HRS TUBULAR HEAT EXCHANGERS

INSTALLATION & OPERATION MANUAL:

HRS TUBULAR HEAT EXCHANGERS

SERIES TYPES: AS3, AS4, DTA, DTI, DTR, G, K, MI, MP, MR, SH, SI, SP

IMPORTANT INFORMATIONThis manual should be read carefully before conducting any installation or maintenance work and/or before use of the heat exchanger.

HRS shell and tube heat exchangers have been designed so that the operation is risk free. In order to avoid damage and unforeseen risks the SAFETY NOTICES listed in this manual must be followed.

Personnel used to install, commission and operate HRS heat exchangers should be experienced in site work and trained on the importance of correct installation and operation of heat exchangers and pressurised systems.

If the user has any doubts or if a more complete explanation of any feature is required please contact our Technical Service Department.

1. HEAT EXCHANGERS TECHNICAL DESCRIPTION

HRS shell and tube heat exchangers complete stainless steel units which are intended for use in various lines of industry (food, industry, industry and environmental industries, among others). Their intended use depends on the mechanical design features and interconnection type. The units are normally manufactured from AISI 300 series stainless steels but can also be manufactured from a variety of other corrosion resistant materials to suit specific applications.

The heat exchanger components are now explained in further details:

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1. Inner Tubes

2. Tube Plate

3. Expansion Bellow

4. Shell

5. Nozzle

6. Service Connection

1.1. ShellThe pipe containing the tubes and forming the pressure vessel for the shell side fluid (normally the service fluid), which provides the source of heating or cooling for the unit.

1.2. Inner tubesThe inner tubes fitted are usually of a thin wall type. By standard HRS heat exchangers are fitted with corrugated inner tubes (for heat transfer enhancement). However, smooth tubes designs are also supplied.

Corrugated tubes

1.3. Tube platesThe plate at each end of the tube bundle into which the tubes are welded. This plate also closes the pressure vessel for the shell side fluid and sometimes acts as the connecting flange for the tube side fluid.

1.4. Shell side connections, nozzlesThe inlet and outlet shell connections for HRS shell and tube heat exchangers are fitted with flanges welded at the end of the nozzles. The diameter of the connection pipe will vary with the size and tube of the heat exchanger and the user must ensure that appropriate gaskets are used, suitable for the pressure and temperature of the installation and resistant to the working fluids. Sometimes other types of connections such as quick release clamps or dairy fittings are used.

1.5. Expension bellowAn expansion bellow is welded in the shell to compensate for differential expansion of shell and inner tubes. If a big difference is observed between the shell and tube side fluid temperatures, a significant difference in length of inner tubes and shell will appear. The expansion joint absorbs the stresses that are caused because of this.

1.6. BafflesBaffles are plates that are welded inside the shell side channel. They perform two important functions:• Baffles provide tube support for tubes that would otherwise sag under their own weight and could

vibrate under the action of fluids flowing across them.• Baffles direct the shell side fluid across the tubes in order to maximise the heat transfer coefficient

particularly when the flow rate on the shell side is restricted.

1.7. GasketsGasket are used between fittings (flanges, clamps etc.) to make sure the connection is seal tight.

1.8. Multi pass designThe standard HRS heat exchangers have a single tube side pass but, if required for specific applications, the units can be supplied as multi pass units with inlet/outlet headers to give the appropriate tube side flow pattern. In this type of unit, the tube side fluid passes two or more times along the tubes, depending on the header configuration. The headers are manufactured from stainless steel and carry internal dividing plates that are positioned to give the required number tube side passes which will vary with the contract requirements.

1.9. Multiple unit designsIn order to achieve long ‘thermal length’ heat exchangers, the HRS shell and tube units can be connected together in series or parallel flow regimes in order to give the design characteristics required. When this type of multiple unit configuration is required all interconnections and a support frame can be supplied by HRS if required. Modules are interconnected on the shell side using welded, flanged or other type of interconnections. Tube side interconnection is by bends which can be fully welded, flanged or fitted with quick release hygienic clamps as specified for the installation.

Example of multiple heat exchangers mounted together in frame:

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1.10. Heat exchanger nameplateEach HRS heat exchanger has a name plate fitted (welded on shell side) that gives the following (important) information:• Heat exchanger model and serial number• Maximum allowable pressure for shell and tube side• Hydraulic test pressure and inspection date• Maximum allowable temperatures for shell and tube side• Corrosion allowance• Shell and tube side volumes• Dry weight• HRS manufacturer contact data

When contacting HRS, always make reference to the heat exchanger model and serial number for easy identification of the model details.

HRS heat exchangers should be never put work under conditions that exceed the values that are on the nameplate.

1.11. Thermal designEach HRS heat exchanger is designed using a thermal design program. From this calculation all the dimensional parameters are defined (shell size, inner tube size, tube lengths, nozzle dimensions, number of baffle plates etc.). When the unit is fully commissioned the real performance should be checked against the thermal design parameters.

1.12. Mechanical designAfter the thermal design, a full mechanical design completed to ensure that the chosen dimensions and material thickness are suitable for the working design conditions (pressures and temperatures).

HRS heat exchangers are designed to comply with different internationally accepted design codes: PED and ASME.

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2. INSTALLATION

2.1. PersonnelPersonnel involved in offloading and transporting the heat exchanger to its final position within the installation should be experienced and qualified under local health and safety legislation to organise and carry out lifting operations. Heat exchangers are often heavy and can easily be damaged if knocked against other equipment or the building structure.

Personnel used to install, commission and operate HRS heat exchangers should be experienced in site work and trained on the importance of correct installation and operation of heat exchangers and pressurised systems.

Heat exchangers often work at high pressure with very hot or very cold fluids which may be dangerous under the definitions given in the European Pressure Equipment Directive 2014/68/EU and the installation and operating standards must meet the safety requirements required for this type of system.

2.2. Receipt of the heat exchangerHRS shell and tube heat exchangers are normally delivered in wooden crates designed to ensure that no damage can occur to the unit during transport or storage at its destination. If there are any signs of mechanical damage to either the crate or the unit inside the crate the transport contractor should be contacted immediately and made aware of the problem. For subsequent records and any later insurance claims we recommend that photographs are taken to show the areas of concern.

The equipment consignment will contain a detailed packing note attached to the transport packaging and receiving personnel should ensure that the consignment is complete, particularly if small removable items such as support feet are shown on the packing list. Any shortages must be reported immediately to the transport contractor and HRS with photographic evidence if appropriate to support any claim. Transport packing is not returnable but should be recycled or disposed of in accordance with environmental legislation in the country of receipt.

2.3. StorageIf the unit is to be stored for any length of time the area for storage must be clean, dry, heated and free from corrosive chemicals or any other substances likely to damage the stainless steel surfaces of the heat exchanger. If HRS has been notified of the intention to store the unit outside in very low temperatures (below freezing point) the unit will have been drained and dried during preparation for dispatch but if this notification has not been given or if the unit has been transported unprotected in bad weather it is possible that there may be some water remaining inside the unit. It is essential for storage or for a standby during operation in low temperatures that the site personnel ensure that the unit has been completely drained of all water, in order to avoid the fluid inside the shell to freeze.

2.4. Unloading/Unpacking/TransportThe nameplate on the unit the general arrangement drawings and the shipping documentation all show the empty weight of the unit. When planning the unloading, unpacking and site transport operations it is essential that this weight is taken into account. The centre of gravity of most units is on the longitudinal centreline at the midpoint of the unit length but will be marked on the general arrangement drawings if it is unbalanced. We recommend that small units are lifted using appropriate slings around the shell of the unit. Large units will be provided with at least two lifting points and appropriate eye bolts should be fitted to these lifting points. If the heat exchanger is a multi-module unit mounted in a support frame the frame will have been provided with at least two lifting points so that eye bolts can be fitted.

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2.5. Preparing the siteThe following guidelines should be followed for preparing the installation location:• Heat exchangers should always be mounted on stable firm supports with sufficient free area around

the unit to allow easy inspection from all sides. Units that are working at elevated temperatures during operation will experience significant thermal expansion and the supports must allow for this movement while the unit is heating or cooling.

• Any pipe work which is prepared before the positioning of the heat exchanger should be left with a loose flange or pipe work section to ensure that there are no excessive loadings on the unit when the pipe work is connected. It is essential that the installer realises that the heat exchanger cannot be used as an anchor or support point for pipe work as excessive loads can damage the connections.

• All pipe work, valves etc. must have appropriate supports and provision for thermal expansion under all working conditions.

2.6. Installation of the unitThe following guidelines should be followed for correct installation:• Visually inspect the unit for any unwanted material inside tubes and nozzles.• Always refer to the general arrangement drawings prior to positioning the unit. It is essential for the

unit to work correctly that the correct fluid flow pattern is used (normally counter flow) and that the necessary valves safety devices and instruments are correctly positioned. If not fitted onto the heat exchanger, appropriate vent and drain points must be included in the pipe work.

• The fixed and sliding supports must be identified correctly to match to the pipe work expansion arrangements.

• In order to protect the heat exchanger from exceeding its design pressure, pressure relief valves must be installed in the pipe work. The pressure relief valve must be located between the heat exchanger and the first isolation valve, for both the shell and tube side pipe work, either upstream or downstream of the heat exchanger.

• It is recommended to install pipework for bypassing the shell and tube side fluids. This way the heat exchanger can be isolated from the process for maintenance.

• Process instrumentation should be placed at key positions to be able to measure the heat exchangers performance:• Temperature transmitters or thermometers upstream and downstream of the heat exchanger for

both shell and tube side fluid (for checking thermal performance).• Pressure transmitters or gauges upstream and downstream of the heat exchanger for both shell and

tube side fluid (for checking fluid pressure loss).• Flowmeters for shell and tube side fluids.

• Horizontal installation:• Unless indicated otherwise, the heat exchanger should be installed in a perfect level position (refer

the general layout drawing of the heat exchanger).• Heat exchanger used for condensing duties are recommended to be installed under a small slope

(1-20). The slope will help to drain the condensate correctly. Installation of a sight glass is recommended on the condensate outlet connection for visual inspection of any condensate build-up during operation.

Wrong Correct

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• Vertical Installation:• When a vertical mounting position is required supports welded to the shell are recommended to

prevent undue stress on connections. If these welded supports have not been requested, please contact HRS for advice on correct mounting.

• Under no circumstances should the weight of the unit be taken on the heat exchanger connections.• The heat exchanger tube and shell side connections should not function as anchor points for the adjacent

process pipe work. The process pipework for shell and tube side fluids should be adequately supported so that its weight does not exert any forces on the heat exchangers connection nozzles.

• Thermal Insulation:• We recommend that the heat exchanger is thermally insulated with a good quality material of

sufficient to give surface temperatures below 60ºC. This will not only reduce energy losses through radiation or heat gain but will also provide the personnel protection demanded by health and safety legislation. Where this is not possible appropriate guards must be fitted to prevent physical contact between the equipment and operating personnel and if this is also not possible then clearly visible WARNING notices must be attached to warn of the potential hazard.

• For cooling duties that can cause water condensation from the ambient air, thermal insulation is recommended for preventing unwanted water build up in the floor area surrounding the heat exchanger.

• For outdoors installation the heat exchanger must be insulated in order to protect it from freezing of fluid inside both the shell and tubes during extremely cold weather. Insulation also reduces any heat loss to the atmosphere.

• Static electricity: Under certain operating conditions static electrical discharges can be produced which may be capable of igniting any flammable or explosive substances in the vicinity. In order to avoid this risk, HRS recommend that earthing strips are fitted to all electrically conducting components which could become charged with static electricity. An appropriate connection to earth should be made by the user/installer from the heat exchanger supports where this has not been specified to HRS and provided with the unit.

• Gaskets should be inspected before placement to make sure they are fully clean and have no damage or defects. Make sure all gaskets are placed in their exact correct positions prior to tightening the connections.

• For tightening bolts in flanged connections, make sure that a torque wrench is used for applying the correct torque, as shown in the following image:

• When the pipe work connections have all been completed and checked and the remaining system completed, it is recommended that the installation should be thoroughly flushed through to ensure that no loose debris remains in the system. A final pressure test is recommended to ensure pressure of the unit and its connections are as design.

Torque application sequence for 4 bolts flange



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3. OPERATION

3.1. Start-up/CommissioningThe following guidelines should be followed during the commissioning/start-up of the heat exchanger:• Fluid Flows:

• The flowrates of the shell and tubes side fluids should be ramped up gradually to its operating value. Any sudden pressure surges must be avoided when the pumps are switched on and fluids are introduced to the heat exchanger. When steam is one of the working fluids, the steam control valve should always be opened with a slow ramp to prevent condensate surges in the heat exchanger.

• The cold fluid should always be introduced first in order to minimise thermal shock.• The vent connections should be left open when the fluids begin to recirculate and closed when the shell

and/or tube side volumes are completely filled.• Special care should be taken when using “snap-action” valves for sending process fluids to or from the

heat exchanger for avoiding water hammer.• All connections should be checked for leaks and tightened where necessary.

3.2. Normal operationOnce the start-up sequence has been completed, the following points should be checked (periodically):• Make sure that the pressure and temperatures on shell and tube side are within the design pressures

(see unit nameplate).• Make sure that the fluid flowrates are according the design parameters. Excessive flow rates can cause

unwanted problems such as tube vibrations.• Any deviation from the defined operation parameters can indicate a problem with the heat exchanger.

See the chapter “Troubleshooting”.• If during operation it is needed to stop the flow of the cold fluid, then the hot fluid should be stopped as

well, either through bypassing the flow or stopping the pump.

3.3. Shut-downThese guidelines should be followed:• The hot fluid should always be stopped first. After that the cold fluid recirculation can be stopped.• Ensure that the shell and tube side are fully depressurised.• The unit must be allowed to cool down to atmospheric temperature before carrying out any maintenance.• When the unit has reached atmospheric temperature it should be drained completely if it is to be left idle

for more than a short time (make sure the unit is depressurised before opening drain valves).

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4. FLUID REQUIREMENTS

4.1. Product side fluidsHRS makes the following general recommendations for the product fluid circuits: • Product fluids will normally be passed through the tube side of a heat exchanger unless central specific

requirements make an alternative flow regime more appropriate.• If the products carry particles it is important to ensure that the minimum inside diameter of the heat

transfer tubes is at least three times the maximum particle size.• If the products are of high viscosity and/or have a tendency to freeze at ambient or working temperatures,

a monotube (tube in tube) style of heat exchanger is normally recommended to ensure that tube blockage can be easily monitored and corrective actions taken as necessary before damage occurs to either the heat exchanger or the system into which it is fitted.

• It is essential that the heat exchanger materials of construction are appropriate for the products being circulated. Products with high salt content in particular can be very aggressive with stainless steel and more resistant grades or duplex materials must be used with these products. If the end user has any doubts contact HRS or a specialist metallurgist for advice and confirmation of compatibility.

• Product fluids should be deaerated before passing through the heat exchanger as any air that is released during heating or cooling can accumulate within the heat exchanger and cause thermal performance problems.

4.2. Service side fluidsThe HRS shell and tube heat exchangers can use a wide variety of service fluids to provide the source of heating or cooling for the product. Typically the service fluids fall into one of three major categories which are described below but if other fluids are to be used for specific contracts the user must ensure that good engineering practices are followed during the storage, use and that disposal of the fluids used are completed safely.

4.2.1. SteamGeneral requirements:• Vertical mounting of the heat exchanger is strongly recommended in preference to horizontal

mounting as this will normally guarantee the avoidance of damaging stresses even if the condensate removal system is not 100% effective.

• The steam supply must be good quality dry saturated steam free from solid particles, air and water droplets with a maximum working pressure at the heat exchanger equal to or less than the value that is marked on the nameplate. Steam line drain traps and filters should be fitted in order to ensure that good steam quality is maintained we recommend that a specialist company be contacted to advice on this requirement.

• The minimum steam line diameter should be that of the heat exchanger connection pipe the size of which will have been checked by HRS to ensure that the diameter is sufficient for the maximum volume of steam passing through the connection during normal service. If the control valve is smaller than the inlet connection the installer must supply transition pipe work before the heat exchanger to match the connection diameter.

The HRS shell and tube heat exchangers can be used with a wide variety of product fluids and it is important that the user has specified the fluid characteristics correctly during the design stage to ensure that the heat exchanger selection is appropriate for the working fluid(s) as well as ensuring that the required thermal performance will be achieved. The user must ensure that good engineering practices are followed during the storage, use and that disposal of the fluids used are completed safely.

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• Specialist advice should be sought by the installer to ensure that steam control valves are sized correctly in order to give a constant and controllable pressure into the heat exchanger. We strongly recommend modulating controls in preference to on/off controls which can cause damaging pressure shocks within the system.

• Manual shut off valves should be installed before and after the heat exchanger to ensure safety during servicing activities.

• A safety relief device should be installed between the manual shut off valves and the heat exchanger.

• A pressure gauge sized in accordance with good practice should be fitted into the steam line immediately before the heat exchanger. Provision should be made to allow easy condensate drainage from the gauge line.

• The steam lines should always be insulated for personnel safety in order to ensure that condensate does not form within the steam lines before the heat exchanger and for energy conservation.

• Before using the unit from cold it is important to ensure that all steam lines are drained correctly and brought slowly to full working pressure and temperature. Always use modulating valves to control the heat exchanger and open these valves slowly in order to allow the heat exchanger to reach its working temperatures without excessive thermal shock.

• Appropriate condensate traps should be fitted.• The heat exchanger should be adequately insulated for both personnel safety and for energy

conservation. If insulation is not possible, appropriate guards and warning notices must be provided in accordance with current health and safety legislation.

It is important to ensure that the condensate removal system allows the condensate formed within the heat exchanger to drain freely under all working conditions particularly under reduced pressure conditions resulting from a temperature control system and/or low load conditions. Failure to do this could damage the heat exchanger as an accumulation of condensate within the unit could result in damaging differential stresses.

4.2.2. WaterThe cooling water source for heat exchanger use will vary with the installation but they can be broadly classified as follows:• Raw water sources: it is important to monitor the chemical composition of the water source to

ensure that it is suitable for use with the AISI 300 series stainless steels, particularly the quantity of chlorides. The water should be filtered through mesh filters to ensure that any solids carried through to the heat exchanger will not cause blockage. The user should bear in mind that there are environmental controls in force in most countries which limit the temperature of raw water sources returned to the environment.

• Fresh water sources: these are normally taken from mains supplied drinking water systems. The chloride levels in these sources are normally low but frequently they will have high carbonate levels which will result in hard water scale formation when heated. The user must have facilities for hard water scale removal (normally using chemical methods) if it is intended to use for cooling services where temperatures are elevated.

• Chilled water sources: these are closed systems which can normally be assumed to be clean non-fouling supplies. It is unlikely that the working temperatures will cause carbonate scale precipitation so little fouling is likely over extended periods.

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General requirement:• Regular chemical analysis should be applied to determine the chloride and carbonate levels

and appropriate actions taken if the quantities found rise above acceptable levels. Appropriate specialist advice should be sought to confirm that any water source is suitable for use with AISI 304/316 materials at the temperature levels likely to be experienced in service.

4.2.3. GlycolGlycol cooling systems using glycol added to fresh water are often used to provide a low temperature cooling medium. There are two types of glycol commonly used in varying proportions.• Ethylene glycol: A family of glycols commonly used in industrial applications in proportions varying

between 5% and 45%. It is important to realise when using ethylene glycols that under many legislations they are considered to be dangerous fluids (they are toxic). The categorisation of the heat exchanger under the European Pressure Directive 2014/68/EU must take this into account.

• Propylene Glycol: A family of glycols commonly used in food processing applications in proportions varying between 5% and 45%. The propylene glycols are not toxic and the categorisation of the heat exchanger under the European Pressure Directive 2014/68/EU should take this into account.

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5. MAINTENANCEThe following guidelines must be followed:• A planned maintenance schedule is recommended for all equipment in order to maximise its performance

and service life. For HRS heat exchangers the only periodic maintenance necessary is to carry out a visual examination to ensure that there are no leaking gaskets or mechanical damage which could cause later problems.

• If any leakage is detected from any flange/fitting it should be retightened as necessary. It is important to note that gaskets and seals manufactured from elastomeric materials naturally deteriorate over time especially when subjected to elevated temperatures and pressures and must be periodically replaced. A gasket change is recommended each time a heat exchanger is dismantled. Gaskets in warehouse storage will also deteriorate in time due to the effects of light and ozone and should be stored away from natural light wherever possible in clean and dry conditions away from chemical storage areas.

• Periodic checks of performance in service are recommended to ensure that the unit is working as intended. Any reduction in heat exchange capacity or increase in fluid pressure losses may be due to a build-up of fouling deposits in one or both of the fluid circuits. These must be removed by CIP or mechanical cleaning to return the unit to its design capacity and to prevent possible long term corrosion damage.

• CIP cleaning does not involve removal of the heat exchanger from the system but if mechanical cleaning is required the unit must be removed to a suitable workshop area for the cleaning operations.

Note: In multi-module units fitted with interconnecting bends on the product circuit and/or interconnecting flanges on the service circuit it is important to follow good engineering practice and identify all matching flanges/fittings before removal to enable the units to be refitted in their original positions after servicing.

Note: After any maintenance has been carried out it is recommended that the unit is pressure tested to the test pressure for each circuit marked on the unit nameplate before being returned to service.

5.1. Spare partsThere are no recommended spare parts for the HRS shell and tube heat exchangers other than spare connection gaskets or O-rings. Recommended spare parts list can always be found in the documentation that is shipped with the order.

5.2. RepairRepair work on a heat exchanger should always be executed by an expert company that is licensed for manufacturing and repairing pressure vessels.

When repair work is needed on an HRS heat exchanger always contact HRS first for consulting the best option for repair. Any unauthorised repair work can result in loss of the guarantee.

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6. CIP CLEANING

Any reduction in heat exchange capacity or increase in fluid pressure losses may be due to a build-up of fouling deposits in one or both of the fluid circuits. These must be removed by CIP or mechanical cleaning to return the unit to its design capacity and to prevent possible long term corrosion damage. HRS heat exchangers are designed to be CIP cleaned but if mechanical cleaning is required the unit must be removed to a suitable workshop area for the cleaning operations.

Before cleaning operations commence it is important to ensure that the shell side fluid circuit (service fluid) is fully drained and open to the atmosphere in order to prevent pressurisation of the shell during the CIP cleaning operations. This is particularly important when a refrigerant fluid is being used as the pressure increase could exceed the safe working pressure and damage the equipment.

6.1. Cleaning operationsAfter completion of the production cycle the heat exchanger system should be cleaned as necessary using alkaline and/or acid washes combined with fresh water flushes. The flow rate used for the CIP cleaning cycles should be at least the level of the product circulation rate but a minimum velocity of 1.5 m/s through the product circuit is recommended for most applications. If in doubt as to the type of cleaning fluids or cycles necessary, the user should contact a specialist cleaning company for advice.

6.2. Severe foulingIn heating systems where product burn on is likely because of the nature of the product specialist advice should be sought to maximize the cleaning cycle efficiency. In applications which result in the wetted surfaces of the tube plates becoming fouled it may be necessary to use a reverse flush in addition to the normal flush in order to ensure that the outlet tube plate surfaces are adequately cleaned.

6.3. CIP fluidsThe following fluids are typically used during CIP cleaning operations:• NaOH: A 1% solution (w/w) of caustic soda in water circulated at a temperature of 70ºC.• HNO3: A 0.5% solution (w/w) of nitric acid circulated at a temperature of 70ºC.

Note: In severe fouling applications it may be necessary to exceed the concentration levels given above but advice from a specialist cleaning company should be sought before taking this step.

• Detergents: There are various proprietary detergents available which contain wetting and cleansing agents and if these are used the manufacturer’s instructions must be followed while still observing the solution strength limits given above.Note: Water used to make up the solutions for CIP cleaning or for subsequent flushing operations must be clean fresh softened and free from chlorides.

Operators must have appropriate experience and training in handling and working with CIP fluids as they can be hazardous in their liquid or vapour form. Appropriate safety equipment such as overalls, gloves and safety goggles must be provided. If there are any doubts on the part of the operator on how to handle and use the fluids you must seek specialist advice.

Disposal of the various solutions after final use must take into account the nature of the substances used and must always be in accordance with environmental legislation in force in the country of use.

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6.4. CIP cleaning flowrateThe recommended CIP flow rate the standard HRS heat exchangers should be 1.5 m/s in the inner tubes. The appropriate flow rate can be calculated with the following formula:

CIP flow = CIP velocity x N x 2830 x DI2

CIP flow: Recommended CIP flow (in m3/hour)CIP velocity: Defined CIP velocity in m/s: HRS recommends 1.5 m/sN: Number of inner tubes in the flow pathDI: Inside diameter of the inner tubes (in m)

6.5. SterilisationThe sterilisation procedures required for specific applications must be determined by the process and system designers. In general terms the process will involve heating the unit using hot water or steam to a temperature which is considered high enough to sterilize the surfaces and holding the units at that temperature until all of the components forming the heat exchanger reach that temperature. For most high pH applications, a temperature of 90ºC will be sufficient but for systems involving low pH products 140ºC may be required.

Before sterilisation operations commence it is important to ensure that the shell side fluid circuit (service fluid) is fully drained and open to the atmosphere in order to prevent pressurisation of the shell during the CIP cleaning operations. This is particularly important when a refrigerant fluid is being used as the pressure increase could exceed the safe working pressure and damage the equipment.

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7. Heat exchanger troubleshooting

Whenever a fault occurs with the heat exchanger where the cause is not immediately apparent it is essential that the full system is checked to ensure that system faults are not causing flows, pressures or temperatures that can damage to the heat exchanger.

The table below should be used for troubleshooting work:

SYMPTOM REMEDY

Change in heat transfer performance or change in pressure drops

Check fluid flow rates on shell and tube side

Check operation of control valves

Check for fouling and clean the heat exchanger if needed

Check if working fluids are as designed for

Visible leakage In case of leakage through gaskets: tighten bolts

Leaks in other parts (not gasket related): Repair may be needed, consult HRS

Product and service fluids mixing Repair may be needed, consult HRS

In case of any doubts over the operational safety of the equipment supplied or situation occur that are not well understood, please contact HRS as soon as possible for advice giving details of the serial number of the unit and a description of the problem encountered.

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8. HRS Heat Exchangers contact information

UNITED KINGDOM SPAIN

HRS Heat Exchangers LtdHRS House, 10-12 Caxton Way

Watford, Hertfordshire WD18 8JYE. [email protected]. +44 (0)1923 232 335F. +44 (0)1923 230 266

HRS Heat Exchangers, S.L.U.Pol. Ind. San Martin

C/ Castillo de la Concepción, 1430564 Lorquí (Murcia)E. [email protected]. +34 968 676 157F. +34 968 676 166

USA WEST COAST USA EAST COAST

HRS Process Technology Inc.11029 N. 24th. Ave., Suite 804

Phoenix, AZ, 85029E. [email protected]

T. +1 623 915 4328

HRS Process Technology Inc.840 Kennesaw Ave., NW B-1, Marietta

Atlanta, GA 30060E. [email protected]

T. +1 770 726 3540

MEXICO RUSSIA

HRS Process Technology Inc.Alcanfores 49-8, Las ÁguilasDelegación Álvaro Obregón,

Ciudad de México (or Mexico City) 01710E. [email protected]

T. +52 (55) 8526 6205 ext 301

HRS Heat Exchangers RussiaSaint-Petersburg,

Malinovskaya str. 8E. [email protected]

T. +7 (812) 677 9314

INDIA MALAYSIA

HRS Process Systems Ltd 201/202 Karan Selene,

851, Bhandarkar Institute RoadPune, Maharashtra, 411004

E. [email protected]. +91 20 2566 3581T. +91 20 2566 3583

HRS Heat Exchangers Sdn BhdB-12-02, Garden Shoppe One City

Jalan USJ 25/1A47650 Subang Jaya

Selangor Darul EhsanE. [email protected]

T. +603 8081 1898

AUSTRALIA

HRS Heat Exchangers Pty Ltd.Unit 8 168-170 Christmas St,

Fairfield 3078, Melbourne, VictoriaE. [email protected]

T. +61 3 9489 1866

Further information available at:www.hrs-heatexchangers.com

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www.hrs-heatexchangers.comwww.hrs-heatexchangers.com

HRS UK +44 1923 232 335 HRS Spain +34 968 676 157

HRS USA +1 770 726 3540

HRS Mexico+52 55 8526 6205

HRS Malaysia +60 3 8081 1898

HRS India+91 20 2566 3581

HRS Australia+61 3 9489 1866

HRS New Zealand+64 9 889 6045

HRS TUBULAR HEAT EXCHANGERS

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