DRAWING

FINAL

S276 PLATE COOLER

'.
 PLAN HI STORY

NO. DATE REV. MARK DESCRIPTION DRAWN CH ECKED APP ROVED

"L >

CONTENTS

TITLE DWG. NO.

• l.
2.
27500M
337.68M
2

2
CENTRAL F.W COOLER
MAIN L.O COOLER
DHPHE-F2068001
DHPHE-F2068002
2
3. O.59M SI T L.O COOLER DHPHE- F2068003

•
H. S. H. l.
Elliee CUSTOMER:

HEAD OFFICE & FACTORY PROJECT NAME S271 / 2/ 6

1575-6, SONGJEONG-DONG, GANGSEO-GU,
BUSAN , KOREA
MAIN PHONE : (051l 970-1070
FAX : 051 970-1071 CLASS : DNV APPROVED : ~
'\ SEOUL OFFICE
HAN SHIN CORE OFFICE, SUITE 1516
11-9, SH IN CHEON-DONG, SONGPA-KU,
SEOUL, KOREA
DATE: 06.03.10 CHECKED
d
PHONE : (02l 421-4707 REV . MARK : DRAWN: S. ROY
FAX : 02 421-4708
( TEL. 970 - 1021 )

\
 DongHwa Enfec
SPECIFICATION FOR DONGHWA ENTEC PLATE HEAT EXCHANGER

Customer : H .S. H .I Hull No. : S27 1/2/6

Item Central F. W cooler Q'ty / Ship· 2 Sets
Phe-type : S100-2 77-TMTL-39 Date: 10- Mar-06

Description Hot Side Cold Side

Media FW S. W

Flowrate : m3/h 380 .00 430 .00

Inlet temperature: 'C 54.32 32.00
Ou tlet tem perature : 'C 36.00 48.79
Press ure drop : kg /cm 2 0 .58 1 0 .900
Velocities at port : m /s 2.990 3.38 4
Velocities at channel : m /s 0.496 0 .56 1
Heat exchanged: kcal/ h 6,951 , 100

• THERMODYNAMIC PROPERTIES :
Speci fic gravity : kg / dm3 1.000 1 .02 5
Specific heat: kcal / kg* 'C 1 .000 0 .940
Thermal conduc tivity: kcallm * h * 'C 0 .54 0 .54
Mean viscosity: CP 0 .6 1 0 .66
Wall viscosi ty: cp 0.66 0 .6 1
Port -hole size: mm 212 2 12
Inlet branch : Code F2 F4
Outlet branch : Code F3 F1

DESIGN OF FRAME/PLATES :
ReI. directions of fluids: Cou nter fl ow
Plate arrangem ent (passes*channel) : 1 * 138 1 * 138
Total num ber o f plates : 277
• Effecti ve / Max. plates: 275 / 329
l.M .T.D. / TR 'C 4.72 / 3.88
Effective heat surface: m2 275.00
Overall K- value (Design cond itions) : kcal / h*m2* 'C 5347
Overall K- value (Clean conditions) : kcal / h*m2*'C 6 150
Plat e m ateria l /Thickness: TITANIUM / 0 .5mm
Material of gasket : Nitrile
Max . working temperature : 'C 70.00
Operating pressu re kg /cm2 2.5 2.7
Test pressu re kg /cm2 4 .2 4.5
Frame type: Industrial/ Marine
Connections ho t side: J IS 5K-200A
Con nections cold side: JIS 5K-200A
Liquid volume in phe : dm3 328 .44 328.44
Frame length : mm 1759 .0
Net weigh t / Full weight o f phe : kg 2036 / 2692.9
Surface margin: % 15.02
1575-6 Songjeong-Dono. Gangseo- Gu. Busan 618-270, Korea
Telephone +82519701083 Telefax : +8 2 519701031
 HEAD COVER

Fl

FOLLOW COVER

S.W. ~1l[
r.w.S1O£
ALTERNATIVE LOCATION OF CONNEcrIONS

"

J95
770

1 1lSTAl«l(IIOOnvn)

1725
2.H2J lOO
fIXED f()(fS 2-2Jxll
S1.IIlNG f()(fS
o
277 '-+------1
+f- _--= +--+-cc-l
lOBI ::::;

' ~
<> f---'C--t-::=:-=:::-----+--';;;~___t277 ,____t'!:"----_1

5! I I, lJJ.1.9-
~

1NS1All.ATlON PI.\N

• THE HEAT EXCHANGER MUST BE INSTALLED WITH

CLEARANCE ON ONE SIDE - MIN. 800mm.

SAVE IWM: : F206IIOO1

 PAGE I / I
- SPARE PARTS & TOOLS LIST USED FOR S271/2/6
-~ -~
BOX NO.
SUPPLY
DRAWING
(per ship)
NO. NAME SKETCH MATERIAL REMARK
PART
WORK SPARE NO. NO.

I SPANNER g;c >

S45C 2
DHPHE-
F206800H

M36/NV55

•
--
I

• -~-

MFR'S NAME
DDlIgHwa Eliiec
SAVE NAME : SPANNER
 DongHwa Enfec
SPECIFICATION FOR DONGHWA ENTEC PLATE HEAT EXCHANGER

Customer: H .S.H.I Hull No . : S271/2/6

Item Ma in L.O coole r Q'ty / Ship: 1 Set
Phe-type : S121-270- TKTM- 78 Date: 1 5-Sep-05

Description H ot Side Cold Side

Media L.O FW

Flowrate : m3/h 400 .00 202.00

Inlet tem perature : "C 53.07 36.00
Outlet temperature: "C 45 .00 42 .48
Pressure drop: kg/cm2 0 .600 0 .056
Velocities at port : m/s 1.382 0 .698
Veloci ties at channel : m /s 0 .293 0 . 147
Heat exchanged: kcal/ h 1,307, 200

• THERMODYNAMIC PROPERTIES :
Specific gravity : kg / dm3 0 .900 1.000
Specific heat : kcal/kg- "C 0 .450 1 .000
Thermal conductivi ty: kcal/ m-h*"C 0.11 0 .54
Mean viscosi ty : cp 55.55 0 .67
Wall viscosity: cp 96.50 0 .57
Port - hole size: mm 320 320
Inl et branch: Code F1 F3
Outlet branch : Code F4 F2

DESIGN OF FRAME/ PLATES:

Rei . directions of fluids : Count er flo w
Plate arr ang em ent (passes-channel) : 1 - 13 4 1 * 135

• To tal number of plates :

Eff ective I Max . plates:
L M.T .D. I TR
Ef fective heat surface:
Overal l K-value (Design conditions) :
"C
m2
kcal/ h*m 2* "C
270
268
9 .77
337 .68
396
I
I
3 19
0.83

Overall K- value (C lean condition s) : kcal/ h *m2*"C 456

Plate material I Thickness: SUS304 10.5mm
Materi al o f gasket: Nitrile
Max. working tem perature : "C 70
Operating pressure kg /c m 2 4.4 1.7
Test pressure kg /c m2 7 .3 2.9
Fram e type: Indu strial / Mari ne
Connections hot side: JIS 5K-300A
Connections cold side: JI S 5K-300A
Liquid volum e in phe : dm3 629 .80 634 .50
Frame length : mm 2 179.0
Net weight / Full weight of phe : kg 4180 / 544 4 .3
Su rf ace margin: % 15. 15

1575-6 Sonojeong-Dong, Gangseo-Gu, Busan 6 18-270, Korea

Telephone +8251 970 1083 Telefax : +82 519701031
 HEAD COVER

FOLLOW COVER

F4 LO. SI)(
LW. ~!)[

ALTERNATIVE LOCAnON OF CONNECT10NS

217'l

2170

212-' 23 ; 10
A') I J. ~I([I) 1O.fS UH

+-+------ PART NAIl[

II
I, I, >171/2/6
"-----t-l+lr
IIIIN LO. C()(l£R

• THE HEAT EXCHANGER MUST BE INSTALLED WTTH

INSTAI1.inON PLAN
CLEARANCE ON ONE SIDE· MIN. 800mm.
 DongHwa Enfec
SPECIFICATION FOR DONGHWA ENTEC PLATE HEAT EXCHANGER

Customer: H .S. H.I. Hull No . : S27 1/2/6

Item SIT L.O cooler Q 'ty / Ship: 1 Se t
Phe-type: S4- 16-TL- 100 Date : 15-Sep-05

Description Hot Side Cold Side

Media L.O F.W

Flowrat e : m3 / h 100 5.00

Inlet tem perature : t 49 .94 36.00
Outlet tem perature : ·c 45.00 36. 40
Pressu re drop: kg /cm 2 0 .176 0 .600
Velocities at port : m /s 0 .345 1 . 727
Velociti es at channel: m /s 0 . 157 0 .686
Heat exchanged : kcal /h 2,000

• THERMO DYNAMIC PROPERTIES :

Specific gravity: kg / dm3 0 .900 1 .000
Specific heat : kcal / kg* ·C 0 .450 1.000
Therm al con ductivity: kcal / m*h*t 0 . 11 0 .54
Mean viscosity: cp 60 .51 0.71
Wall viscosity: cp 114 . 17 0 .59
Port - ho le size: mm 32 32
Inlet branch: Code F1 F3
Ou tlet branch : Code F4 F2

DESIGN OF FRAME/PLATES:
Rei. directions o f Iluids : Counter fl ow
Plate arrangement (passes*channel) : 1 * 7 1 * 8

• Total num ber of plates :

Effective / Max. plates:
L.M.T.D. / TR
Effective heat surface:
Overall K-value (Design condi tions) :
t
m2
kcal/h * m 2 * ·c
16
14
11 . 12
0 .59
306
/
/
40
0 .44

Overall K-value (Clean condi tions) : kcal/h*m2* t 352

Plate material / Thickness: SUS316 / 0 .5 mm
Material of gasket : Nitrile
Max. working temperature : t 65
Operating pressure kg /cm2 3 .0 2.4
Test press ure kg/cm2 5.0 4 .0
Frame type: Industrial / Ma rine
Connec tio ns hot side : JIS 5K-25A
Connec tions cold side: JIS 5K-25A
Liquid vol ume in phe : dm3 1 . 19 1 .36
Fram e length : mm 350.0
Net weight / Full weight o f phe : kg 21 / 23 .6
Surface margin : % 15 .03

1575-6 Soncieong-Oonc, Gangseo-Gu. Busan 618-270. Korea

Telephone +825 1 9701083 Telefax : +82 51 9701031
 HEAD COVER

Fl

FOLLOWCOVER

F4 F3~-_1/ = LO. so:

- r.W. SI)[

ALTERNATIVE LOCATION OF CONNECTIONS

11 "\
; } J

IISlRUWM BOSS
150 1NS1Al1.\TlON PIJ.N
IJ(H; HW.I Slm.Y
• THE HEAT EXCHANGER MUST BE INSTALLED WITH
CLEARANCE ON ONE SIDE· MIN. SOOmm.

SAl[ H/jj[ : f206iOOl

 INSTRUCTION MANUAL

PLATE COOLER

•
,

•
DongHwrB Enfec
1575-6, SONG JEONG- DONG, KANGSEA-KU, BUSAN, KOREA

TEL: + 82-(0) 51- 970-1114 FAX: + 82- (0)51- 970 - 1131

Web Site: www.dh.co.kr

 INSTRUCTION DATA
DongHwa Enfec FOR REV . NO . : 0
OPERATION & MAINTENANCE PAGE : 2 Of43

CONTENTS

PAGE NO

I. FOREWORD & INTRODUCTION 4

2. PRINCIPLE OF PLATE HEAT EXCHANGER 5

3. MAIN COMPONENTS AND THEIR FUNCTIONS 6

• (i)

(ii)
PLATES
CORNER HOLES OF PLATES
- PLATE STYLE
- CHANGING OF PLATES
GASKETS
7
8
9- 11
12
12- 13
- TYPES OF GASKETS 14
- GLUEfNG , IS

4. FUNCTION OF PLATE HEAT EXCHANGER IS

SCHEMA TIC DIAGRAM , 15- 16

ARRANGEMENT OF PLATES & GASKETS 16- 17
NAMEPLATE 18- 19
HEA T TRANSFER 19

•
PRESSURE DROP 20

5. INSTALLATION OF PLATE HEAT EXCHANGER 21

SPACE REQUIREMENTS 21
PlPE INSTALLATION 21 - 22
- TRANSPORT,LlFTING & STORAGE 22- 23

6. COMMISIONING & OPERATION 23

- COMMISIONING & PRE-CHECKS 23

PROCEDURE FOR START-UP 24
- PROCEDURE DURING OPERATION 25
SHUT -DOWNffROUBLE 26- 28
RlSK FACTORS 28

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DongHwa En'iec FOR REV.i'() . : 0
OPERATION & MAINTENANCE PAGE : 3 OF 43

7. OPENING or PLATE HEAT EXCHANGER 28

OPENING PROCEDURE 28- 30

CLOSING OF PLATE PACKAGE 30- 3 1

8. MAINTENANCE 32

CHLORIN E AS GROWTH INHIBITOR 32

CLEANING 32- 36

• 9. ASSEMBLING OF PH E

TIGHTENING OF PLATE PACKAGE

REPLACEMENT OF PLATES & GASKETS
36

37
38- 39

10. FAULT DET ECTION AND REMEDIES 39-42

I!. REBUILDING AND SPARE PARTS 42

"
- ORDERING PROCEDURE 42
- SPARE PARTS 42
,
12. NS NETWORK 43

IJongHlI'a En tee REV 0

)
I
 INSTRUCTION DATA
DongHwa Enfec FOR REV .NO. D
OPERATION & MAINTENANCE PAGE 4 OF 43

1. FOREWORD & INTRODUCTION

FOREWORD

This manual o f instructio n is a guide [or install ati on, operati on, maintenance fo r
new DONG H WA ENTEC pl ate heat exchange r. It is meant fo r those w ho are
responsible [or the install ation, use and maintenance of the heat exchangers. We
recommend you to read this manual carefull y befo re co mmencing any work .

• lNTRODUCTION

TIllS manual is applicabl e to all heat exchangers produced by DongHwa Entcc.

We are not responsibl e fo r any damage du e to incorrect installation , use or
maintenance o [ our heat exchangers as well as not co mpl ying with our instructio n
manu al.
,
Please note that our pl ate heat exchangers are speciall y designed and bu ilt fo r
the operating condi tions (Pressure, temperature, capac it y, type of fluid etc.) provided
by the customer. Sudden pressure peaks beyond the no rma l operating pressure, which
can occur during starting up or stopping o f the system can severely damage tile heat
exchanger and should be prevented . Wc are not respo ns ible [o r any damage as a result
of any operation dev iating from the ori ginal des ign conditions.

• If you would like to contact DONGlfW A ENTEC about any pl ate heat
exchanger, then pl ease re[er to the pl ate type, seri al and draw in g number as menti oned
in the name plate of our item.

PLATE HEAT EXC HANGER TYPE: _ _ _ _ _ _ _ __ _

SERIAL NUMBER : _ _ _ _ _ _ __ _ _ __ _ __

DRAWIN G NUMB ER: _ __ __ __ _ _ _ __

fungflwa Entec REV 0

 INSTRUCTION DATA
DongHwa Enfec FOR REV.NO. 0
OPERATION & MAINTENANCE PAGE 5 OP 43

2. PRINCIPLE OF THE PLATE HEAT EXHCHANGER

A plate heat exchanger consists of a frame , which co nsists o f a head cover,

follower cover, support pill ar, carrying bar, guiding bar, and a number of ti ghtening
bo lt. In between head and followcr cover, a numb er of plates are pressed together.

Heat is transferred from one medium to ano ther medium tlu·ough alternate metal
plates, which have been pressed into a speci al pattern. The ho t and cold fluid s alternate
between each of the plates. Because each of the plates has a large surface area, the

• plates provide each o f the fluid s with an extreme ly large heat transfer area. So, it is
capable of trans ferrin g much more heat due to high heat trans fer e ffi ciency o f the plates .

Each plate is supplied with an elastomeric gasket, so that the plates fo rm a

closed system o f parallel 110w channel s, throu gh which the medias 110w alternately at
every second interval. Each plate is equipped with a d o uble sealing system that keeps
the l1uids between the channels. The gaskets are glued o n to the pl ates, whi~1 secure
ti ghtness between fluid s and the atmosphere . There shouldn ' t be any mixin g between
two fluid s. Every second plate has to be turned 180 degrees so th at the plates form a
closed system of flow charmels, through which the fluids 110w altematively. The bead s
include connections to permit the entry of the process l1uid into the pl ate pack. l'he
channel formed by two adjacent plates is the key to the heat exchanger efficiency. Units
are c ustom selected to effectively optimize the available pressure drop. Pl ate heat
exchangers are well suited for applications, which require close temperature approaches .

IJongHwa Entec REV o

 INSTRUCTION DATA
DongHwa Enfec FOR REY.I'() . : 0
OPERATION & MAINTENANCE PAGE: : 60F43

3. MAIN COMPONENTS AND THEIR FUNCTIONS

Upper b.r Colunu1

• FoIlowec

Pial. pockag •

•
Fig: 1 Exploded view of a plate heat exchanger

fung/lwa Entec REV 0

 INSTRUCTION DATA
DongHwa Enfec FO R REV.NO. D
OPERATION & MAINTENANCE PAGE 7 01' 43

The above figure shows the exploded view of the plate heat exchanger. The different
P3lts of the heat exchanger is mentioned by numbers, which are as follow s.

\. HEAD
2. UPPER BAR
3. LOWER BAR
4. PLATE PACKAGE
5. COLUMN
6. FOLLOWER
7. TIGHTEN BOLT S (TIE BOLTS)

• Other components of the plate heat exchanger are plates, gaskets, nameplate, hot
and cold inlct/outlet connections, air vent valve, drain va lve, pressure gauge,
thennometer, and roller. Sometimes filters are also connected with system.
The two bars are suspended between the frame plates. The plates hang from a
canying bar and are kept in line by a guiding bar at the lower cnd. COrUlection holes
penn it the fluid to enter into the heat exchanger. With the package of plates hanging, a ,
number of tightening bolts are used to press the thin plates together, to bring them into
metallic contact and to pressure the gaskets, enough to seal off the narrow passages
which have now been formed between the plates.
Heat is transferred through the surface, which is contained by the gasket , except
for some small areas near the corners. The number of plates of the heat exchanger is
detemlined by the size of the heat transfer surface required for the system .

• DESCRIPTION OF MAIN COMPONENETS OF PLATE

REA T EXCHANGER

1. PLATES
Each plate is made from "pressable" materials such as stain less steel, titanium
and is fornled with a series of corrugation. The corrugated plates are ductile enough for
pressing. The plate package consists of plates with a groove along the rim of the plate
and around the port. The number of plates as well as size and dimension depends on the

IJongHwa Entec REV 0

 INSTRUCTION DATA
DongHwa En'iec FOR REV.~. 0
OPERATION & MAINTENANCE PAGE 8 Of 43

requi red thenna l output. Depending on the thenna l appli cati on, stain less steel or
ti tanium pl ates are sel ected . The heat transfer pl ates separate the two process fluid s; the
chalUlel is the space establ ished by two hea t trans fer pl ates, through which process
flui ds are distributed and heat transfer is carried out. T he channel fornl ed b y two
adjacent pl ates is the key to the pl ate heat exchanger's hi gh e ffi c iency. T he fluid shear
stresses arc also higher in case o f plate heat exchangers, wltich always tend to keep the
channels much eleaner.

- T he co rner holes of the plates -

Depending on the required liquid fl ow in the pl ate heat exchanger the 4 corner

• holes have to be opened. The corner holes named with numbers staning le ft side on the
top of the plate (to be seen from the gasket side) as no. 1 a fter that continues no .2, 3 and
4 clockwise. The corner hol es arc opened as yo u see on the diagram drawin gs,
describin g the liquid flow in the plate heat exchanger. (FIG 3.) The op enings of the
corner holes are described in a code. For instance: 1234 means that all th e corner holes
arc opened. Code 0204 means that hole 2 and ho le 4 are open, and the ho les 1 and 3 are
closed.
The DO NGH WA plates are designed so they can be used both as right and as
left plates. The plates just have to be turned 1800.

2 2

• L R

FIG: 2

lJong/fwa En t ec REV o
 INSTRUCTION DATA
DongHwa Enfec FOR REV .NO. 0
OPERATION & MAINTENANCE PAGE 9 OF 43

Right and left plates :

On a ri ght plate the fl ow runs fro m hol e 2 to hole 3 or reverse from ho le 3 to

hole 2. On a left plate the fl ow runs from ho le 1 to hole 4 or reverse from hole 4 to
hol e I. (FIG 2)
PLA1E HCAl EXCHANGER 0AGRAM

;L TS -!L TS f" TS 13 TS TS

I I
• nI
I
I
F1 -1> I I

, I I
F2 ~ ,
L lA :A
I
A A
,: I , I
, re
I
f-3 -1>

F4 ~- ~ ~ ¥ Iv '¥

• 1234 1234 1234 1234

FIG: 3
1234 1214 1234 1234 1234 0000

Plate Style:

DongHwa uses two types of plates. Low theta plate (Ts Type) and high theta
plate (TL type). The high theta plate lets the media "stay longer" on the plate by having
a bigger angle in the herringbone. Furthermore a high theta will normally have smaller
pressing depth than the low theta . This creates more turbulence and thereby more heat
transfer. So in case of TL type plate, velocity is more. So, heat dissipation and
efficiency is also more in this case. Fig. 4 shows the TL and Ts type of plates.

fungflwa En t ec REV 0
 INSTRUCTION DATA
DongHwa Enfec FOR REV .NO . D
OPERATION & MAINTENANCE PAGE to 01' 43

,
,

• ,
,

,
,
,
,
,
,

TS TL
FIG: 4

• The arrangement of plates depends on the total no of plates, plate style and
surface area of the system. So the arrangement of plates is very much important, which
depends on quantity of Ts and TL types of plates. Differentiating a heat transfer plate
from a channel is extremely important and fundamental to the analysis of plate heat
exchanger.

From the below figure we can observe that on a plate hanging verticall y, the
gasket rests in a groove that includes the heat transfer area. The arrow marks on the \eft
and right side indicates the two corners of left side and right side respectively. After
that we can name the plates, which has mentioned in below figure (F IG : 5- 7)

fungHwa Entec REV 0

 INSTRUCTION DATA
DongHwa En'iec FOR REV ./{) . 0
OPERATION & MAINTENANCE PAGE : 11 OF 43

• FIG: 5

•
FIG: 6
In above figure, if we name the left plate as A plate and right plate as B plate,
tben next figure shows that by turning the A plate upside down, we can get B plate.

Dong/lwa En tee REV 0

 INSTRUCTION DATA
DongHwa En'iec FOR REV.NO. D
OPERATION & MAINTENANCE PAGE 12 01' 43

A B

•
FIG: 7

Changing of plates
Changing and mounting of plates can be done after disconnection and removal of
the assembling bolts. Before mounting of spare parts, please check if the new plates arc
completely identical with the old plates to be changed. For removal of plates the condition

•
is such that the plates should be removed two by two so that the plate stack after reduction
is still mounted by turning right and left plates. The plates to be removed should have all
four comers opened. It is also necessary to correct the minimum tightening measure after
a possible reduction.
The reduction of number of plates means that the transmission area of the plate
heat exchanger is reduced corresponding to the plates being removed. A removal of
plates may cause a rise in pressure drop over the plate heat exchanger.

2. GASKETS
Each heat transfer plate is fitted with gasket. The groove along the rim of the plate
and around the ports hold a gasket, usually made up of a rubber type material. The gaskets
are used partly to seal and partly to distribute the process fluids . The main purpose of
gasket is to prevent intermixing of the media and leakage to the outside. An elastomer

IJongHwa En tee REV 0

 INSTRUCTION DATA
DongHwa En'iec FOR REV.fO. 0
OPERATION & MAINTENANCE PAGE 13 OF 43

gasket is included in each plate, which contains the pressure and control the flow of each
medium. The gasketed plates are assemhled in a pack, mounted on upper and lower guide
bars and compressed between two elld frames by compression bolts. Gasket material is
chosen to withstalld the operating temperature at hand and the properties of the process in g
fluid. Heat is trans fen·ed through the surrounding, which is contained by the gasket,
except for small areas near the corner. Any leakage of fluid across either gasket escapes
from the heat exchanger tlu·ough the slots. It is impol1ant that these openings are not
pennitted to plug. If that should happen, then there is a risk of leakage. In that region of
the plate, there might be a local pressure builds up, which cou ld make one medium leak

•
over and mix with the other. Care should be taken not to cut or scratch the gaskets while
handling plates .

FIG: 8

IbngHlI'a En t ec REV 0
 INSTRUCTION DATA
DongHwa En'iec FOR REV.NO. D
OPERATION & MAINTENANCE PAGE 14 OF 43

• ~
FIG: 9

TYPES OF GASKETS

- New gasket -
On the enclosed diagram an order list for the gaskets is shown. The first plate
after the head and intermediate frames is to be mounted with a gasket grooves. These
gaskets are cut out of ordinary gaskets. Therefore please note the cutting out of the old

•
gaskets before removing them .

- Glue less or glued gaskets -

Some plate heat exchangers are delivered with glue less (snap type) gaskets. In
these units it is possible to change the gaskets without using glue. However, the gasket
on the first plate after the head and intemlediate frame should be glued on as shown in
FIG 4.

- Glue type-

PLlOBOND 25 / SCOTCHGRIP 847 are nitrile rubber glues on soluble basis

(25% solid materials). The glues are partly thermoplastic so that old gaskets can be
unsticked by boiling-water heating.

fung/{wa Entec REV 0

 INSTRUCTION DATA
DongHwa Enrec FOR REV. NO. D
OPERATION & MAINTENANCE PAGE 15 OF 43

- Detergent -

For cleanin g and degreasing new gaskets and gasket grooves use (ACETONE).
It is very important that every detergent is evaporated be fore pUllin g glue on.

- Glueing-
After wiping gaskets and gasket grooves with a cloth moistened w ith degreas ing
substance the glu ein g itself can begin . The glueing areas must be quite cl ean and free
from any dust and fin gerprints. The gaskets are covered by a brush with a thin coat o f

• glue on the glueing area and are placed on a clean and d ry place to dry. The glucin g
starts in the plate ends and continues along the straight ed ges.
When the glucin g is fini shed, the pl ates are hung into the fra mes again and the
plate heat exchanger is c lamped together. T he pl ate heat exchanger can be warm ed up
by hot water if the glue is to dry quickl y- but w ithout pressure o n the w ater. If there is
not an y possibility to heat the pl ate heat exchanger it must stand as wannl y as possibl e
and in order to let off gluc vapor from the pl atc heat exchanger the conditions are to be
ulUnountcd.

NOTICE: Solvents are danoerous to inhale

• 4. FUNCTION OF THE PLATE HEAT EXCHANGER

- Schematic Flow Diagram -

The diagram (FIG: 10) shows the plate heat exchanger. It shows the pl ate
compos ition and the liqu id fl ow in the pl ate stack. When the plates are pressed together,
the holes at the corners fonn continuous channels, leading the fluid fro m the inlets into
the plate package, where they are distributed into the narrow passages between the
pl ates. There are two arrow marks, A & B . The bold A arrow m arks show right pl ates
and B arrow marks show left plates. During the passage through the system, the hot

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fluid will give some o f its heat energy to the thin wall , whi ch instantl y looses it aga in to
the cold fluid on the other sid e. Th e hot fluid loses its temperature and the cold fluid is
hea ted up same time. Fin all y, the fluid s are led into simil ar hol e-tunnel s at the other end
o f the plates and di scharged from the heat exchanger. After cl amping of the plate pac k,
the pl ates, which are fitted with gaskets-ensure an effecti ve seal between fluid s and
atmosphere. In addition , intennixing of the fluid s is eliminated by a doubl e gasket sea l
around the inlet p0l1S. Every second plate in th e stack has to be turned 180 · , so that th e
plates fonn a closed system of parallel flow channel s, throu gh which the medias flow
alternately at every second interval.

• A

•
FIG: 10

ARRANGEMENT OF PLATES & GASKET

In order to fonn a passage of fluid flow between plates and proper heat transfer,
the plates should be properly arranged. The main point of consideration for plate
arrangement is that the two adjacent plates should make a honeycomb structure
everywhere. The plates should be arranged upwards and downwards alternatively for
making this honeycomb structure.

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A B c D

FIG: II

• Rather than TL (thennal long) & TS (thennal short) Plate styles, the fi gure above (FIG:
11) shows four different pl ate types.

A: start pl ate with gas ket.

B: Left hand fl ow pl ate w ith gas ket.
C: Right hand fl ow pl ate w ith gasket.
0 : End plate with gasket.

A pl ate, whieh has four holes through whieh the fluid fl ows into the nozzle, is always
pl aced next to the head cover. The fluid cannot fl ow through the defl ecto r as all gaskets
are clogged. After assembling A plate, 2 nd pl ate should be B or C pl ate depend s on the
fl ow directions o f the hot and co ld fluid s .

• In case o f B plate, fluid fl ows through the left side. So, left side connecti ons are opened
and ri ght side connections are closed.
In case of C plate, fluid onl y flows through the right sid e. So, only ri ght sid e
connecti ons are opened a nd left side connections are closed.

III case of 0 plate, whic h is pl aced at the end, all left and right side ho les are closed.
Thi s means all four connections are closed.

The 2 nd plate can be upward s or downwards, which depends on the fluid fl ow directions
of the heat exchan ger. But after assembling the 2nd plates, the B & C plates are arranged
in upwards and downwards directions alternatively up to the end to fornl the
honeycomb structure. There is 11 0 chance o f mi xing o f fluid s due to thi s kind of

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arrangement of fluid s. The fluid flows tlu·ough left side cormection always passes in left
side and fluid flows through right side connection always flows through right side.

The main point of consideration for assembling plates is that the plates should
be placed upwards and downwards alternatively throughout the heat exchanger for
making the honeycomb structure everywhere. Due to this kind of arrangement, it can
handle a large quantity of fluid and pressure loss
is also very small.

• NAMEPLATE

------~ On the head a nameplate is mounted .

r:--3 DONGHWA ENTEC The concerned plate is stamped with
importan t information about the plate
heat exchanger. The nameplate
indicates the serial no, operating
5[rM( NO I b I ll'
1+01 SO( COlO 90C
presslfluid quantity, weight, ti ghtening
rLUII) OU~I<TITY ~ .... /~ , ~ Id' /tv measure, class and plate type. The
oP(ft',TINC PR[ss.c:::::::E:::::: liAR I I : J StJI
fN/OUTL£T T(MP. c=L::J 'c ~ ·c
figure below (FIG: J 2) shows the name
plate for our pl ate exchanger.

• --
.)-_ ..... _-- ..
------.--
......... _--
---
"1 ... _
....... ---~-
---~--­
.... _ .. _ _ _ _
-.. For Example,
PLATE TYPE: S121-232
TillS means S 121 is the plate type and
232 is total no. of plates

FIG: 12

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NOTICE:
1 . The Plate heat exchanger must not be a sse mhled under the stated
minimum a ssembling measure. Please contact Dongllwa Entec
distribntor if it is leaking when tighte ned to the minimum
measurement.
2 . The starting up must be done without shocks and against closed
valves .

• HEAT TRANSFER

The pUlpose of the system is to transfer heat from o ne medium to another

medium and heat passed very easi ly through the thin wa ll separati ng the two fluid s
from each other. For sensi ble heat transfer, the duty can be expressed by:

Q = (w x Cp x DT) HS ... --- -------------------- (I)

Q = (w x Cp x DT) cs -------------------------- (2)
Q = U xAx LMTD ------------------ (3)

Effecti ve heat transfer area in a pl ate heat exchanger is calculated by

•
multipl ying the total number of plates in the exchanger minus two, by th e effective area
per plate.

A = (No. Of plates - 2) x area per plate ----------------------- (4)

Two plates are subtracted from the total number of plates for detennining the
area because the first and last plates have fluid only o n one side. So, they are
noneffective in transferring heat.

Corrugated plates, when pl aced in an exchanger, fonn a three-dimensional fl ow

path with a nominal gap twiee the pressing depth of the pl ate.

The high heat fl ow through the walls can be reduced by the fonnation of
deposits of various kinds on the wall surfaces. Consequentl y a layer of deposits can
severely reduce the overall heat transfer rate.

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Thermal length (0) is a dimensionless number that allows the designer to re late
the pcrfom1allce characteristics of channel geometry to those of a duty requirement.

The thennal length of a charlllel describes the abi lity of the charulel to a ffect a
temperatu re change based o n the log mean temperature diff<:rence (LMTD).

El = Temp . Change I LMTD

= (T in - T out) I LMTD
The thennal length of a chalUlel is a fun ction o f the charulel di ameter, plate
length and the angle of the conugations, along with the ph ysical propenies of the

• process fluids and available pressure drop .

For any chosen channel geometry, the thenn allength required by the dut y can-
(I)
(11)
Match the characteli sti cs of the channel.
Excced what is achievable by the channel at th e allowable pressure drop .
(lfl) l3 e less than that achievabl e by the channel at the allowable pressure drop .

To have the most eco nomica l and efficient exchanger, it is criti ca l to choose, for
each fluid , a channel geometry that matches the theml al length requirement of each
fluid .

PRESSURE DROP

• Pressure drops are wasted energy. All equipments includ ed offer resistance to
fluid fl owin g through them. Some pressure drop is unavo idab le, but fo r a given
apparatus it should be kept as close as poss ible to the designed value.

The fonnation of depos its on the heat transfer sUlfaces instantly leads to a
reduction of the free space between the plates. This means that more energy is needed
to get the desired flow tlu'ough the apparatus.

A reduced ability by the heat exchanger to hold the desired temperatures, in

co mbination with an increased pressure drop on any of the media, indicates that fouling
or clogging is taki ng place. So proper maintenance and cl eaning should be carried out.

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5. INSTALLATION OF THE PLATE HEAT EXCHANGER

For Installation of a plate heat exchanger, two things are very important to consider.
Space requirements .
Pipe installations.

- SPACE REQUIREMENTS

•
7.
/ ' .~

/:
()
, .
/. ".-'.

FIG: 13
The plate heat exchanger requires enough space with regard to opening for
inspection or servicing (renewal of pl ates, tightening of package etc.) without any

• problem. It is necessary for thc plates and the assembling bolts to have so mueh space
that they can be mounted and dismounted without problems. (FIG 13) The follow
cover has to be pulled back to the column before opening for serv ice can be done
without problems.

- PIPE INST ALLA nON

Before installing any piping to the heat exchanger, make sure that all foreign
objects have been rinsed out of the system. During pipe installation to system, there
should not be any stress or strain imposed by the pipe system, on to the heat exchanger.
To make

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the plate heat exchanger yield the spec ifi ed duty the pipe install ation has to be mounted
according to our drawin g. By co nstruction of the pipe insta ll ati on it must be co ns idered
th at the rubber liners in th e head of the pl ate heat exchanger can be removed . The pipe
co nnection always has to be mounted in a way, preventing the plate heat exchanger
fro m being overloaded . The pipe connecti on mus t be so fl ex ibl e that an extra ti ghtening
o f the plate heat exchanger can be made.

We reconunend you to fo llow the steps as below for pip ing connect ions.

- Heavy pipe wo rk loads to be suppOlled . T his w ill prevent heavy forces onto the
heat exchanger.

• Always install fl exible connections onto the fo llow cover to prcvent vibrations .
These fl exibl e connecti ons also prevent ex pans io n o f th e pipe work, causcd b y
temperature influence onto the heat exchanger.
- These fl ex ibl e co nnections need to be lifted in a longitudinal directio n to the pl ate
package.
- The pipe work need s to be thoroughl y cl eaned and flu s hed be fore corUlecting up to
the heat exchanger.
- Make sure that the pipe work, cormected to the heat exchanger is secured against
any pressure leaks and tempcrature shocks.
- Always install vents on the top of the heat exchanger fo r p ro per venting.
,

Transport, Lifting & Storage

•
For sa fe transpoltation, it is desirable to transport item , va lve or pipe w ithout
assemblin g. install shackl e on the fixed frame and movin g frame and hoo k ba r on the
shackle before transportati on with crane. Please keep in mind not to lift the itcm by
using the connections or studs around them .

& NOTICE:
To prevent personal injury always use appropriate hoisting equipment.
If you have to lift the heat exchanger, straps should be used. They shou ld
be places as like shown in above figure (FIG: 14)

In case of storage o f the unit for a longer peri od , certain precautions should be
taken in order to prevent unnecessary d amage to the equipment.

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• FIG: 14

It is preferable to store the heat exchanger inside room with temperature around
15 to 20 C and humidity of max .70%. If thi s is not poss ible, then place the heat
exchanger in a wooden case which is provided with a lining on the inside against
" penetration of moisture.

There should not be any ozone producing equipment in the room, like electric
, motors or arc-welding equipment as ozone destroys many rubber materials. Also don ' t
store organic so lvents or acids in the room and avoid heat or ultraviolet radiation.

• 6. COMMISIONING AND OPERATION

COMMISIONrNG AND PRE-CHECKS

Conunissioning should only be done by staffs, which has been trained speciall y
for the job. Control, maintenance and repair of the installation should be done by
authorized, trained and properly trained staff.
Maintenance and cleaning should always be done with a shut down heat exchanger.
Check if all connections are correctly fitted or not. The media flowing through
the heat exchanger should not contain any bigger particles and if necessary, filters
should be fitted . Check the pressure and temperatures of the media and make sure that
the values are not more than the spccified value on the identification plate.

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6.1 PROCEDURE FOR START-UP

Before starting up for first time o r after a long run shut down of system, make
sllrc that thc platc pack is compressed to the ri ght measurement.
It is very important that the system , to which the heat exchanger is connected, is
protccted against sudden and extreme variations of temperature and pressure to avoid
any damages. It also applies to piping system and all equ ipmcnts.

Before thc initial start-up,

Check that the operating data does not exceed that given on the heat exchanger's

• namcplate .
Check that all tightening bolts are properly ti ghtened.

6.1.1 rumps

Before starting any pump, check if th ere is any instructions for any pump to be
stal1ed first. Pumps feeding the hea t exchanger must be provided with regulating va lves.
If the pumps can deliver a higher pressure than the rated pressure for the heat
, cxchanger, sa fety valves must be installed . The pumps must not suck in air.

6.1.2 Start-up

•
To avoid pressure shock the pumps must be started against c loscd va lves. The
valves in the inlet and outlet should be opened at same time as far as poss ible. The (low
rate is then increased slowly until operating temperature is reached . Hammering must
bc avoided; otherwise the rubber gaskets may be displaced and leakage rcsult. Check
that the exit valve is fully opened during starting condition. Then, opcn the vent, start
the pump, opcn the valve slowly.

6.1.3 Venting
Immediately after start-up the equipment must be vented. Remaining ai r can
cause air locks and serious scorchi ng of the plates, reducing the heat transfer capacity
and increasing the risk of corrosion.

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6.2 PROCEDURE DURJNG OPERATION

During opera ti on, temperatures and pressure drops must be regularly checked.
Increased pressure drop and/or falling temperatures indi cate that there arc coatings o n
the pl ates. The plate heat exc hanger now needs cleaning. During operation, the same
precautions against ri ses of pressure must be observed as during start-up . The foll owin g
points must be observed for running.

Working prcssurc

• On the head of the plate heat exchanger a nameplate is mounted . The maximum
working pressure is stated and it must not be exceeded.

P"cssurc pulsation and vibrations

, No pressure pulsations and vibrations mu st be trans fen'ed from positive pumps

or equipment like that. If these are transferred to the plate heat exchanger fatigue
fracture in the plates can arise.

,- Longcr working pauscs

A plate heat exchanger, which is out of work for a longer period, ought to be
emptied and cleaned . After emptying and cleaning the plate heat exchanger is ti ghtened

•
gently and covered with black plasti c to pre-vent the gaskets from being damaged by
dayli ght. Before the plate heat exchanger is put to work again it mu st be tightened
according to minimum measure.

For operation,

Starl cold nuid first than the hot nuid.

The operation steps should be as follows.

Fully vent the system.
- Close isolati on valves between pump and exchanger.
- Fully open valve fitted into return line from the heat exchanger.
Start the circulation pump.

Gradually open closed valve fitted to inlet line of exchanger.

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- Vent system once again if necessary.

The above steps should be repea ted for secondary fluid .

CHECK FOR PROPER OPERATION

C heck the pressurc pul scs in the system caused by pumps or cont ro l valvcs. If
found , stop operation and rectify. Continuous pressure pul ses will result in fati gue
failure o f the pl atcs.
Vi suall y check the unit for leakages.

•
Check that all vents are closed to prevent air being sucked into thc system .

& NOT I CE: When in operation, the conditions should not be

changed. The max. conditions specified on thc identification name
" plate should not be exceeded.

6.3 SHUT-DOWN I TROUBLE

• 4.3.1 Shut-down for a short-period

If the plate heat exchanger has to be shut down for a short period, please fo llow
the following procedure.

Slowl y close the control valve in the ho t circuit while maintainin g the full
fl ow in the cold circuit.
Switch o ff the hot circuit pump.
Cool down the heat exchanger to the level of cold medium .
Slowly close the contro l valve in the cold circuit.
Switch off the cold circuit pump.
Close all remaining isolating valves.

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6.3.2 Shut-down for a long-period

If the unit is to be taken off for an extended peri od of time, the please foll ows
the following procedures as below.
A lIow the unit to coo l down.
Drain all circuits.
Lubricate ti ghtening bolts.
Loosen the bolts until the plate pack is relaxed .
The bolts should not be removed or loosened to such an extent that dil1 is
not allowed to enter in between the plates.

• Cover the plate pack with bac k plastic to exclude any sunlight

6.3.3 External Leakage

Maybe the plate heat exchanger is running with a higher working pressure than
mentioned on the nameplate. Ln that case the pressure has to be controlled and if
too high it has to be reduced u1U11edi ately to what is written on the nameplate.
- Tigh)en the plate heat exchanger to the minimum measure, which is mentioned on
the nam epl ate . It goes without sayi ng that the plate heat exchanger has to be
pressureless before ti ghtening.
The plate " cat exchanger is separated for inspection. Check that the plates are
without sca lin g and undefom1ed .

Check the gaskets. They have to be elastic, undefom1ed and to have a clean

•
surface. All gaskets and plates are cleaned carefully - even a grain of sand on the
gasket surface can cause a leak. A plate stack, assembling to a mmimum measure
after cleaning, has to be tight. If a leakage is still present the gaskets normally have to
be changed. If there is a leakage through the drain holes of the gaskets the reason can
be a defective gasket ill the drained zone or a corroded plate in the drained zone.

6.3.4 Inside Leakage

!fthe liquid is mixed it is due to holes ill one or more plates. The leaks can only
be repaired by changing the defective plates. A suspected leakage can be located in onc
of the following ways:

Remove a pipe on one of the bottom pipe eormeetions - then put the opposite side
under pressure. After the pressure is stabilized the liquid must not run off from the

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removed pipe co nnection. If the liquid continues to run off thcrc is a leak on one
or more plates. The plate stack is demounted and eve,y s inglc plate is cxamined
carefully.

The plate heat exchanger is separated and all the plates are dried. After drying the
plates are put into the plate heat exchanger and assembled. Now the liquid is
circulated with full capacity but only on one si de (cvery second plate interval).
The other half of the plate interval is kept without pressure and without liquid.
The circulation is stopped aftcr a few minutes and the platc heat exchanger is
opened carefully so that no water is sprayed on the dry platc side. The plates are

•
examined carefully and thus it is possible to find the wet areas on the d,y plates .
The areas have to be controlled with capillary liquid.

- The plate heat exchanger is separated and all plates are contro ll ed with the
capilla,y liquid.

6.3.5 RlSK F,",CTORS DURING START-UP AND SHUT- DOWN

A liquid in mot ion in a pipe system represents a lot of energy. So, it shou ld be
handled very carefull y.
The stopping of fluid should be managed smoothly.
Fast closing valves should not be used unless the pipes of the system are very
short.

• Valves must be opcratcd gradually. If thc pipe is longer and fl ow rate is higher,
then its importance will bc much more.

7. OPENING OF PLATE HEAT EXCHANGER

OPENING PROCEDURE
Before opening the plate heat exchanger, it must be cooled below 35 'C, and it
must not be pressurized . I f the plate heat exchanger is opened at a temperature higher
than 35 "C, the gaskets can get loose from the plates.
The steps involved for opening are as follows:

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(I) Remove pipe connection from heat exchanger.

(2) Remove protected cover from ti ghtening bolt.
(3) Open the ti ghtening bolt from the frame as a rule in the heat exchanger.
(4) Move the follower cover for disassembling the plate from frame .
(5) Open ing of pl ate package

a. Slowly closc the valves on the inl ets.

b. Switch off pumps and c lose the va lves o n both outlets.
c. If system is hot, th en wait till temp . will be cooled down to min . 40 QC.
d. Drain and di smantle any pipe bends connected to the pressure plate so that

•
it can be moved freely along the canying bar.
e. Check sliding surface of carryi ng bar and pressure plate cooler.
f. C lean the threads of the tightenin g bolts and lubri cate wit h grease.
g. Mark the no . of plates in sequence.
h. Loose and remove the bolts, whi ch are no t fitted w ith bearing boxes. Open
the pair of bo lts that are fitted with bearin g boxes altcmati vely and
diagonally. ,

NOTICE:
I. Ensure that unit n.
pressurized and drained of hot and aggressive
product before unit is opened to prevent personal injury.
2. Edges should be sbarp. \Vhen handling plates, gloves s hould be
worn . You have to disassemble tbe plate eooler after drain at

• hot/cold side .

00 00 00 00

00
X
00
2
00
FIG: 15

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00 1
00

• 00 00 00 00

FIG: 16
...
The above two fi gures (F IG 15 & 16) show the sequ ence of opening of bolt
structure for plate package.

,
CLOSING OF PLATE PACKAGE

Thc steps involved for closing of the plate package are mentioned as follows.

• (i) Check that all sealing surfaces (surfaces in contact with heat transfer
medium) should be free from any kind of dusts .
(ii) Check that all gaskets are in good and correct condition.
(iii) Clean and lubricate the sliding surfaces of the carrying bar.
(iv) Inspect the pressure plate cooler.
(v) The plates should be hanged in proper order.
(vi) Press the plate assembly together and it should form a honeycomb structure.
(vii) Place the bolts that are fitted with bearing boxes in position.
(viii) Clean and lubricate the threads with a thin layer of grease.
(ix) Tightening of the bolts should be carried out alternately and diagonally.
(x) Check the position of the bolts during tightening.

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00 3
00

X
E
2

00 00 00 0
• FIG: 17

00 00 00

• 00 00 00 00

FIG: 18

The above two figures (F IG 17 & 18) show the sequence of closing of bolt
structure for plate Package.

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DATA
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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J

8. MAINTENANCE

C HLORINE AS GROWTH INlIlBlTOR

Chl orine, commonl y used as growt h inhibitor in coo ling water systems, red uces
the corros ion resistance of stainless steels. Chlorin e weakens the protecti on layer of
these steels making them more susceptible to corros io n attacks. It is a matter o f tim e
exposure and concentration. But titanium is not affected by chlorine.

• CLEANING

All marine systems, where sea water is used are ex posed to fo uling. Fouling may
occur in ports and at the plate 's entry regio n. It can increase th e pressure drop and
reduce the low rate resulting in insufficient heallrans fer. So cleaning is very much
necessary to remove these fouling. Foulings on the plates ca n be removed manua ll y or
by C II' (cleaning in place). "

The cleaning of the pl ate heat exchanger depends on the capacity as we ll as

the cOlTosion resistance of the system. ,
This cleaning section consists o f four parts.
- Manual cleaning.
- CIP cleaning.

•
- Cleaning material s .
- Control of cleaning.

MANUAL CLEANING
The pl ate heat exchanger is separated and the plates are pulled from each other.
Use a soft and a qualified cleaning material for cleaning the pl ates. If the cover thick,
from scale or organic material the plates are put in a vat with a qualified cleaning
material. Neither the plates nor the gaskets can bear heavy-handed / robust treatm ents.

CLEANING OF PLATES
Use nylon or other types o f soft scrubbing brushes with detergent.
Use acetone or other types of solvents which do not contain chlorine to remove
old gasket glue. Alternatively use and LP gas flame heating the reverse side of the

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plate.
Do not use any other type of gas which may produce a harder name. Boiling water
can be used with some success.
- Consu lt a cleaning spec iali st for a suitablc choice of detergent. Ensure that a ll
detergents used are compatible with th e plate and gasket materia l before use.
In case the plates are removed for chemical cl eaning, make sure they arc re-fitted
in the same order.
Always remove plates one by one and number them properly.
A high pressure cleaner can be used with absolute care and never add abrasives.
- If the cover is thick from scale or organic material the plates can be put in a balTe l

•
with qualified cleaning material.

Before cleaning chemical cl ea ned plates, they need to be thorou ghly rinsed
with fresh water.

Important:

"
Cleaning is an imponant pan, innu encing the effectiveness of the plat e heat
exchanger. Insuffic ient cleaning can have the followin g results.
too low circulation now.
Insuffici ent thelmal output. ,
Life time of the heat exchanger will be shonened .

If a plate has to be renewed because of serious damage, one should make sure

• that the plates next to this plate arc also being replaced .

NOTICE:
1. Never use metal brush , steel wool or sand/glass paper or as like
this type. A high pressure cleaner can be used witb care.
2. Never add with any sand or otber abrasives.
3. Alwavs use eloves and eve 20eeles when usin !! detereents.

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•
FIG: 19

CIP C LEANING

CIP = C lea ning in Place, which means cleaning of the exchanger, without
reasse mbly. Please note' that even thongh CIP clea ning is performed frequently, it
will not make periodic inspections unnecessary.
A circulation system, in wh ich a suitable detergen t can be circu lated, is
estab li shed. If the product to be flu shed out has a high viscos ity, the circu lati ng quantity

• must be big enough to reach a sufficient speed for llushing out the product. If the
products pump for the detergent parallel to the fonner, it is assumed that the fouling on
the plates are so luble in a detergent, which does not attack plates and gaskets.

Examples of CIP cleaning:

Product rests and cooling/heatin g liquids are drawn off.

Rinse with cold or tepid water.
Warm cleaning flui d c ircu lates.
Rinse with cold or tep id water.
Rinse with cold or tepid water.

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Cleaning materials
A qualified cleanin g materi al is one, whi ch can remove the scaling on thc plates
without damaging the pl ates and gaskets. Sta inl ess steel has a passivated (protecting)
fi lm. Thi s film mu st not be destroyed, as the film assists in preserv ing the resistance of
the stai nl ess steel.

We advise you to ask for a confirmation from the supplier of the cleaning
detergent that it will not damage the materials of the heat exchanger.

If the solution requires recirculation, select a fl o w that is as high as possibl e and

• certainl y no less than the service or product flows .

Follow the instructions carefull y as given by the detergent supplier/cleaning speciali st.
We recommend that for recircul ated c leaning detergent methods, th e fluid should be
pumped throu gh the exchanger for no less than 30minutes.

Rinsing: •
A fter usin g any type o f cleaning age nt , always rinse thoroughl y with fres h water.
If cleanin g in pl ace, thcn rec irculatc fresh water fo r at least 10 minutes.

' . Detergents
Some Cleanmg
Oil and grease is removed with a water cmuls ifying oil solvent i.e. BP systcm
cl eaner.

• Organic and grcase cover is removed w ith sodium hydrox ide (NaOH)
max imum concentration 1.5% max. temp.85 ·C .
Concentration = 5.00 Itr. 30% NaOH per 100 Itr. water.

Stone and limestone is removed with nitric acid (HN0 1) -

max co nccntration 1.5% - max . temp . 65 ·C .
Mixtu re o f 1.5% concentration = 2.4ltr. 62% (HNO J ) per 100 Itr. o f water.
N iuic ac id also has an effective build up err,.:.;t on the p assivation film o f stainl ess steel.

Control of Cleaning
Cleaning is an important part, influencing on the effecti veness of the pl ate heat
exchanger. Therefore the plate heat exchanger has to be separated for inspection and

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OPERATION & MAINTENANCE PAGE 36 OF 4J

especially in the cOlrumsslonll1g period. You will obtain important expenence

concerning circulation times, temperatures, and chemi cal concentrations.
- too short cleaning period.
too low chemical consumption compared to the sca ling of the plates.
too long rurUling intervals between the c1eanings.
If the plate heat exchanger is out of operation for a long time, it is advisable to
empty it, separate the plates, and clean the unit. Clamp the plate heat exchanger lightly
together and leave it covered in order to protect the gaskets against dirt and effect of
light.

• 9. ASSEMBLING OF PLATE HEAT EXC HANGER

I) Check that the surface of the gasket is clean before tightening.

2) Press the plate and pressure p late to the frame plate, then mount the two bolts (used
in disassembly).
3) Tighten them keeping parallel the pressure plate and the frame plate as in
di sasseinb ly. The tightening size should be that given on the nameplate attached to
the frame plate. Measure the size at least in four pos itions.
4) When the opposed two bolts are tightened almost securely, tighten the remaining
bolts. '

•
RIGHT PATTERN WRONG PATTERN
(HONEYCOMB)

FIG : 20

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OPERATION & MAINTENANCE PAGE 37 Of 43

The above figu re (F IG: 20) shows the pate s ide view honeycomb structure of the p lates.

TIGHTENING OF THE PLATE PACKAGE

•
,
FIG: 21

Lightly oil the ti ghten ing bolt th reads. Don ' t a ll ow oi l or grease onto the gaskets or
the gasket seating faces on the back o f the pl ates. Wet or contaminated plates can

• misa ligned during ti ghtening. In thi s case, di smantle, cl ean and dry all areas in
contact with gaskets.
Ensure clamping is unifonn for keeping the frames and pl ates parall el thro ughout
the operation. Avo id skewing the frame plates by more than 5 mm.
T ightening is complete when the di stance between the inside faces o f both frame
pl ates equals the "A " distance as shown in above fi gure (F IG: 2 1). The ti ghtenin g
di stanee can be calcul ated by as fo llows.
Assembly distance = No . o f pl ates * dim ensionin g fac tor (Max. - Min .)
Dimensioning factor (Max. - Min.) vari es depend ing on the pl ate types.
Finall y check that all bo lts are in tension and e lean any split oi l off the frame pl ates.
On compl etion, the unit can be pressure tested at the mentioned value in the name
pl ate.

If the dim ension "A" is not reached with appli cati on o f max imum ti ghtenin g
torque,
Check the number of plates and d imension "A" in datasheet.

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Check th at all the nuts and beari ng boxes are running free ly. If not, clean and
lubri cate or replace.

If the unit does not full y sea l, it may be ti ghtened step by step to give dim ension
"A" min . The max imum ti ghtening torq ue must not be exceeded.

Under no circumstances, distance "A" should not be smaller than " A"
min. Tightening of the plate package can only be done with a fully
depressurized unit .

• REPLACEMENT OF PLATE AND GASKET

REMOVAL OF PLATE

I) Damaged pl ates ca n be easily repl aced by the sam e spare pl ates. ,

2) T he damaged plate and the adj acent pl ate, two in sum (onl y the pl ate with· four
holes) may be sa fely removed without repl acement. Howeve r the performance of
the un it is slightl y lowered.
For removal of p lates, pu sh the pressure pl ate agai nst the support co lumn and the'"
Remove pl ates.

* Note that the ti ghtening size in this case is shortened by two pl ates.

•
But for inseltion o f pl ates, hang the plates w ith their backs towards the pressure
pl ate (the side wi thout gasket).

REPLACEMENT OF GASKET (GLUE TYPE)

( I) Remove the old gasket from the plate, and then wipe the gasket groove with a e lean
cloth moistened w ith a so lvent (meth yl eth yl ketone, toluene, xylene,
trichloroethylene etc.)
If it is hard to be removed , remove it wanning the rear side w ith a gas burner or po ur
a solvent into the gasket groove and leave it for whil e.

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NOTE: Do not use a gas burner and solvent at the same time. Use a
propane burner or a driver (IOOOW). Do not use an acetylene burne r .

(2) Apply a thin layer of cement with a brush over the rough s ide of the gasket and
the gasket groove of the plate.
(3) Allow the cement to dry for three to five minutes, and when it does not fee l
st icky when touched with [mgers, app ly the face to the gasket groove .
(4) Apply the gasket co ntrolling the length not to elongate it too much.
(5) When all are applied, pile up only A-plate (or B-plate) and press them from above

• (6)
(with a weight), and leave them a half to one day .
Dry them fully and install to the frame .

& NOTICE
Avoid such places where ventilation is poor or nea r fire in cementing
gaskets.
,

REPLACEMENT OF GASKET (NON-GLUE TYPE)

• SONDEX-LOCK is a non-glu e gasket designed as a conventional gasket. It is

designed with a special clip-on feature, which locks it to recess in the gasket groove on
the plate.

10. FAULT DETECTION AND REMEDIES

A condition for proper functioning of the plate heat exchanger is strict

compliance with the permissible values for pressure and temperature
mentioned 011 the name plate. Exceeding these values, even as short-
lasting pressure peaks will cause damage to the unit and be the cause of
problems.

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Problem Possible Cause Possible Solution

Leakage At the co nnections - Check the rubber liners (if fitted)
- Check th e flange packing ( if fitted)
- Check the O-ring on the first plate.
- Fit the pipes tension-free.

Mixing of primary and - Check the plates for hol e and/or

secondary circuit cracks.
In plate package - Check the assembly tightening
distance.

• The operating conditions

- Check the condition of the packings .
- Check the proper posi tion of the
packings.

- Adjust the operating conditions

deviate from the specifi cation properly_
•
-
Insuffic ient Air in the System - De-aerate the pipe system
Capacity - Chcck the pipe work for possible air
traps. ,
The operating conditions - Adjust the operating conditions
deviate from the spec ifi cation properly.

•
The heat exchanger is dirty - Clean the heat exchanger

The connections have been - Redo the fitting work

interchanged
Too high Flow larger than the design - Adjust the flow perfectly
pressure flow
drop Channels in plale(s) blocked - Flush/C lean properly.

Inco rrect measurement - Check the pressure indicator for

correct measurement

Medium deviating from the - Addition of for instance anti-freezc

design will increase the pressure drop

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OPERATION & MAINTENANCE PAGE 41 OF 43

Too high Air in the system - De-aerate the pipe system .

pressure - Check the pipe work for possible air
drop traps.

for nearl y all leakage problems, it will be necessary to di smantl e the unit before
any attempts to rectify the problem. Mark the leakage area(s) with a marker or simil ar
before taking apart the exchanger.

"Cold leakage" is caused by a sudd en change in temperature. The sea ling

properties of certain elastomers are temporarily reduced when the temperature changes
suddenly. No action is required as the gaskets should re-seal after the temperature has

• been stabilized .

Gasket failllres gellerally occllr as a reslllt offo lio wings:

• Old age.
• Excess ive exposure to ozone.
• High operating temperature above the temp. limit of the material.
• Ex posure to pressure gauges.
• Chemica l attack.
• Phys ical damage, resulting from poor assembly practi ce or mi salignment of
pl ates (check the hang in g system at top of the pl ate for distortion).

Decrease ill performallce is generally a reslllt of:

• •
•
•
•
•
Plate surfaces require cleaning or dc-scaling.
Pumps or associated controls have failed.
Plate chalU1els blocked.
Liquid fl ows not as per design specifi cation.
Associated cruller/cooling towerlboi ler under sized.
• Cooling water temperature to the exchanger is hi gher than the design.
• Heating media temperature to the exchanger is lower than the design.
• Steam fl ow not sufficient - control valve mal functi on.
• Steam trop broken or jammed - unit becomes filled with condensa te.
• Pl ate package has been assembled incorrectl y.
• Unit is running in co-current flow , instead of counter current - c heck with
drawing and alter pipe work if necessary. Check direction of pump flows.
• Air lock has developed in the plate package or pipe work.

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OPERATION & MAINTENANCE PAGE 42 OF 43

11. REBUILDING AND SPARE PARTS

ORDERING PROCEDURE

The plate heat exchanger is module built up and there fore fl exible as regards
enlargements or reduction i.e. it is easy to change the capacity by respectively enlarging
or reduc ing the number of plates.
DONGHW A files contain all data of delivered plate heat exchangers. We
gladly fOlWard suggestions/quotations concerning rebuild of an existing plate heat

•
exchanger. DONGHW A only has to know the manufacture number stamped on the
nameplate and the modifications you want. DONGHWA then delivers with the
necessary parts for rebuild a complete description of the way in which the plate heat
exchanger is rebuilt. AftelWards the rebuilt plate heat exchanger data will be put into
DONGHWA file s to keep them up-to-data .

SPARE PARTS
The type designation of the plate heat exchanger and th e manufacture number
(is one the nam e plate which is placed on the head cover) ought to be mentioned by
ordering spare parts. TillS is to prevent fault delivery. '
By ordering plates it is important to mention the right pattern code and if it is right
or left pl ates, pl ease refer the plates of our manual.
By ordering a complete set of gaskets and the glue for these and the cleaning fluid ,

•
it is enough to mention the manufacture number or the number of the drawing .
For ordering single gaskets, it is important to mention the correct quality. The
quality appears from the diagram and the color marks on the gasket.
For ordering assembling bolts, it is necessary to measure the old assembling bolts
to secure delivery o f the right size of bolts.

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