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Compabloc Manual Newest
Compabloc Manual Newest
This Instruction Manual IM-001 Rev. B is based on the IM-001 Rev. A with additional information.
It takes into account the CPL range, laser welded units with improved plate profile.
It takes into account the PED requirements, which are applicable only for new equipments.
After installation, be aware of National rules for eventual repair or modifications and periodical
inspections.
Scope of applications
CP units (TIG welded with highly cleanable plate profile),
CPL units (laser welded with new plate profile)
CPK (laser welded with highly cleanable plate profile) and
HCP units (hygienic design).
• Standard Normal range: CP15, CP20, CPL30, CPK40, CPL50 & CPK50, CPL75 & CPK75
• Standard Hygienic range: HCP15, HCP20, HCPL30 & HCPK40
• On request and old models: CP30, CP40, CP50 & CP75
In this manual is used, unless specified otherwise, the generic name of the family (CP) and not the type or model
name (CPK, CPL).
Please note that there is a complete interchangeability between CP, CPL & CPK
blocks (and only the block, not the platepack) e.g. a CPL block can replace
without any modification a CP block.
Compabloc is a welded plate heat exchanger without interplate gaskets allowing a large heat transfer area in a
very compact space.
It is designed and manufactured, as a standard, with the following “Pressure Vessel Codes”: ASME VIII Div.1
with design pressure up to 30 barg (440 psig)-depending on models and materials -and design temperature of
-29/+350°C (-20/+660°F).
PED (CE Marking, based on AD 2000 as standard Pressure Vessel code) with standard type approval for design
pressure up to 30 barg-depending on models and materials -and design temperature established for -10/+300°C
and -40 /+200 °C.
CPL50 & CPL75 models, in 316L & assimilated material, can be designed up to 38 barg (with special graphite
gaskets), Design & Manufacture of Compabloc is made as per Quality System Management according to
ISO 9001:2000 (Registration Number 950328).
Note! For each model, design pressures and temperatures are marked on the type plate.
Those must not be exceeded during operations.
Make sure that the PED category matches your operating conditions.
Compabloc is made from stacks of welded plate packs inserted in a rigid rectangular bolted frame for
mechanical strength and the separation of the various circuits. Each circuit can be fitted with a detachable
baffle plate assembly.
Only 4 panel gaskets are installed, as indicated on the bursted view Page 4 Figure 3.
Four carbon-steel panels fitted with nozzles enable the connection of the pipework. Optionally, these
panels can be lined with the same materialas the plates themselves. The plates, baffle plates and panels
linings can be made from stainless steel 316L, titanium, Hastelloy, etc...
• PTFE sheets: starting October 2004, a PTFE is installed between the Carbon Steel heads and the end plates.
As a consequence each unit includes 2 PTFE sheets (top & bottom heads) which have the purpose to avoid
eventual corrosion between the heads and end plates, but also to minimize the friction between the CS and
stainless or alloys parts.
• Baffle system
In case of risk of water hammer or very viscous product, reinforced baffle system must be installed. (see baffle
section 4.2.5)
• Painted panels
In order to avoid rust, the inner face of unlined panels is painted with the same primer paint system as the outside.
Make sure the fluids you use are compatible with the paint system. Otherwise lined panels or unpainted panels
have to be used.
UPPER HEAD
GASKET
PANEL
PLATE PACK
BAFFLE LOWER
COLD HEAD HOT
CIRCUIT B CIRCUIT A
SUPPORT GIRDER
Compabloc is a heat exchanger used for heating or cooling, with or without heat recovery, steam heater,
condenser, 2 pass process condenser, reflux condneser, reboiler, gas cooler etc...(see end of the Manual)
Each of those duties requires a specific installation and the installation must be in conformity with the thermal
data sheet and the quote/general assembly drawing of the unit.
Note! Unless specifically designed to do so, exchangers will not operate under
vacuum and will not operate empty. If necessary, a vacuum relief valve should
be installed. In case of Full Vacuum operation or possibility, make sure your
Compabloc has been designed for Full Vacuum (FV design).
• Operating pressures
Unlike most of heat exchangers, Compabloc must have a minimum differential pressure around 2 bars
between the operating pressures of each circuit. An identical operating pressure on both circuit would
make the plate pack acts like an accordion, and therefore creating fatigue with the risk of a decreased
lifetime.
By and large, the bigger the differential pressure between the 2 circuits the better, in the range of the
design pressures!
• Flowrate
Minimum flow rate is 20 % of the design flow rate indicated on the thermal data sheet. In the case of exchangers
with steam, super heated water or thermal fluid entering the hot circuit, it is necessary to maintain a minimum 20 %
flow rate in the cold circuit (controls and adjustments must be set to take this flow rate into account). A cold circuit
flow rate stop may lead to a partial spraying and a recondensation. When the operation is frequently repeated, the
exchanger could damage itself and its environment.
• Corrosion risk
The material of the parts in contact with the fluids has been specified or choosen based on a given data supplied
by the customer (fluid, composition, temperature). Should the fluids and operating temperatures going through
the unit being different of those specified in the data sheet, it is customer’s responsability to ensure that there is no
corrosion risk. Special attention must be given to the chloride content of the streams, as this is a frequent cause of
corrosion on Stainless Steel materials. If the fluids and working temperature are different of the specified ones in the
data sheet, contact Alfa Laval for material validation.
All units delivered in EEC are potentially following the PED (Pressure European Directive) with a level of risk
depending on many parameters such as:
• Nature of the fluid (gas, liquid, steam, fluid vapour pressure)
• Danger level of the fluid
• Design Pressure
• Volume of each circuit
• Design temperature
Those parameters will determine a PED Category to which is linked a risk analysis as per the PED.
Make sure that the category of your unit matches what it has been planned for.
2 Installation
• To allow maintenance and inspection, we recommend leaving a 50 to 60 cm (19 to 24”) wide space all around the
Compabloc unit to facilitate panel dismantling. At the top of the exchanger, it is necessary to have a 100 cm (40’’) in
free space to allow the possible setting of a panel-handling device.
• Follow good engineering practice both in the design and operation of the plant. Take appropriate precautions to
avoid hydraulic shocks (water hammer), thereby exceeding the design pressure of the equipment (see Start up
section 3.2).
• The connecting pipework should be provided with valves in order to isolate the unit. Valves are essential between
any pump and the Compabloc.
• All valves should have a slow valve action. Flow rates should be increased slowly and gradually during start up and
reduced gradually during shut down.
• Do not use piston-type pumps. For positive displacement pumps a pressure relief by-pass line including a time-
controlled valve with slow action is recommended. Other precautions used include adjustable speed pumps, pump
shut-off by pressure-controlled switches, pressure-relief clocks, ascending pipes and rupture discs.
• When specifying pumps and heat exchangers, allow ample margins for pressure drop increases above stated
design values. These are the results of possible variations in fluid properties, flow rates, scaling or deposits on the
heat transfer surfaces.
• When using live steam as heating medium, provide a steam trap, preferably with automatic venting of non-
condensibles.
• Make a random check of the torques of the panels bolting before insulating the unit (see para 3.1 for more details)
and piping it.
• Pipework
No specific precautions need to be taken when connecting the exchangers. However, if the connection pipework
includes long, straight runs, it is essential to insert the correct bends, and expansion members and to position the
pipe supports at a maximum 2 meters (72 in) distance from the unit (see “maximum allowable stresses and strains
in and on the nozzles” in section 3).
• Filters
If the service conditions requires, or if the fluid is particle laden, install a 3 mm (1/8”) maximum filter mesh (2 mm
(1/12”) for CP15), upstream from the exchanger.
• Connections/nozzles
All connections/nozzles are marked and should be piped accordingly. In case of doubt, check with the arrangement
drawing.
Note! Always use real control valves with a PID system, set up at the maximum
proportionnal range. Avoid operating periods with only one circuit in
operation.
SUPPORT
SLAB
CLEARANCE REQUIRED
FOR SET UP OF
PANEL HANDLING
SUPPORT EQUIPMENT
CUT-OFF VALVES
PIPEWORK THAT
ALLOWS DISMANTLING
TO ACCESS THE PANEL
PARTITION WALL
Figure 4 big
FX FY &FZ MX MY & MZ
ND Model
N N Nm Nm
25 500 500 80 40 All
Those standard loads & moments are designed to ensure nozzles and nozzle welds integrity and include a safety
factor for the exchanger stability. For specific case, please consult us.
2.3 Lifting
The exchangers must only be moved by means of the lifting rings or of the lifting lugs supplied with the unit.
• Horizontal Compabloc
CP15-CP20-CP30-CP40
Lift the exchanger using two soft slings fixed on the lifting lugs as indicated
Personal protection
Make sure the unit has a personal protection (a grid is generally enough) or an appropriate insulation so that
nobody can be hurt or burnt by touching by inadvertence the panels surface
3.2 Start up
In order to ensure a long life time, start up must be gradual and smooth. Flow rates adjustment should be slowly in
order to avoid the risk of water hammer.
Note! Water hammer is a short lasting pressure peak that can appear during start up or
shut down of a system, causing liquids to travel along the pipe as a wave at the
speed of sound. This can cause considerable damage to the equipment.
• Check that the Compabloc is correctly installed, with the cold circuit flowing upward (in case of gas/air release).
• Generally speaking, unless specific recommendation, the cold circuit must be filled in and started first.
• Fill in the cold circuit, leaving the vent open (CP50 and CP75 only, other models are self venting).
• Start the pump for this circuit with the exchanger inlet valve still closed; open this valve slowly.
• When all the air has been out, close the vent (CP50 and CP75 only).
• Once the cold circuit is running, open progressively the valves of the hot circuit (taking at least 5 minutes), while its
vent is open. Apply the same procedure as for the cold circuit.
• In all cases, start up should be progressive and must not exceed 10°C/h to avoid thermal shocks or unnecessary
stress on the unit.
• In case of thermalcyclic duty or high temperatures, we recommend a slow start up with a temperature gradient of
60°C / h in order to minimize the stress.This value should be applied for each re-start up between 2 batches in case
of severe thermal cycling duty.
It is the opposite procedure of start up, with generally the hot circuit being closed first and the cold circuit still
running.
• Slowly close the valve controlling the flow rate of the pump you are about to stop.
• When the valve is closed, stop the pump.
• If the Compabloc is shut down for several days, it should be drained. Draining should also be done if the process is
shut down and the ambiant temperature is below freezing temperature of the media.
• Depending on the media processed, it is also recommanded to rinse and dry the unit if the shutdown is supposed
to last.
3.5 Re-start up
Important: After a long shut down (2-3 months) control the tightening torque of all bolts and nuts before start up.
Start up has to be as per section 3.2.
Note! After a long shut down (2-3 months), control the tightening torque of all bolts and
nuts, before new start up. (See para 4.2.6.4 for torque values)
Draining
Note! If fluids are hot, allow the unit to cool before draining to prevent possible injury to
operators.
Draining is easy as the lower nozzles allow a self draining for the CP15 to CP40, while for CP50 and CP75, flanged
drains have to be used. They should be piped to the draining circuit or connected to an evacuation system.
Note! Make sure no toxic, hazardous nor lethal vapors or liquids are released to
the atmosphere or to the ground, which could cause injuries or damage the
environment.
4 Maintenance
Be careful You must follow the national rules available for your country about
periodical visits and possible requalification.
Generally speaking, we strongly recommand to monitore the pressure drop through the unit and to carry out chemical
cleaning once a set up maximum pressure drop value has been reached. By and large, the more often cleaning is
carried out, the better the heat transfer performances.
Chemical cleaning is the most efficient way to clean the unit and CIP (Cleaning In Place) allows efficient cleaning without
opening the unit. Select a chemical cleaning agent which will remove scale deposits and which is compatible with the
materials from which the exchanger is made.
This method allows the cleaning solution to be recycled and eliminates the need to dismantle the exchanger, thus
reducing the downtime of the installation. The circulation of the cleaning solution must be upstream, if possible with a
flow of 50 % of the nominal flow.
Citric acid
Silt Phosphoric acid
Silicates Alumina Complexing agents
Diatonic organisms Sodium polyphosphates
Bacteria, protozoa Sodium hydroxide. Small quantities of hypochlorites increase the efficiency
In case of doubt, consult AlfaLaval or any company specialised in cleaning, to check the compatibility and
efficiency between the fouling, the cleaning agent and the materials.
After every chemical cleaning, rinse the exchanger thoroughly and drain it.
If chemicals cannot be used for cleaning, the panels should be removed to permit access to the exchange
surfaces.
Clean with steam or high pressure water (Hydroblast can be made up to 500 barg). Do not go above 500 barg.
As the corrugation are oriented at 45°, it is possible to have a good access of the heat exchange surface by an
orientation at 45° of the cleaning device (hydroblast gun or cleaning bar).
Figure 8 Figure 9
SCREW OR NUT TO BE
FIRST UNSCREW
PANEL TO BE
DISMANTLED
So as to avoid any girder deformation, first it is necessary to release the bolts (mark 4) (screws for CP15,
CP20, CPL30 or nuts for any models) and then progressively loosen any bolts of the panel being dismantled,
starting with the bolts of the girder (mark3) then the bolts of the bottoms (mark 1 & 2).
CP15 MODEL
NUMBER OF PLATES
PANELS
30 50 70 90
Thickness 30 mm 10 15 20 25
Thickness 40 mm 15 20 25 30
Thickness 50 mm 20 25 35 40
CP20 MODEL
NUMBER OF PLATES
PANELS
25 40 60 80 100
Thickness 40 mm 25 30 40 50 60
Thickness 60 mm 35 50 65 80 95
CP30 MODEL
NUMBER OF PLATES
PANELS
60 80 100 130 160 200 240
CP40 MODEL
NUMBER OF PLATES
PANELS
120 160 200
CP50 MODEL
NUMBER OF PLATES
PANELS
100 150 200 250 300
CP75 MODEL
NUMBER OF PLATES
PANELS
150 200 250 300 350 400 450 500
Thickness 100 mm 800 1000 1200 1400 1600 1800 2000 2200
Thickness 120 mm 900 1200 1400 1700 1900 2200 2400 2700
Thickness 140 mm 1100 1400 1700 2000 2300 2600 2900 3200
Thickness 160 mm 1200 1600 1900 2200 2600 2900 3300 3600
Thickness 180 mm 1400 1800 2200 2500 2900 3300 3700 4100
There are two different types of baffle: bolted baffles or stamped baffles.
Prior to dismantle the baffles, locate their position in the exchange block, in order to reassemble them correctly.
It is almost impossible to put back the baffle cage (baffles + their support) as one piece, the best is to put back the
baffle one by one, as the platepack may have bent a little after use.
a) Dismantling
• Loosen all the baffle plate attachment nuts.
• Remove the half-baffles from the V-shaped slot in the column liners.
• Remove the baffle plate assembly by unscrewing the nuts at the ends of the threaded rod.
b) Reassembly
• Without tightening, fit the two half-baffle plates head to tail onto the threaded rods, in such away as to grip a
sealing strip so that its raised edge is on the fluid inlet side (see sketch).
• Insert the baffle plate assembly by unscrewing the nuts at the ends of the threaded rods.
• Position the baffle plates vertically and check that the sealing strip is effectively in contact with a plate.
• Once the baffle plate assembly is in place, tighten the nuts.
• Fit the panels as shown in section 4.2.6
Figure 12
DIRECTION
OF FLOW
DIRECTION
OF FLOW
Nota: The panel must press on the raised end of the sealing strip to ensure effective sealing. When
reassembling, ensure that the end of the strip protudes by approximately 3 mm (i.e. 2 mm for the seal
thickness + 1 mm for the stip fold back).
Figure 13
THREADED ROD
PANEL
LINER IF USED
HALF-BAFFLE PLATES
SEALING
STRIP
a) Dismantling
• Pull the ladder made by the two uprights (beams) and the baffle plates.
• Take the triangular PTFE Cord gaskets off the triangular part of the longitudinal girder lining.
b) Reassembly
• Take the grease off the triangular groove of the longitudinalgirder lining.
• Put the self-adhesive triangular PTFE Cord gasket in this groove and make it take its form, as shown in
Figures 14 and 15.
Figure 14 Figure 15
HEAD
LONGITUDINAL GIRDER
LONGITUDINAL GIRDER LINING
GROOVE
• Bring the baffle plate progressively in the exchange block. Ensure it is reassembled in accordance with the
position noted down before disassembling (figure 16).
• Ensure the gasket is correctly mounted and fit the baffle plates on the plates (figure 16).
• Check the distance between the frame and the sealing strips (figure 17).
HEAD
Figure 16
DETAIL: Stamped Baffles
(Half-baffles + Frame)
Figure 17
FEET
AT TRANSFER PLATE
BAFFLE
Note! The maximum differential pressure a baffle can stand is 2-3 bar. In case of
very viscous mediums or risk of sudden high flowrate surges (water hammer),
reinforced baffles must absolutely be used. In this case vertical tubes are going
through the baffle, creating a baffle cage making the whole baffle construction
more rigid & stiffer.
After reassembling the baffle plates using the procedure described in Section 4.2.5 above, clean the gasket thoroughly,
taking care not to scratch them with a metalobject.
b) Vitex (now obsolete) or Goretex BG gaskets (which replaces Vitex as much less swelling)
• Vitex gaskets are presented as PTFE self-adhesive ropes.
• Use the Vitex 10x3 for CP15, CP20, CP30, CP40 and the Vitex 14x5 for the CP50 and CP75.
Or (much better!)
Goretex BG 30-10 for CP15 to CP40 New Series = S3-3-10-20
BG 30-15 for CP50 New Series = S3-3-15-20 Spring 2002
BG 30-20 for CP75 New Series = S3-3-20-20
• Glue the gasket in the middle of the gasket face of the exchange block.
• Round the gasket in the angles with a radius as small as possible without creating a pleat.
• Make the junction facing a stud bolt of a panel according to the following method:
Figure 18
HEAD LINING
HEAD
STUD
Note! Compabloc sealing can be assured only with gaskets supplied by AlfaLaval.
• For the CP40, CP50 and CP75, set the panelon 6 studs;
Figure 19
6 STUDS 6 STUDS
• Insert the studs progressively as the panelis positioned and fit the nuts without tightening them.
• Proceed in the same way for the opposite paneland then the two panels of the other circuit.
• Tighten allfour panels simultaneously, using only the heads studs mark 1 & 2 for panels of less than 100 plates. For
panels of more than 100 plates, studs mark 3 can be used also, to fit the panels in the frame rail fitting. Ensure the
gasket does not move, and that the panelstay parallel to the frame. Ensure the panel fitting on the frame railand the
heads has been performed correctly.
The bolted frame of the different models shows some specifications. See Figures 20 & 21.
• For CP50 and CP75, ensure the bolts mark 5 (connection girder/head) are overtighten.
• When the four panels are correctly fitted, bring all the girder bolts into contact with the panels.
• Tighten bolts mark 1 & 1’ in staggered rows with a spanner or with bolting machine. When panels are into contact,
tighten bolts mark 2 and then 3.
• Tighten to half the tightening torque, turning around (so as not to forget any bolt).
• Finish tightening respecting the torques given in the table of section 4.2.6.4 for standard gaskets, or specific
tightening torque given on the GA drawing.
Note ! • If the four panels have been dismantled, proceed progressively on each panel.
• If only one panel has been dismantled, do not forget to tighten at the same time
bolts on the girder of the adjacent panels (mark 4 Figure 20 page 22).
Figure 20
CP15 A CP40
Figur 21
CP50 - CP75
After reassembly, a hydraulic test at the pressure indicated on the type plate is mandatory.
• Hydraulic test should be carried out with one circuit empty, the other circuit being full & pressurized at the test
pressure.
• The pressure of the circuit in test may decrease due to the trapped gas compression or a slight plate adjustement.
In that case, it does not mean that the heat exchanger is leaking, read just the test pressure, it should be stabilized
after half an hour.
A heat exchanger is leaking when a leak is effectively observed between 2 circuits or when it leaks externally.
(See Section 5)
Note! Always perform the hydraulic with the 4 panels fully tightened in place.
5 Trouble shooting
(see Trouble shooting questionnaire at the end of this Manual)
External leak is generally caused by a gasket, panel liner failure or core failure.
a) Gasket leak
The leak due to gaskets can be detected by fluid dripping and accumualtion on the ground. Check that the gasket
is correctly positioned, tighten the panel if possible or replace the gasket.
b) Panel liner leak
This leak is generally detected by liquid coming out through the Argon hole located near by the butt weld on the
flange tube. It means that there is a crack or a spot weld failure on the panel liner. The unit must be shut down.
A dye penetrant examination of the liner can confirm that this is well the cause. Full vacuum and/or sudden and
brutal partial vacuum is often the cause. Check if the unit is designed for it.
c) Core leak
If the gasket and panel liners are sealed, the external leak may come from the core itself.
Contact Alfa Lava lafter Sales service to do the diagnosis.
This leak is generally detected when one stream is mixed with the other stream and means that a cross
contamination between the 2 circuits has happened. The best is to call an After Sales Service. The only thing to do
in this case, is to isolate the unit, drain it, remove the panels and make a dye pen examination on the welds to know
where is the leak. For repair, consult our Alfa Laval After Sales Service. A Compabloc expertise report can be sent
upon request, allowing to fine tune the possible cause of the problem.
A classical system where the outlet process temperature drives the control valve at the service inlet is perfect as long
it is a PID system and the control valve is correctly sized. An oversized control valve creates the risk of
ON/OFF operation which is not good for any equipment as it turns a control valve into a ON/OFF valve, thus creating
fatigue and stress.
It is generally a continuous process with the purpose to heat a fluid by condensing live or secondary steam
(while with process condensers the purpose is to condense the vapours, not to heat the cooling medium).
2 cases
• Steady flowrate on the media to be heated
It is mandatory that a controlsystem as indicated on the Figure 22 below is installed:
The control system must be based on a condensate level control and not on steam control.
The TIC drives the condensate control valve located after the steam trap.
The steam trap is essential as it will allow only the condensate to pass.
The condensate control valve must not be oversized! It should operate within 80-110 % of its range
to avoid ON/OFF behavior.
The system will act as a liquid level control allowing a smooth control as long as PID system is installed with it.
Check the design so that the condensate connection has a much smaller diameter than the steam inlet;
a ratio of 1:3 is generally the best when there are no or very small amount of inert in the steam.
Figure 22 Figure 23
Steam heater – liquid level control Steam heater – by-pass control
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H235 H234
For pharmaceuticals/fine chemical applications, the system is a batch system, starting with low flow rates and heat
load, reaching a peak after a while and decreasing afterward.
For other applications, it can also be a continuous process.
As explained above the control system is different, as the purpose is to condense as much as possible of the
process vapours which most of the time include non condensable such as N2.
Generally no control is installed as the system is usually operating with a constant cooling medium flow rate where
the return temperature will vary depending the heat load.
It is the condensation heat load which will control everything as long as there is enough heat transfer area.
Note! For all condensation duty, make sure the Compablocs have been designed for
Full Vacuum. If not consult Alfa Laval asap. Also make sure a vacuum relief
valve is installed in order to avoid sudden and brutal vacuum when shutting
down the unit.
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7 Notes
1 General data
Side 1 Side 2
Design temperature °C °C
Gasket material
Lining
Fluid
Operating temperature °C °C
5 To check eventually
Sketch Comments
Sketch Comments
Fatigue
Gaskets
Corrosion
Process conditions (start up)