Vahterus Plate & Shell Fully Instruction manual

OPERATION &
MAINTENANCE MANUAL
ENGLISH
for Vahterus Plate & Shell Heat Exchangers

All rights reserved. It is not permitted to copy, photograph or publish in any other way this
manual for any purpose without the permission of Vahterus Oy. Plate & Shell is registered
trademarks of Vahterus Oy.
C303-3-rev.6 /16.4.2018

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1 GENERAL...................................................................................................... 5
1.1 INTRODUCTION ............................................................................................... 5
1.2 PRODUCTS ...................................................................................................... 5
1.3 STRUCTURE..................................................................................................... 6
1.4 TECHNICAL CHARASTERISTICS.................................................................... 6
2 ASSEMBLY OF THE HEAT EXCHANGER.............................................................. 7
2.1 LIFTING............................................................................................................. 7
2.2 PIPES................................................................................................................ 8
2.2.1 GENERAL............................................................................................. 8
2.2.2 STEAM APPLICATIONS (CONDENSER) ............................................. 9
2.3 INSULATION ................................................................................................... 10
2.4 PRESSURE TEST........................................................................................... 10
2.5 MOUNTING BRACKETS................................................................................. 10
3 PERMITTED CONDITIONS FOR OPERATING.................................................10
3.1 DESIGN........................................................................................................... 10
3.2 FLUIDS.............................................................................................................11
3.3 FLOW RATES.................................................................................................. 12
4 OPERATION ................................................................................................ 12
4.1 PRINCIPLE OF THE HEAT EXCHANGER...................................................... 12
4.1.1 LIQUID – LIQUID ................................................................................ 13
4.1.2 CONDENSER ..................................................................................... 14
4.1.3 DX-EVAPORATOR.............................................................................. 14
4.1.4 FLOODED EVAPORATOR.................................................................. 15
4.1.5 DROPLET SEPARATOR ..................................................................... 15
4.1.6 STEAM GENERATOR (KETTLE)........................................................ 16
4.1.7 EXHAUST GAS ECONOMICER (EGE) .............................................. 16
4.2 GENERAL START-UP ..................................................................................... 16
4.3 GENERAL SHUT DOWN ................................................................................ 17
4.4 START-UP AND SHUT DOWN OF STEAM APPLICATIONS .......................... 17
4.5 RECOMMENDED PERIODICAL INSPECTIONS OF PSHE
HEAT EXCHANGERS ..................................................................................... 20
5 CLEANING THE HEAT EXCHANGER......................................................... 20
5.1 GENERAL ....................................................................................................... 20
5.2 RECOMMENDATIONS FOR CLEANING........................................................ 21
5.2.1 BACKWARDS FLOW .......................................................................... 21
5.2.2 CHEMICAL CLEANING ...................................................................... 22
5.2.3 MECHANICAL CLEANING ................................................................. 23
5.2.4 ANALYZE AFTER CLEANING ............................................................ 23

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5.3 OPENABLE MODEL ....................................................................................... 23
5.3.1 PREPARATIONS................................................................................. 23
5.3.2 OPENING THE EXCHANGER AND REMOVING THE PLATE PACK. 24
5.3.3 MOUNTING THE PLATE PACK .......................................................... 25
5.3.4 BOLT/ NUT TIGHTENING PATTERN.................................................. 25
6 EXPANDABLE PLATE PACK ...................................................................... 26
7 SPARE PARTS / SPECIAL TOOLS ............................................................. 26
8 PACKING AND STORAGE .......................................................................... 26
9 TROUBLESHOOTING ................................................................................. 28
9.1 COMPLAINTS REPORT ................................................................................. 30
9.2 MEASURES FOR REPLACEMENT ................................................................ 30
9.3 INFORMATION ABOUT THE REPAIR ............................................................ 30
9.4 CRITERIA OF LIMITING CONDITIONS FOR THE EQUIPMENT................... 30
10 RECYCLING................................................................................................. 31

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1 GENERAL
1.1 INTRODUCTION
Operating instructions of the Vahterus Plate &Shell Heat Exchangers (PSHE) contain Technical
Data Sheet, Dimensional drawing and this Operation & Maintenance manual.
This manual is your general guide to the proper installation, operation and maintenance of the
Vahterus Plate and Shell Heat Exchanger and PSHE droplet separator. Please read it and fol-
low the instructions given. PSHE is a totally welded plate heat exchanger without any gaskets
between the plates. Vahterus accepts no liability for damage caused through the incorrect instal-
lation, operation or maintenance of the unit.
1.2 PRODUCTS
Plate & Shell Fully welded
Fully welded model – a welded pack of circular plates
inside a welded pressure vessel. The applications for
this type are liquid–liquid, condenser, evaporator and
cascade. This model cannot be opened. This heat ex-
changer can be single or multi pass. (See Chapter 4.1.:
Principle of heat exchanger)
Plate & Shell Openable
Openable model. Fully welded plate pack inside an open-
able shell. The plate pack can be taken out of the shell.
Plate & Shell Compact
All connections are on the end plate. Can be single or
multi pass.

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Plate & Shell Combined
Heat exchanger with combined droplet separator.
Plate & Shell VES
Heat exchanger with external dropled separator.
Plate & Shell EGE
Exhaust gas economizer.
1.3 STRUCTURE
Vahterus Plate and Shell Heat Exchangers are designed and manufactured in compliance with
legislation relating to pressure equipment.
The design code used is given on the Vahterus Technical Data sheet.The codes generally used are:
• ASME VIII Div.1, based on an individual design for each heat exchanger.
• Pressure Equipment Directive (CE): the design is based on PED classication and modules
e.g. type approvals by NoBo.
1.4 TECHNICAL CHARASTERISTICS
General range of parameters:
Volume: from 0.0002 m3to 5 m3.
Temperature: from -196°C to +600°C.

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Pressure:
• 10 / 16 / 25 / 40 / 60 bar(g) standard range
• up to 170 bar(g) on request
Materials:
• Carbon Steel (P235GH, P265GH, P355NL2, SA516Gr70, SA333 etc.)
• AISI 316/316L, 1.4404 / 304L, 1.4403
• Titanium Gr. 1
• Hastelloy (C22 & C276)
• Nickel 201
• SMO 254, EN 1.4547
• AISI 904, EN 1.4539
• Duplex, EN 1.4462
• other materials on request
Working mediums:
• Liquid of all groups
• Gas of all groups
• Steam (superheated & saturated) of all groups
• 2 phase mediums (i.e. liquid-gaseous mixture) of all groups
• Refrigerants group 1
• R170 (ethane)
• R1150 (ethylene)
• R290 (propane)
• R717 (ammonia)
• R1270 (propylene)
• Refrigerants group 2
• R134a
• R744 (CO2)
• R404a
• R410a
• R407F
• R507a
• all the other refrigerants from group 2
2 ASSEMBLY OF THE HEAT EXCHANGER
2.1 LIFTING
Plenty of space should be provided around the heat exchanger for mounting, insulation and
maintenance. With the openable model, there should be available space equal to the total length
at the front in order to remove the plate pack.
Ensure that there is adequate space above the heat exchanger in order to lift it freely.
The heat exchangers are provided with welded lifting lugs or lifting eye lugs. If lifting lugs are not
assembled, lift the heat exchanger with textile belt around the shell.

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

Lifting (eye) lug Lifting force
(direct lift)
1T (WELDED) 1,000 kg
3T (WELDED) 3,000 kg
5T (WELDED) 5,000 kg
7T (WELDED) 7,000 kg
M16 (DIN 582) 700 kg
M20 (DIN 582) 1,200 kg
!NB!
When heat exchangers are combined with droplet separators you should take account of
their considerable overall weight and lifting gear and used lifting lugs are in the range. It is
essential that the entire unit is supported by crane or hoist by the lifting lugs until it is bolted in
position.
If necessary the combination can have permanent extra support by the lifting lugs in the sur-
rounding support structures.
Do not use the mounting brackets or nozzles to lift the heat exchanger.
Vahterus will assist in planning of the liftings if needed, and separate lifting instructions are
available at Vahterus. Please contact Vahterus Service.
!WARNING
Do not weld anything to the heat exchanger (including the shell, end plates and the sides
of the pipes) without the manufacturer’s permission, since this could harm the durability of
pressure envelope and internal structures of the heat exchanger.
2.2 PIPES
2.2.1 GENERAL
Install the unit so that the piping and heat exchanger can be drained easily.
The heat exchanger is not normally provided with separate drain and ventilation connections. If
the client’s process requires these, they should be installed in the pipelines as close as possible

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to the heat exchanger, or, if they are being installed in the exchanger, they should be specied
separately when the exchanger is being ordered.
Check the following:
1. All piping to be xed to the exchanger is to be ushed prior to connecting the unit.
2. All connections are marked and should be connected according to the GA drawing.
3. The piping system must be exible so that thermal expansion does not overload the noz-
zles and so that heat exchanger is not subjected to vibration.
4. All pipe connections to and from the heat exchanger must be equipped with shut-off
valves. It is recommended to use valves with slow valve action. It should be possible to
increase ow rates gradually and reduce them gradually when the system is being shut
down or start up.
5. If there are solids in the process uids, the use of lters is recommended. Further informa-
tion is available from Vahterus Service.
6. The piping must be equipped with a relief valve to prevent unintentional excess of design
pressure.
7. If multiple units are being arranged in parallel, you should ensure that ow is evenly
distributed to the exchangers.
Openable model
Connections between the plate pack on the openable model and the pipes must be made either
with ange or threaded connections.
2.2.2 STEAM APPLICATIONS (CONDENSER)
The pipelines should be manufactured according to good steam ow manufacturing practices.
In steam applications the unit is placed horizontally to prevent condensate from remaining on the
surface of the plates.
It is recommended, where necessary, to install a steam trap (drain) in front of and behind the
heat exchanger and a droplet separator in front of it. The separators in front of the exchanger are
installed before the valve. These will prevent condensate from accumulating behind the valve.
When the water vapour is on the shell side, the heat exchanger is provided with a striker plate,
which is welded to the HOT IN connection to prevent water hammer. However, the customer
should also try other ways to prevent water hammer in the heat exchanger.
!WARNING
When the valve is closed, condensate might accumulate in the steam pipeline if no atten-
tion has been paid to drainage. When the valve is opened, accumulated water passes into
the heat exchanger at high speed, possibly resulting in mechanical damage.
!NB!
If the exchanger is operating in a partial vacuum or where the pressure on the steam side is
able in some cases to lower the pressure on the condensate side, the use of a condensate
pump should be considered.

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When a condensate side control is being used, the condensation temperature on the hot side
must not be any higher than the evaporating temperature on the cold side; e.g. if there is water on
the cold side, the pressure of the steam must be lower than the pressure of the water, to prevent
the water from boiling.
2.3 INSULATION
If the temperature on the shell side is below -10°C or above 65°C, insulation is recommended to
avoid burns or frostbite.
2.4 PRESSURE TEST
All PSHE units have been pressure-tested, as follows:
a) all plate packs – leak test (pneumatic pressure test under water)
b) whole unit – pressure test (hydraulic pressure test)
If you need to perform a pressure test prior to using the heat exchanger, the test pressure is
given on the Technical Data sheet and on the nameplate. The pressure shall increased slowly
to prevent pressure schocks. During manufacturing in certain cases the water as pressurizing
media is not acceptable for the media (refrigerant or oils) in the user`s process, the pressure test
is waived and made additional NDT to the welds.
!NB!
Pressure testing of the plate pack in the openable heat exchanger should always be carried
out with the plate pack positioned in the shell and the bolts on the cover plate tightened, in
accordance with the instructions in this manual.
When pneumatic leak or pressure testing is being carried out, ensure that conditions are safe,
given the possibility that there could be a pressure discharge similar to an explosion should the
heat exchanger or testing equipment get broken.
Never apply pressure to the plate pack outside the shell.
2.5 MOUNTING BRACKETS
Vahterus standard brackets are only designed to bear the weight of the heat exchanger. The
design does not allow for specic requirements, such as stress and strain caused by the piping,
wind load or earthquakes.
3 PERMITTED CONDITIONS FOR OPERATING
3.1 DESIGN
The design pressures and temperatures are marked on the nameplate and Technical Data sheet.
Never exceed the design pressures or temperatures. Ambient temperatures may not be higher/
lower than the design temperature range.