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LYHEOG woNvLaaDov | SONSaS TS ‘WALNVAO dO 44AL sv ‘SOR SMEALIVEVHO ‘ ININOWOD 1s “Ta WAN aa 9H 24a Taans ARV owe vert Uerr aaVod/ad/ad ON S3VMANOD va cwauisAsans = @vava vox | z. Nanya Nowavoy eziccosorr “ON dO | _LVAH ALVA? WALL coreany nay! a “TWASVAVE VHS IHSRLLVW MW OLTXZ ? LOAPOWd NV 1d ALITWn0 ONRIALOVANNVI SYN SMU NLOVANNVf GEA ECOFLEX India Pvt Ltd ] GEAM (431-22, chakan m.0.c., Phase-ty, Village - Nighoje, Tal - Khed, Pune - 410 501 OST) T PROCEDURE. PROGEDURE NO._| GEA/HT/001 Rev.0. DATED | 30/06/2011 (Doc. No. PE.V5-344-179-NO0S Revi0 PAGE Bof 10 1] SCOPE & PURPOSE This fests carried out for two purposes. To test the integrity of pressure retaining parts To test for leakage. Primary and Secondary sides of all Plate Heat Exchangers shall be subjected to hydrostatic test, It shall be taken care that pressure chambers of combination unit heat exchangers that have been designed to operate independently shall be hydrostaticaly tested as separate Plate Heat Exchanger; that is; each chamber shall be tested without pressure in the adjacent chamber. The test pressure shall be 1.5 times of the design pressure. 2 | REFERENCE STANDARD “Test Pressure shall be as per Approved Data Sheet / Approved Drawing ‘Approved MOP 3 SETUP t Hydrostatic test should be cari oit attemp >16 deg\C but need not to exceed 64 degC ‘The test pressure shall not be applied until the Plate Neat Exchanger and its contents are at ‘about the same temperature. Vents shal be provided at ali high points ofthe Plate Heat Exchanger in the position in which it isto be tested to purge possible ar pockets while the Plate Heal Exchanger is fled with water. Before applying pressure the test equipment shal be examined to see that itis tight and that all low pressure filing lines and other apparatuses that should be subjected to the test pressure have not been disconnected. For hydrostatic pressure testing the double gauge technique shall be used. {An indicating gauge shall be connected directly to the Plate Heat Exchanger. If the indicating ‘gauge is not readily visible to the operator controling the pressure applied, an adkitional indicating gauge shall be provided where it willbe visible to the operator throughout the duration o the test for large Plate Heat Exchangers Jedicating pressure gauge used in testing shall preferably have dials graduated over a range of about double the iniended maximum test pressure, but in no case shall the range be less than 1.5 times that pressure, and no more than four times that pressure. ‘Al gauges shall be calibrated against a dead-weight tester or a calibrated master gauge. Gauges shall be re-calibrated at any time that there is reason fo believe that they are in eror. They shall however be calibrated prior and after the completion test from govemment / ISO raled laboratory PROCEDURE. r Pressure shall be applied to both the side of plate al same time, then only to one side and finally o other side. Pressure shall be maintained for minimum 30 minutes for each of above ‘conditions and for such addtional time as may be necessary to conduct the examination for the leakage. re on one side ix The opening to this side shall be ‘covered with blank flanges. The lower opening on the other side shall not be covered. Primary side of PHE is filed with water and the Vent opened in order to remove the air pockets while filing the system. The pressure shall be gradually increased til hydrostatc test pressure is reached. Test Pressure shall be maintained for minimum 30 minute and for additional time as ‘may be necessary to conduct the examination for the leakage. jndary side): The primary side is drained. Step — (ij is repeated for secondary sie. Iv. Pressure will be indicated during testing by calibrated pressure gauges which should be assembled at the highest point ofthe Piate Heat Exchanger. ¥. The minimum time the pressure held during pressure testing Is 30 minute. PREPARED BY [WA REVIEWED BY — [RNG APPROVED EY SIGNATURE SIGNATURE | ‘SIGNATURE DATE, WET DATE, Dei DATEGEA | 431-32. chakan M.0.c., Phase-v, Village - Nighoje, GEA ECOFLEX India Pvt Ltd Tal - Khed, Pune - 410 501 HYDROSTATIC TEST PROCEDURE PROCEDURE NO. | GEA/HT/001 Rev.0. DATED | 30/6011 [DOc. No. PEVE-44-17S NOOB Revd PAGE —[7of10__] 5. | STEPS FOR LEAKAGE CHECK Leakage shall be checked visually all around plaie heat exchanger exiemally and internally on the ‘other side through ports. 6. | CORRECTIVE STEPS IN CASE OF LEAKAGE Release the pressure ‘Make sure that current compression dimension ‘a’ Max must not vary by more than maximum 2mm among the individual tightening bolts. if the compression dimension ‘a’ Max is incorrect, in that cate, tighten gradually in non - pressurized state and achieve the ‘a’ Max. ‘After this conduct the hydro test once again, by using Fluorescent Red Dye. IT PHE stil shows leakage the possible cause can be ascertained by opening the PHE. Mark the place where the leakage occurs. Open the PHE as per manufacturer procedure, ‘At the point of leakage, check whether the plate is correctly positioned af the plate mounting may be bent, so comect if possible. Check the plate gasket for the defect or foreign matter, remove the foreign matter ifis there. If gasket is found damaged replace the damage gasket. Complete record of above shall be kept in the hydrostatic test record sheet. inst the frame plate, Cany out Hydrostatic Test once again as per the above procedure, 7. | ACCEPTANCE NORMS No Leakage or Pressure Drop during the test duration. PREPARED BY | WIA [REVIEWED BY [RNG TABPROVED BY ‘SIGNATURE T SIGNATURE ‘SIGNATURE DATE. BT [DATE 300671 DATE.rc GEA ECOFLEX india Pvt Ltd GEA | 10122, crakan w.1.0.C., Phase-tv, Village - Nighoje, Tal- Khed, Pune - 410 501 D.P.TEST PROCEDUI PROCEDURE NO._| GEAMI)P/001 Rev.0" oo [DATED [301062077 ‘BOC. NO. PE-VS-344-179-NOOS Rev. “TPAGE, Bof 10 [TT score “This procedure covers the DP Test of folowing components 7 DP Test of Heat Transfer Plates (Goth Suraccs}. ii__DP Test of Weld Joint 2 | REFERENCE STANDARD ASME SECTION - VIIDIVISION APPENDIX 8 (For Weld Joints) i,_ASTME— 165 ‘3 [Dprkit Deans | ‘DPT Ki fo be used shall De 1ST marked. Folowings are ihe detals which are regulary in use DPT Kit Make, Pradeep Metal / Checkmate enetrant Penetrant make Pradeep Metal, Thane —_] Developer Developer make Pradeep Metal, Thane Cleaner Cleaner make Pradeep Metal, Thane Penetraril ype ‘Solvent Removable Visible Red Dye Developer "Non = Aqueous ~ Wet Type Developer PURPOSE OF THE TEST i. To check surface defects on the weid joints ji, To check surface defects on both surfaces and thro’ and thro’ pin holes or cracks on the H.T. Plate thickness 0.6 mm. | AREA OF COVERAGE 1. 100% - Surface area of HT. Plates H.__100% surface er of wos ts 6. | EXAMINATION PROCEDURE FOR HT. PLATES. i. Both the surfaces shall be thoroughly cleaned using Cleaner, and dried before applying Dye. fi Onany one surface selected frst (say Face — 1), dye penetrant is applied by spray method or by using brush. ji, The dwell time for penetrant is 15 minutes minimum. iv. After dwell time, the excess penetrant is removed by manual wipe using dry cloth frst and then with cleaner moist cloth v. After face — 1 is cleaned property: Developer is applied by spray method (only) on face ~ 1 and ‘that face (Face - 1) shall be examined for surtace defects after sufficient dwell time of developer. Steps () to (v) shall be repeated for Face — 2 also in order to examine surface defects on face =2also, vil, While doing step (v) for Face ~ 2, Developer can be put on Face ~ 1 also to check for any thro’ and thro’ hole. vil. Inspection shail be carted out in sufficient itumination ix. Wherever on any spot, the doubt arises for surface defect or thro’ and thro’ hole, steps shall be ‘repeated again to ascertain about defects, 7. [EXAMINATION PROCEDURE FOR WELD JOINTS Steps for caving out DP test of weld johns shal be exsily te came a ASME Secon VI Dion |, Appenci 8 | ACCEPTANCE NORMS HT. PLATES. Weld Joints. #2r—,_| No surface defects on any face and No thro’ and thro’ hole. PEP#°CXI Acceptance Norms as per ASME Section Vill Division — |, Appendix 8 [PREPARED BY] MIA REVIEWED BY _[ RNG APPROVED BY ‘SIGNATURE. ‘SIGNATURE ‘SIGNATURE DATE O06TT DATE 3O08TL DATEGEA ECOFLEX India Pvt Ltd GEA | 43132, chatan m.0.c., Phasesv, Vilage - Nighoje, Tal - Khed, Pune - 410 501 VACUUM TEST PROCEDURE DATED | 3008071 | PROCEDURE NO, | GEAWPI001 Revo Plan No.. 7.096-000. PAGE 9.OF 10 DOC. NO, PE-V5-344-179.NOOS Rev. INSTRUCTION FOR VACUUM TEST 1 | PRIOR TO OPERATION PROCEDURE:- T. Valves of vacuum pump and those of the leakage testing device must be closed. 2. Switch on vacuum pump. 3. Let the unit ‘warm up’, the display of sensor must change to green area, 4. This indicates Vacuum pump ready to use for testing. 2 | ACTUAL OPERATION/TESTING PROCESS:. 1. Heat Exchanger Plate positioned on top of testing table with special inlay gasket. 2. Open the valve of the vacuum pump. 3. The heat exchanger plate must be suctioned to testing table so that it cannot be lifted off any more. 4. Vacuum display must now drop up to 10 mbar. 3 | ACCEPTANCE CRITERIA.. T. Now if Green light emitting bulbs will show the acceptance. 4 REJECTION CAITERIA:- T. IF the vacuum as specified is not suctioned: Red light bulb will turn ON and hooting hese plates will be rejected. sound will be ther REVIEWED By [RNG ‘APPROVED BY [ SIGNATURE SIGNATURE TE 30087 ATE:‘GEA ECOFLEX India Pvt Ltd Tal - Khed, Pune - 410 501. IGEA ‘A31-32, Chakan M.1.D.C., Phase-tV, Vilage - Nighoje, [ PAI "PROCEDURE NO_| GEATPPIO01 Re DATED [307062071 DOC. NO. PE-V5-944-179-NOOS REV.O, PAGE 10 of 10 Painting Instructions for Plate Heat Exchanger (External and Internal surface) {1 | Frame plate Surface Preparation:- | TT Sand Blasting according te Standard purity grade 2. Acceptance standard: SA 2.5 Grade "2 | PRIMER CoAT: 1. Epoxy-Zine phosphate Primer: Two pack polyamide cured epoxy resin medium suitably pigmented with zinc phosphate. 2. Ratio of components 24h 3. Dry film thickness/coat + 40um-60um 4. No of coats 22 5. RALNo +: RAL 7035 6. DFT : Min 80m Intermediate COAT: T.Epoxy-Resin Paint 7 Twa pack air drying high build epoxy resin based Paint with MIO. 2. Ratio of components. 24 3. Dry film thickness/coat +: 40um-6Oum 4. No of coats it 5. DFT : Min SOum 4 | TOP Coat: T. Polyamide cured epoxy paint; Two pack polyamide cured epoxy resin suitably pigmented. 2. Ratio of Components a 3. Dry coat thickness +: 40um-6Oum 4, No of coats 22 5. Paint shade : Sea Green 6.15 No. 218217 7. DFT : Min 80um 5 | TOTAL DFT: Minimum 210 microg PREPARED B) RUG APPROVED BY | SIGNATURE. [SIGNATURE DATE HoT DATE