Kelvion KBloc Operating Instructions Manual Download Page 4

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K°Bloc – Fully welded plate heat exchangers - English Version 2.2 - 01.2016

5 SETTING UP AND CONNECTING THE K°BLOC .................................. 28

5.1 INSPECTING THE EQUIPMENT UPON DELIVERY .................. 28

5.1.1

TRANSPORT VARIANTS ......................................... 28

5.1.2

TRANSPORT PARTICULARITIES............................ 29

5.2 SPACE REQUIREMENT AT THE PLACE OF INSTALLATION .. 29
5.3 REMOVING AND DISPOSING OF TRANSPORT

PACKAGING................................................................................ 30

5.4 TRANSPORTING THE K°BLOC TO THE PLACE OF

INSTALLATION AND SETTING IT UP ........................................ 31

5.4.1

TRANSPORTING AND SETTING UP A K°BLOC
DELIVERED IN UPRIGHT POSITION ...................... 31

5.4.2

TRANSPORTING AND SETTING UP A K°BLOC
DELIVERED IN HORIZONTAL POSITION ............... 36

5.5 CONNECTING THE K°BLOC...................................................... 51

5.5.1

OPTIONAL SAFETY ACCESSORIES ...................... 51

5.5.2

INSTALLING PIPING ................................................ 52

6 COMMISSIONING AND DECOMMISSIONING, OPERATION ............... 55

6.1 COMMISSIONING ....................................................................... 55

6.1.1

PRE-CONDITIONS ................................................... 56

6.1.2

COMMISSIONING..................................................... 56

6.2 OPERATION................................................................................ 60
6.3 DECOMMISSIONING .................................................................. 61

6.3.1

SHORT-TERM PUTTING OUT OF OPERATION ..... 61

6.3.2

DECOMMISSIONING - MAINTENANCE .................. 63

6.3.3

LONG-TERM PUTTING OUT OF OPERATION ....... 64

6.4 STORAGE ................................................................................... 65
6.5 DISPOSAL ................................................................................... 65

7 MAINTENANCE....................................................................................... 66

7.1 OPENING THE K°BLOC ............................................................. 67

7.1.1

PREPARATIONS ...................................................... 67

7.1.2

DISMOUNTING THE PANEL .................................... 69

7.2 REPLACING THE GASKETS ...................................................... 76
7.3 REMOVING THE BAFFLE PLATE BRACKET ............................ 77
7.4 CLOSING THE K°BLOC.............................................................. 78

7.4.1

INSTALLING A SINGLE PANEL ............................... 79

7.4.2

TIGHTENING THE PANEL ....................................... 82

7.5 LEAKAGE TEST .......................................................................... 93
7.6 OUTSIDE CLEANING.................................................................. 94
7.7 CIP CLEANING ........................................................................... 95

Summary of Contents for KBloc

Page 1: ...Operating Instructions Vers 2 2 01 2016 K Bloc Fully welded plate heat exchangers ...

Page 2: ...s finned tube heat exchangers cooling tower systems in modular form and refrigeration plate heat exchangers for multiple fields of applica tion These operating instructions are your personal guide explaining design function installation operation maintenance troubleshooting transport and repairs of our Plate heat exchangers in an easy to understand and clear manner They in particular aim to avoid ...

Page 3: ...P 13 3 OVERVIEW AND DESCRIPTION 14 3 1 INTENDED USE 14 3 2 FUNCTIONAL DESCRIPTION 15 3 3 BASIC DESIGN 16 3 4 PANEL GASKETS 17 4 IMPORTANT SAFETY INFORMATION 18 4 1 OPERATIONAL SAFETY 18 4 2 SAFETY INFORMATION 19 4 2 1 INFORMATION ON TRANSPORTATION AND SETTING UP 19 4 2 2 OPERATIONAL INFORMATION 20 4 2 3 MAINTENANCE INFORMATION 20 4 2 4 DISMOUNTING INFORMATION 21 4 3 OBLIGATIONS OF UNIT OPERATING C...

Page 4: ...ZONTAL POSITION 36 5 5 CONNECTING THE K BLOC 51 5 5 1 OPTIONAL SAFETY ACCESSORIES 51 5 5 2 INSTALLING PIPING 52 6 COMMISSIONING AND DECOMMISSIONING OPERATION 55 6 1 COMMISSIONING 55 6 1 1 PRE CONDITIONS 56 6 1 2 COMMISSIONING 56 6 2 OPERATION 60 6 3 DECOMMISSIONING 61 6 3 1 SHORT TERM PUTTING OUT OF OPERATION 61 6 3 2 DECOMMISSIONING MAINTENANCE 63 6 3 3 LONG TERM PUTTING OUT OF OPERATION 64 6 4 S...

Page 5: ...5 7 8 CLEANING BY REVERSE FLUSHING 96 7 9 CLEANING THE PLATE PACK WITH THE K BLOC OPENED 96 7 9 1 CLEANING PLATES WITH A CHEVRON PATTERN 96 7 9 2 CLEANING PLATES WITH DOUBLE DIMPLE PATTERN 98 8 TROUBLESHOOTING 99 8 1 INSUFFICIENT PERFORMANCE 99 8 2 LEAKS 100 9 TECHNICAL TERMS 102 ...

Page 6: ...DATA The technical data of your K Bloc can be taken from the technical documen tation that is included in the delivery 1 2 NAME PLATE Every K Bloc manufactured by Kelvion has a rating plate The K Bloc name plate is fitted on one of the panels The K Bloc name plate gives you the following information Manufacturer K Bloc Type Serial no Allowable pressures Allowable temperatures Test pressures Volume...

Page 7: ...n 2 2 01 2016 7 1 3 TECHNICAL DOCUMENTATION An assembly drawing is delivered with every K Bloc unit This assembly drawing includes among other information the outer dimensions tensioning parameters of threaded bolts to be respected weight and type size and position of piping connections ...

Page 8: ...ormation on how to install your K Bloc safely and properly transport it put it into operation operate it maintain it dismount it and remove faults These original Operating instructions contain information and rules of conduct aiming for safe heat exchanger operation Read these original Operating instructions carefully before starting work on the K Bloc Keep these original Operating instructions so...

Page 9: ...es Many details are simplified The actual conditions of an individually manufactured K Bloc cannot be reflected here You find binding views and dimensions of the K Bloc delivered to you in the technical documentation supplied 2 4 EMPHASIZED TEXT SECTIONS Important information contained in these Operating instructions are empha sized by symbols or a special font The following examples illustrate th...

Page 10: ...he dot marks measures that consider this note 2 4 2 SAFETY INSTRUCTION SAFETY INSTRUCTION To carry out the work safely follow precisely the steps described below 1 Step one of a safety instruction Important note regarding this step 2 Step two of a safety instruction Result of this step The safety instruction is finished the goal of the safety instruction has been re ached ...

Page 11: ...es Failure to observe the warning may cause serious damage to your health including death The arrow marks a precautionary measure you have to take in order to avoid the hazard CAUTION Warning of injuries Failure to observe the warning may cause damage to your health The arrow marks a precautionary measure you have to take in order to avoid the hazard IMPORTANT NOTE Warning of material damage Failu...

Page 12: ...he action is finished the goal has been reached 2 4 5 SEQUENCE OF ACTIONS Partial goal of the first sequence of actions Carry out the following steps Start of first procedure instruction 1 Step one of the first sequence of action First alternative instruction to the step Second alternative instruction to the step Last alternative instruction to the step 2 Second step in a sequence of actions Impor...

Page 13: ...ps Start of second procedure instruction The only step of the first sequence of action Problem A fault that was to be expected has occurred Origin of fault Measure for fault removal Partial goal of the second sequence of actions has been reached The sequence of actions is finished the goal of the sequence of actions has been reached 2 4 6 TIP TIP Further useful information ...

Page 14: ...eat accepting flow medium It is basically designed for mostly stationary use The K Bloc was designed and built specifically for the operating conditions you have specified The operating conditions are documented in the tech nical documentation min max allowed pressure min max allowed temperature flow rates type and composition of flow media loads if allowed Deviating from these allowable operating...

Page 15: ...angers offer a large heat transfer surface with very compact design They have been dimensioned to suit your applica tion The basic structure of a K Bloc is shown below The specific execution depends on the application K Bloc are made from fully welded heat exchanger plates The individual plates are welded together on two longitu dinal sides and at the corners This creates two pressure resistant an...

Page 16: ...tructure of a K Bloc is shown below The specific execution depends on the application Components of the K Bloc Legend No Designation 1 Threaded holes for lifting equipment 2 Top head with lifting lug 3 Threaded bolt 4 Column 5 Baffle plate bracket 6 Threaded holes for push off bolts 7 Nuts and washers ...

Page 17: ...ETS The panel gaskets are wear parts and sensitive to chemical thermal and mechanical damage The gasket material and its properties are selected on the basis of the customer s specifications pressure temperature media 8 Panel 9 Connections 10 Gasket 11 Plate pack 12 Bottom head 13 Baffle plate 14 Foot Legend No Designation ...

Page 18: ...equipment page 24 Notes decals on the K Bloc page 26 4 1 OPERATIONAL SAFETY The K Bloc has been manufactured in accordance with the state of the art and the recognized safety rules The K Bloc can still be the origin of hazards to persons and material assets if you fail to observe this chapter fail to observe the warnings in these Operating instructions fail to use the K Bloc in accordance with the...

Page 19: ...devices shackles and round slings must be used for all transporta tions The transportation has to consider the weight of the K Bloc and the posi tion of the point of gravity Prepare the K Bloc for transportation as follows Secure the K Bloc against slipping off and tipping over observe the posi tion of the point of gravity Secure any moving parts Observe the following information during transporta...

Page 20: ...properties Bring the K Bloc to the operating temperatures of the two circuits by means of the flow media at low pressure Avoid quick temperature changes maximum temperature change 5 K min Respect the maximum temperature difference of the flow media of 200 K max between the hot and the cold side Ensure that under all setting up and operating conditions the tempera ture never falls below the freezin...

Page 21: ... welded plate heat exchangers English Version 2 2 01 2016 21 4 2 4 DISMOUNTING INFORMATION When performing maintenance work on the K Bloc never remove the corner bolts Removing the corner bolts will void the warranty Corner bolts variant 1 and variant 2 ...

Page 22: ...of certain K Bloc components due to unfavourable ambient conditions all maintenance inspection work is carried out at regular intervals You must fix the intervals as a function of field of use flow media hazard potentials and regulations in force for the operations that the personnel regularly inspects the K Bloc for leaks Leaks must be repaired without delay if required 4 3 2 TRAINING OF PERSONNE...

Page 23: ...ities may be carried out only by a properly qualified specialist or an instructed person being supervised by a specialist Specialists are persons who on account of their technical training know ledge and experience as well as due to their knowledge of relevant provi sions are able to assess the work entrusted to them identify possible dangers and take suitable safety measures A specialist must com...

Page 24: ... media provide earthing When using cold flow media below 0 C fit an insulation in order to prevent freezing up of the K Bloc provide a protection against accidental contact in order to avoid frost bites of persons set up warning signs alerting persons of the low temperatures When using hot flow media above 50 C provide a protection against accidental contact to keep persons from suffering burns se...

Page 25: ...igh weight of the panels Secure the heavy panels so they will not fall over or fall down when opening the K Bloc Damage to the K Bloc Vertical K Bloc units may tip over easily Put up a K Bloc delivered in a horizontal position only directly before it is installed Secure the upright PHE against tipping over by bolting it to the ground Remove the lifting devices used only after the K Bloc has been f...

Page 26: ...g Large size K Bloc units with lifting eyes that cannot be clearly identified have this decal pointing to further markings Slinging point for lifting Only a lifting eye or several lifting eyes marked with this decal is approved for lifting and for suspended transportation of the entire K Bloc unit on vertical K Bloc units on the lifting eye s on the top cover plate on horizontal K Bloc units on th...

Page 27: ...English Version 2 2 01 2016 27 Transport safeguard An eye marked with this decal can be used as trans port safeguard for securing the loaded K Bloc unit against slipping Overview of notes decals on the K Bloc Cont Notes decals Meaning Use this lug for fastening during transport only ...

Page 28: ...iscover that the unit is damaged upon delivery despite careful packaging absolutely note the scope and type of damage in the freight documents and have these documents signed by the deliverer 5 1 1 TRANSPORT VARIANTS The completely assembled K Bloc is packed either horizontally or vertically depending on the version The piping connections are plugged 5 1 1 1 K BLOC DELIVERED IN UPRIGHT POSITION So...

Page 29: ...ax CAUTION Relieve the pressure at the associated drain valve before dismounting the transport flanges 5 2 SPACE REQUIREMENT AT THE PLACE OF INSTALLATION Ensure sufficient free space around the K Bloc The required free space of at least 1 m on all sides is a guideline value and recommended by Kelvion This free space enables sufficient access to the K Bloc and makes mainte nance work easier Recomme...

Page 30: ...f installation Remove the transport packaging only at the place of installation if possible Carry out the following steps 1 Remove the transport packaging Leave the transport plugs on the piping connections if you do not fit the piping immediately Leave the K Bloc bolted down to the transport sup port until it has been transported to its final place of installation 2 In case of seaworthy packaged ...

Page 31: ...loc to its place of installation Transporting and setting up a K Bloc delivered in upright position page 31 Transporting and setting up a K Bloc delivered in horizontal position page 36 5 4 1 TRANSPORTING AND SETTING UP A K BLOC DELIVERED IN UPRIGHT POSITION Requirement The K Bloc is still packaged Tools required Lifting equipment with sufficient load carrying capacity Load holding devices round s...

Page 32: ...g capa city Wear safety shoes at all times Lift and lower the K Bloc evenly and slowly Transport the unit vertically at all times Never transport the K Bloc at the threaded bolts Fasten the load holding devices only at the marked fastening points for transporting the K Bloc Never attach the lifting slings to the connections Avoid any pendulum movements of the K Bloc Carry out the following steps 1...

Page 33: ...hangers English Version 2 2 01 2016 33 2 Guide a suitable round sling through each of the installed shackles 3 Hang the round slings into the hook of the lifting equipment The vertical type K Bloc delivered in upright position has now been properly fastened to the lifting equipment ...

Page 34: ...teps 1 Carefully lift the K Bloc Make sure that you lift the K Bloc only as high as necessary 2 Transport the K Bloc carefully to its intended place of installation Make sure that you lift the K Bloc only as high as necessary 3 Put down the K Bloc carefully at its intended place of installation The vertical type K Bloc delivered in upright position has now arrived at its place of installation ...

Page 35: ...t the place of installa tion Carry out the following steps 1 Remove the transport packaging see section 5 3 Removing and disposing of transport packaging page 30 2 Carefully lift the K Bloc Make sure that you lift the K Bloc only as high as necessary 3 Put down the K Bloc carefully at its intended position 4 Anchor the K Bloc to the foundation using suitably dimensioned bolts and nuts ...

Page 36: ...K BLOC DELIVERED IN HORIZONTAL POSITION All horizontal type K Bloc are transported in horizontal position Some vertical type K Bloc units are also transported in horizontal position due to their weight and height Depending on the type K Bloc units must be fastened to the lifting equipment and lifted in different ways Horizontal type K Bloc standard K Bloc page 37 Horizontal type K Bloc special des...

Page 37: ...Bloc delivered in horizontal position standard K Bloc properly WARNING Danger of injury by heavy weight of K Bloc The K Bloc may slip off and fall down during transport when incorrectly fastened You may suffer serious injuries and bruises in such an accident Never stand underneath suspended loads Always use approved load holding devices with sufficient load carrying capacity Always use approved li...

Page 38: ...xchangers English Version 2 2 01 2016 38 1 Fit one shackle each to the lifting eyes above the support angles of the horizontal type K Bloc standard K Bloc 2 Guide one suitable round sling each through one of the two installed shackles ...

Page 39: ...al type K Bloc delivered in horizontal position standard K Bloc to the place of installation Carry out the following steps 1 Carefully lift the K Bloc Make sure that you lift the K Bloc only as high as necessary 2 Transport the K Bloc carefully to its intended place of installation Make sure that you lift the K Bloc only as high as necessary 3 Put down the K Bloc carefully at its intended place of...

Page 40: ...posing of transport packaging page 30 2 Carefully lift the K Bloc Make sure that you lift the K Bloc only as high as necessary 3 Put down the K Bloc carefully at its intended position 4 Anchor the K Bloc to the foundation using suitably dimensioned bolts and nuts 5 Remove the two shackles and round slings from the lifting eyes above the support angles The horizontal type K Bloc delivered in horizo...

Page 41: ...Bloc delivered in horizontal position special design K Bloc properly WARNING Danger of injury by heavy weight of K Bloc The K Bloc may slip off and fall down during transport when incorrectly fastened You may suffer serious injuries and bruises in such an accident Never stand underneath suspended loads Always use approved load holding devices with sufficient load carrying capacity Always use appro...

Page 42: ... heat exchangers English Version 2 2 01 2016 42 1 Fit two shackles each to the support angles of the horizontal type K Bloc special design K Bloc 2 Guide one suitable round sling each through one of the four installed shackles ...

Page 43: ... horizontal type K Bloc delivered in horizontal position special design K Bloc to the place of installation Carry out the following steps 1 Carefully lift the K Bloc Make sure that you lift the K Bloc only as high as necessary 2 Transport the K Bloc carefully to its intended place of installation Make sure that you lift the K Bloc only as high as necessary 3 Put down the K Bloc carefully at its in...

Page 44: ...ing and disposing of transport packaging page 30 2 Carefully lift the K Bloc Make sure that you lift the K Bloc only as high as necessary 3 Put down the K Bloc carefully at its intended position 4 Anchor the K Bloc to the foundation using suitably dimensioned bolts and nuts 5 Remove the four shackles and round slings from the support angles The horizontal type K Bloc delivered in horizontal positi...

Page 45: ...ng capacity Fastening a vertical type K Bloc delivered in horizontal position properly WARNING Danger of injury by heavy weight of K Bloc The K Bloc may slip off and fall down during transport when incorrectly fastened You may suffer serious injuries and bruises in such an accident Never stand underneath suspended loads Always use approved load holding devices with sufficient load carrying capacit...

Page 46: ...pper transport lifting eye for the vertical K Bloc of the double eye version Take care that when the K Bloc is lifted at a later stage the tensile forces act on the transportation lifting lugs as shown in the following illustration If transportation lifting lug are used in the horizontal position there is a danger of the transportation lifting lug buckling Therefore always en sure before lifting t...

Page 47: ...sh Version 2 2 01 2016 47 4 Guide a suitable round sling through each of the installed shackles 5 Hang the round slings on each side into the respective hook of the lifting equipment The vertical type K Bloc delivered in horizontal position has now been properly fastened to the lifting equipment ...

Page 48: ...d in horizontal position at the place of installation Carry out the following steps 1 Carefully lift the K Bloc on both sides Make sure that you lift the K Bloc only as high as necessary 2 Move the K Bloc to a vertical position by suitably lifting at the Transport lifting eye and lowering at the foot the lifting equipment ...

Page 49: ... been set up Setting up a vertical type K Bloc delivered in horizontal position at the place of instal lation Carry out the following steps 1 Remove the transport packaging see section 5 3 Removing and disposing of transport packaging page 30 2 For the vertical K Bloc double eye and crosswise double eye type fit the second shackle at the opposite opening of the transport lifting eye 3 Guide one su...

Page 50: ...2 01 2016 50 7 Anchor the K Bloc to the foundation using suitably dimensioned bolts and nuts 8 Remove the shackle and round sling from the lifting eye The vertical type K Bloc delivered in horizontal position has now been set up at its place of installation Done ...

Page 51: ...zardous flow media e g explosive flammable caustic toxic under high pressure very hot or very cold ensure that the safety accessories below are provided or fitted Required safety accesso ries Properties of flow media highly explosive flammable high pressure Collecting tray x x Splash protection x x x Earthing lug x x Insulation Warning sign Required safety accesso ries Properties of flow media ver...

Page 52: ...1 2016 52 5 5 2 INSTALLING PIPING Requirement All inlet and outlet lines to from the K Bloc are closed and secured against unintended opening Tools required Standard tool set Legend Description Symbol 1 Surface temperature below 0 C 2 Surface temperature above 50 C ...

Page 53: ...ive equipment during all work WARNING Hazard due to deactivated safety equipment When deactivating safety equipment for installation maintenance or commissioning work you or other persons may be seriously injured and you have to ensure that this produces no hazard to persons and material assets Make sure at all times that no persons can be injured due to safety equipment that has been put out of o...

Page 54: ...mitted for your K Bloc from the technical documentation Ensure that the forces and torques transmitted from the piping to the K Bloc connections are not too high Carry out the following steps 1 Check on the K Bloc if all safety accessories required for the flow medium used are fitted see chapter 5 5 1 Optional safety accessories page 51 2 Open the valve on K Bloc units filled with compressed air o...

Page 55: ...ONING OPERATION This chapter gives you information on how to put the K Bloc into and out of operation and how to operate it Commissioning page 55 Operation page 60 Decommissioning page 61 Storage page 65 Disposal page 65 6 1 COMMISSIONING This chapter gives you information on how to put the K Bloc into operation Pre conditions page 56 Commissioning page 56 ...

Page 56: ...ons in hazard area of the K Bloc Can nobody be injured during the commissioning of the K Bloc Have all nuts been tightened to the torques or tightening dimensions specified in the technical documentation Is the K Bloc free of residues from previous processes cleaning media Do you know what to do in case of malfunction Are all persons working in the hazard area wearing their protective clothing 6 1...

Page 57: ...tective equipment during all work WARNING Hazard due to deactivated safety equipment When deactivating safety equipment for installation maintenance or commissioning work you or other persons may be seriously injured and you have to ensure that this produces no hazard to persons and material assets Make sure at all times that no persons can be injured due to safety equipment that has been put out ...

Page 58: ...eezing temperature of the flow media used IMPORTANT NOTE Damage to piping connections and to K Bloc due to exces sive pressure variations forces and torques When excessive forces and torques are transmitted on the K Bloc connec tions through the piping the piping connections and or the K Bloc may be damaged You can take the forces and torques permitted for your K Bloc from the technical documentat...

Page 59: ...d are fitted see chapter 5 5 1 Optional safety accessories page 51 2 Check if all nuts have been tightened to the torques or tightening dimen sions specified in the technical documentation and correct if necessary 3 Vent the K Bloc completely 4 Always open or close the valves of the piping connected to the K Bloc slowly 5 Avoid sudden condensation of gases by suitable process control 6 Check if al...

Page 60: ...d pressure variations resulting in the pressure conditions being reversed e g by opening closing a throttle valve may damage the plate pack and cause leaks between the circuits Unless otherwise specified in the technical documentation the recom mended differential pressure between the two circuits is more than 1 bar The operator must check if the K Bloc works correctly at regular intervals Keep an...

Page 61: ... the prescribed safety equipment relevant for the flow medium in question Wear your personal protective equipment during all work WARNING Hazard due to deactivated safety equipment When deactivating safety equipment for installation maintenance or commissioning work you or other persons may be seriously injured and you have to ensure that this produces no hazard to persons and material assets Make...

Page 62: ...ting conditions the tempera ture never falls below the freezing temperature of the flow media used IMPORTANT NOTE Damage to piping connections and to K Bloc due to exces sive pressure variations forces and torques When excessive forces and torques are transmitted on the K Bloc connec tions through the piping the piping connections and or the K Bloc may be damaged You can take the forces and torque...

Page 63: ...one 6 3 2 DECOMMISSIONING MAINTENANCE Carry out the following steps 1 Put the unit out of operation by the short term procedure see chapter 6 3 1 Short term putting out of operation page 61 2 Ensure that the K Bloc is at the ambient pressure level 3 Wait for the K Bloc to reach the ambient temperature level 4 Drain the K Bloc completely While draining ensure that the media contained in the K Bloc ...

Page 64: ... and flush the K Bloc and let it dry completely Plug the piping connections with blind plugs in order to avoid ingress of moisture or dirt into the K Bloc during standstill Take care of protected storage until the unit is put back into operation Carry out the following steps 1 Put the unit out of operation for maintenance see chapter 6 3 2 Decom missioning maintenance page 63 2 Clean and flush the...

Page 65: ...ir humidity causing no corrosion 6 5 DISPOSAL This chapter gives you information on how to dispose of the K Bloc The fundamental rules below apply to disposal Dispose of all parts in accordance with the local and legal disposal regu lations In case of parts contaminated with dangerous substances observe the particular local and legal regulations Upon request Kelvion will take care of disposing of ...

Page 66: ...tion on how to maintain the K Bloc Opening the K Bloc page 67 Replacing the gaskets page 76 Removing the baffle plate bracket page 77 Closing the K Bloc page 78 Leakage test page 93 Outside cleaning page 94 CIP cleaning page 95 Cleaning by reverse flushing page 96 Cleaning the plate pack with the K Bloc opened page 96 ...

Page 67: ...e following steps 1 Put the K Bloc out of operation see chapter Commissioning and decommissioning operation Decommissioning maintenance page 63 2 Clean the threaded bolt threads 3 Apply a little grease to the visible threads of the threaded bolts The nuts can be slackened off easier The risk of damage of threaded bolts during dismounting is reduced ...

Page 68: ...c Fully welded plate heat exchangers English Version 2 2 01 2016 68 4 Mark the panel to be dismounted This ensures that the panels are fitted at their initial positions during as sembly at a later date Done ...

Page 69: ... see chapter 7 1 1 Preparations page 67 Before opening the K Bloc it must be ensured that a new original gasket is available for each panel to be dismounted Before opening the K Bloc it must be ensured that the lifting equipment available for removing the panel is sufficiently dimensioned You must wear suitable protective clothing WARNING Danger of injury due to hazardous flow media When using haz...

Page 70: ... many nuts and washers need to be dismounted If parts are damaged flawless function of the K Bloc can no longer be guaran teed When opening check if the nuts washers and threaded bolts are damaged and replace them by original spare parts if necessary Save the dismounted nuts and washers carefully Clean the threaded bolts before opening IMPORTANT NOTE Damage of K Bloc by simultaneous removal of mor...

Page 71: ...ing the corner bolts Simultaneous removal of one or more corner bolts may cause malfunctions or damage to the K Bloc Never remove or slacken off the corner bolts Carry out the following steps 1 Slacken off the marked nuts at the adjoining panels so that no play will result Slacken off the nuts alternatingly moving from the outside towards the centre ...

Page 72: ... 2 2 01 2016 72 2 Slacken off the marked nuts at the panel to be dismounted so that no play will result Slacken off the nuts alternatingly moving from the outside towards the centre 3 Slacken off the marked nuts so that play results but do not remove the nuts ...

Page 73: ... along with the associated washers and store them carefully 5 Slacken off and turn the marked nuts up to the end of the respective threaded bolt 6 Secure the panel so it will not fall down Attach sufficiently dimensioned and undamaged lifting slings to the lif ting points screw in lifting eyes The panel was secured against falling down ...

Page 74: ...glish Version 2 2 01 2016 74 7 Move the panel away carefully Removing the panel is easier on larger K Bloc units because of the threaded holes provided for push off bolts 8 Slacken off and remove the marked nuts along with the associated washers ...

Page 75: ... 2016 75 9 Remove the panel attached to the lifting sling carefully When removing ensure that the threaded bolts are not damaged Put down the panel so that the connections are not exposed to a load The remaining nuts were slackened off and the panel was removed and put down as well Done ...

Page 76: ...t technical maintenance manual Contact your Kelvion Sales Office IMPORTANT NOTE Danger of leaks due to wrong gasket material Deviating from the K Bloc gasket replacement technical maintenance manual from the gasket material and its original dimensions may cause leaks and or irreversible damage to the K Bloc When replacing gaskets use only original gaskets by Kelvion Carry out the following steps R...

Page 77: ...pack the baffle plate bracket and or the baffle plates For removing never use conventional tools made of carbon steel Always use tools made of austenitic materials or plastic The plate pack is sensitive to mechanical forces of any kind Improper handling will cause damage and impaired function Cleaning the plate pack generally does not require removing the baffle plate bracket Inspecting the plate ...

Page 78: ...g a baffle plate bracket so you can refit it properly afterwards The baffle plate bracket should always be removed as a complete component 7 4 CLOSING THE K BLOC Before you can close the K Bloc again the following pre conditions must be met The K Bloc gasket was replaced see chapter 7 2 Replacing the gaskets page 76 Obtain information in advance if the panel must be tightened to the gap dimension ...

Page 79: ...ate bracket is incorrectly installed the K Bloc may be damaged when installing the panels or during operation In addition the function of the K Bloc may be impaired Be sure to install the baffle plate bracket in the correct position and align ment IMPORTANT NOTE Damage to panels by improper handling Improper handling of panels may damage the connections the sealing faces and the gaskets Do not tip...

Page 80: ...nsure that the threads of threaded bolts and the gasket will not be da maged when positioning the panel Ensure that all end plate collars and columns engage in the panel reces ses and that the gasket has not slipped 4 Fit all nuts with the associated washers Tighten the nuts only hand tight 5 Remove the lifting equipment attached to the panel ...

Page 81: ...e 7 4 2 1 Tightening the panel to the specified torque on panels with corner bolt hole page 82 Tighten to the specified torque see 7 4 2 2 Tightening the panel to the specified torque on panels without corner bolt hole page 86 Tighten to the specified gap size see 7 4 2 3 Tightening the panel to a gap dimension page 90 Done Panel with corner bolt hole Panel without corner bolt hole ...

Page 82: ...loc must be tightened 7 4 2 1 TIGHTENING THE PANEL TO THE SPECIFIED TORQUE ON PANELS WITH CORNER BOLT HOLE Requirement You must know the permitted tightening torques You can find these in the technical documentation or the K Bloc name plate Carry out the following steps 1 Tighten all nuts of panel I to 20 of the maximum torque crosswise from 1 to 22 according to the exemplary figure below The colo...

Page 83: ...0 of the maximum torque When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel III towards the outside The corner bolts marked in colour here may be tightened only to 25 of the permitted torque Figure 7 4 2 1 b F...

Page 84: ...The coloured corner bolts of panel I here 21 and 22 may be tighte ned only to 25 of the allowed torque 6 Tighten the nuts framed in figures Figure 7 4 2 1 b and Figure 7 4 2 1 c on the two adjoining panels II and III to 60 of the maximum torque When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tightening procee...

Page 85: ...1 to 20 The coloured corner bolts of panel I here 21 and 22 may be tighte ned only to 25 of the allowed torque 10 Tighten the nuts framed in figures Figure 7 4 2 1 b and Figure 7 4 2 1 c on the two adjoining panels II and III to 100 of the maximum torque When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tighten...

Page 86: ... WITHOUT CORNER BOLT HOLE Requirement You must know the permitted tightening torques You can find these in the technical documentation or on the name plate of the K Bloc Carry out the following steps 1 Tighten all nuts of panel I to 20 of the maximum torque crosswise from 1 to 22 according to the exemplary figure below Figure 7 4 2 2 a ...

Page 87: ...he maximum torque When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel III towards the outside Figure 7 4 2 2 b Figure 7 4 2 2 c 3 Tighten all nuts of panel I see Figure 7 4 2 2 a crosswise to 40 of the maximum...

Page 88: ...0 of the maximum torque When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel III towards the outside 7 Tighten all nuts of panel I see Figure 7 4 2 2 a crosswise to 80 of the maximum torque here 1 to 22 8 Tight...

Page 89: ...Figure 7 4 2 2 c on the two adjoining panels II and III to 100 of the maximum torque When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel III towards the outside Done ...

Page 90: ...en the panels and the columns and end bottom top heads Requirement Take the permitted gap size from the technical documentation or the name plate Carry out the following steps 1 Tighten all nuts of panel I crosswise to a 5 mm gap according to the figure below here 1 to 22 Figure 7 4 2 3 a Panel with corner bolt hole Panel without corner bolt hole ...

Page 91: ...mm When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel III towards the outside Figure 7 4 2 3 b Figure 7 4 2 3 c 3 Tighten all nuts of panel I see Figure 7 4 2 3 a crosswise to a 5 mm gap according to the figu...

Page 92: ... mm When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel II towards the outside When tightening proceed alternately from the centre of the line of bolts framed in red of the adjoining panel III towards the outside 7 Tighten all nuts of panel I see Figure 7 4 2 3 a crosswise to a 5 mm gap according to the figure below here 1 to 22 according t...

Page 93: ...nd the environment Never exceed permitted pressure and temperature levels Do not use any unapproved media in the K Bloc IMPORTANT NOTE Damage to the K Bloc due to extreme pressure variations In the leakage test the K Bloc is tested at defined pressure levels The K Bloc may be damaged if the pressure test is not performed properly Respect pressure variations of max 2 bar min 1 4404 316L and 0 5 bar...

Page 94: ...tment of the plates This does not mean that the K Bloc is leaking Readjust the leakage test pressure and check if the pressure is stable after half an hour Are there any leaks Attempt to remedy the leaks using the troubleshooting table see chapter Troubleshooting Troubleshooting page 99 Done 7 6 OUTSIDE CLEANING Carry out the following steps 1 Clean the outside of the K Bloc at regular intervals 2...

Page 95: ...ng medium you use is completely removed from the K Bloc after the cleaning process is complete that the cleaning media will not attack the plate pack and gasket mate rial that you reach a suitable temperature and do not let the cleaning agents take effect for an unnecessarily long time that the safety regulations and recommendations of the cleaning media manufacturers are observed that you collect...

Page 96: ...ticles are removed from the K Bloc by briefly reversing the flow direction 7 9 CLEANING THE PLATE PACK WITH THE K BLOC OPENED Depending on the plate pattern the cleaning process must be carried out in different ways 7 9 1 CLEANING PLATES WITH A CHEVRON PATTERN Requirement The K Bloc was opened see chapter 7 1 Opening the K Bloc page 67 IMPORTANT NOTE Danger of material damage on the K Bloc from ha...

Page 97: ...hemical burns and burns Wear your personal protective equipment Make yourself familiar with the handling of aggressive cleaning agents Ensure that the cleaning medium you use is completely removed from the plate pack after the cleaning process is complete Carry out the following steps Clean the plate pack with a high pressure jet cleaner Hold the cleaning jet at an angle of 45 relative to the corr...

Page 98: ... corrosion Never use hard cleaning tools Work carefully and thoroughly when cleaning WARNING Danger of injury due to aggressive cleaning media When using aggressive cleaning media you may suffer from intoxication chemical burns and burns Wear your personal protective equipment Make yourself familiar with the handling of aggressive cleaning agents Ensure that the cleaning medium you use is complete...

Page 99: ... transfer and or excessive pres sure loss Deposits on the plate pack plates Open the K Bloc and clean the plate pack see Mainte nance Opening the K Bloc page 67 chapter Operation flow media etc differing from the design case Have the K Bloc design with new operating data checked by Kelvion Damaged baffle plates Open the K Bloc and straighten slight mechanical damage of baffle plates in built in co...

Page 100: ...temperatures too high too low Check operating tempera tures according to rating plate data Incorrectly positioned gaskets Open the K Bloc according to the opening procedure see Maintenance Opening the K Bloc page 67 Check the seat of gaskets and replace gaskets if neces sary Dirty gaskets Open the K Bloc according to the opening procedure see Maintenance Opening the K Bloc page 67 Clean the gasket...

Page 101: ...l leak Defective metal compo nents If a defective gasket can be excluded contact your Sales Office Leaks between K Bloc connection and pipe work Excessive load of K Bloc connection from pipework Reduce connecting loads to permitted values Incorrect position of connection gasket Slacken off connections and correct gasket seat Dirty gasket Slacken off K Bloc connec tion and clean the gasket Defectiv...

Page 102: ...umns Threaded bolts washers nuts The threaded bolts are fitted in the bottom top heads and in the columns The panels are fastened by means of washers and nuts Assembly lifting lug Assembly lifting fixture Component intended for lifting the K Bloc panels Lifting fixtures include e g load rings and lifting eyes Top head Upper pressure bearing plate of the K Bloc Plate pack Fully welded combination o...

Page 103: ...Chapter 9 K Bloc Fully welded plate heat exchangers English Version 2 2 01 2016 103 ...

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Kelvion KBloc, Operating Instructions Manual

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