion) after using ALFA
CARBON and ALFA PHOS.
ALFA NEUTRA; For neutralization of ALFA
CARBON and ALFAPHOS.

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4.2 Extraordinary maintenance
Extraordinary maintenance means to inspect all parts
of the heat exchanger completely.
Natural acid liquid should be used for extraordinary
maintenance, the volume of acid will depend on the
level of fouling.
1. Open the heat exchanger.
2. Remove gaskets from the plates.
3. Remove deposits using a soft brush and running
water.
.4. Rinse with water using a high pressure hose.
Incrustation –Scaling
Calcium carbonate
Calcium sulphate
Silicates
Sediment
Corrosion products
Metal oxides
Silt
Alumina
Diatomic organism and
their excrement of
various colors
Cleaning agent
Nitric acid
Sulfuric acid
Citrix acid
Phosphoric acid
Complex agents (EDTA, NTA)
Sodium polyphosphates
Concentration max 4% and temperature max 60 ℃for the cleaning agents.
Biological growth - Slime
Bacteria
Nematodes
Protozoa
Alkalescent cleaning agent
Sodium hydroxide
Sodium carbonate
Concentration max 4% and temperature max 80 ℃for the cleaning agents.
Note! Water of more than 330 ppm CI may not be used for the preparation of cleaning solutions.

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Follow steps below to clean oil residues, tar and fats:
1. Open the heat exchanger.
2. Remove gaskets from the plates.
3. Hydrocarbon based deposits may be removed by
using a soft brush and paraffin or naphtha based
solvent (e.g. kerosene).
4. Dry with a cloth or rinse with water.
Note! The following solutions should not be used:
Ketone (e.g. Acetone, Methylethylketone, Methylisobutylketone)
Esters ( e.g. Ethylacetate, Butylacetate )
Halogenated hydrocarbons (e.g. Chlorothene, Carbon tetrachloride, Freon)
Aromatics (e.g. Benzene, Toluene)