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ULTRAMAX
www.tranter.com
TABLE OF CONTENTS
1. INTRODUCTION
1.1. Product Description And Types
1.1.1. ULTRAMAX Design 1.1.2. ULTRAMAX Congurations
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3
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3. OPERATION
3.1. Critical Operating Principles 3.2. Starting Up 3.3. Shutting Down 3.4. Periodic Flow Rate Increases
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10 10 11 11
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4 4 4
4. MAINTENANCE
4.1. Troubleshooting
4.1.1. External Leaks 4.1.2. Internal Leaks
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2. INSTALLATION
2.1. Lifting The ULTRAMAX 2.2. Mounting And Flow Control
2.2.1. General Recommendations 2.2.2. Location And Mounting 2.2.3. Piping 2.2.4. Valving And Pumps 2.2.5. Vents And Drains 2.2.6. Filters 2.2.7. Special Recommendations For Steam Service 2.2.8. Vacuum Operation
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6 6 6 7 7 7 8 8
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* Tranter must have serial or drawing number to properly identify your equipment.
ATTENTION: When ordering parts or service, always provide the manufacturers serial number of the exchanger. This information appears in the General Assembly Drawing and on the exchangers nameplate. For parts, service or performance ratings, contact one of Tranters authorized Service Centers (see contact information in Section 6.4.). Available parts are limited to frames and tie bolts.
1. INTRODUCTION
This manual is intended as your general guide for the proper installation, operation and maintenance of your ULTRAMAX AllWelded 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 1.1.
Left Panel
Top Panel
Core
Bottom Panel
Right Panel
Figure 1.2.
1. INTRODUCTION (continued)
1.1.2. ULTRAMAX Congurations
Large-capacity or multi-pass configurations of the UM-20 unit incorporate up to ve cores within a single frame. The ULTRAMAX line offers six different plate lengths, including the largest plate size in its class, with an area of 0.989 m2 (10.65 ft2).
UM-107
UM-92
UM-77
UM-62
UM-48
UM-20
Figure 1.3.
ULTRAMAX Plates.
CAUTION: Unless specically stamped on the nameplate, ULTRAMAX exchangers should not be operated under vacuum or empty. The hydraulic forces encountered under these conditions 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.
WARNING: Never lift the exchanger by the nozzle tubes or apply any forces to the connections while lifting.
Figure 2.1.
Figure 2.2.
Figure 2.3.
Mount the ULTRAMAX securely using leveling shims as necessary and anchor bolts.
2.2.3. Piping
1. Consult Table 2.1. to avoid overloading nozzles during installation and in the completed conguration. 2. Employ elbows and expansion couplings to accommodate thermal expansion, pulsation and hydrodynamic shock that could damage the exchanger or its nozzles. 3. Position pipe supports no more than 2 m (79 in.) from the connections to prevent stress on the connection tubes. 4. Flush all approach piping thoroughly before connecting the unit.
Figure 2.4. 6
Follow piping recommendations to prevent stress on connections and enable efcient servicing.
2.2.6. Filters
The plate pack channel is designed for use with clean uids; thus, bers or particulate matter can plug this channel. External lters should be used when solids are present. Contact your factory representative to determine proper ltration procedures/devices.
2. INSTALLATION (continued)
2.2.7. Special Recommendations For Steam Service
1. Install pressure relief valves and oat & thermostatic (F&T) steam traps to prevent condensate accumulation in the plate pack 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 should be used to prevent backow of condensate into the exchanger and system-induced stall conditions. 3. Vacuum breakers and air vents should be installed at the plate pack channel inlet to prevent condensate backow into the plate due to the vacuum produced by condensation of steam during shut-down. 4. If the ULTRAMAX is used as a steam condenser, control the process on the steam side. If it must be controlled on the condensate side, the condensate control valve should operate within 80110% of its range to avoid on/off cycling.
PLC
Figure 2.5.
Correctly engineered condensate handling will prevent system-induced stall conditions, protect equipment from damage, improve thermal control and save energy.
2.3.1. Liquid/Liquid
In a basic system, the temperature transducer signal at the process outlet 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 could damage the exchanger through fatigue and stress.
PLC T
PLC
Figure 2.8.
Figure 2.6.
If the process flow rate varies, a bypass system should be congured for more accurate process control. In this strategy, the hot channel ow is set, but not controlled. The loop controller regulates the recirculation ow rate, to attain the target outlet temperature, 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.
PLC
Figure 2.9.
Figure 2.7.
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.
3.2. Starting Up
1. 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 and ULTRAMAX 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 has been 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 channel outlet should be no more than approximately 10C (18F) per min. If feasible, the temperature rise should be as slow as possible.
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 mechanical and thermal shock and may cause material fatigue. 4. Starting up and shutting down should be managed to minimize differential 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 minimize differential expansion between the plate pack and panel assemblies. Follow the stated start-up and shut-down steps in order. 6. The maximum temperature rise measured at the hot channel outlet 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.
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If water hammer is suspected as cause, see Section 2.2.7. for recommendations. If corrosion is suspected as the cause of the failure, check the chloride content of the uids. If high, contact the factory for advice. If corrosion is suspected as the cause of the failure, check the chloride content of the uids. If high, contact the factory for advice. Re-evaluate cleaning schedule to avoid unscheduled shut-downs. Investigate and install proper ltration.
Gradual reduction in heat transfer performance. Sudden reduction in heat transfer performance.
Fouling in the internal plate and/or pressure core channel. Slug, large particulate or debris.
Execute CIP procedures (see Section 4.2.). Backush or utilize CIP procedures.
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SUGGESTED CLEANERS
Citric, nitric, phosphoric or sulfamic acid
Calcium carbonate
10% nitric acid (1 volume concentrated nitric acid with specic gravity 1.41 to 9 volumes of water), Oakite 131 Citric, nitric, phosphoric, or sulfamic acid (To improve cleaning add detergent to acid.) Back ush per cleaning-in-place procedure below Sodium carbonate or sodium hydroxide
Biological growth
4. If possible, pump the cleaning solution opposite the normal ow direction for back-ushing action. 5. Pump the cleaning solution at ow rates up to 1.5 times the normal 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 capable of dissolving deposits at lower ow rates and/or lengthen the CIP cleaning cycle. 6. Hydraulic shock must be avoided; use centrifugal CIP pumps that can attain the CIP ow rate and operating pressure gradually. 7. After completing the cleaning cycle, ush the exchanger and approach piping with clean water.
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Self-Priming Pump
pH
Figure 4.1.
Basic CIP conguration for one ULTRAMAX channel, showing isolation valves and countercurrent cleaning.
Figure 4.2.
If the ULTRAMAX is shut down during winter, be certain the unit is completely drained to avoid freezing-induced fracture. For extended shut-downs, thoroughly ush both channels using fresh water with low chloride content to prevent pitting corrosion of the stainless steel plates.
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5. NOMENCLATURE
Nozzle Class S=4, 6 and 8 in. L=10 and 12 in. Pressure Class US = 10.3 bar (150 psi) SS = 20.7 bar (300 psi) MS = 34.5 bar (500 psi)
ULTRAMAX
UMS-107-M-09-US-64
Heat Transfer Surface Area Per Plate (10 x ft2) Theta Of Plate (M=Medium) Number Of Heat Transfer Plates
Figure 5.1.
For additional information on this unit, contact Tranter, Inc. at Phone: (800) 414-6908
Figure 5.2.
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6.2. Returns
Units or parts are not to be returned without rst obtaining permission from your nearest Tranter, Inc., plant. Parts authorized for return must be properly packaged and labeled and in good condition upon arrival at the Tranter, Inc., plant. All credits for returned materials will be subject to restocking and transportation charges.
This manual is also available on-line at www.tranter.com. Visit our website at www.tranter.com for parts and quotations, or e-mail us directly at sales@tranter.com.
To obtain additional information on operation and maintenance, contact your local Tranter, Inc., representative or the nearest Tranter, Inc., factory-authorized Service Center.
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North/South America
Europe
Middle East/Asia
Tranter, Inc.
Wichita Falls, TX USA Tel: (940) 723-7125 Fax: (940) 723-5131 E-mail: sales@tranter.com
Tranter International AB
Stockholm, Sweden Tel: +46 (0)8 442 49 70 Fax: +46 (0)8 442 49 80 E-mail: info@se.tranter.com
The ULTRAMAX All Welded Plate Heat Exchanger is covered under US Pat No. 6,516,874.
www.tranter.com
UM-IOM-2Interim-0307 650644 2006 Tranter, Inc.