Plate Heat Exchanger Installation and Operation Manual

Thermaline
th
1531 14 St NW, Auburn, WA 98001
Toll Free: 1.800.767.6720 / Phone: 253.833.7118 / Fax: 253.833.7168 / www.thermaline.com
Table of Contents
Description .............................................................................................................................................................................. 3
1.1 Safety Precautions ........................................................................................................................................................ 3
1.2 Application .................................................................................................................................................................... 3
1.3 Working Principle .......................................................................................................................................................... 3
1.4 Corrosion ....................................................................................................................................................................... 4
Installation .............................................................................................................................................................................. 4
2.1 Clearance....................................................................................................................................................................... 4
2.2 Foundations .................................................................................................................................................................. 5
2.3 Leveling ......................................................................................................................................................................... 5
2.4 Cleanliness .................................................................................................................................................................... 5
2.5 Fittings ........................................................................................................................................................................... 5
Operation ................................................................................................................................................................................ 5
3.1 General .......................................................................................................................................................................... 5
3.2 Startup........................................................................................................................................................................... 6
Maintenance ........................................................................................................................................................................... 6
4.1 Inspection...................................................................................................................................................................... 6
4.2 Fouling ........................................................................................................................................................................... 6
4.3 CIP (Clean In Place)........................................................................................................................................................ 6
4.4 Inspection and Manual Cleaning ................................................................................................................................... 6
4.5 Leaks Internal and External ........................................................................................................................................... 7
General Description ................................................................................................................................................................ 7
5.1 Frame ............................................................................................................................................................................ 7
5.2 Port Identification, Location and Labeling .................................................................................................................... 8
5.3 Gaskets .......................................................................................................................................................................... 8
5.4 Plates ............................................................................................................................................................................. 9
5.5 Flow Plates .................................................................................................................................................................. 10
5.6 Pass Plates ................................................................................................................................................................... 11
5.7 Gasket Installation and Orientation on the Plate ....................................................................................................... 12
5.8 Double Wall Plates ...................................................................................................................................................... 15
5.9 Drain Holes .................................................................................................................................................................. 16
5.10 Port Rings .................................................................................................................................................................. 17

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6.0 Disassembly................................................................................................................................................................. 17
6.1 Assembly ..................................................................................................................................................................... 18
6.1 Closing and Tightening ................................................................................................................................................ 19
6.2 Hydro Testing .............................................................................................................................................................. 20
6.2 Plate Cleaning.............................................................................................................................................................. 20
6.2 Plate Inspection........................................................................................................................................................... 20
6.3 Plate Testing While Assembled in the Heat Exchanger .............................................................................................. 22
6.3 Gasket inspection ........................................................................................................................................................ 22

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Description

1.1 Safety Precautions

-Always read the installation instructions thoroughly (See chapter, Installation).

-Always use a lifting crane or device when handling the heat exchanger.

Operation

-Always read the operation section thoroughly (See chapter, Operation).

-Never introduce hot fluid suddenly when heat exchanger is empty or cold.

-Never shock the heat exchanger with cold fluid when hot.

Transportation

-Always transport the heat exchanger in a protected position.

-Always ensure that the unit is securely fixed during transportation.

-Never lift or elevate in any way other than described in this manual.

1.2 Application
-Thermaline gasketed plate heat exchangers are designed to process a wide range of fluids and are hygienic in design
meeting FDA and 3-A guidelines for food processing as well as rugged design for industrial uses. Corrugations on the
plates may vary in pitch and depth and are optimized for performance.

1.3
1.3 Working Prin
rinciple
-Plate heat exchangers all function similarly in that product flows through channels created by two mating plates with
hot fluid on one side of the plates and cold fluid on the opposite side.

- All gasketed plate heat exchangers are designed to allow full disassembly of the unit for thorough cleaning. All
elastomers are designed to leak to atmosphere in the event of a failure eliminating the potential for cross contamination
due to seal failure.

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 Figure 1 shows a cut away view of a typical plate heat
exchanger. Gaskets are positioned to create a seal
between the plates and prevent intermixing of the fluids.

Figure 1 - Plate Heat Exchanger

1.4
1.4 Corrosion
-Corrosion is a function of the process fluid and environment. Material selection is ultimately the customers
responsibility and materials selected should be compatible with the process.

Installation
Thermaline plate heat exchangers are designed to be freestanding and can include wall or ceiling mounts. Most models
have provisions for lifting and transportation. Frames are built to customer specifications with either adjustable feet,
mounting plates with bolting holes or wall mount brackets.

2.1 Clearance
-When installing the heat exchanger, be sure to provide sufficient clearance around the unit for tie bolt and plate
removal.

Figure 2 illustrates the access needed to remove plates

from a heat exchanger.

Figure 2 Plate Removal Example

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2.2 Foundations
-Foundations must be adequate in strength to support the heat exchanger in order to prevent the unit from settling and
imposing excessive strains on the exchanger. Foundation bolts should be set to allow for setting inaccuracies.

2.3 Leveling
-The heat exchanger must be set so that pipe connections can be made without the use of excessive force. However,
small forces might be unavoidable, at which point small forces are then acceptable.

2.4 Cleanliness
- Protective plugs should not be removed from connections until just prior to installation.

- The entire system should be cleaned before starting operation. All exchanger openings should be inspected for foreign
material before operation.

2.5 Fittings
-By-pass valves.
User may install valves and by-passes in the piping system to permit inspection and repairs.

-Test connections.
The user may opt to install a thermometer well and/or pressure gauge connections close to the exchanger.

-Vents.
The user may install vent valves close to the exchanger.

-Pulsation and vibration.

Care should be taken to eliminate or minimize transmission of fluid pulsations and mechanical vibrations into the heat
exchanger.

-Safety relief devices.

It is the users responsibility to install the required safety devices.

Operation

3.1 General
The heat exchanger must not be operated at conditions, which exceed those specified on the data plate.
Caution: If the heat exchanger surface temperature is expected to be hot or there are local regulations related to
surface temperature, it is the users responsibility to either insulate the unit or take precautions by labeling the unit
with a warning about the hot surface temperature to avoid risk of personnel injuries

Special Instructions: Before placing the heat exchanger in operation, reference should be made to the provided
technical documentation for any special instruction.

Regulations: Local safety and health regulations must be considered.

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 Improper start-up or shutdown sequences may cause leaking in the connections to the heat exchanger. It is the
customers responsibility to ensure a proper start-up and operation when running media with a higher risk for
damages on the heat exchanger.

3.2 Startup
-During start-up all vent valves should be opened and left open until all passages have been purged of air and are
completely filled with fluid. Fluid must be introduced in a manner to minimize differential expansion.
Caution: Adjustments of flow rates should be made slowly to avoid the risk of pressure surge or water hammer.
Water hammer can cause considerable damage to the equipment.
-Shutdown operation: The heat exchanger must be shut down in a manner that minimizes different expansions.
When shutting down the system, the heat exchanger should be drained completely.

-Temperature shocks: The heat exchanger should not be subjected to abrupt temperature fluctuations. Hot fluid
must not be suddenly introduced when the unit is cold nor cold fluid suddenly introduced when the unit is hot.

-Gaskets: The heat exchanger is pressure tested before leaving the manufacturers shop in accordance with various
standards. However, normal relaxing of the gasketed joints may occur in the interval between testing in the
manufacturers shop and installation at the job site. Therefore, all external joints may require retightening after
installation and, if necessary, after the heat exchanger has reached operating temperature.

Maintenance

4.1 Inspection
At regular intervals and as frequently as experience indicates, an examination should be made of the interior and
exterior condition of the unit. Neglect in keeping all plates clean may result in decreased performance of the heat
exchanger.

4.2 Fouling
Heat exchangers are subject to fouling or scaling and should be cleaned periodically. A light sludge or scale coating
on the plates greatly reduces its thermal efficiency not only on the product side but the media side as well. An
increase in pressure drop and/or reduction in performance usually indicate that cleaning is necessary.

4.3 CIP (Clean In Place)

lace)
-Plate heat exchangers are designed to be chemically cleaned in place. CIP is a function of the process and adequate
time, temperature, flow and concentrations are needed for satisfactory cleaning.

Caution: Chemicals used for cleaning must be compatible with materials of construction.

4.4
4.4 Inspection and Manual Cleaning
Before disassembly the user must assure that the unit has been locked out, de-pressurized, ambient temperature
and drained.

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4.5 Leaks Internal
nternal and External
-External leaks: All plate heat exchangers are designed so that an elastomer failure will leak to the ground. Identify
the leaking elastomer and follow disassembly/assembly procedures to replace the elastomer.

-Internal leaks: Internal leakage can cause intermixing of fluids and will not be visible. Plate heat exchangers used in
sanitary applications should be tested regularly with the Thermaline Cross Contamination Tester (CCT 4.0) Visit
www.Thermaline.com/cct to find out more.

Figure 3 shows the CCT 4.0 Installed on heat exchanger

testing for internal defects.

Figure 3 - Thermaline's Cross Contamination Tester 4.0

General Description

5.1 Frame
-Frames consist of a fixed head, movable head, top/bottom rails, end support and tie bolts.

-Frames can be free standing with ball/tabbed feet or can be equipped with a bracket mount.

-Heat exchangers with multiple sections require center frames dividing each section.

Figure 4 shows the typical

frame components found
on a plate heat exchanger.

Figure 4 - Plate Heat Exchanger Part Diagram

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5.2 Port Identification, Location and Labeling
Labeling
-Ports are labeled clockwise starting from upper left and always viewed from the front of the heat exchanger.

Figure 5 shows the port labels used. The Fixed

head is prefixed with F and movable head is
prefixed with M.

Figure 5 - Fixed and Movable Head Labeling

-Center frames are prefixed with the sections they fall between and the orientation of the port.

Figure 6 shows the labeling used for all Center

frame ports, horizontal and vertical.

Figure 6 - Center Frame Port Labeling

5.3
5.3 Gaskets
-Gaskets are made from a variety of materials compatible with your process. Original Gasket materials are noted on
assembly documentation.

-The first gasket in each section is a start gasket which has rings around all four ports in order to create a seal against the
fixed head or center frame.

-Start gaskets can be made of one piece or several pieces to make up the gasket

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 Figure 7 shows a Start gasket which is
used to start each section of the heat
exchanger

Figure 7 Start Gasket

-All remaining gaskets are flow gaskets. Flow gaskets are either diagonal or parallel and are model specific.

-Flow gaskets are glueless and clip to the plate

Figure 8 shows the difference

between a Diagonal flow and
Parallel Flow plate.

Figure 8 Diagonal and Parallel flow plates

-Flow gaskets are equipped with a leak detect to prevent fluids from intermixing in the event of an elastomer failure.

Leak Detect Vents

to Atmosphere

Figure 9 shows the location of Leak

tect Vents Leak Detect Vents detect vents placed in the gasket.
to Atmosphere

Figure 9 - Gasket Leak Vents

5.4
5.4 Plates
-Plates are made from a variety of materials compatible with your process original materials are noted on assembly
documentation.

-Plates have various corrugation patterns and can be mixed to optimize performance.

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 Figure 10 - Example of
plate patterns.

Left: Washboard

Middle: CH

Right: CDX

Figure 10 Plate Corrugation Patterns

-Most plate models are bi-directional with an N stamped on one end signifying North. These plates, when installed
in a frame, will alternate between North and South.

Figure 11 shows an N Stamped on the North side of a

T8 plate.

Figure 11 N Stamp

-Certain plate models hang in a frame in only one direction therefore requiring two different plates to make a pair a
Left plate and a Right plate.

5.5
5.5 Flow Plates
-Plate port locations are labeled clockwise starting from upper left as 1 and always viewed from the gasketed side.

-A number in the callout represents a port hole in the location and a 0 in the location callout represents a block in the
port location.

Figure 12 shows a flow plate ported 1234, with all

four ports open.

Figure 12- Flow Plate Labels

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5.6
5.6 Pass Plates
-Pass plates are used to direct flow internally by blocking ports.

-Plate port locations are labeled clockwise starting from upper left as 1 and always viewed from the gasketed side.

-A number in the callout represents a port hole in the location and a 0 in the location callout represents a block in the
port location.

Figure 13 - Example of pass plates:

Left: 0000 all four port locations blocked

Middle: 1034 upper right port location blocked

Right: 1200 both bottom ports blocked

This is only a sample there are many other

combinations

Figure 13 - Pass Plates

-Pass plates are directional and port callouts must be read with the plate in the correct direction. Bi-directional plates
are read with the N facing up and non-directional plates called out as Left or Right.

-Models T4, T8, T13, T20 and T28 feature the Patent pending Smart Identification System (SIS). SIS is a tab protruding
from the body of a plate with the location of the plate within the plate pack and the port callout.

Figure 14 shows the Smart

Identification System (SIS)
Identifying a pass plates port callout
and location.

Figure 14 Smart Identification System Plate

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 Figure 15 shows the (SIS) Plates
installed in a frame.

Figure 15 SIS plates Installed in Frame

5.7 Gasket Installation and Orientation on the Plate

Parallel flow Bi-directional plates: (Bi-directional plates can be installed with either end up and will alternate between
North and South during assembly)
-All plates are viewed from the gasket side.
-Each plate is stamped with an N denoting the North side of the plate. The plates will alternate between North and
South orientation when installed into the unit.
-The first plate in each section is the start plate and requires a start gasket which has port rings around all four ports.
Start gaskets may be a single piece or made up of several pieces.
-All remaining plates in the unit require a flow gasket. With the N facing up the gasket port rings will cover the left
ports leaving the right open to flow.
-All odd numbered plates (1,3,5,7 etc.) including the start plate, will be installed N (North) facing up just below the top
rail.
-All even numbered plates (2,4,6,8 etc.) will be installed in the South orientation by rotating the plate 180 so the N
faces downward above the bottom rail.

Figure 16 shows two Bi-directional parallel flow

plates. The Left plate is in the South orientation
and is considered an even numbered plate. The
Right plate is in the North orientation and is
considered an odd numbered plate. The pictured
plates have identical gaskets and gasket
orientation. The left and right plates are simply
rotated to the South and North orientation
respectively.

Figure 16 Parallel Bi-Directional Flow Plates

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Diagonal flow Bi-directional plates: (Bi-directional plates can be installed either end up and will alternate between
North and South during assembly)
-All plates are viewed from the gasket side.
-Each plate is stamped with an N denoting the North side of the plate. The plates will alternate between North and
South when installed into the unit.
- The first plate in each section is the start plate and requires a start gasket which has port rings around all four ports.
Start gaskets may be a single piece or made up of several pieces.
-All remaining plates require a flow gasket. The flow gasket is the same for North and South plates it is the orientation
in which the gasket is installed onto the plate that determines if the plate is a North plate or South plate.
-All odd numbered plates (1,3,5,7 etc.) including the start plate, will be installed N (North) facing up just below the top
rail. For all North plates, the flow gaskets MUST be installed with the port rings around the upper right port and lower
left port.
-All even numbered plates (2,4,6,8 etc.) will be installed South by flipping the plate so the N faces downward above
the bottom rail. For all South plates, the flow gaskets MUST be installed with the port rings around the upper left port
and lower right port.

Figure 17 shows two Bi-directional diagonal

flow plates. The Left plate is in the South
orientation and is considered an even
numbered plate. The Right plate is in the
North orientation and is considered an
odd numbered plate. Each plate requires the
same gasket but the gasket must be
installed in a different orientation to make a
South or North plate.

Figure 17- Diagonal Bi-direction Flow Plates

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Diagonal flow directional plates: (Directional plates can only be installed in one orientation)
-All plates are viewed from the gasket side.
-Left Plates and Right Plates are different! Plates are pressed as either a left or right plate and require a left or right
gasket respectively.
Left plates: With the gasket installed flow will connect between the upper right port and the lower left port.
Right plates: With the gasket installed flow will connect between the upper left port and the lower right port.
-The first plate in each section is the start plate and requires a start gasket which has port rings around all four ports and
may be made up of several pieces.
-All remaining plates require a flow gasket. The flow gaskets are Left and Right gaskets and can only be installed onto
their respective plates.
-All odd numbered plates (1,3,5,7 etc.) including the start plates are typically Left plates
-All even numbered plates (2,4,6,8 etc.) are typically Right plates.

Figure 18 shows Directional diagonal flow plates. These

plates hang in only one direction and gaskets are not
interchangeable between a left plate and right plate. A
Left plate permits flow across the plate from the upper
right port to the lower left port. A Right plate permits
flow across the plate from the upper left port to the
lower right port.

Figure 18 Directional Flow Plates

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5.8 Double Wall Plates
-Double Wall Plates are two plates nested together to form a safety barrier between the fluids in the event a plate fails
the fluid will leak externally rather than into the adjacent fluid.
-Plate pairs have large apposing cutouts in the port area and require a thick ring gasket to seal through the large cutouts.
-Double wall plates can be either diagonal or parallel flow.

Figure 19- Double Wall Plates

Figure 19 depicts an exploded view of

Thermalines double wall plate configuration.

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5.9 Drain Holes
-Certain process applications require a drain hole in lower blocked pass plates for self-draining.
-Drain holes are noted on a units assembly drawing with an *.
-Drain holes are also labeled on SIS plate ID tabs.

Figure 20 is an example of drawing block

denoting pass plates with drain holes (*) and
their numbered location within the plate
pack.

Figure 20- Block Plate ID for Technical Drawings

Figure 21 shows a 3/16 Drain hole in a

plate with the lower ports blocked.

Figure 21 Drain Hole in a Block Plate

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5.10 Port Rings
-Fluids exiting the movable head or an intermediate grid require port ring(s) to seal the rear of the plate to the heads or
intermediate grid.
-Port rings are typically the same materials as the gasket. Refer to assembly documentation.

Figure 22 shows Port rings in movable head

used to create a seal between the head
and the adjacent plate.

Figure 22 Port Rings on a Movable Head

Plate and Gasket Documentation

-Technical specifications pertaining to the heat exchanger can be found on a units technical drawing under the gasket
text block.

-The gasket text block notes the plate type, plate material, gasket type and gasket material.

Figure 23 shows the gasket text block found

in a technical drawing which identifies the
parts used in a unit and proper orientation
of the heat exchangers plates.

Figure 23 Gasket Text Block

6.0 Disassembly
-To disassemble a unit be sure to, drain fluids, lock out as necessary, cool to ambient temperature and remove pipes.
-Loosen one Tie bolt at a time no more than moving in a star pattern until the plates are decompressed.
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-Once the movable head is loosened, plates are ready to be removed.
-Please visit www.Thermaline.com/common/videos and watch the Thermalines plate heat exchanger maintenance
videos.

Note- Models T4 and T8 the plates rest in-between the upper and lower rails. Care should be taken as plates may fall out
when the movable head is slid along the rails.
Caution: Plates may have sharp edges.

6.1 Assembly
-Arrange the plates in order according to the assembly drawing specific to your heat exchanger.
-Refer to section 5.7 for plate and gasket orientation.

Note: The assembly drawing numbers only the pass plates, flow plates are not numbered on the drawing.

-In figure 23 below, #1 is the start plate ported 1200 and plates 2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17 and 18 are all
flow plates ported 1234. Flow plates are not labeled in the drawing but expected to be installed. (Refer to 5.6 for port
callouts)

-Plate #19 is a pass plate ported 0034. Plates 20,21,22,23,24,25,26,27,28,29,30,31,32,33,34,35 and 36 are all flow plates
ported 1234. Flow plates are not labeled in the drawing but expected to be installed.

-Plate #37 is a pass plate ported 1200. Plates 38,39,40,41,42,43,44,45,46,47,48,49,50,51,52,53 and 54 are all flow plates
ported 1234. Flow plates are not labeled in the drawing but expected to be installed. Plate #55 is a pass plate ported
0034.

Figure 24 Plate Flow Diagram

Figure 24 is a typical flow diagram found in a

units technical documentation.

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6.1 Closing and Tightening
Tightening
-Once all the plates are installed into the heat exchanger frame ensure the port rings, if applicable are installed in the
movable head and intermediate grids.
-Slide all plates to the rear of the heat exchanger and one at a time inspect the gasket to ensure the gasket attachments
are attached properly and the gasket is set in the gasket groove. Ensure the first plate has the proper start gasket, move
it to the front and continue to inspect each plate one at a time moving it to the front of the unit until all plates have
been inspected for proper sequencing and gasket attachment.
-Make one last check that the port rings, if applicable, are installed.
-Slide the movable head forward until it contacts the plates.
-Clean the tie bolt threads and lube the threads with anti-seize.
-Install one tie bolt in each corner and tighten the bolts by hand to square the movable head to the fixed head.
-Continue tightening each bolt one at a time in a crisscross pattern, no more than at a time, until there is light
pressure from the plates being compressed.
Caution: Do not tighten the unit completely with only four tie bolts.
-Install remaining bolts.
-Re-square the movable head to the fixed head.
-Continue tightening the tie bolts, no more than at a time, in a zigzag pattern to the specified dimension on the
assembly drawing.
-The compressed dimension is measured between the inside of the fixed head and the inside of the movable head.

Figure 25 shows the proper tightening

dimension measurements taken from
inside the fixed and movable heads.

Figure 25 Tightening dimension for a Plate Heat Exchanger

-The tightening dimension on the assembly drawing is expressed as a range of maximum and minimum distance for
which the gaskets will seal. Tighten the unit to the average of the two dimensions. Measurement should be taken at
each tie bolt adjusting the tie bolts within (+/-) 1/16 of each other.

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 Figure 26 is an example tightening dimension from an
assembly drawing. Refer to your assembly documentation for
your tightening dimension.

Figure 26 Technical Drawing Tightening Dimension

6.2 Hydro Testing

-Once the unit is tightened to the average dimension install the pipes and test with water by operating the system.
-Units may also be tested with tap water or other means not exceeding the MAWP (Maximum Allowable Working
Pressure).
-If the unit leaks externally, inspect the leaking area to ensure the gasket is seated and there are no visible defects in the
area. If a defect is found, shutdown system and relieve pressure from the unit. Then remove pipes to the unit,
disassemble the unit, repair the defect, reassemble and retest.
-If no visible defect is found shutdown the system and relieve the pressure. Tighten the tie bolts incrementally in a star
pattern and retesting until the leak stops, being careful not to exceed the minimum dimension.

6.2 Plate Cleaning

Cleaning
-Plates can be cleaned with a soft bristled brush and cleaning solutions compatible with the plate materials. Stubborn
glues and foulants may need to be soaked in heated baths of 20% caustic or phosphoric acid baths.
-Thermaline service centers provide chemical cleaning services.

6.2 Plate Inspection

-Plates are susceptible to corrosion attacks that may leave pinholes and cause fluids to intermix.
-Visually inspect the plate for any obvious defects paying close attention to the points where the plates come in contact
with one another. If a pinhole exists, most it is commonly found to be at the contact points.

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 Figure 27 shows the contact points on a plate after a plate
has been in service.

Figure 27 Plate Contact Points

-To aid in the visual inspection of pinholes and cracks, hold the plate to a bright light to perform a visual light inspection.
-A visual and light inspection may not reveal all defects. A dye test may be used to locate smaller defects.

Figure 28 shows the results of a Pin hole detected with 2 part

dye test system.

Figure 28 Results of a Plate Dye Test

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6.3 Plate Testing
Testing While Assembled in the Heat Exchanger
xchanger
-Plates may be tested for cross contamination while assembled in the unit as an entire plate pack using the Thermaline
CCT 4.0.
-CCT 4.0 is a pass/fail test or a primary test. If the unit passes there is no need proceed with secondary testing such as
dye testing.

Figure 29 shows Thermalines CCT 4.0 testing a two section

heat exchanger for leaks and pinhole cracks.

Figure 29 Thermalines CCT 4.0

-CCT 4.0 can be operated by any trained personnel through Thermalines online CCT training exercise.
-Visit Thermaline.com for maintenance plan options and more information on the CCT program.

6.3 Gasket inspection

-Gaskets have a widely varying service life and their service life is dependent on your process.
-Gaskets should be inspected for cracks and defects when inspecting the unit.
-Pinch or roll the gasket to expose defects. Visit www.Thermaline.com/common/videos for a maintenance video about
gasket inspection.
-Replace defective gaskets as necessary.

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Notes:

Thermaline
th
1531 14 St NW , Auburn, WA 98001
Toll Free: 1.800.767.6720 / Phone: 253.833.7118 / Fax: 253.833.7168 / www.thermaline.com

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