MoreBeer WC7035-MB User manual

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INSTRUCTION MANUAL
WC7035-MB WC7150-MB
Plate Heat Exchanger
A. Overview of the Plate Exchanger:
1. The Plate Heat Exchanger allows two kinds of uids with dierent temperatures to exchange heat indirectly or cool through the plate.
A plate exchanger has a number of advantages: ecient thermal exchange, high eciency, low heat loss, large exchange area, quick
assembly, easy and safe to operate, simple connections, and long service life.
2. Examples of Plate exchangers used in food & drink manufacturing:
• Beer Products: beer, wort
• Wine products: rice wine, wine, etc.
• Dairy products: milk, milk powder, milk beverages, yogurt, etc.
• Vegetable protein beverages: peanut milk, milk tea, soy milk, soy milk drinks, etc.
• Fruit drinks: fresh juice, juice tea, etc.
• Tea drinks: beverages of tea, aloes, fruit & vegetables, etc.
• Seasonings: soy sauce, rice vinegar, tomato juice, sweet and pungent sauces, etc.
3. Application to industrial liquids processing, including:
• Pharmaceutical production
• Dyeing
• HVAC thermal exchange
• Chemical industry
• Power stations, heating for swimming and bathing
• Petroleum
• Metallurgy
• Domestic hot water
Important Safety Information
Please read this entire instruction manual for important safety information before using your heat exchanger.
Failure to follow these warnings could result in serious injury or death.
General Precautions:
•Nuts not suciently torqued can cause the heat exchanger to leak.
•Follow all instructions and warnings provided with cleaning agents when cleaning and sanitizing.
•Pressurized cleaning chemicals can be an eye hazard. Wear goggles while cleaning.
•Do not exceed 3 BAR of pressure in any ow path, this can cause damage to your heat exchanger seals.
•Do not exceed 1.5 BAR of pressure between paths, this can cause damage to your heat exchanger seals.
Heat Hazards:
•Do not touch the heat exchangerduring operation. The surfaces may be hot and can cause severe burn damage to skin.
•The exit cooling water can scald. Ensure you have the heat exchanger exit plumbed safely so hot water does not come into contact with
the operator or bystanders.
•Wear rubber gloves and boots while operating toprevent scalding in the event of a loose connection.
Pressure Hazards:
•Double check all connectionsbefore starting the process.
•Contents of the heat exchanger may be under pressure. Conrmthat the pressure has been released before detaching any connections.
•Nuts not torqued suciently can cause the heat exchanger to leak.

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• Shipbuilding
• Machinery
• Paper-making
• Textile
• Geothermal utilization
• Environmental protection
• Refrigeration, etc.
4. The Plate exchanger transfers heat three to ve times more eciently than a tube-in-tube exchanger. The eciency of the heat ex-
change can reach above 90%. .
TIP: For brewery operations, expect to use one batch size of tap water and one batch size of chilled liquor in 30 minutes to cool one batch
when the pumps and heat exchanger are properly sized. (i.e.: A 10 bbl brewery would use 10 bbl of cooling water and 10 bbl of chilled
liquor to cool 10 bbl of wort).
B. Structure
1. This Heat Exchanger contains a double bracing frame which consists of the following components:
a. End Panels
b. Plates
c. Exchanger Seals
d. Top & Bottom Guides
e. Clamping Bolts
f. Process Connections For Fluids
C. Plates
1. The application will determine how many plates a heat exchanger should have. There are gaps between the plates to create ow paths
for the uids to move through. Seals on the plates allow the two dierent uids to go in separate directions while allowing the heat
exchange to occur.
Plates are cut and pressed from a sheet of stainless steel (SUS304) and have corrugated and chevron shapes, which are used for the
following:
• Larger areas of exchange.
• The pressed shapes increase the plates’ stiness, allowing the two uids to have dierent pressures.
• The waves speed up the ow, allowing less debris to accumulate.
• The shape allows for turbulent ow at lower velocities, increasing exchange eciency.
D. Seals
The seals inside the heat exchanger are removable. Seals
should be replaced if there are any signs of cracking. If the
heat exchanger does not seal before the plate’s contact, the
seals must be replaced otherwise, the plates may be damaged
during the tightening sequence. (Metal on-metal operation is to
be avoided.)
E. Operation
The plate exchanger consists of a series of parallel plates that are placed adjacent to each other to allow the formation of a series of chan-
nels for uids to ow between them. The exchanger is operated with the uids owing in opposite directions maximizing the dierence
in temperature between the uids and increasing exchange eciency.
The plates allow hot and cold uids through alternating channels in the exchanger so that a plate is always in contact on one side with hot
uid and the other with cold uid. During ow, heat exchange will occur through the plates in proportion to the temperature dierential
of the two uids.
See the ow chart on the next page as an example (only one stage is shown):

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Flow Chart of Plate Exchanger:
F. Installation
1. There are lifting eyes on the two clamping panels. Lifting ropes should NOT be attached to the connecting pipes, plate guides, or plates.
2. There should be 3 feet of clearance around the exchanger for maintenance.
G. Assembly
•Failure to follow proper assembly will result in poor performance of the heat exchanger.
•Nuts not torqued suciently can cause the heat exchanger to leak.
TIP: The connections for using the heat exchanger as a two-stage cooling system are labeled on the unit. The product ow is marked wort
in and wort out. The stage one path is marked water in and water out. The stage two path is marked as glycol in and glycol out. Proper
connection is required for proper cooling. This is not the only way the heat exchanger can be used. i.e., wort could be circulated from the
mash, and hot liquor could be circulated through the water pathway to use the heat exchanger to increase wort temperature.
1. Make the six connections that connect the heat exchanger to product, water, and chilled liquor.
2. An optional vent valve can be used at the exit to bleed air from the heat exchanger. It is important that no trapped air remains in the
heat exchanger during operation.
3. It is important to keep the passageways clean. Debris should be kept out of the heat exchanger to avoid blockage.
4. In some applications, you may need to include a lter at the entrance and exit to avoid particles or microbers in the media.
TIP: If there is no glycol available the stages can be connected in series.

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H. Preparation Before Use
•Nuts not suciently torqued can cause the heat exchanger to leak.
•Sanitizing with hot water is a safety hazard. Ensure hot water does not come into contact with the operator or bystanders.
•If sanitizing with chemicals, follow all of the chemical supplier instructions.
1. Check if the clamp nuts are at sucient torque to not leak at the intended pressure.
2. Perform a leak test with 1.25x of the intended operating pressure 30 minutes before using.
3. Rinse the exchanger with tap water for 20 minutes.
4. It is important to purge all air from the heat exchanger to maintain eciency. If needed, add a purging valve to the highest point of
the product path.
5. Sanitize with hot water (180—200°F), and then turn on the product pump to expel all the water in the exchanger until there is no water
left. (For beer wort production, the exit of the heat exchanger should be at 180°F for 30 seconds to be considered sanitized).
6. If the intended use requires the heat exchanger ows to be at dierent pressures (i.e. for use with steam), turn on the low-pressure
valve rst and then the high-pressure valve. When done, slowly shut o the high-pressure ow followed by the low-pressure ow
when stopping the exchanger. It should be noted that following this procedure will preserve the lifespan of this device by minimizing
the stress on the plates.
I. Cleaning After Each Use
1. Rinse thoroughly after each use. Cleaning after each batch is necessary because debris might accumulate on the plates during use. It
is unnecessary for the exchanger to be taken apart for cleaning after each use. Since internal debris can be expelled from the device
by running water in the opposite direction (back-ow) of the media with a hydraulic pressure lower than the operating pressure. In
addition, cleaners that are non-corrosive to the stainless steel can be used. (Non-chlorinated caustic followed by an acid rinse is com-
mon practice).
J. Maintenance
1. Disassembly of the heat exchanger will be required to clean all debris from the heat exchanger completely. This maintenance interval
needs to be specied based on the facility’s processes and should be performed at least every 100 batches in a brewery.
2. After disassembly, clean the surfaces of the plates with a nylon brush. It is very important to maintain the exact order and orientation
of the plates during disassembly and cleaning to maintain the proper function of the heat exchanger. Do not scratch the plates during
cleaning.
3. During assembly, the plates are pressed between the panels by torquing the bolts. It is essential to torque evenly in a cross pattern
to ensure the seals remain parallel and do not leak. Measure the distance between the panels in all four corners and make sure they
remain equal.
TIP: It is normal for this measurement to be slightly smaller each time the exchanger is reassembled until nally the plates are metal on
metal, and the seals require replacement.
4. Regular inspection of the assembly torque is required to prevent leaks.
5. To replace the seals:
1. Remove the old seal and any glue that is left on the plate. Ensure the plate is clean and dry.
2. Apply 3M 1099 glue (can be purchased online or a hardware store) to the back of the new seal and press it into the groove. Wait
72 hours for the glue to dry and then reassemble the device.
Troubleshooting
Before troubleshooting, it is important to know the basic operating parameters of your process. There are six temperatures and three ow
rates that are indicative of how the process is running:
• Product inlet temperature
• Product outlet temperature
• Product ow rate
• Cooling water inlet temperature
• Cooling water outlet temperature
• Cooling ow rate
• Chilled liquor inlet temperature
• Chilled outlet temperature
• Chilled liquor ow rate

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A change in any of these parameters can indicate a problem in your process. While measuring all of these parameters is not necessary
for normal operation, it is crucial for troubleshooting.
TIP: A typical ale cooling run will look something like this:
• Product inlet temperature: 180–212°F
• Product outlet temperature: 68–72°F
• Product ow rate: (depends on exchanger size, once measured it should remain consistent batch to batch)
• Cooling water inlet temperature 60–78°F
• Cooling water outlet temperature 160F–180°F
• Cooling ow rate: equal to product ow rate
• Chilled liquor inlet temperature 28–32°F
• Chilled outlet temperature: equal to product outlet temperature or slightly warmer
• Chilled liquor ow rate: as needed to set chilled liquor outlet temperature
Problem: Cause:
Product outlet temperature is too high
• Product ow rate is too high
• Cooling water inlet temperature is too high
• Cooling water inlet ow rate is too low
• Chilled liquor inlet temperature is too high
• Chilled liquor inlet ow rate is too low
• Heat Exchanger is contaminated with debris
Cooling water outlet is too low and the
product outlet temperature is too high Cooling water ow rate is too high
Chilled liquor outlet is too low and the
product outlet temperature is too high. Chilled liquor ow rate is too high
Chilled liquor temperature increases
during the run
• Insucient volume of chilled liquor in the process. The process will require the same
volume of chilled liquor as product.
• The returned chilled liquor is mixing with the tank. Return the chilled liquor with a tan-
gential port in a laminar ow to the top of the chilled liquor tank.
Operator Notes
Operation notes can document changes in the heat exchanger performance. Any performance loss can indicate a blockage in part of the
heat exchanger.
Items Unit Hot Side Stage One Stage Two Notes
Media
Temperature at the entrance F
Temperature at the exit F
Flow gph
Operating Pressure PSI
Pressure drop permitted PSI
Stage one Temperature F
Stage one ow rate gpm
Stage two temperature F
Stage two ow rate gpm