Work Instruction

Title: Cooling Water Exchanger Reference: MMEC-WI-1002

110-EP-061A/B/C/D/E/F & G
Revision: 1

Effective date: October 2012

Total pages: 7

Revision date: September 2015

Custodian: Signature Date

Head of Static Maintenance Jayagopu Rajagopal

Approved by:

Maintenance Manager Steven Siccard

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Cooling Water Exchanger Reference: MMEC-WI-1002
110-EP-061A/B/C/D/E/F&G Revision: 1
Page: 2 of 7

Content
Page

1. Application ………………………………………………….. 3

2. Purpose …………………………………………………….. 3

3. Definitions …………………………………………………… 3

4. General Safety Awareness & PPE ……………………….. 3

5. Environmental Aspects …………………………………….. 3

6. Tools & Equipment Required …………………………….. 3

7. Permit to Work Procedure (PTW) ………………………... 3

8. Maintenance Procedures …………………………………. 3

9. Record Keeping…………………………………………. 7

10. Development Team ……………………………………….. 7

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Cooling Water Exchanger Reference: MMEC-WI-1002
110-EP-061A/B/C/D/E/F&G Revision: 1
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1. Purpose
To provide a Standardized set of Guidelines for Scheduled Preventive maintenance of Plate
Type Heat Exchanger, Tag No: 110-EP-091A/B/C/D/E/F & G

2. Definition
MSDS - Material Safety Data Sheet
PPE - Personal Protective Equipments
PTW - Permit to Work
CIP - Cleaning in Place
PHE - Plate Heat Exchangers

3. General Safety Awareness & PPE

3.1 Observe the All the Hazards in the Work Area
3.2 Check all the Lifting Gears are having Current Color
Code
3.3 Check all the Hand Tools are in the Good Condition
3.4 Complete all PTW Procedures before Starting the Work
3.5 Be aware the Location of Fire Fighting Equipments
3.6 Check the MSDS for the Chemicals/Liquids Going to use
3.7 Use all the Personnel Protective Equipments.

4. Environmental Aspects
Disposal of Waste Materials Like used Oil/Grease, Waste Rags; used Gaskets are to be
according to the Waste Disposal Policy/Rules from the SHE Department.

5. Tasks & Responsibilities

Mechanical Technicians/Mechanical Supervisors are the Responsible for over the entire Job.

6. Tools & Materials Required

6.1 Lifting Tackles with the Current Color Code
6.2 Hand Tools with Good Condition

7. Permit to Work Procedures

7.1 Check the Work Order in SAP
7.2 Complete the Cold Work Permit procedure
7.3 Check the necessary Process Isolation is completed from Operation Side
7.4 If required use Electrical Isolation Permit / Lock Out & Tag Out procedure for downstream
Rotary Equipments.
7.5 Follow Hot work Permit procedure, if Hot Work arise

8. Maintenance Procedures

8.1 General Advice / Dangers

8.1.1 If People may be injured by Product Leakage, install a protection Shroud (Splash
Guard). If the PHE is equipped with a protections shroud, this must NOT be removed as
long as the PHE is under Pressure.

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Cooling Water Exchanger Reference: MMEC-WI-1002
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8.1.2 Shutdown should take place slowly. Make sure the Unit is NOT under pressure and is
empty before starting the Work

8.1.3 Cool the heat exchanger before starting the work, If possible, allow the heat exchanger
to stand and cool overnight.

8.1.4 When handling heat exchanger plates, always use gloves to prevent injuries to the
hands – the plate edges are sharp!

8.1.5 Make sure that the workroom is sufficiently ventilated when gluing gaskets on to the
heat transfer plates.

8.2 Opening the Heat Exchanger

8.2.1 No special tools are required. A ratchet spanner is all that is needed for maintenance
and repair.
8.2.2 Shutdown should take place slowly. Make sure the unit is NOT under pressure and is
empty before starting the work.
8.2.3 Cool the Heat exchanger. If possible allow the heat exchanger to stand and cool
overnight.
8.2.4 Disconnect any connection to the moveable cover.
8.2.5 Clean the thread of the tightening bolt.
8.2.6 Apply a thin film of oil to the thread.
8.2.7 Painting a diagonal line cross the plate back to ensure that the plates are reassembled
in the right order.
8.2.8 Note the current A dimension
8.2.9 Remove Bolts 1.
8.2.10 Slacken nuts 2, 3 and 4 alternatively so that the movable cover can move parallel with
the frame plate.
8.2.11 Remove bolts 3 and 4.
8.2.12 Slacken nuts 2 alternatively.

8.3 Taking out the Plates

8.3.1 If two or more plates have stuck together they must be separated carefully so that the
gaskets are kept on the correct plate.
8.3.2 The plates support each other in pairs. If a plate has been so damaged that it must be
taken out and cannot be repaired with an identical one, the adjacent plate must also be
taken out of the heat exchanger.
8.3.3 If the number of plates is changed, so is the A-Dimension. Special plates, such as the first
and last plates and turning plates in multipass heat exchangers, must be replaced with
Identical plates.

8.4 Cleaning the Plates

.

8.4.1 The heat exchanger is opened according to Section 8.2

8.4.2 Steel wool or brushes of carbon steel must not be used, nor any stainless steel should be
used on Titanium plates.

8.4.3 In the first step the heat exchanger surface is cleaned by rinsing with a powerful jet of
water and scrubbing with a nylon or similar brush.

8.4.4 Take care not to damage the gaskets.

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Cooling Water Exchanger Reference: MMEC-WI-1002
110-EP-061A/B/C/D/E/F&G Revision: 1
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8.4.5 The Gaskets must be wiped dry with a cloth. Solid particles adhering to the gaskets cause
damage and result in damage and result in leakage when the unit is put back in Operation.

8.4.6 The Lower portion of each plate as hung in the unit should be inspected carefully and
cleaned appropriately as this is the primary area where residual solid material tends to
accumulate

Do not use chlorine or chlorinated water to clean stainless steel or Nickel

alloys

8.5 Plate Cleaning Guidelines

8.5.1 Do not use hydrochloric acids, or water containing in excess of 300 ppm chlorides, with
stainless steel.

8.5.2 Do not use phosphoric or sulfamic acid for cleaning titanium plates.

8.5.3 Limit cleaning solution concentration to 4% strength, with temperature not exceeding 60ºC
unless otherwise specified.

8.5.4 General guidelines for cleaning are tabulated below:

Type of Fouling Suggested Cleaners

Calcium Sulphate, Silicates Citric, Nitric, Phosphoric or Sulfamic Acid

Calcium Carbonate 10% Nitric Acid

Alumina, Metal Oxides, Silt Citric, Nitric, Phosphoric acid (To improve cleaning add detergent
to acid)

Biological growth Sodium Carbonate or Sodium Hydroxide (NaOH)

Greasy deposit Kerosene and a soft brush. After cleaning, rinse thoroughly with
water.

8.5.5 Adjusting the Gaskets

A Gasket that has come loose, either partly or entirely must be glued in place. If only a short
length has become detached, gluing can be carried out immediately before cleaning, with the
plate still sitting in the frame. If the entire gasket has become detached, the plate should be
taken out of the heat exchanger.

8.6 Cleaning the Gasket groove

8.6.1 Clean the plates from residues of old gasket.
8.6.2 Small patches of glue that are securely stuck to the gasket groove may remain there.This
should be removed.

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Cooling Water Exchanger Reference: MMEC-WI-1002
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8.6.3 Wash the gasket groove so that it is completely free of oil and other greasy substances,
using a rag and acetone or other solvent not containing chlorine compounds.
8.6.4 All the plates should be thoroughly dried .

8.7 Gluing the Gasket

8.7.1 Glue is applied with a small flat brush to those parts of the plate’s gasket groove in which
the gasket lies. These parts of the gasket groove are easily recognized as they differ in
color arising from previous residues of glue.
8.7.2 The gasket is then placed into position on the plate. After drying for about 30 seconds (the
time depends on the thickness of the glue film and how much the glue film has been
diluted), the glue holds the rubber gasket firmly in place in the groove, thus facilitating
mounting.
8.7.3 The plate must then be held under light pressure with the aid of other plates or a stiff sheet
of other material of suitable weight for about half an hour.

8.7.4 When the glue joint has dried the gasket should be coated with talc to prevent the plates
subsequently sticking to each other. The plates are then ready to assemble into the
frame.

8.8 Assembly
8.8.1 Before the Heat exchanger is assembled, inspect all gaskets and surfaces that lie against
the gasket. Particles that may jeopardize the integrity of the seals or damage the gasket
or sealing surfaces must be removed. Note that contaminants usually collect at the
lower part of the plates.

8.8.2 Plates that have been provided with new gaskets must be checked to make suite that the
gaskets are in the correct gasket groove. Also check the half thickness gaskets on the
first and last plates.

8.8.3 Use the plate sequencing specification sheet, to make certain that the plates pack is
assembled correctly.

Plate packup length to be measured before and after dismantling the

plates.

8.9 Tightening the Heat Exchanger

8.9.1 The nuts must be tightened alternatively. The moveable cover plate must always be
moved parallel to the frame at all times, and not drawn out of alignment.
8.9.2 Tighten bolts 3 alternately
8.9.3 As the resistance increased also tighten bolts 1 and 2, always alternately.
8.9.4 Tighten bolts alternately.
8.9.5 Check the dimension along the heat exchanger.

8.10 Hydraulic Test of The Plate Exchanger

Hydraulic test is performed to detect gasket leak.
`Gasket leak can be eliminated by tightening the bolts within the limit of the authorized
allowance indicated on the type plate or heat exchanger drawing. A significant leak is a result
of a defective assembling; in this case do not tighten the exchanger

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rests with the user to ensure it is in line with the authorised version on the ORYX GTL IMS Document Center.
Cooling Water Exchanger Reference: MMEC-WI-1002
110-EP-061A/B/C/D/E/F&G Revision: 1
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The gasket leakage will be outside where it happened or through gasket vent holes. In order
to make the operation easier, colour the spot where it happened; It is not possible for one
fluid to enter the opposite circuit due to the double corner of the gasket in the opening parts,
except if one plate is defective.

Hydraulic test of one circuit (i.e. A) enables detection of defective plate, the other side (i.e. B)
being empty at atmospheric pressure.

A hole in a plate would allow leakage between circuits. This is visible by water draining into
the open circuit (B). When the plate pack is open, the defective plate would be 1 of the 2
which are constituting the wet channel of circuit B.

9. Record Keeping

Record all the abnormalities, results of inspection and repair action details to be updated in the
history sheet.

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rests with the user to ensure it is in line with the authorised version on the ORYX GTL IMS Document Center.