东风7G型内燃机车用户手册4——第四章 板式散热器.doc

2005年第一次铁道部东风7G型内燃机车投标标书检修手册 Operating Instructions 操作指南Plate Heat Exchangers 板式换热器 Preface 前言1.0 General (概述) 1.1Identification of unit/series (单元、系列的确认)2 1.2Intended purpose (使用说明) 3 1.3General advice dangers (注意事项)3 2.0Functional description (功能描述) 2.1Structural design, the main components of a PHE (结构设计板式换热器的主要组成部分)3 2.1.1Plates (板片)4 2.1.2Dimension sheet and flow diagram(外型图与流向图)5 2.1.3Gaskets (密封件) 6 2.1.4Frames (框架) 8 2.2Working principle (工作原理)8 2.3Special unit configurations (特殊单元的结构)8 2.3.1Intermediate plate intermediate elements (中间板，中间结构) 9 3.0Installation (安装) 3.1Requirements at installation site (安装现场的要求) 9 3.2Handling and installation (处理与安装)9 3.3Pipe assembly (管道安装) 9 4.0 Operation (操作) 4.1Initial operation (初始操作) 10 4.2Starting up the PHE (启动换热器) 10 4.3operation of the PHE (板式换热器操作) 10 4.4Brief stoppages (暂时停车) 10 5.0Prolonged stoppages (延长停机) 5.1Storing the PHE (板式换热器的存储) 11 5.2Shutting down (关闭)11 6.0Maintenance (维修) 6.1Cleaning the closed PHE (清洗封闭的板式换热器) 11 6.1.1CIP process (就地清洗过程) 12 6.1.2Channel-alternating technique (更换通道清洗) 12 6.1.3Back flushing system (反冲系统) 13 6.2Cleaning the opened PHE (清洗打开的板式换热器) 13 6.2.1Loosening and opening the PHE (拆卸板式换热器) 13 6.2.2Manually cleaning the Plates (人工清洗板片) 14 6.3Replacing plates (更换板片) 15 6.3.1Carry beam with a guiding rail (带导轨横梁的框架) 15 6.3.2Round guiding bars (圆导轨) 16 6.3.3Carrying beam without a guiding rail (横梁无导轨)16 6.4Replacing gaskets (更换密封件) 17 6.4.1Replacing LOC-IN gaskets (更换嵌入式密封圈)17 6.4.2Application of GEA ECOFLEX High-Temperature Adhesive (使用GEA高温粘合剂) 17 6.4.3Application of GEA ECOFLEX Special Adhesive (使用GEA特殊粘合剂) 19 6.5Replacing ring gaskets and rubber Inserts(更换管道接口密封圈与橡皮塞 ) 20 6.6Closing the PHE (封装板式换热器)20 6.7Maintenance/care (维护与保养) 21 7.0Trouble-shooting (故障) 7.1Danger warnings and safety precautions (危险警报与安全措施)22 7.2Possible faults (常规故障)22242 Preface These operating instructions are your guide to the installation, operation and maintenance of GEA ECOFLEX Plate Heat Exchangers (PHE). We advise you to study these instructions carefully and to make them accessible to staff entrusted with the installation, operation and maintenance of the PHEGEA ECOFLEX accepts no responsibility or liability for damage caused by incorrect installation, operation or maintenance or by failure to observe these operating instructions. If you have any further queries, please contact your GEA ECOFLEX agent or the service departments of GEA ECOFLEX GmbH. 1.0 General 1.1 Identification of unit/series Each GEA ECOFLEX PHE is provided with a fabrication label. his is attached to the outside of the PHEs fixed plate It gives details of: 1.Plate heat exchanger type 2.Serial no 3.Maximum working pressurebar 4.Maximum working temperature 5.Content(side 1/side 2)Itr 6.Year of construction 7.Compression dimensions a max. / a min. Mm In any correspondence with GEA ECOFLEX concerning your PHE, please always quote the complete serial number and the number of the current flow diagram. The flow diagram is situated in the rear cover of these instructions. The rear cover of these instructions also contains the specific documentation describing your PHE. Manufacturers name and address 制造商名称及地址: GEA ECOFLEX GmbH Voss-Strasse 1 1/13 D-31157 Sarstedt Germany Phone:+49-5066/601-0 Fax:+49-5066/601-106 China: WUHU GEA KHI MACHINERY COOLING CO.,LTD. Yan An North Road 241009 Wuhu, Anhui, Peoples Republic of China Teh0086 553 5842872, 5842873 Fax:0086 553 5842870 中国地区： 芜湖基伊埃川崎机械制冷设备有限公司 中华人民共和国安徽省 芜湖经济技术开发区(延安北路) 电话：05535842872，5842873 传真：05535842870 邮编：241009 前言 本操作指南用于指导GEA爱客板式热交换器用户安装、操作、维护保养。我门建议在安装，使用，维护板式换热器前，所有操作者应仔细阅读本手册。 GEA ECOFLEX（爱客）对于由于未确按本手册进行安装、操作、维护而造成的后果概不负责。 如有任何疑问及要求，请与GEA爱客当地办事处或德国ECOFLEX服务部联系。 1.0 概述 1.1 单元与系列确认 每一台GEA ECOFLEX板式热交换器都标有其铭牌。它位于板式热交换器固定框架上。主要内容包括： 1.热交换器型号 2.序列号 3.最大工作压力(bar)巴。 4.最大工作温度()摄氏度。 5.容量(1号区、2号区)L升 6.制造日期。 7.板片安装尺寸“a最大值”“a最小值”mm。 与GEA爱客公司有关板式换热器方面的通信来往中，请告知你方完整的系列号码及最新流程图的号码。 流程图以及专门描述文件均放在指导书后面。 Internet: WWW.gea-ecoflex.de 1.2 Intended purpose These operating instructions are generally applicable to all PHE manufactured and supplied by GEA ECOFLEX. GEA ECOFLEX wishes to point out that this PHE has been specially designed and manufactured for the customer-specified operating conditions concerning pressure, temperature, flow rates and type and composition of flow-through media. Sudden pressure surges exceeding these operating conditions, e.g. when suddenly starting or stopping the PHE, may cause damage and must be avoided at all costs. GEA ECOFLEX accepts no liability for the serviceability of the PHE under operating conditions deviating from those specified. If a change in the specified operating conditions becomes necessary, GEA ECOFLEX must be consulted. The PHE may only be operated under new operating conditions after the PHE documentation has been examined, approved and altered by GEA ECOFLEX. During the installation and operation of the PHE, follow the regulations and instructions applicable at the installation site, e.g, the accident prevention regulations. 1.3 General advice/dangers When working on your PHE, follow the following advice: 1.All work on the PHE is to be carried out in compliance with the existing regulations, e.g. the accident prevention regulations. 2.Before starting work on the PHE, make sure that it is not under pressure, cold (max.40) and empty. 3.If people may be injured by product leakage, install a splash protector. If the PHE is equipped with a splash protector, this must not be removed as long as the PHE is under pressure. 4.When handling PHE plates, always wear suitable protective gloves to prevent injuries to the hands. 1.2 使用说明 本操作指南适用于所有GEA爱客公司生产或提供的板式换热器。 任何操作规程的改变都应经爱客公司审核，批准，改编发行。 在板式换热器的安装与操作中，请严格按照本规程执行，谨防事故发生。 GEA爱客公司的产品是根据顾客给出的工艺参数而专门设计并制造的，这包括操作压力，温度，流量，流体的类型及物理、化学性质。任何超过设计要求的压力突变都可能造成换热器的损坏，比如说突然停机与突然开机。在使用中要严格遵守操作规范，杜绝此类事故发生。 对于违反规范引起的一切后果，由顾客自负。 1.3注意事项与安全须知： 以下事项，请在使用中严格遵守： 1、所有的操作都需按现有规程进行，比如事故防范条款等。 2、在开机前确认换热器未受压，常温(不超过40)，空负载。 3、如果使用的介质在泄漏时对人体有伤害，可以安装防喷挡板。在操作中，不要拆除该挡板。 4、在操作中，请戴好防护手套，防止物料对手的伤害。 2.0 Functional description 2.1 Structural design,the main components of a plate heat exchanger Plates and gaskets The plate pack consists of contoured heat exchange plates with gaskets. The number and arrangement of the plates as well as their shape and size-are dictated by the demanded thermodynamic performance. Depending on the application conditions, such plate materials as chrome-nickel steels, chrome-nickel molybdenum steels, titanium and other materials may be employed. Chlorides in the medium reduce the corrosion resistance of chrome-nickel steels and chrome-nickel molybdenum steels (including Hastelloy, lncoloy and lnconell). The intensity of the effect of the chlorides depends on the temperature, concentration and pH of the medium. The gasket groove has been pressed onto the perimeter of the plate to receive specially produced gaskets. The gaskets are designed to seal the plate channels from each other and to prevent external product leakage. The gaskets are mode of NBR, EPDM, Viton, silicone rubber and other special materials. The choice of material depends primarily on its compatibility with the medium and on the temperature and pressure conditions. PHE frame The frame consists of the fixed plate (2), pressure plate (3), carrying beam (5), guiding bar (6) and support column (7). The tightening bolts (4) press the plates (1) together. 2.0 功能介绍 2.1 板式换热器的设计结构，主要部件： 板与其密封 板片组由带密封件的一组相同轮廓的板片组成。板片的数量与安排及其外形、尺寸都由所需的热动力参数确定。 根据不同的应用条件，板片材料可以选择铬镍不锈钢、铬镍钼不锈钢、钛或其它材料。 介质中的氯分子会降低铬镍不锈钢，铬镍钼不锈钢的防腐性能（包括耐酸的哈氏合金，耐热的英科合金，耐热/蚀的英科镍）。氯的化学作用的强弱取决于介质的温度、浓度、PH值。 密封的外形适合于不同的板片沟槽。密封的作用是将相邻板片的通道分隔开，同时也防止产品的外漏。密封件的材料有丁腈橡胶(NBR)，三元乙丙橡胶(EPDM)，氟橡胶(Viton)，硅橡胶和其它材料。密封材料的选择需根据介质、操作温度、压力来确定。 板式热交换器的框架 该框架包括固定板(2)，承压板(3)，支承梁(5)，导轨(6)，支柱(7)。固定螺栓将板片(1)压在一起。88Construction and operation / XXXXXXXXXPipe connections The pipe connections (8) are positioned either on the fixed plate (2) alone or on the fixed plate and the pressure plate (3). The position of the pipe connections is described from an outside position looking onto the particular frame plate.On the fixed plate, the connections 1F-4F are numbered consecutively anticlockwise. On the pressure plate, the connections 1L-4L are numbered consecutively clockwise. The choice of connection layout as shown in the figures depends on the plant conditions and the PHE series. 接管 接管(8)既可以仪处在固定板(2)上，也可以处在固定板与承压板(3)上。接管位置的命名参见左图。其平面视图皆山热交换器外部向内投影。在固定板上，接口1F4F逆时针排列。承压板上，接口1L4L 顺时针排列。 选用的接管型式(见下图)取决于工艺条件与热交换器系列。接管型式：平焊法兰 对焊法兰 橡皮塞 金属衬套 丝口连接 抱箍连接 2.1.1 Plates The plates and gaskets are the main components of your PHE.GEA ECOFLEX distinguishes between three different plate systems. A. VARITHERM (VT) systemUnder the VARITHERM system, the PHE is given wide ranging applications through the use of differently contoured plates with the same connection sizes and external dimensions.The system comprises a series of horizontal and vertical profiles which are employed individually or combined.The horizontal profiles feature high heat transfer coefficients with relatively high pressure drops whilst the vertical profiles feature lower pressure drops with lower heat transfer coefficients.By combining the two, it is possible to adapt the heat transfer coefficients and pressure drops to the specific requirements.The plates are installed in the frame with alternate plates rotated by 180. This means that if the same plate type is used an L plate be comes an R plate. In this way the flow channels are sealed from one another, and the plates give each other the necessary support.This does not apply to the special VT 402 series with a diagonal flow pattern, this series is equipped with special L and R plates. 2.1.1 板片 板片及其密封是板式换热器的主要组成部分。GEA爱客公司共有3种板片系统。 A“变热”(VT)系统 在变热系统中，有各种不同波纹而外形、接口相同的板片供选用。 该系统还包括一系列波纹平行或垂直分布的板片，既可单独使用，也可组合使用。 平行分布的板片，具有较高的传热系数，同时也产生较大的压降。垂直分布板片，恰好相反，压降较小，传热系数也较低。 通过这两种不同的板片组合，可以满足指定的传热与压降要求。 在安装时，相邻板片翻转达180。同一种板片，L型翻转达180即为R型，见图。通过这样的排列，相邻板片互相密封，板片之间互相支撑。但VT402系列除外，它具有特殊的L与R型板。 B. FREE FLOW system(FA) The FREE FLOW system is distinguished by a largely unrestricted flow of the heat exchange media over the plate surface. The special feature of this system is the broad flow cross section between the plates and the coarse contours. The plate contours generally consist of horizontal profiles. FA 159 and FA 161 The product flows diagonally across these plates. The difference between plates A and B is shown by the adjacent figure. The plates have holes drilled into the sides through which guide bolts are inserted. FA 184 and FA 192 These plates have a parallel flow pattern. Plates A and B differ in the width of flow channel. Plate A: Broad channel, i.e. tall gasket. Plate B: Narrow channel, i.e. shallow gasket. In this case, metal webs are spot-welded onto the back of the plate (in the leakage chamber). Each plate pack consists of the same number of plates A and B, which are installed alternately A-B-A-B. B自由流 Free Flow 系统 (FA) 自由流系统的特点是允许介质有更大空间流动。在结构上，板片的 间隙及横截面较大，波纹间隔也较大。 通常情况下，板片的波纹采用水平分布。 FA 159与FA l61 物料由对角方向流动。A板与B板的差别见右图。在两边都有螺孔， 用来安装导向螺栓。 FA 184与FA 192 该类型的板片为并行流动。板片A与B的差别枉于：通道的宽度。 板型A：宽通道，例如厚密封圈。 板型B：窄通道，例如薄密封圈。在此情形下，在板片的背面点焊上金属网(在泄漏区中)。 所有的板片组含有相同数量的A、B板，排列方式为A-B-A-B交替。 C.CONCITHERM plate evaporator system(CT) CONCITHERM means the concentration of liquids by evaporation with the indirect application of heat. The design principle is based on the VARITHERM and FREE FLOW systems. We distinguish between two series: 1.CONCITHERM 187(CT 187) This principle consists of a product plate A with horizontal pro files and a steam plate B with vertical profiles. These two plate types are arranged alternately in an A-B-A-B sequence. The gaskets are fitted without adhesive(LOC-IN system). 2.CONCITHERM 93 (CT 193) In this series, two plates are welded together to form a cassette, the cassettes being installed one after the other like separate plates. The steam channel is welded tight and does not contain any gaskets. The product channel is sealed with a specially profiled gasket. The start and end plates are individual plates. These are permanently welded to the frame plates and the connection pipes and do not have any gaskets. C简热 CONCITHERM 板式蒸发器系统 (CT) 简热系统用于通过间接加热使流体浓缩。该设计原理建立在“变热”，“自由流”系统的基础上。 我们提供两个系列的板片： 1. CT l87 该系列包括用于物料的水平分布的A板，用于蒸汽的垂直分布的B板。这两种板型交替排列，A-B-A-B。密封圈为无粘胶型(LOC-IN嵌入系统)。 2. CT 193 在该系列中，两片板被焊接在一起组成板盒，安装时将板盒象板片样组合在一起。蒸汽通道无密封圈，紧密焊接在一起。物料通道由特殊的密封圈密封。 初始板与末端板为单独的板片。它们永久的焊接在框架上，并与接管焊接，不含密封圈。 2.1.2 Dimension sheet and flow diagram Each PHE is supplied with a dimension sheet or, alternatively, an assembly drawing and a flow diagram. These are situated in the inside sleeve of the rear cover. The dimension sheet shows the external dimensions as well as details of the type, size and position of the pipe connections. The flow diagram shows the particular product flows of each PHE (intemal flow). The flow diagram shown in the figure starts on the left at the fixed plate. Proceeding from left to right, this is followed by the individual plates as thick lines and the product flows as thin continuous or dotted lines each with directional arrows. The internal flow is shown beneath the flow diagram in abbreviated numerical form. An example: 3+3 3+2 3+3 means: Flow medium from the left 2 flow paths each with 3 parallel flow channels. 3+2 means: Flow medium from the right 2 flow paths with 2 and 3 parallel flow channels. The flow diagram also gives the item numbers of the individual plates these are also the spare part numbers (please quote when ordering spare parts). Beneath the flow diagram is a little box with the heading plates with information on the plate type employed and on the plate and gasket materials. 2.1.2 外形尺寸表与流向图 每台热交换器都附有一张尺寸表(或安装图)，及流向图。 外形尺寸表上标有热交换器的外形尺寸，以及型号，长度及接管位置。流向图描述了热交换器内物流流动的分布。 左图显示，物流由左端固定板进入。图中，每一条粗线代表板片，细连线或点划线显示物流流动，箭头代表流动方向。 内部流动方式由下列形式表示。 3+3 3+2 其中3+3表示，左端物料有两部分串联。每部分包括3条并联通道。 其中3+2表示。右端物料有两部分串联，各包括2、3条并联通道。 流向图同时给出了各板片的编号。同时也标有板片的定购备件号。 在流向图下方有一栏，以Plates(板片)开头，标有板片型号与板片及密封材料。 The position and number of transfer ports in the plates are marked by combinations of numbers from 1 to 4 after the oblique stroke of the item number. As a general rule, the plates are described with the gasket side of the plate facing the viewer. This means that the flow pattern of the plates is defined with. L: Flow to or from top left -Ring gasket top right R: Flow to or from top right -Ring gasket top left For the arrangement of the ports required for the flow pattern, the following applies: Port 1: top left Port 2: top right Port 3: bottom right Port 4: bottom left Any intermediate elements are marked by a rectangle on the flow diagram, Details of the position and type of pipe connections are shown on the connection sheet supplied in this case. The connection sheet is situated in the inside sleeve of the rear cover. 板片上的转换口由数字14表示。参见左图，板片系列号加斜杠，然后是开口号。 一般来说，板片总是以带密封的一面来定义。如图所示，板片的流向定义为： L：物料流向或流自左上方接口，密封圈在右上方。 R：物料流向或流自右上方接口，密封圈在左上方。 为满足不同的流向，采用不同的接口： 接口1：左上方 接口2：右上方 接口3：右下方 接口4：左下方 任何中间板片型号由流向图中的直角标注表明。 接管的位置与类型的细节在接管图中标出，随机附带。 2.1.3 Gaskets We distinguish between gaskets made of elastomers and hard gaskets, each with high fitting precision. The elastomer gaskets are sectional formed frame-type gaskets (2-eye gaskets and 4-eye gaskets as the final gasket), which are available in various materials. The hard gaskets consist of asbestos-free fibers (NBR-bound aramide fibers).They are cut out of panels. These gaskets are sensitive to mechanical damage and must not be bent! All gaskets are designed to enable both media at the transfer ports to be separated from each other by means of a double gasket guidance system. In. the event of any leakage in this area, the leakage chamber formed in this way has the task of outwardly discharging the liquid via gaps in the sealing webs(leakage grooves)so that any leakage immediately becomes apparent. Thes