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170/150 Minera
electrolyte
NT150L Mexico
plates: 254SMO 墨西哥矿业公司 200 m³/h from 58°C to 66°C
gaskets EPDM
by 133°C steam
170/160 SPCC
4%H2SO4&
NT250L (Southern Peru Copper)
plates: AISI904L 南秘鲁铜业公司 400 m³/h from 64°C to 76°C
gaskets EPDM
by 121°C steam
170/1350 BHP
electrolyte
NT150S Billiton Copper
plates: 254SMO Australia 310m³/h from 53°C to 64°C
gaskets EPDM 澳大利亚必和必拓铜业公司
by 143°C steam
基伊埃板式热交换设备(上海)有限公司
1 / 69
Document No: GEFXC/QM1000 Revision No: A2
Chapter (章节) 1
CONTENTS(目录) Page (页码) No. 1 of 1
Rev. (版本) A2
Date(日期) 09.01.2008
REVISION DATE
(版本) (日期)
COVER PAGE(封面) A2 09.01.2008
1. CONTENTS(目录) A2 09.01.2008
2 / 69
Document No: GEFXC/QM1000 Revision No: A2
Chapter (章节) 1
GLOSSARY OF TERMS & ABBREVIATIONS Page (页码) No. 1 of 2
Rev. (版本) A2
(术语和缩略语) Date(日期) 09.01.2008
TERMS(术语)
CODE ASME Boiler & Pressure Vessel Code Section VIII Division 1 and any
(规范) referenced codes and standards(ASME 压力容器规范第 VIII 节第一分
册以及其它相关标准规范)
3 / 69
Document No: GEFXC/QM1000 Revision No: A2
Chapter (章节) 2
GLOSSARY OF TERMS & ABBREVIATIONS Page (页码) No. 2 of 2
(术语和缩略语) Rev. (版本) A2
Date(日期) 09.01.2008
ABBREVIATIONS (缩略语)
AI Authorized Inspector(授权检验员)
AIA Authorized Inspection Agency(授权检验代理)
AIS Authorized Inspector Supervisor(授权检验主管)
ASME American Society of Mechanical Engineers(美国机械工程师协会)
ASTM American Society of Testing & Materials(美国试验材料协会)
BPHE Brazed Plate Heat Exchanger(钎焊板式换热器)
COC Certificate Of Compliance(合格证)
GEA GEA Ecoflex China Co. Ltd.(基伊埃板式热交换设备(上海)有限公司)
GRIR Goods Receipt Inspection Report(产品验收报告)
GM General Manager(总经理)
HT Heat Treatment(热处理)
HTR Heat Treatment Requisition(热处理要求)
HR Human Resources(人力资源)
MAWP Maximum Allowable Working Pressure(最高允许工作负荷)
MDR Manufacturer’s Data Report(制造数据报告)
MT Magnetic Particle Inspection(磁粉探伤)
MTE Measurement & Test Equipment(检测设备)
MTR Material Test Report(材料测试报告)
NCR Non-conformity Report(不符合项报告)
NB National Board of Boiler & Pressure Vessel Inspector(锅炉压力容器检验员)
NDE Non-destructive Examination(无损检测)
OA Order Acknowledgement(订单确认)
PO Purchase Order(采购订单)
POS Purchase Order Specification(采购订单规程)
PQR Procedure Qualification Record(鉴定记录程序)
PT Liquid Penetrant Examination(液体渗透检测)
PWHT Post Weld Heat Treatment(焊后热处理)
QA Quality Assurance(质量保证)
QAP Quality Assurance Plan(质量保证计划)
QC Quality Control(质量控制)
QCM Quality Control Manager(质量控制经理)
RT Radiographic Examination(射线检验)
UT Ultrasonic Examination(超声波检验)
WPQ Welder’s Performance Qualification(焊工资质)
WPS Welding Procedure Specification(焊接程序规程)
SIR Stage Inspection Report(检验报告)
4 / 69
Document No: GEFXC/QM1000 Revision No: A2
Chapter (章节) 3
STATEMENT OF AUTHORITY Page (页码) No. 1 of 1
Rev. (版本) A2
(授权声明) Date(日期) 09.01.2008
SCOPE:
Assembly of unit in a clean,careful and professional way for better performance of unit
along with customer satisfication
PURPOSE:
To assembly plates with gaskets and then with the frame, opening and the complete unit
in a proper way carefully for better performance.
PROCEDURE:
The assembly of the plate heat exchanger (PHE) should be done as per the production
plan.
The proper plate types should be taken out from the warehouse for assembling.
During assembly of gaskets with plates, make sure that the gaskets are fixed very properly
in the exact location of the grooves of the plates.
During assembly of plates (plates with gaskets) with the frame, please check the
cleanliness of the plates. In case of any presence of dusts in the plates and gaskets, it
should be cleaned properly before putting into the frame.
When assembling one unit, the production manager should take care of receiving exact
number of plates (plates with gaskets) from warehouse and handover to the factory people
for assembly work of the complete unit should be at a time continuousely that means the
plates should not be kept open for a long time because there is possibility of dust particles
stick to the plates.
After assembling the plates, the tightening of bolts should be done in the proper sequence
as per the procedure in a diagonal manner properly.
After tightening of bolts, the dimension of ‘A’ should be checked very carefully as per the
drawing and it should be same everywhere throughout the unit.
Plate pack should form the honeycomb structure after tightening of all the bolts.
GEA Ecoflex China Co., Ltd.
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Website: www.gea-ecoflex-ap.com
After proper assembly, make sure that the unit is properly cleaned and then it should be
ready for hydropressure test.
During hydropressure test, it should be done in a completely dry place with the desired
pressure.
During 30minutes of testing, one thick paper pad should be kepy below the plate pack for
easy checking of any leakage if any.
After successful hydropressure test, the unit should go for packing.
Before packing, all dimensions, name plates, painting, sticker etc. has to be checked very
carefully to minimise the mistakes if any.
WORK INSTRUCTION:
OPENING PROCEDURE
Before opening the plate heat exchanger, it must be cooled below 35ºC, and it must not be pressurized. If the
plate heat exchanger is opened at a temperature higher than35ºC, the gaskets can get loose from the plates.
The steps involved for opening are as follows:
a) Remove pipe connection from heat exchanger.
b) Remove protected cover from tightening bolt.
c) Open the tightening bolt from the frame as a rule in the heat exchanger.
d) Move the follower cover for disassembling the plate from frame.
e) Opening of plate package
Slowly close the valves on the inlets.
Switch off pumps and close the valves on both outlets.
If system is hot, then wait till temp. will be cooled down to min. 40 0C.
Drain and dismantle any pipe bends connected to the pressure plate so that it can be moved freely along the
carrying bar.
Check sliding surface of carrying bar and pressure plate cooler.
Clean the threads of the tightening bolts and lubricate with grease.
Mark the no. of plates in sequence.
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.
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Website: www.gea-ecoflex-ap.com
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: 1
FIG: 2
The above two figures (FIG 1 & 2) show the sequence of opening of bolt structure for plate package.
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Website: www.gea-ecoflex-ap.com
CLOSING OF PLATE PACKAGE
The steps involved for closing of the plate package are mentioned as follows.
a) Check that all sealing surfaces (surfaces in contact with heat transfer medium) should be free from any kind
of dusts.
b) Check that all gaskets are in good and correct condition.
c) Clean and lubricate the sliding surfaces of the carrying bar.
d) Inspect the pressure plate cooler.
e) The plates should be hanged in proper order.
f) Press the plate assembly together and it should form a honeycomb structure.
g) Place the bolts that are fitted with bearing boxes in position.
h) Clean and lubricate the threads with a thin layer of grease.
i) Tightening of the bolts should be carried out alternately and diagonally.
j) Check the position of the bolts during tightening.
FIG: 3
FIG:4
The above two figures (FIG 3 & 4) show the sequence of closing of bolt structure for plate
package.
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Website: www.gea-ecoflex-ap.com
ASSEMBLING OF PLATE HEAT EXCHANGER
FIG: 5
The above figure (FIG: 5) shows the pate side view honeycomb structure of the plates.
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: 6). 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.
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Website: www.gea-ecoflex-ap.com
FIG: 6
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.
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.
Chlorine, commonly used as growth inhibitor, in cooling water system, 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 attacked by cholrine. The intensity
of the effect of the chlorides depends on the temperature, concentration and PH of the medium.
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Website: www.gea-ecoflex-ap.com
CLEANING
All systems, where sea water is used is more exposed to fouling but in other cases to less extent. Fouling may
occur in ports and at the plate’s entry region. It can increase the pressure drop and reduces the flow rate resulting
in insufficient heat transfer. So cleaning is very much necessary to remove those fouling from the plate heat
exchanger (PHE).
Deposits on the Heat Transfer (HE) plates can resulet in following things.
a) impair the heat transfer between flow through media.
b) Increase pressure loss
c) Can cause or accelerate HE plate corrosion.
Fouling on the plates can be removed by manual cleaning or by CIP (cleaning in place).
The cleaning of PHE depends on the capacity as well as the corrosion resistance of the system.
A. MANUAL CLEANING
The PHE is separated and the plates are pulled from each other.
For coarse contamination, use a high pressure cleaner jet to loosen the particles.
Wash each plate from both sides with flowing warm water and a soft brush.
In any circumstances, neither the plates or gaskets can bear heavy handed or robust treatments.
CAUTION
- At every cleaning, make sure that no dirts or foreign particles can settle on or under the gaskets,
which leads to leakge.
- Hard cleaning tools (e.g. brushes with metal bristles) can damage the metallic surfaces of the HE
plates and gasket surfaces. Damaged metal surfaces can lead to corrosion of the HE plates. Damge
gasket surfaces can lead to leakages of the PHE when restarting it. So never use hard cleaning tools.
- Ensure that the stream of the high pressure jet always directs face-on at the gaskets in order to avoid
loosening them.
B. CHEMICAL CLEANING
use nylon or other types of soft scrubbing brushes with detergent.
Use acetone or other types of solvents which don’t contain chlorine to remove old gasket glue.
Alternatively use LP gas flame heating on the reverse side of the plate.
Do not use any other type of gas which may produces 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.
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
If the plates are removed for chemical cleaning, be sure that they are re-Website: www.gea-ecoflex-ap.com
fitted the same order.
Always remove plate one by one and number them properly.
A high pressure cleaner can be used with absolute care and never add abrasives.
Stubborn contamination, such as coatings on the plate surface, which are not released by soaking in an open
chemical bath.
Before reassembling the cleaned HE plates, always rinse them with sufficient clean water. Remove foreign
matter on the gaskets with a soft brush.
Important Instructions:
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 input.
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 beinng replaced.
NOTICE
never use metal brush, steel wool or sand/glass paper or similar to this type. A high pressure cleaner can be
used with proper care.
Always use gloves and eye goggles when using detergents.
Only use chloride free or low chloride water with a low hardness value for the cleaning liquid.
Chemical cleaning processes can attack the gasket materials and create leaks. Always use cleaning agents
that do not attack the gasket materails. Choose a suitable temperature and do not let the cleaning agent take
effect on the materials for a long time unnecessarily.
The use of agreesive cleaning agents presents poisoning, chemical burns and buring dangers.
The used cleaning agent should be completely removed from the PHE after cleaning.
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 pasivated protecting film, which must not be destroyed as the film assists in
preserving the resistance of the stainless steel.
We would like to recommend you to get confirmation from the qualified supplier of cleaning detergent maker
that it will not damage the materials of PHE.
If the solution requires circulation, 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 or cleaning specialist. We recommend that for
circulated cleaning detergent methods, the fluids should be pumped through the PHE for no less than 30 minutes.
Rinsing:
After using any type of cleaning agent, always rinse throughly with fresh water. If cleaning in place,
the recirculate fresh water for minimum of 10 mintues.
Cleaning Detergent:
Oil and grease is removed with a water emulsifying oil solvent.
Organic and grease cover is removed with sodium hydroxide (NaOH).
Maximum concentration 1.5%, max. temp 85ºC.
Concentration = 5.00 ltr. 30% NaOH per 100 ltr. Water
Stone and lime stone is removed with nitric acid. (HNO3)
Maximum concentration 1.5%, max. temp. 65ºC.
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:
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Cleaning is an important part, influencing on the effectiveness of PHE. Website: www.gea-ecoflex-ap.com
Therefore the PHE has to be separated for inspection and especially in the commissioning period. You will obtain
important experience concerning circulation times, temperatures, and chemical concentrations.
too low cleaning period.
too low chemical consumption compared to the scaling og the plates.
too long running intervals between the cleanings.
If the PHE is out of operation for a long time, it is recommended to make it empty by separating the plates and
clean it properly. Clamp the PHE lightly together and leave it covered in order to protect the gaskets against dirt
and effect of light.
GEA Ecoflex China Co., Ltd
#218,Lane 1409, Jidi Road
Huacao township, Minhang District,
Shanghai 201107
P. R. China
Tel.: +86 21 62 96 08 72
Fax: +86 21 63 90 05 56
Email: info.china@gea-ecoflex.com
Website: www.gea-ecoflex-ap.com
Primer:
- two componenet epoxy resin primer
- requires a surface preparation in accordance with ISO 8501-1 SA 2 1/2.
- NDFT: 50 µm
Top Coat:
- two component polyurethane solvent-based coating.
- NDFT: 50 µm
- All RAL tones are possible, other tones (Munsell, BS....) are also possible by customer request.
Total NDFT of this paint system: 100 µm.
Other paint systems for intermediate and high corrosiveness fluids at required temperatures as per the
requirements by customer. But this should be strictly mentioned during initial contract stage by the customer.
COMMISSIONING PROCEDURE
Procedure:
1. Befor starting up, make sure that Phe is not operated with inadmissible flow through media, pressures
and temperatures.
2. Before starting for the first time or after a long time shut down, make sure that the plate pack is
compressed to the correct tightening measurement.
3. It’s important that the system to which PHE is connected is protected aganist sudden and extreme
variations of temperature and pressure to avoid damages. This is applicable not only to the PHE but also
to the piping system and every peice of equipment included in it.
4. All piping connections should be firmly connected to the unit before start-up.
5. All air should be completely removed from the PHE.
6. Sudden start up of pump should be prohibited.
7. Pressure surges in the unit should also be avoided.
8. The minimum and maximum parameters on the name plate should not be exceeded during operation.
9. In case of long time shut down, the unit should be depressurized and completely emptied with some
basic cleaning.
Flow Inspection Record Sheet Of Assembly Line (Sample)
1/5
Welding Procedure Specification (WPS)
Variables
essential variables
Affect the bend ability and tension ability of joint
non essential variables
Can’t produce visible affection on bend ability and tension ability of joint
supplemental essential variables
Affect the toughness of joint
Essentials listed in AWS D1.1
2/5
Welding Procedure Specification (WPS)
3/5
Type of qualification test
The type and number of qualification tests required to qualify a WPS for a given thickness, diameter, or both,
shall conform to Table 2 (CJP), Table 3 (PJP) or Table 4 (fillet). Details on the individual NDT and mechanical
test requirements are found in the following subsections:
(1) Visual Inspection
(2) NDT
(3) Face, root and side bend
(4) Reduced Section
(5) All-Weld-Metal Tension
(6) Macro-etch
Number and type of test specimens and range of thickness qualified-Fillet joint
4/5
Welding Positions
5/5