INSTALLATION & OPERATION MANUAL:

HRS TUBULAR
HEAT EXCHANGERS
SERIES TYPES: AS3, AS4, DTA, DTI, DTR,
G, K, MI, MP, MR, SH, SI, SP
 CONTENTS
1. HEAT EXCHANGER TECHNICAL DESCRIPTION | 4
1.1. Shell | 4
1.2. Inner tubes | 4
1.3. Tube plates | 4
1.4. Shell side connections, nozzles | 4
1.5. Expansion bellow | 5
1.6. Baffles | 5
1.7. Gaskets | 5
1.8. Multi pass design | 5
1.9. Multiple unit design | 5
1.10. Heat Exchanger nameplate | 6
1.11. Thermal design | 6
1.12. Mechanical design | 6

2. INSTALLATION | 7
2.1. Personnel | 7
2.2. Receiving of the heat exchanger | 7
2.3. Storage | 7
2.4. Unloading/unpacking/transport | 7
2.5. Preparing the site | 8
2.6. Installation of the unit | 8

3. OPERATION | 10
3.1. Start up/Commissioning | 10
3.2. Normal operation | 10
3.3. Shut down | 10

4. FLUID REQUIREMENTS | 11
4.1. Product side fluids | 11
4.2. Service side fluids | 11

5. MAINTENANCE | 14
5.1. Spare parts | 14
5.2. Repair | 14

6. CIP CLEANING | 15
6.1 Cleaning Operations | 15
6.2. Severe fouling | 15
6.3. CIP fluids | 15
6.4. CIP cleaning flowrate | 16
6.5. Sterilisation | 16

7. HEAT EXCHANGER TROUBLESHOOTING | 17

8. HRS HEAT EXCHANGERS CONTACT INFORMATION | 18
IMPORTANT INFORMATION
This 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:

1. Inner Tubes
2. Tube Plate
3. Expansion Bellow
4. Shell
5. Nozzle
6. Service Connection

1.1. Shell
The 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 tubes

The 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 plates

The 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, nozzles

The 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.

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1.5. Expension bellow
An 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. Baffles
Baffles 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. Gaskets
Gasket are used between fittings (flanges, clamps etc.) to make sure the connection is seal tight.

1.8. Multi pass design

The 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 designs

In 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 nameplate
Each 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 design

Each 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 design

After 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. Personnel
Personnel 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 exchanger

HRS 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. Storage
If 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/Transport
The 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 site
The 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 unit

The 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.

Wrong Correct

• 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.

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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:

Torque application sequence Torque application sequence Torque application sequence

for 4 bolts flange for 8 bolts flange for 12 bolts flange

• 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.
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3. OPERATION
3.1. Start-up/Commissioning
The 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 operation

Once 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-down
These 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
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.

4.1. Product side fluids

HRS 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 fluids

The 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. Steam
General 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.

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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. Water
The 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. Glycol
Glycol 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. MAINTENANCE
The 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 parts

There 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. Repair
Repair 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 operations

After 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 fouling

In 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 fluids

The 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 flowrate
The 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/s
N: Number of inner tubes in the flow path
DI: Inside diameter of the inner tubes (in m)

6.5. Sterilisation
The 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 Check fluid flow rates on shell and tube side
change in pressure drops
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.

HRS | 17
8. HRS Heat Exchangers contact information
UNITED KINGDOM
HRS Heat Exchangers Ltd
HRS House, 10-12 Caxton Way
Watford, Hertfordshire WD18 8JY
E. info@uk.hrs-he.com
T. +44 (0)1923 232 335
F. +44 (0)1923 230 266
USA WEST COAST
HRS Process Technology Inc.
11029 N. 24th. Ave., Suite 804
Phoenix, AZ, 85029
E. info@us.hrs-he.com
T. +1 623 915 4328
MEXICO
HRS Process Technology Inc.
Alcanfores 49-8, Las Águilas
Delegación Álvaro Obregón,
Ciudad de México (or Mexico City) 01710
E. info@hrs-he.com
T. +52 (55) 8526 6205 ext 301
INDIA
HRS Process Systems Ltd
201/202 Karan Selene,
851, Bhandarkar Institute Road
Pune, Maharashtra, 411004
E. info@hrsasia.co.in
T. +91 20 2566 3581
T. +91 20 2566 3583
AUSTRALIA
HRS Heat Exchangers Pty Ltd.
Unit 8 168-170 Christmas St,
Fairfield 3078, Melbourne,Victoria
E. info@au.hrs-he.com
T. +61 3 9489 1866
SPAIN
HRS Heat Exchangers, S.L.U.
Pol. Ind. San Martin
C/ Castillo de la Concepción, 14
30564 Lorquí (Murcia)
E. info@hrs-he.com
T. +34 968 676 157
F. +34 968 676 166
USA EAST COAST
HRS Process Technology Inc.
840 Kennesaw Ave., NW B-1, Marietta
Atlanta, GA 30060
E. info@us.hrs-he.com
T. +1 770 726 3540
RUSSIA
HRS Heat Exchangers Russia
Saint-Petersburg,
Malinovskaya str. 8
E. mail@hrs-heatexchangers.ru
T. +7 (812) 677 9314
MALAYSIA
HRS Heat Exchangers Sdn Bhd
B-12-02, Garden Shoppe One City
Jalan USJ 25/1A
47650 Subang Jaya
Selangor Darul Ehsan
E. info@my.hrs-he.com
T. +603 8081 1898
Further information available at:
www.hrs-heatexchangers.com
HRS | 18
 HRS UK HRS Malaysia
+44 1923 232 335 +60 3 8081 1898

HRS Spain HRS India

+34 968 676 157 +91 20 2566 3581

HRS USA HRS Australia

+1 770 726 3540 +61 3 9489 1866

HRS Mexico HRS New Zealand

+52 55 8526 6205 +64 9 889 6045

www.hrs-heatexchangers.com