LT Cooler New Type From DongHwa

INSTRUCTION MANUAL
PLATE COOLER
1575−6, SONG JEONG− DONG, GANGSEO−GU, BUSAN, KOREA
TEL : + 82−(0) 51− 970−1114 FAX : + 82− (0)51− 970 − 1131
Web Site : www.dh.co.kr

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OPERATION & MAINTENANCE PAGE : 2 OF 43
CONTENTS
PAGE NO
1. FOREWORD & INTRODUCTION 4
2. PRINCIPLE OF PLATE HEAT EXCHANGER 5
3. MAIN COMPONENTS AND THEIR FUNCTIONS 6
(i) PLATES 7
- CORNER HOLES OF PLATES 8
- PLATE STYLE 9~11
- CHANGING OF PLATES 12
(ii) GASKETS 12~13
- TYPES OF GASKETS 14
- GLUEING 15
4. FUNCTION OF PLATE HEAT EXCHANGER 15
- SCHEMATIC DIAGRAM 15~16

- ARRANGEMENT OF PLATES & GASKETS 16~17
- NAMEPLATE 18~19
- HEAT TRANSFER 19
- PRESSURE DROP 20
5. INSTALLATION OF PLATE HEAT EXCHANGER 21
- SPACE REQUIREMENTS 21
- PIPE INSTALLATION 21~22
- TRANSPORT,LIFTING & STORAGE 22~23
6. COMMISIONING & OPERATION 23
- COMMISIONING & PRE-CHECKS 23

- PROCEDURE FOR START-UP 24
- PROCEDURE DURING OPERATION 25
- SHUT-DOWN/TROUBLE 26~28
- RISK FACTORS 28
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7. OPENING OF PLATE HEAT EXCHANGER 28
- OPENING PROCEDURE 28~30

- CLOSING OF PLATE PACKAGE 30~31
8. MAINTENANCE 32
- CHLORINE AS GROWTH INHIBITOR 32

- CLEANING 32~36
9. ASSEMBLING OF PHE 36
- TIGHTENING OF PLATE PACKAGE 37

- REPLACEMENT OF PLATES & GASKETS 38~39
10. FAULT DETECTION AND REMEDIES 39~42
11. REBUILDING AND SPARE PARTS 42
- ORDERING PROCEDURE 42
- SPARE PARTS 42
12. A/S NETWORK 43

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1. FOREWORD & INTRODUCTION
FOREWORD
This manual of instruction is a guide for installation, operation, maintenance for

new DONGHWA ENTEC plate heat exchanger. It is meant for those who are
responsible for the installation, use and maintenance of the heat exchangers. We
recommend you to read this manual carefully before commencing any work.
INTRODUCTION
This manual is applicable to all heat exchangers produced by DongHwa Entec.

We are not responsible for any damage due to incorrect installation, use or
maintenance of our heat exchangers as well as not complying with our instruction
manual.
Please note that our plate heat exchangers are specially designed and built for
the operating conditions (Pressure, temperature, capacity, type of fluid etc.) provided
by the customer. Sudden pressure peaks beyond the normal operating pressure, which
can occur during starting up or stopping of the system can severely damage the heat
exchanger and should be prevented. We are not responsible for any damage as a result
of any operation deviating from the original design conditions.
If you would like to contact DONGHWA ENTEC about any plate heat
exchanger, then please refer to the plate type, serial and drawing number as mentioned
in the name plate of our item.
PLATE HEAT EXCHANGER TYPE: ___________________________
SERIAL NUMBER: __________________________________________
DRAWING NUMBER: _______________________________

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2. PRINCIPLE OF THE PLATE HEAT EXHCHANGER
A plate heat exchanger consists of a frame, which consists of a head cover,

follower cover, support pillar, carrying bar, guiding bar, and a number of tightening
bolt. In between head and follower cover, a number of plates are pressed together.
Heat is transferred from one medium to another medium through alternate metal
plates, which have been pressed into a special pattern. The hot and cold fluids alternate
between each of the plates. Because each of the plates has a large surface area, the
plates provide each of the fluids with an extremely large heat transfer area. So, it is
capable of transferring much more heat due to high heat transfer efficiency of the plates.
Each plate is supplied with an elastomeric gasket, so that the plates form a
closed system of parallel flow channels, through which the medias flow alternately at
every second interval. Each plate is equipped with a double sealing system that keeps
the fluids between the channels. The gaskets are glued on to the plates, which secure
tightness between fluids and the atmosphere. There shouldn’t be any mixing between
two fluids. Every second plate has to be turned 180 degrees so that the plates form a
closed system of flow channels, through which the fluids flow alternatively. The heads
include connections to permit the entry of the process fluid into the plate pack. The
channel formed by two adjacent plates is the key to the heat exchanger efficiency. Units
are custom selected to effectively optimize the available pressure drop. Plate heat
exchangers are well suited for applications, which require close temperature approaches.

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3. MAIN COMPONENTS AND THEIR FUNCTIONS
Fig: 1 Exploded view of a plate heat exchanger

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The above figure shows the exploded view of the plate heat exchanger. The different
parts of the heat exchanger is mentioned by numbers, which are as follows.
1. 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 inlet/outlet connections, air vent valve, drain valve, pressure gauge,
thermometer, and roller. Sometimes filters are also connected with system.
The two bars are suspended between the frame plates. The plates hang from a
carrying bar and are kept in line by a guiding bar at the lower end. Connection holes
permit 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
determined by the size of the heat transfer surface required for the system.
DESCRIPTION OF MAIN COMPONENETS OF PLATE

HEAT EXCHANGER
1. PLATES
Each plate is made from “pressable” materials such as stainless steel, titanium
and is formed 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

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required thermal output. Depending on the thermal application, stainless steel or

titanium plates are selected. The heat transfer plates separate the two process fluids; the
channel is the space established by two heat transfer plates, through which process
fluids are distributed and heat transfer is carried out. The channel formed by two
adjacent plates is the key to the plate heat exchanger’s high efficiency. The fluid shear
stresses are also higher in case of plate heat exchangers, which always tend to keep the
channels much cleaner.
- The corner holes of the plates -

Depending on the required liquid flow in the plate heat exchanger the 4 corner
holes have to be opened. The corner holes named with numbers starting left side on the
top of the plate (to be seen from the gasket side) as no.1 after that continues no.2, 3 and
4 clockwise. The corner holes are opened as you see on the diagram drawings,
describing the liquid flow in the plate heat exchanger. (FIG 3.) The openings of the
corner holes are described in a code. For instance: 1234 means that all the corner holes
are opened. Code 0204 means that hole 2 and hole 4 are open, and the holes 1 and 3 are
closed.
The DONGHWA plates are designed so they can be used both as right and as
left plates. The plates just have to be turned 1800.
FIG: 2

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Right and left plates:
On a right plate the flow runs from hole 2 to hole 3 or reverse from hole 3 to
hole 2. On a left plate the flow runs from hole 1 to hole 4 or reverse from hole 4 to
hole 1. (FIG 2)
FIG: 3
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.

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L /TS H/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 H and L 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 vertically, the
gasket rests in a groove that includes the heat transfer area. The arrow marks on the left
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 (FIG: 5~7)

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FIG: 5
FIG: 6
In above figure, if we name the left plate as A plate and right plate as B plate,
then next figure shows that by turning the A plate upside down, we can get B plate.

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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 are
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 corners 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

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gasket is included in each plate, which contains the pressure and control the flow of each
medium. The gasketed plates are assembled in a pack, mounted on upper and lower guide
bars and compressed between two end frames by compression bolts. Gasket material is
chosen to withstand the operating temperature at hand and the properties of the processing
fluid. Heat is transferred 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 through the slots. It is important that these openings are not
permitted 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 could 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

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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 intermediate frame should be glued on as shown in
FIG 4.
- Glue type -
PLIOBOND 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.

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- Detergent -
For cleaning and degreasing new gaskets and gasket grooves use (ACETONE).
It is very important that every detergent is evaporated before putting glue on.
- Glueing-
After wiping gaskets and gasket grooves with a cloth moistened with degreasing
substance the glueing itself can begin. The glueing areas must be quite clean and free
from any dust and fingerprints. The gaskets are covered by a brush with a thin coat of
glue on the glueing area and are placed on a clean and dry place to dry. The glueing
starts in the plate ends and continues along the straight edges.
When the glueing is finished, the plates are hung into the frames again and the
plate heat exchanger is clamped together. The plate heat exchanger can be warmed up
by hot water if the glue is to dry quickly- but without pressure on the water. If there is
not any possibility to heat the plate heat exchanger it must stand as warmly as possible
and in order to let off glue vapor from the plate heat exchanger the conditions are to be
unmounted.
NOTICE: Solvents are dangerous to inhale !
4. FUNCTION OF THE PLATE HEAT EXCHANGER
- Schematic Flow Diagram -
The diagram (FIG: 10) shows the plate heat exchanger. It shows the plate
composition and the liquid flow in the plate stack. When the plates are pressed together,
the holes at the corners form continuous channels, leading the fluid from the inlets into
the plate package, where they are distributed into the narrow passages between the
plates. There are two arrow marks, A & B. The bold A arrow marks show right plates
and B arrow marks show left plates. During the passage through the system, the hot

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fluid will give some of its heat energy to the thin wall, which instantly looses it again to
the cold fluid on the other side. The hot fluid loses its temperature and the cold fluid is
heated up same time. Finally, the fluids are led into similar hole-tunnels at the other end
of the plates and discharged from the heat exchanger. After clamping of the plate pack,
the plates, which are fitted with gaskets-ensure an effective seal between fluids and
atmosphere. In addition, intermixing of the fluids is eliminated by a double gasket seal
around the inlet ports. Every second plate in the stack has to be turned 180°, so that the
plates form a closed system of parallel flow channels, through which the medias flow
alternately at every second interval.
FIG: 10
ARRANGEMENT OF PLATES & GASKET
In order to form 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: 11
Rather than H (thermal long) & L (thermal short) Plate styles, the figure above (FIG:
11) shows four different plate types.
A: start plate with gasket.

B: Left hand flow plate with gasket.
C: Right hand flow plate with gasket.
D: End plate with gasket.
A plate, which has four holes through which the fluid flows into the nozzle, is always
placed next to the head cover. The fluid cannot flow through the deflector as all gaskets
are clogged. After assembling A plate, 2nd plate should be B or C plate depends on the
flow directions of the hot and cold fluids.
In case of B plate, fluid flows through the left side. So, left side connections are opened
and right side connections are closed.
In case of C plate, fluid only flows through the right side. So, only right side
connections are opened and left side connections are closed.
In case of D plate, which is placed at the end, all left and right side holes are closed.
This means all four connections are closed.
The 2nd plate can be upwards or downwards, which depends on the fluid flow directions
of the heat exchanger. But after assembling the 2nd plates, the B & C plates are arranged
in upwards and downwards directions alternatively up to the end to form the
honeycomb structure. There is no chance of mixing of fluids due to this kind of

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arrangement of fluids. The fluid flows through left side connection 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.
NAME PLATE
On the head a nameplate is mounted.

The concerned plate is stamped with
important information about the plate
heat exchanger. The nameplate
indicates the serial no, operating
press/fluid quantity, weight, tightening
measure, class and plate type. The
figure below (FIG: 12) shows the name
plate for our plate exchanger.
For Example,
PLATE TYPE: HT301-232
This means HT301 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 assembled under the stated
minimum assembling measure. Please contact DongHwa Entec
distributor if it is leaking when tightened to the minimum
measurement.
2. The starting up must be done without shocks and against closed
valves.
HEAT TRANSFER
The purpose of the system is to transfer heat from one medium to another
medium and heat passed very easily through the thin wall separating the two fluids
from each other. For sensible heat transfer, the duty can be expressed by:
Q = (w x Cp x DT) HS --------------------------- (1)

Q = (w x Cp x DT) CS --------------------------- (2)
Q = U x A x LMTD ------------------ (3)
Effective heat transfer area in a plate heat exchanger is calculated by

multiplying the total number of plates in the exchanger minus two, by the 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 determining the
area because the first and last plates have fluid only on one side. So, they are
noneffective in transferring heat.
Corrugated plates, when placed in an exchanger, form a three-dimensional flow

path with a nominal gap twice the pressing depth of the plate.
The high heat flow through the walls can be reduced by the formation of
deposits of various kinds on the wall surfaces. Consequently a layer of deposits can
severely reduce the overall heat transfer rate.

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Thermal length () is a dimensionless number that allows the designer to relate
the performance characteristics of channel geometry to those of a duty requirement.
The thermal length of a channel describes the ability of the channel to affect a
temperature change based on the log mean temperature difference (LMTD).
 = Temp. Change / LMTD

= (T in – T out) / LMTD
The thermal length of a channel is a function of the channel diameter, plate
length and the angle of the corrugations, along with the physical properties of the
process fluids and available pressure drop.
For any chosen channel geometry, the thermal length required by the duty can-
(I) Match the characteristics of the channel.
(II) Exceed what is achievable by the channel at the allowable pressure drop.
(III) Be less than that achievable by the channel at the allowable pressure drop.
To have the most economical and efficient exchanger, it is critical to choose, for
each fluid, a channel geometry that matches the thermal length requirement of each
fluid.
PRESSURE DROP
Pressure drops are wasted energy. All equipments included offer resistance to
fluid flowing through them. Some pressure drop is unavoidable, but for a given
apparatus it should be kept as close as possible to the designed value.
The formation of deposits on the heat transfer surfaces instantly leads to a

reduction of the free space between the plates. This means that more energy is needed
to get the desired flow through the apparatus.
A reduced ability by the heat exchanger to hold the desired temperatures, in

combination with an increased pressure drop on any of the media, indicates that fouling
or clogging is taking place. So proper maintenance and cleaning 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
FIG: 13
The plate heat exchanger requires enough space with regard to opening for
inspection or servicing (renewal of plates, tightening of package etc.) without any
problem. It is necessary for the plates and the assembling bolts to have so much 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 service can be done
without problems.
- PIPE INSTALLATION
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 specified duty the pipe installation has to be mounted
according to our drawing. By construction of the pipe installation it must be considered
that the rubber liners in the head of the plate heat exchanger can be removed. The pipe
connection always has to be mounted in a way, preventing the plate heat exchanger
from being overloaded. The pipe connection must be so flexible that an extra tightening
of the plate heat exchanger can be made.
We recommend you to follow the steps as below for piping connections.
- Heavy pipe work loads to be supported. This will prevent heavy forces onto the
heat exchanger.
- Always install flexible connections onto the follow cover to prevent vibrations.
These flexible connections also prevent expansion of the pipe work, caused by
temperature influence onto the heat exchanger.
- These flexible connections need to be lifted in a longitudinal direction to the plate
package.
- The pipe work needs to be thoroughly cleaned and flushed before connecting up to
the heat exchanger.
- Make sure that the pipe work, connected to the heat exchanger is secured against
any pressure leaks and temperature shocks.
- Always install vents on the top of the heat exchanger for proper venting.
Transport, Lifting & Storage

For safe transportation, it is desirable to transport item, valve or pipe without
assembling. Install shackle on the fixed frame and moving frame and hook bar on the
shackle before transportation with crane. Please keep in mind not to lift the item 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 should
be places as like shown in above figure (FIG: 14)
In case of storage of the unit for a longer period, certain precautions should be
taken in order to prevent unnecessary damage 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 this is not possible, 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 solvents or acids in the room and avoid heat or ultraviolet radiation.
6. COMMISIONING AND OPERATION
COMMISIONING AND PRE-CHECKS
Commissioning should only be done by staffs, which has been trained specially
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 specified value on the identification plate.

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6.1 PROCEDURE FOR START-UP
Before starting up for first time or after a long run shut down of system, make
sure that the plate pack is compressed to the right measurement.
It is very important that the system, to which the heat exchanger is connected, is
protected against sudden and extreme variations of temperature and pressure to avoid
any damages. It also applies to piping system and all equipments.
Before the initial start-up,

- Check that the operating data does not exceed that given on the heat exchanger's
nameplate.
- Check that all tightening bolts are properly tightened.
6.1.1 Pumps
Before starting any pump, check if there is any instructions for any pump to be
started first. Pumps feeding the heat exchanger must be provided with regulating valves.
If the pumps can deliver a higher pressure than the rated pressure for the heat
exchanger, safety 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 closed valves. The
valves in the inlet and outlet should be opened at same time as far as possible. The flow
rate is then increased slowly until operating temperature is reached. Hammering must
be avoided; otherwise the rubber gaskets may be displaced and leakage result. Check
that the exit valve is fully opened during starting condition. Then, open the vent, start
the pump, open the valve slowly.
6.1.3 Venting
Immediately after start-up the equipment must be vented. Remaining air can
cause air locks and serious scorching of the plates, reducing the heat transfer capacity
and increasing the risk of corrosion.

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6.2 PROCEDURE DURING OPERATION
During operation, temperatures and pressure drops must be regularly checked.

Increased pressure drop and/or falling temperatures indicate that there are coatings on
the plates. The plate heat exchanger now needs cleaning. During operation, the same
precautions against rises of pressure must be observed as during start-up. The following
points must be observed for running.
- Working pressure
On the head of the plate heat exchanger a nameplate is mounted. The maximum
working pressure is stated and it must not be exceeded.
- Pressure pulsation and vibrations
No pressure pulsations and vibrations must be transferred from positive pumps

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

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 tightened
gently and covered with black plastic to pre-vent the gaskets from being damaged by
daylight. Before the plate heat exchanger is put to work again it must be tightened
according to minimum measure.
For operation,
Start cold fluid first than the hot fluid.
The operation steps should be as follows.

- Fully vent the system.
- Close isolation 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.
- Vent system once again if necessary.

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The above steps should be repeated for secondary fluid.
CHECK FOR PROPER OPERATION

- Check the pressure pulses in the system caused by pumps or control valves. If
found, stop operation and rectify. Continuous pressure pulses will result in fatigue
failure of the plates.
- Visually check the unit for leakages.
- Check that all vents are closed to prevent air being sucked into the system.
NOTICE: When in operation, the conditions should not be

changed. The max. conditions specified on the identification name
plate should not be exceeded.
6.3 SHUT-DOWN / 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 follow
the following procedure.
- Slowly close the control valve in the hot circuit while maintaining the full
flow in the cold circuit.
- Switch off the hot circuit pump.
- Cool down the heat exchanger to the level of cold medium.
- Slowly close the control valve in the cold circuit.
- Switch off the cold circuit pump.
- Close all remaining isolating valves.
6.3.2 Shut-down for a long-period
If the unit is to be taken off for an extended period of time, the please follows

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the following procedures as below.

- Allow the unit to cool down.
- Drain all circuits.
- Lubricate tightening bolts.
- Loosen the bolts until the plate pack is relaxed.
- The bolts should not be removed or loosened to such an extent that dirt is
not allowed to enter in between the plates.
- Cover the plate pack with back 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. In that case the pressure has to be controlled and if
too high it has to be reduced immediately to what is written on the nameplate.
- Tighten the plate heat exchanger to the minimum measure, which is mentioned on
the nameplate. It goes without saying that the plate heat exchanger has to be
pressureless before tightening.
- The plate heat exchanger is separated for inspection. Check that the plates are
without scaling and undeformed.
Check the gaskets. They have to be elastic, undeformed 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 minimum 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 in the drained zone or a corroded plate in the drained zone.
6.3.4 Inside Leakage
If the liquid is mixed it is due to holes in one or more plates. The leaks can only
be repaired by changing the defective plates. A suspected leakage can be located in one
of the following ways:
- Remove a pipe on one of the bottom pipe connections - then put the opposite side
under pressure. After the pressure is stabilized the liquid must not run off from the
removed pipe connection. If the liquid continues to run off there is a leak on one
or more plates. The plate stack is demounted and every single plate is examined
carefully.

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- 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 side (every second plate interval).
The other half of the plate interval is kept without pressure and without liquid.
The circulation is stopped after a few minutes and the plate heat exchanger is
opened carefully so that no water is sprayed on the dry plate side. The plates are
examined carefully and thus it is possible to find the wet areas on the dry plates.
The areas have to be controlled with capillary liquid.
- The plate heat exchanger is separated and all plates are controlled with the
capillary liquid.
6.3.5 RISK FACTORS DURING START-UP AND SHUT- DOWN
- A liquid in motion in a pipe system represents a lot of energy. So, it should be

handled very carefully.
- 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 operated gradually. If the pipe is longer and flow rate is higher,
then its importance will be much more.
7. OPENING OF PLATE HEAT EXCHANGER
OPENING PROCEDURE
Before opening the plate heat exchanger, it must be cooled below 35℃, and it
must not be pressurized. If the plate heat exchanger is opened at a temperature higher
than 35℃, the gaskets can get loose from the plates.
The steps involved for opening are as follows:
(1) Remove pipe connection from heat exchanger.

(2) Remove protected cover from tightening bolt.
(3) Open the tightening bolt from the frame as a rule in the heat exchanger.

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(4) Move the follower cover for disassembling the plate from frame.
(5) Opening of plate package
a. Slowly close the valves on the inlets.

b. Switch off pumps and close the valves on both outlets.
c. If system is hot, then wait till temp. will be cooled down to min. 40 0C.
d. Drain and dismantle any pipe bends connected to the pressure plate so that
it can be moved freely along the carrying bar.
e. Check sliding surface of carrying bar and pressure plate cooler.
f. Clean the threads of the tightening bolts and lubricate with grease.
g. Mark the no. of plates in sequence.
h. Loose and remove the bolts, which are not fitted with bearing boxes. Open
the pair of bolts that are fitted with bearing boxes alternatively and
diagonally.
NOTICE:
1. Ensure that unit is pressurized and drained of hot and aggressive
product before unit is opened to prevent personal injury.
2. Edges should be sharp. When handling plates, gloves should be
worn. You have to disassemble the plate cooler after drain at
hot/cold side.
FIG: 15

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FIG: 16
The above two figures (FIG 15 & 16) show the sequence of opening of bolt
structure for plate package.
CLOSING OF PLATE PACKAGE

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

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8. MAINTENANCE
CHLORINE AS GROWTH INHIBITOR

Chlorine, commonly used as growth inhibitor in cooling water systems, reduces
the corrosion resistance of stainless steels. Chlorine weakens the protection layer of
these steels making them more susceptible to corrosion attacks. It is a matter of time
exposure and concentration. But titanium is not affected by chlorine.
CLEANING
All marine systems, where seawater is used are exposed to fouling. Fouling may
occur in ports and at the plate’s entry region. It can increase the pressure drop and
reduce the low rate resulting in insufficient heat transfer. So cleaning is very much
necessary to remove these fouling. Foulings on the plates can be removed manually or
by CIP (cleaning in place).
The cleaning of the plate heat exchanger depends on the capacity as well as
the corrosion resistance of the system.
This cleaning section consists of four parts.
- Manual cleaning.
- CIP cleaning.
- Cleaning materials.
- Control of cleaning.
MANUAL CLEANING
The plate heat exchanger is separated and the plates are pulled from each other.
Use a soft and a qualified cleaning material for cleaning the plates. 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 treatments.
CLEANING OF PLATES
- Use nylon or other types of 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 flame. Boiling water
can be used with some success.
- Consult a cleaning specialist for a suitable choice of detergent. Ensure that all
detergents used are compatible with the plate and gasket material before use.
- In case the plates are removed for chemical cleaning, make sure they are 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 barrel
with qualified cleaning material.
Before cleaning chemical cleaned plates, they need to be thoroughly rinsed

with fresh water.
Important:
Cleaning is an important part, influencing the effectiveness of the plate heat

exchanger. Insufficient cleaning can have the following results.
- too low circulation flow.
- Insufficient thermal output.
- Life time of the heat exchanger will be shortened.
-
If a plate has to be renewed because of serious damage, one should make sure
that the plates next to this plate are 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 with care.
2. Never add with any sand or other abrasives.
3. Always use gloves and eye goggles when using detergents.

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FIG: 19
CIP CLEANING
CIP = Cleaning in Place, which means cleaning of the exchanger, without

reassembly. Please note that even though CIP cleaning is performed frequently, it
will not make periodic inspections unnecessary.
A circulation system, in which a suitable detergent can be circulated, is
established. If the product to be flushed out has a high viscosity, the circulating quantity
must be big enough to reach a sufficient speed for flushing out the product. If the
products pump for the detergent parallel to the former, it is assumed that the fouling on
the plates are soluble in a detergent, which does not attack plates and gaskets.
Examples of CIP cleaning:
- Product rests and cooling/heating liquids are drawn off.

- Rinse with cold or tepid water.
- Warm cleaning fluid circulates.

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Cleaning materials
A qualified cleaning material is one, which can remove the scaling on the plates
without damaging the plates and gaskets. Stainless steel has a passivated (protecting)
film. This film must not be destroyed, as the film assists in preserving the resistance of
the stainless 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 flow that is as high as possible and
certainly no less than the service or product flows.
Follow the instructions carefully as given by the detergent supplier/cleaning specialist.
We recommend that for recirculated cleaning detergent methods, the fluid should be
pumped through the exchanger for no less than 30minutes.
Rinsing:
After using any type of cleaning agent, always rinse thoroughly with fresh water.
If cleaning in place, then recirculate fresh water for at least 10 minutes.
- Some Cleaning Detergents

Oil and grease is removed with a water emulsifying oil solvent i.e. BP system
cleaner.
Organic and grease cover is removed with sodium hydroxide (NaOH)

maximum concentration 1.5% max. temp.85℃.
Concentration = 5.00 ltr. 30% NaOH per 100 ltr. water.
Stone and limestone is removed with nitric acid (HNO3) –

max concentration 1.5% - max. temp. 65℃.
Mixture of 1.5% concentration = 2.4 ltr. 62% (HNO3) per 100 ltr. of water.
Nitric acid also has an effective build up effect on the passivation film of stainless steel.
Control of Cleaning
Cleaning is an important part, influencing on the effectiveness of the plate heat
exchanger. Therefore the plate heat exchanger has to be separated for inspection and

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especially in the commissioning period. You will obtain important experience

concerning circulation times, temperatures, and chemical concentrations.
- too short cleaning period.
- too low chemical consumption compared to the scaling of the plates.
- too long running intervals between the cleanings.
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 EXCHANGER
1) Check that the surface of the gasket is clean before tightening.

2) Press the plate and pressure plate 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
disassembly. The tightening size should be that given on the nameplate attached to
the frame plate. Measure the size at least in four positions.
4) When the opposed two bolts are tightened almost securely, tighten the remaining
bolts.
FIG: 20

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The above figure (FIG: 20) shows the pate side view honeycomb structure of the plates.
TIGHTENING OF THE PLATE PACKAGE
FIG: 21
- Lightly oil the tightening bolt threads. Don’t allow oil or grease onto the gaskets or
the gasket seating faces on the back of the plates. Wet or contaminated plates can
misaligned during tightening. In this case, dismantle, clean and dry all areas in
contact with gaskets.
- Ensure clamping is uniform for keeping the frames and plates parallel throughout
the operation. Avoid skewing the frame plates by more than 5 mm.
- Tightening is complete when the distance between the inside faces of both frame
plates equals the “A " distance as shown in above figure (FIG: 21). The tightening
distance can be calculated by as follows.
Assembly distance = No. of plates * dimensioning factor (Max. ~ Min.)
Dimensioning factor (Max. ~ Min.) varies depending on the plate types.
- Finally check that all bolts are in tension and clean any split oil off the frame plates.
- On completion, the unit can be pressure tested at the mentioned value in the name
plate.
If the dimension “A” is not reached with application of maximum tightening

torque,
- Check the number of plates and dimension “A” in datasheet.

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- Check that all the nuts and bearing boxes are running freely. If not, clean and
lubricate or replace.
If the unit does not fully seal, it may be tightened step by step to give dimension
“A” min. The maximum tightening torque 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
1) Damaged plates can be easily replaced by the same spare plates.

2) The damaged plate and the adjacent plate, two in sum (only the plate with four
holes) may be safely removed without replacement. However the performance of
the unit is slightly lowered.
For removal of plates, push the pressure plate against the support column and then
Remove plates.
* Note that the tightening size in this case is shortened by two plates.
But for insertion of plates, hang the plates with their backs towards the pressure
plate (the side without gasket).
REPLACEMENT OF GASKET (GLUE TYPE)
(1) Remove the old gasket from the plate, and then wipe the gasket groove with a clean
cloth moistened with a solvent (methyl ethyl ketone, toluene, xylene,
trichloroethylene etc.)
If it is hard to be removed, remove it warming the rear side with a gas burner or pour
a solvent into the gasket groove and leave it for while.

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NOTE: Do not use a gas burner and solvent at the same time. Use a
propane burner or a driver (1000W). Do not use an acetylene burner.
(2) Apply a thin layer of cement with a brush over the rough side 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 feel
sticky when touched with fingers, apply the face to the gasket groove.
(4) Apply the gasket controlling 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
(with a weight), and leave them a half to one day.
(6) Dry them fully and install to the frame.
NOTICE
Avoid such places where ventilation is poor or near fire in cementing
gaskets.
REPLACEMENT OF GASKET (NON-GLUE TYPE)
SONDEX-LOCK is a non-glue 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 on 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 connections - Check the rubber liners (if fitted)
- Check the 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 hole and/or

secondary circuit cracks.
In plate package - Check the assembly tightening
distance.
- Check the condition of the packings.
- Check the proper position of the
packings.
The operating conditions - Adjust the operating conditions

deviate from the specification properly.
Insufficient Air in the System - De-aerate the pipe system

Capacity - Check the pipe work for possible air
traps.
The operating conditions - Adjust the operating conditions

deviate from the specification 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 plate(s) blocked - Flush/Clean properly.
Incorrect measurement - Check the pressure indicator for

correct measurement
Medium deviating from the - Addition of for instance anti-freeze

design will increase the pressure drop

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

pressure - Check the pipe work for possible air
drop traps.
Abnormally, Low pressure drop in central - Open the L.O cooler’s air vent valve
Central clr’s cooler according to L.O during conversion of L.O pump.
pump is pump’s conversion - To be connected from air vent valve
change of L.O side to L.O sump. tank with
copper tube.
For nearly all leakage problems, it will be necessary to dismantle the unit before
any attempts to rectify the problem. Mark the leakage area(s) with a marker or similar
before taking apart the exchanger.
“Cold leakage” is caused by a sudden change in temperature. The sealing

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 failures generally occur as a result of followings:
 Old age.
 Excessive exposure to ozone.
 High operating temperature above the temp. limit of the material.
 Exposure to pressure gauges.
 Chemical attack.
 Physical damage, resulting from poor assembly practice or misalignment of
plates (check the hanging system at top of the plate for distortion).
Decrease in performance is generally a result of:
 Plate surfaces require cleaning or de-scaling.

 Pumps or associated controls have failed.
 Plate channels blocked.
 Liquid flows not as per design specification.
 Associated chiller/cooling tower/boiler under sized.
 Cooling water temperature to the exchanger is higher than the design.
 Heating media temperature to the exchanger is lower than the design.
 Steam flow not sufficient - control valve malfunction.
 Steam trop broken or jammed – unit becomes filled with condensate.
 Plate package has been assembled incorrectly.

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 Unit is running in co-current flow, instead of counter current – check with

drawing and alter pipe work if necessary. Check direction of pump flows.
 Air lock has developed in the plate package or pipe work.
11. REBUILDING AND SPARE PARTS
ORDERING PROCEDURE
The plate heat exchanger is module built up and therefore flexible as regards
enlargements or reduction i.e. it is easy to change the capacity by respectively enlarging
or reducing the number of plates.
DONGHWA files contain all data of delivered plate heat exchangers. We
gladly forward suggestions/quotations concerning rebuild of an existing plate heat
exchanger. DONGHWA 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. Afterwards the rebuilt plate heat exchanger data will be put into
DONGHWA files to keep them up-to-data.
SPARE PARTS
The type designation of the plate heat exchanger and the manufacture number
(is one the name plate which is placed on the head cover) ought to be mentioned by
ordering spare parts. This is to prevent fault delivery.
- By ordering plates it is important to mention the right pattern code and if it is right
or left plates, please 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 of the right size of bolts.

A / S NETWORK
●Netherland
France●
●Greece
●Korea
China● ●Japan America●
●India
43
Singapore●
● Indonesia
●South Africa
●Australia Brazil
●
CHINA DONGHWA ENTEC SHANGHAI BRANCH OFFICE JAPAN SEIKA COPORATION HIROSHIMA BRANCH
Chenhui Rd Shanghai Zhangjiang Hi-Tech Park (Hiroshima) 4-25, Fukuro-machi, Naka-ku, Hiroshima-shi
Tel : +86-21-5027-1828 Tel : +81-082-248-5831
GREECE FRANMAN LIMITED INDONESIA PT. ESPRIT ENGINEERING

220,Syngrou Avenue,Athens,176 72 KM7 TanJung Uncang Batam Indonesia
T. +30 210 953 2350 T. +62 (778) 392 811
BRAZIL DANTHERM SOUTH BALTIMORE AIRCOIL COMPANY LTD.
Av. Atalaia, Jardim Cumbica, Guarulhos, Sao AFRICA Philippi 7781, P.O.B. 88, Philippi 7785, Cape
Paolo, T. +55 116 412 8188 Town, T. +27 114 533 146
SINGAPORE SINGAPORE OFFICE FRANCE BARRIQUAND ECHANGUERS
BLK 4No 58Pandanloop Singapore 128273 9-13 Rue Saint-Claude, F-42334 Roanne Cedex
Tel : 776-3344(5Lines) Tel : +33-477-442-220

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INSTRUCTION MANUAL

1575−6, SONG JEONG− DONG, GANGSEO−GU, BUSAN, KOREA

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

Web Site : www.dh.co.kr

2. PRINCIPLE OF PLATE HEAT EXCHANGER 5

3. MAIN COMPONENTS AND THEIR FUNCTIONS 6

4. FUNCTION OF PLATE HEAT EXCHANGER 15

- SCHEMATIC DIAGRAM 15~16

5. INSTALLATION OF PLATE HEAT EXCHANGER 21

6. COMMISIONING & OPERATION 23

- COMMISIONING & PRE-CHECKS 23

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7. OPENING OF PLATE HEAT EXCHANGER 28

- OPENING PROCEDURE 28~30

- CHLORINE AS GROWTH INHIBITOR 32

- TIGHTENING OF PLATE PACKAGE 37

10. FAULT DETECTION AND REMEDIES 39~42

11. REBUILDING AND SPARE PARTS 42

12. A/S NETWORK 43

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1. FOREWORD & INTRODUCTION

This manual of instruction is a guide for installation, operation, maintenance for

This manual is applicable to all heat exchangers produced by DongHwa Entec.

PLATE HEAT EXCHANGER TYPE: ___________________________

SERIAL NUMBER: __________________________________________

DRAWING NUMBER: _______________________________

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2. PRINCIPLE OF THE PLATE HEAT EXHCHANGER

A plate heat exchanger consists of a frame, which consists of a head cover,

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3. MAIN COMPONENTS AND THEIR FUNCTIONS

Fig: 1 Exploded view of a plate heat exchanger

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DESCRIPTION OF MAIN COMPONENETS OF PLATE

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required thermal output. Depending on the thermal application, stainless steel or

- The corner holes of the plates -

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Right and left plates:

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- Glue less or glued gaskets -

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

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NOTICE: Solvents are dangerous to inhale !

4. FUNCTION OF THE PLATE HEAT EXCHANGER

- Schematic Flow Diagram -

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ARRANGEMENT OF PLATES & GASKET

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A: start plate with gasket.

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On the head a nameplate is mounted.

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Q = (w x Cp x DT) HS --------------------------- (1)

Effective heat transfer area in a plate heat exchanger is calculated by

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

Corrugated plates, when placed in an exchanger, form a three-dimensional flow

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 = Temp. Change / LMTD