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Malaysia : HISAKAWORKS S.E.A. SDN. BHD.Lot 4882, 5 Japan SS 13/2, 47500 Subang Jaya, Selangor Darul Ehsan, MalaysiaPhone: 60-3-5621-8588 Fax: 06-3-5621-7588

China : HISAKA (SHANGHAI) COMMERCE CO., LTD.699 West Nanjin Road, Shanghai 200041, ChinaPhone: 86-21-5211-0701 Fax: 86-21-5211-0720

PLATE HEAT EXCHANGER

MAINTENANCEA Guide to the Comprehensive Maintenance Program for HISAKA Plate Heat Exchanger

HE-CE00030210.10. －　.SAN

Plate Heat Exchanger is high-performance and trouble free but ……Periodic maintenance is necessary to secure the operation.

Watch the operating condition :

� Leakage of fluids due to deterioration of the gaskets

� Decreasing thermal performance due to depsoits and

fouling on plate surface

� Intermixing of the fluids due to corrosion, crack and

pin hole on the plates

Professional maintenance work can prevent :

� The deformation or damage to plates by un-

reasonable opening and tightening

� Insufficient cleaning of plate

� Tiny corrosion, crack and pin holes of the

plates may be overlooked

Thermal perfor-mance will bedecreased as timegoes on by depositand fouling on theplate after long timeoperation.

Changing of overall heat transfer coefficient7,000

6,000

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Operating timeMaintenance

Design

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Corrosion, cracks and pinholesCorrosion may occur to used platescausing pin-holes or cracks. Thiswill result in fluid leakage orintermixing of the two fluids.

Hot side inlet

Upper guide bar

S-frame

Cold side outlet

Cold side inlet

Hot side outlet

Guide bar support

Lower guide bar

Plate

Gasket

Baseplate

E-frame

Tightening bolts and nuts

Basic Construction of a PHE aA PHE is basically made upof heat transfer plates thatare press-formed from thinsheets of corrosion-resistant metal such asstainless steel or titanium. Asealing gasket is applied toeach plate and it is thensuspended onto an upperguide bar before it istightened to the correctdimension.

[ Maintenance call stickerThis sticker which is labeled onto each unit shows our "mainte-nance calls".

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aPlease inform the manufacturing (MFG) no. of the unit

For Maintenance call.

Osaka…TEL.+81-72-966-8910Tokyo…TEL.+81-3-5250-0760ASEAN…TEL.+60-3-5621-8588

2 ––– Upgrade service

●"Slit-in" gasket…There are twotypes of gaskets, i.e. glued type andglue-free type called "Slit-in". Al-though the glued type provides ro-bust adhesion strength but the "slit-in" glue-free type is easier to install/remove the gaskets. Replacing"Slit-in" gasket is less time consum-ing, it is shorter only 1/10 of the timeto replace than the glued type.

The existing PHEs in the plants canbe replaced with "Slit-in" type or slitscan be made to the existing PHEs.

●Monitoring of plates and gaskets…Although plates is made of corrosionresistant material, defects such aspin-hole or crack may occur on theplates depending on the operatingconditions. Through our "MonitoringService", any defects such as platecorrosion, changes in plate thick-ness and gasket deterioration canbe detected and reported.

3 ––– On site Servicing

●On site maintenance…Ourspecially trained and experiencedstaff will provide full maintenanceservice at site. We provide compre-hensive and skillful support to anymaintenance program to be per-formed.

1––– Cleaning service

●Maintenance for plates… In theevent that "Full Service Package"is not applicable, we can offerplates only cleaning and reas-semble service after cleaning.

●Maintenance service by con-tract… By periodical maintenanceservice contract, defects of the unitcan be detected earlier. Therefore,accidents and unscheduled opera-tion stoppage can be avoided.

●Plate rotation… The plate ro-tation service replaces used plateswith new plates kept in our factory.This reduces downtime and quickrestart of operation due to shortertime required for PHE maintenance.

Spare parts stock… The spare partssuch as plate, gasket, tightening bolt& nut, rubber boot, nozzle, etc. areprepared.

Cleaning-in-place (CIP) Unit… Mo-bile CIP unit. By circulating the clean-ing chemicals through the unit, the de-posit on the plate surface can be re-moved without disassembly.

Automatic tightening device… Inorder to carry out the opening andtightening work of larger units easiliy,a dedicated pneumatic tightening de-vice shall be recommended. Uniformtightening can be correctly performedto the unit.

As a leading supplier of Plate Heat Exchanger (PHE) in the world,

HISAKA offers professional maintenance service program that main-

tains the PHE performance over the product's life cycle ensuring

the satisfaction of our customers. Our core maintenance program,

"Full Service Package", provides multifaceted support to achieve

optimum condition of the units at site.

"Full Service Package" offers a comprehensive maintenance pro-

gram to restore the original performance at HISAKA authorized

service facilities. This program consists of plate cleaning, gasket

replacement, dye penetration test, re-assembly and final inspec-

tion before shipping. We can offer the maintenance program to

match various operating conditions, enabling operation to be sus-

tained in many processes.

PLATE HEAT EXCHANGEER MAINTENANCE

"Full Service Package" OPTIONS

� Disassembly : The overhaul offrame is important to secure the platesfirmly. Inspecting the connection partsand replacing the stud bolts & nuts, etc.,if they are damaged.

� Cleaning : The plates are soaked ina cleaning chemical tank to remove thescale, sediment and dirt on the plate sur-face and finally washed away with wa-ter jet.

� Assembly : Now that the mainte-nance is completed, the plates aremounted onto the frame, which hasbeen overhauled separately. The platearrangement and the seal line of theplates are carefully checked.

� Tightening the plates : Using a tight-ening device for PHE, the plate pack is tight-ened to the correct dimension.The dedicated tightening device can handlelarge number of plates in a short time.

Leak Test : After tightening, the unitis tested by air to ensure no leakagebetween plate channels. This leak testconfirms all plates are defect free. (DPTinspection is an option)

Basic flowchart of "Full Service package" for Hisaka Plate Heat Exchanger

HISAKA’s PHE maintenance program ensures top performance and lasting trouble free use

A wealth of maintenance options giving reliable support

� Disassembly : After visual inspec-tion of the PHE, the unit is disassem essof the plates while the frame is given anoverhaul.

� Gluing the gaskets : After cleaningthe plates, new gaskets are glued to theplates. At the same time, we ensure thenew gaskets are firmly adhering to thegroove in the correct position.

cCertified sticker after "FullService package"After completion of "Full Servicepackage", the certified sticker is puton the unit. Maintenance data isregistered in the Hisaka data basewith serial number on the sticker.

Estimation of allowableoperating perssure

There is a linear correlationbetween the compression ratio ofgasket and the operating pres-sure. The allowable operatingpressure can be estimated bycompression ratio, which can becalculated by the followingequation :

Measured thickness – Tightening dimension of gasket

Measured thickness

� Soaking in degreasing tank : Theold gaskets with adhesive residue onthe gasket groove are removed aftersoaking the plates in the degreasingtank.

Final Inspection : Upon comple-tion of all the above maintenance pro-cesses, the unit is pressure tested hy-draulically to ensure no leakage fromthe unit. After the final inspection, a cer-tified sticker is put on the unit.

Dye Penetrant Test (DPT) inspection (Liquid Penetrant Examination)

It is difficult to detect tiny holes caused bypitting and crevice corrosion on the plate’ssurface without professional skill andexperience.The Dye Penetrant Test checks thesedefects for the penetration through theplate. The Dye Penetrant is applied to oneside of the plate, and coating the other sidewith the developing fluid. The penetrationcan be found easily by DPT.

b Test recordAfter "Full Servicepackage", a set ofmaintenance reportis sent to the owner.

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