Manual de Intercambio de Calor 04

7/27/2019 Manual de Intercambio de Calor 04

1/16

Installation AndOperation Manual

ULTRAMAX ALL-WELDED HEAT EXCHANGER

www.tranter.com


2/16


3/16

1.1. Product Description And TypesULTRAMAX All-Welded Plate Heat Exchangers provide a highheat transfer rate in a very compact space. They are individually congured for challenging applications involving liquids, gases,steam and two-phase mixtures, at temperatures and pressuresthat are beyond the capability of gasketed plate & frame units.For every individual ULTRAMAX unit, be sure to compare theoperational ratings stamped on the nameplate (Figure 5.2., Page14) with the process design specications before installation toavoid the possibility of damage.

1. INTRODUCTIONThis manual is intended as your general guide for the proper installation, operation and maintenance of your ULTRAMAX All- Welded Heat Exchanger. You should study this manual thoroughly before operating the unit and follow the instructions with care.

WARNING: Tranter, Inc., accepts no responsibility or liability for damage caused by incorrect installation, operation or maintenance attributed to failure to observe these instructions.

Figure 1.2.Exploded views of UM-48 through UM-107 (left) and UM-20 units.

Top Panel

Core

Left Panel

Right Panel

Bottom Panel

CAUTION: For each model, design pressure and temperature aremarked on the nameplate. These must not be exceeded.

1.1.1. ULTRAMAX Design Working in much the same way as a conventional, gasketedplate & frame heat exchanger, the ULTRAMAX embossed metalplates are arranged alternately into cassettes and welded to formchannels for hot and cold media. The plate pack is enclosed ina welded core with nozzles and installed in a box of four boltedsteel plates to provide pressure integrity to the plate core.

Plate

Plate Cassette

Plate Pack

Figure 1.1.ULTRAMAX plate pack components.


4/16

4

1. INTRODUCTION(continued)1.1.2. ULTRAMAX CongurationsLarge-capacity or multi-pass configurations of the UM-20unit incorporate up to ve cores within a single frame. TheULTRAMAX line offers six different plate lengths, including thelargest plate size in its class, with an area of 0.989 m2 (10.65 ft2).

Figure 1.3.ULTRAMAX Plates.

1.2. SERVICE LIMITS

1.2.1. Design ConditionsDesign operating conditions for each ULTRAMAX heatexchanger appear stamped on the exchangers nameplate (seeFigure 5.2., Page 14) and are shown on the general arrangementdrawing furnished with the unit. The ULTRAMAX exchangershould never be operated under conditions that exceed thosestamped on the nameplate.

The ULTRAMAX attains maximum efciency and reliability when applied to steady state conditions. The unit is notnormally recommended for dynamic applications, such asbatch processes.

The ULTRAMAX is an all-welded design. Intermixing is possiblein the event of a plate or weld failure. For critical applications where any possibility of uid intermixing must be avoided, a secondary heat exchanger with an intermediate loop shouldbe used.

1.2.2. Maximum Differential TemperaturesThe ULTRAMAX All-Welded Heat Exchanger is limited to a maximum differential temperature (hot uid inlet temperatureminus cold fluid inlet temperature) of 170C (300F).Exceeding this limitation may result in mechanical damage tothe equipment.

1.2.3. Flow Rate ConsiderationsThe minimum ow rate is 10% of the rated ow rate as shownon the specications sheet shipped with each unit. With unitsusing steam, superheated water or thermal uid in the hot circuit,it is necessary to maintain a minimum of 20% of the rated ow rate in the cold circuit. In applications where the temperatureof the hot circuit uid is higher than the saturation temperatureof the cold circuit uid, low ow rate alarms should be builtinto the control circuit, since a drop below the 20% thresholdcould cause ashing in the ULTRAMAX and condensation in

the piping. This could result in destructive water hammer thatcould damage the ULTRAMAX, other system components ornearby personnel.

CAUTION: Unless specically stamped on the nameplate,ULTRAMAX exchangers should not be operated under

vacuum or empty. The hydraulic forces encountered under theseconditions could damage the unit and pose a hazard to nearby personnel. If vacuum conditions could be encountered in your

application, a vacuum relief valve should be provided.

UM-20UM-107 UM-92 UM-77 UM-62 UM-48


5/16

2. INSTALLATION

2.1. Lifting The ULTRAMAXTo lift the ULTRAMAX, use the lifting lugs provided for that purpose. The exchanger must only be moved by means of the lifting rings or lugs provided.

WARNING: Never lift the exchanger by the nozzle tubes or apply any forces to the connections while lifting.

Figure 2.1.Lifting the horizontal conguration ULTRAMAX safely.

Figure 2.2.Lifting the vertical conguration ULTRAMAX safely.


6/16

6

2. INSTALLATION(continued)

Figure 2.3. Mount the ULTRAMAX securely using leveling shims as necessary and anchor bolts.

2.2. Mounting And Flow Control

2.2.1. General Recommendations Always follow generally accepted piping and equipment controlpractices. Observing the following recommendations will helpensure long operating life and trouble-free maintenance.

Horizontal and vertical congurations are constructed differently.Be sure to mount the unit in accordance with the orientationspecied on the Application Data Sheet and drawings.

The unit should be mounted so that it fully drains and canbe vented.

2.2.2. Location And Mounting1. Locate the exchanger in an area free of interference from

piping or other equipment.

2. Provide sufcient clearance along each side of the unit toallow access to the connections.

3. Use shims as necessary to level the heat exchanger.

4. Mount the unit securely to the foundation using anchor bolts.

2.2.3. Piping1. Consult Table 2.1. to avoid overloading nozzles during

installation and in the completed conguration.

2. Employ elbows and expansion couplings to accommodatethermal expansion, pulsation and hydrodynamic shock thatcould damage the exchanger or its nozzles.

3. Position pipe supports no more than 2 m (79 in.) from theconnections to prevent stress on the connection tubes.

4. Flush all approach piping thoroughly before connecting the unit.

Figure 2.4.Follow piping recommendations to prevent stress on connections and enable efcient servicing.

No More Than2 m (79 in.) From

Connections

Removable ForEase Of Access

Anchor BoltsShims As Necessary

Table 2.1. Maximum Nozzle Loading

Force

Nozzle, DN(ANSI RF)

Directcompression,N (lb)

Radial force,N (lb)

Torsionmoment,Nm (ft lb)

Bendingmoment,Nm (ft lb)

25 (1) 452 (102) 452 (102) 2 (2) 2 (2)

38 (1.5) 795 (179) 795 (179) 186 (137) 186 (137)

50 (2) 600 (135) 600 (135) 160 (120) 80 (60)

65 (2.5) 750 (170) 750 (170) 260 (190) 130 (95)

80 (3) 1000 (225) 1000 (225) 300 (220) 150 (110)

100 (4) 1400 (315) 1400 (315) 740 (540) 370 (270)

150 (6) 2700 (605) 2700 (605) 1600 (1180) 800 (590)

200 (8) 4400 (990) 4400 (990) 4500 (3320) 2200 (1660)

250 (10) 5800 (1300) 5800 (1300) 7600 (5600) 3800 (2800)

300 (12) 7000 (1570) 7000 (1570) 12000 (8850) 6000 (4425)


7/16

2.2.4. Valving And Pumps1. Operating pressures must be as stable as possible. One circuits

pressure should be higher than the other circuit by at least1 bar (14.5 psig). Pressure uctuations resulting in pressureinversions between the channels may damage the plate pack and lead to intermixing.

2. Position shut-off valves such that the exchanger can beunbolted and removed without having to remove the valves.

3. Globe or buttery valves are recommended; these should bemaintained in good working order.

4. To prevent water hammer, two-stage valves or slow-acting,throttling-capable valves should be used.

5. Do not oversize control valves; this can create on/offbehavior which may damage the heat exchanger.

6. Control sequences should be planned to prevent thermalor mechanical stresses from occurring during start-up, loadswings and shut-down.

7. Pumps serving the heat exchanger should be equipped withthrottling valves.

8. When the maximum pump discharge pressure exceedsthe maximum design pressure of the exchanger, a pressurereducing valve should be installed at the exchanger inlets.

9. Positive displacement pumps (especially reciprocating pumps)should be equipped with vibration dampers to minimizeharmonics and pulsation.

10. Positive displacement pumps must also be equipped with a pressure relief valve between the pump discharge and the heatexchanger inlet.

NOTE: Any phase changes or degasication should be indicated at time of initial design.

2.2.5. Vents And DrainsStandard ULTRAMAX models are not supplied with vent and draincouplings. If required, please advise factory at the time of order orbefore nal drawing approval. The following cases may dictate theuse of vents and drains:

1. Two-phase ow in either circuit.

2. Gas condensation applications in which noncondensable gasesare present.

3. Multi-pass designs.

In these cases, always connect the vent and drain couplings tothe draining and venting circuits through valves. The vent valveshould always be open, allowing continuous self-venting.

2.2.6. FiltersThe plate pack channel is designed for use with clean uids; thus,bers or particulate matter can plug this channel. External ltersshould be used when solids are present.

Contact your factory representative to determine proper ltrationprocedures/devices.


8/16

8

2. INSTALLATION(continued)2.2.7. Special RecommendationsFor Steam Service1. Install pressure relief valves and oat & thermostatic (F&T)

steam traps to prevent condensate accumulation in the platepack channels. This will protect the exchanger from possible water hammer damage.

2. When the unit is operating with partial vacuum or when back pressure may exceed steam pressure, condensate pumps shouldbe used to prevent backow of condensate into the exchangerand system-induced stall conditions.

3. Vacuum breakers and air vents should be installed at the platepack channel inlet to prevent condensate backow into the platedue to the vacuum produced by condensation of steam during shut-down.

4. If the ULTRAMAX is used as a steam condenser, controlthe process on the steam side. If it must be controlled on thecondensate side, the condensate control valve should operate within 80110% of its range to avoid on/off cycling.

PLC

T

Figure 2.5.Correctly engineered condensate handling will prevent system-induced stall conditions, protect equipment from damage, improve thermal control and save energy.

2.2.8. Vacuum OperationIf the ULTRAMAX exchanger will operate under either constant orintermittent vacuum (e.g., under upset conditions), make sure thatthe circuit of concern is rated for full vacuum as indicated on the Application Data Sheet and drawing. Install a vacuum break at theoutlets to prevent liquid backow and water hammer problems.

ATTENTION: Tranter is not a steam system design company. Accordingly, Tranter is not liable for ULTRAMAX units that fail when employed in substandard steam system designs. Buyersshould consult professional steam system engineers.


9/16

2.3. Common System Hook-upsOnly typical control systems are shown. The user must designand install process control systems to meet the needs of thespecic application.

2.3.1. Liquid/LiquidIn a basic system, the temperature transducer signal at the processoutlet controls the control valve at the service inlet through a PID-based controller. The control valve must not be oversized,eliminating the possibility of on/off operation that coulddamage the exchanger through fatigue and stress.

PLC

T

Figure 2.6. A basic liquid/liquid control scheme.

2.3.2. Process Fluid HeatingConstant Flow RateThe control strategy is based on condensate control. Energy delivered to the process uid will be steady and constant, whichis an ideal application for the ULTRAMAX. The cold channelprocess ow rate must be coordinated with the hot channel heattransfer rate specied for the exchanger.

The temperature signal at the process outlet processed by a PID-based loop controller regulates the condensate control valvedownstream of the steam trap. This valve must not be oversized,operating within 80110% of its range to avoid on/offbehavior. For balanced ow velocities, the condensate outlet mustbe much smaller than the steam inlet; a ratio of 1:4 is generally acceptable. Consult steam tables for accurate sizing.

T

Figure 2.7. A basic uid heating control scheme using condensate control.

2.3.3. Steam Or Vapor Condensing/LiquidIn a continuous process, steam condenses within the exchanger while heating a uid. As a process condenser, the exchangeruses chilled water to condense vapor. Generally no control isinstalled, since systems usually operate with a constant cooling medium ow rate. The return temperature is dependent on theheat load.

PLC

T

Figure 2.8. A basic heating (steam condensing) control scheme.

PLCT

Figure 2.9. A basic uid heating control scheme using bypass loop control.

2.3.4. Process Fluid HeatingVariable Flow RateIf the process flow rate varies, a bypass system should becongured for more accurate process control. In this strategy, thehot channel ow is set, but not controlled. The loop controllerregulates the recirculation ow rate, to attain the target outlettemperature, irrespective of the steam ow rate.

In heating applications, always maintain a minimum of 20%maximum ow rate in the cold channel to prevent the possibility of ashing, recondensing and water hammer in the piping.

ATTENTION: Tranter assumes no liability for or relating to the delay, failure, interruption or corruption of any ULTRAMAX unit in connection with use of this IOM.Before relying on the information contained in this IOM,buyers should independently verify its accuracy, currency,completeness and relevance for individual applications.Buyers should obtain appropriate professional advice from

a professional process design company.


10/16

10

3. OPERATION

3.1. Critical Operating Principles All operators should familiarize themselves with the following operating principles, which are critical in preventing damage tothe unit.

CAUTION: In steam applications, never leave the steam on with theliquid side turned off. Turn the steam off rst and on last.

1. Water hammer, if suspected, must be diagnosed and eliminated,or damage may result to the ULTRAMAX.

2. Pumps should always be started against closed valves.

3. Valves must be set to open and close gradually. Sudden opening and closing of the valves will subject the exchanger to mechanicaland thermal shock and may cause material fatigue.

4. Starting up and shutting down should be managed to minimizedifferential expansion between the plate pack and shell assemblies.Follow the stated start-up and shut-down steps in order.

5. Starting up and shutting down should be managed to minimizedifferential expansion between the plate pack and panelassemblies. Follow the stated start-up and shut-down stepsin order.

6. The maximum temperature rise measured at the hot channeloutlet should be no more than approximately 10C (18F)per min. If feasible, the temperature rise should be as slow as possible.

Figure 3.1. Always start the cold side rst, then the hot side.

Figure 3.2. Always shut down the hot side rst, then the cold side.

2. EstablishSteam Flow

1. Establish ColdChannel Flow

1. Shut Off Steam Flow

2. Shut Off ColdChannel Flow

3.2. Starting Up1. Inspect the unit carefully for integrity.

2. After extended storage or time off-line, ensure that the

approach piping is free of scale or contamination that may clog the uid passages.

3. Make sure that all inlet and outlet connections are tight.

4. Always establish the cold side ow rst, then the hot side ow.

5. Make sure the cold side inlet valve between the pump andULTRAMAX unit is closed.

6. Fully open the shut-off valve at the outlet (if one was installed).

7. Open the vent valve to evacuate air.

8. Start the pump.

9. Slowly open the feed valve. Close the vent valve when all air hasbeen removed.

10. Wait several minutes, then repeat Steps 59 for the hot side,taking approximately 5 min. to fully open the inlet valve.The maximum temperature rise measured at the hot channeloutlet should be no more than approximately 10C (18F)per min. If feasible, the temperature rise should be as slow as possible.


11/16

4.1.2. Internal LeaksInternal plate leaks result in cross contamination between thetwo circuits. A unit with internal leaks requires factory serviceor replacement.

4.1. Troubleshooting

4. MAINTENANCE

SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION REMARKS

External leakage at box panels. Cracked plate pack core. Contact Tranter for advice. If water hammer is suspectedas cause, see Section 2.2.7.for recommendations.

Internal leak (crosscontamination).

Plate cracked (water hammer)or hole in plate (corrosion).

Contact Tranter for advice. If corrosion is suspected asthe cause of the failure, check the chloride content of theuids. If high, contact thefactory for advice.

Reduction in thermalperformance; no increase inpressure drop.

Plate(s) cracked (waterhammer) or hole in plate(corrosion).

Contact Tranter for advice. If corrosion is suspected asthe cause of the failure, check the chloride content of theuids. If high, contact thefactory for advice.

Gradual reduction in heat

transfer performance.

Fouling in the internal plate

and/or pressure core channel.

Execute CIP procedures

(see Section 4.2.).

Re-evaluate cleaning

schedule to avoid unscheduledshut-downs.

Sudden reduction in heattransfer performance.

Slug, large particulate ordebris.

Backush or utilize CIPprocedures.

Investigate and install properltration.

4.1.1. External LeaksExternal leaks emerging from the box panel joints indicaterupture of the plate pack core. The unit requires factory serviceor replacement.

3.3. Shutting DownFollow Steps 14 for the hot side rst, then repeat the procedurefor the cold side. Always decrease the ow to the hot side untilclosed. Then shut down the cold side ow.

1. Slowly close the hot side inlet valves.

2. Switch off the pump.

3. Close the outlet valves.

4. Drain and vent the unit.

5. Repeat Steps 14 for the cold side.

3.4. Periodic Flow Rate IncreasesThe rate of heat transfer surface fouling is affected by uidvelocity. Tranter recommends that the ow rate be increased if possible at regular intervals. The increased turbulence within the

channel retards the rate of fouling. The frequency and duration of this preventive cleaning practice will vary depending on operating uid velocities and fouling tendencies of the medium.


12/16

12

CAUTION: Always add cleaning solution concentrates to thedilution water and mix well before circulation begins.

4.2.1. Clean-in-place (CIP) Guidelines And Procedures1. Drain both channels and ush the process circuit with cold, fresh water. If the cooling circuit uses seawater, ush this channel also.

2. Flush both channels with warm water, 4050C (100120F),until the efuent water is clear.

3. When mixing the cleaning solution, use chloride-free or low chloride water with a low hardness value.

4. If possible, pump the cleaning solution opposite the normalow direction for back-ushing action.

5. Pump the cleaning solution at ow rates up to 1.5 times thenormal working ow rate, where possible, without exceeding the maximum nozzle velocity of 8.5 m/sec (28 ft/sec).

If high CIP ow rates cannot be attained, use a solution capableof dissolving deposits at lower ow rates and/or lengthen theCIP cleaning cycle.

6. Hydraulic shock must be avoided; use centrifugal CIP pumps thatcan attain the CIP ow rate and operating pressure gradually.

7. After completing the cleaning cycle, ush the exchanger andapproach piping with clean water.

4. MAINTENANCE(continued)

TYPE OF FOULING SUGGESTED CLEANERS

Calcium sulphate, silicates Citric, nitric, phosphoric or sulfamic acid

Calcium carbonate 10% nitric acid (1 volume concentrated nitricacid with specic gravity 1.41 to 9 volumes ofwater), Oakite 131

Alumina, metal oxides, silt Citric, nitric, phosphoric, or sulfamic acid (Toimprove cleaning add detergent to acid.)

Barnacles, mussels, seaweed, wood chips Back ush per cleaning-in-place procedurebelow

Biological growth Sodium carbonate or sodium hydroxide

Table 4.1 CIP Cleaning Solutions4.2. Cleaning The ULTRAMAXThe ULTRAMAX Heat Exchanger is engineered and constructedfor many years of reliable performance. Some uids under certaintemperature and pressure conditions, while compatible with

ULTRAMAX technology, can tend to scale or foul the platesover time.

The ULTRAMAX, as an all-welded unit, is essentially a weldedpressure vessel that cannot be disassembled in its standardconguration. The same design that gives the ULTRAMAX itsperformance also makes in-line maintenance the only practicalcleaning strategy.

Accumulation of deposits inside the process circuit reduce theheat transfer rate and cause excessive pressure drops through thesystem. The operator must establish optimal methods, frequency and cleaning solutions to remove deposits without damaging the plates.

Following are some general guidelines for cleaning.

1. Do not use hydrochloric acids, or water containing in excessof 300 ppm chlorides, with stainless steel.

2. Do not use phosphoric or sulfamic acid for cleaning titaniumplates.

3. Limit cleaning solution concentration to 4% in strength, with temperatures not exceeding 140F unless otherwisespecied.

CAUTION:1. When handling any cleaning solutions, closely follow the

safety recommendations provided by the cleaning solutionmanufacturer.

2. Always wear protective goggles and rubber gloves.3. When diluting acid, always add acid to water.4. Do not use hydrochloric acid (HCl or muriatic acid) for

cleaning stainless steel plates.5. Caustic soda and concentrated nitric acid can cause serious

injuries to skin and mucous membrane.


13/16


14/16

14

Figure 5.2.ULTRAMAX identity plate and nameplate.

For additional information on this unit, contact Tranter, Inc. at Phone: (800) 414-6908

5. NOMENCLATURE

ULTRAMAX

Heat Transfer Surface Area Per Plate (10 x ft2)

Theta Of Plate(M=Medium)

Plate Thickness(09=0.9mm)

Pressure ClassUS = 10.3 bar (150 psi)SS = 20.7 bar (300 psi)

MS = 34.5 bar (500 psi)

Number Of HeatTransfer Plates

UMS-107-M-09-US-64

Figure 5.1.ULTRAMAX model code sequence.

Nozzle ClassS=4, 6 and 8 in.L=10 and 12 in.


15/16

6. ADDITIONAL INFORMATION

6.1. Damaged ShipmentsOur equipment is carefully packaged and shipped in goodcondition. Shipments are made at the consignees risk. Uponreceipt of shipments, carefully inspect the packaging and

equipment for damage. In the event of loss or damage all claimsshould be made to the carrier.

6.2. ReturnsUnits or parts are not to be returned without rst obtaining permissionfrom your nearest Tranter, Inc., plant. Parts authorized for return mustbe properly packaged and labeled and in good condition upon arrivalat the Tranter, Inc., plant. All credits for returned materials will besubject to restocking and transportation charges.

6.3. Information And SupportThis manual is also available on-line at www.tranter.com. Visit our website at www.tranter.com for parts and quotations, or e-mailus directly at [email protected].

6.4. Authorized Service CentersTo obtain additional information on operation and maintenance,contact your local Tranter, Inc., representative or the nearestTranter, Inc., factory-authorized Service Center.Tranter, Inc.Factory/Sales/Engineering Ofce1900 Old Burk Highway

Wichita Falls, TX 76306Tel. 1-800-414-6908 Fax: 940-723-5131E-mail: [email protected]

Tranter Service Center 1213 Conrad SauerHouston, TX 77043Tel. 1-800-414-6908 Fax: 713-467-1502E-mail: [email protected]

Tranter Midwest Service Center 30241 Frontage RoadFarmersville, IL 62533Tel. 217-227-3470E-mail: [email protected]

Tranter International AB Wakeeld Factory Tranter Ltd, Unit 50Monckton Road Industrial Estate

Wakeeld WF2 7AL EnglandTel. +44-1924 298 393 Fax: +44-1924 219 596E-mail: [email protected]

Tranter International ABRegementsgatan 32PO Box 1325SE-462 28 Vnersborg SwedenTel. +46 521 799 800 Fax: +46 521 799 822E-mail: [email protected]

Tranter International ABKthe-Paulus-Strasse 9Postfach 10 12 14DE-31137 Hildesheim Germany Tel. +49-512 175 2077 Fax: +49-512 188 8561E-mail: [email protected]

Tranter International ABVia Ercolano, 24IT-20052 Monza MI Italy Tel: +39-039 28 282 210 Fax: +39-039 834 315E-mail: [email protected]

Tranter Ind e Com de Equipamentos Ltda Av. Leonil Cre Bortolosso, 88 Galpo 1 -Vila Quitana 06194-971 Osasco, SP BrazilTel. +55 11 3608-4154E-mail: [email protected]

Tranter India Pvt. Ltd.Gat. No. 985, Sanaswadi Tal. ShirurDist.Pune -412 208 (India)Tel. +91-2137 392 300 Fax: + 91 2137 252 612E-mail: [email protected]


16/16

www.tranter.com

The ULTRAMAX All Welded Plate Heat Exchanger is covered under US Pat No. 6,516,874.

At the forefront of heat exchangertechnology for more than 70 years

Tranter top quality, high-performance, proprietary products are on the job in demanding industrial andcommercial installations around the world. Backed by our comprehensive experience and worldwide presence,Tranter offers you exceptional system performance, ap-plications assistance and local service. Tranter is closeto its customers, with subsidiary companies, agents,distributors and representatives located worldwide.Contact us for a qualied discussion of your needs.

North/South AmericaTranter, Inc. Wichita Falls, TX USA Tel: (940) 723-7125Fax: (940) 723-5131E-mail: [email protected]

EuropeTranter International ABStockholm, SwedenTel: +46 (0)8 442 49 70Fax: +46 (0)8 442 49 80E-mail: [email protected]

Middle East/AsiaTranter India Pvt. LtdPune, India Tel: +91 20-30519300Fax: +91 20-30519350E-mail: [email protected]

Date post:	02-Apr-2018
Category:	Documents
Upload:	enescon-sac
View:	220 times
Download:	0 times

Manual de Intercambio de Calor 04

Documents