Preventive Maintenance Tips

Heat Exchangers - Shell and Tube; Plate Both the primary side water loop and the secondary side recirculation systems are treated systems. Under normal operation, these units do not require frequent inspection and cleaning. If a unit experiences continuous leakage, however, it will be necessary to open the unit and do a thorough cleaning job as recommended by the equipment manufacturer. Each heat exchanger manufacturer recommends a time schedule for cleaning the units. Based on our observation of plate heat exchangers used on District Energys district heating system, the cleaning frequency should be on an as-needed basis. The need to open the heat exchanger can be detected by any of the following: 1. A leak cant be stopped by tightening the bolts according to the manufacturers specifications. 2. An increase in pressure drop across the heat exchanger. 3. Lack of heat transfer causing inadequate heat to the building. The heat exchanger shop drawing records will provide the information needed for the proper pressure drop through the unit. Any pressure drop higher than the shop drawings indicate means excess fouling, and the unit will need to be cleaned. Any inspection or cleaning process should be done during the summer months when the system is down and the units are cold. It is essential that the cleaning instructions included with each manufacturers service manual be carefully followed. Plate Heat Exchangers - Gasket Different plate heat exchanger manufacturers supply their heat exchangers with different types of sealing materials between the plates. The most common types of gasket materials we have seen on our district heating system are Nitrile and Ethylene Propylene Rubber (EPR or EPDM).

Based on published data for different types of elastomers for seals, the gasket materials have the following temperature ranges: Nitrile: Nitrile: EPR or EPDM: -40F to 225F for the low temperature -40F to 250F for the high temperature -80F to 300F

In published material from the heat exchanger manufacturers, it is stated that EPR or EPDM rubber has superior resistance to hot water temperatures and steam and has good resistance to compression set or volume swell. Two major suppliers of plate heat exchangers have recommended the following specifications for gasket materials which are used on District Energys system: All plate heat exchangers shall have a gasket material made of Ethylene Propylene Rubber (EPR or EPDM), peroxide cured, with a maximum design temperature of 350F. The gaskets should not have more than a 50 percent change in hardness when exposed to liquid at 212F, or more than a 10 percent change in volume. Gaskets should be crush-proof at all temperatures within their operational range when tested in accordance with the T-13-0375 code procedure.

DISTRICT ENERGY DOES NOT RECOMMEND THE USE OF NITRILE GASKET MATERIAL

Plate Heat Exchangers - Shroud All plate heat exchangers should have a metal shroud over the plate area to reduce the potential for hot water spraying into the equipment room and damaging other equipment if a gasket leaks. The cover is required by code under OSHA standards. Suggested Procedure for the Shutdown of Heat Exchangers in Customer Buildings If it becomes necessary to shut down the buildings heating plate heat exchangers, the following suggested steps should be taken: If the building is served by two plate heat exchangers, one unit can be isolated completely without affecting the operation of the heating system. 2

Each of the plate heat exchangers is sized for 100 percent standby and/or 66 percent of the total heating load of the building. Therefore, one unit can serve the building temporarily until repair or maintenance is completed on the other unit without lack of adequate heat in the building. As soon as maintenance work is completed, the unit can be put back in service as needed. It is essential that plate heat exchangers be started up and shut down according to the recommendations in the manufacturers instruction manual. If the plate heat exchangers must be shut down during the heating season, the following requirements should be observed: a. Ventilation equipment should be put into the off position. b. Hot water heating pumps should be put into the off position. No equipment should be calling for heat at this time. c. The primary supply and return water valves on the heat exchangers can be shut off. The isolation valves on the secondary side of the heat exchangers can be shut off.

Plate heat exchangers should not be heated and cooled quickly. The units should be left alone for 24 hours to cool naturally and allow the stainless steel plate to contract normally. Quick cooling of the units will start leaks at the gaskets and will force scaling, dirt, and debris to lodge between the plates and the gaskets. If the ventilation system and heating pumps remain running, the heat exchangers will be forced to cool quickly, the metal will contract, and the secondary side treated hot water will leak to the floor. To bring the plate heat exchangers back on the system, the secondary hot water heating isolation valves on the heat exchangers should be opened; the hot water heating pumps should be started; and the primary side isolation valves should be opened slowly. The units should not be heated and cooled quickly. Some plate manufacturers recommend that the units be heated up to operating temperature over a 24-hour period. When the secondary hot water heating system is stabilized, the ventilation equipment can be started. Under normal conditions, do not isolate the unit completely. Keep one hand valve in the open position on both sides of the heat exchanger. Primary Side Control Valves

The control valves on each of the heat exchangers are of a semi-industrial quality. The valves are capable of operating under critical high pressure and temperature conditions, such as those experienced on District Energys primary system. Due to unbalanced water conditions on the secondary side of the system, these valves can experience abnormal operating conditions, such as hunting. This condition will increase the wear-and-tear on the valves. The control valves should be opened for cleaning and adjustment on a yearly basis and worn parts should be replaced. Strainers: Strainers are normally furnished with a blowdown valving assembly mechanism. The strainers are equipped with a water pressure gauge across them or else they have plugs upstream and downstream for pressure gauge insertion. Frequent checking of the pressure gauges will give you a good indication of the pressure drop through the strainers. Normally the maintenance manual for the equipment or the shop drawings shows the expected pressure drop for the unit under clean conditions. If that pressure drop is exceeded, it is appropriate to open the blowdown valve and purge the strainer for a few seconds to flush out the accumulated sediment. Under normal conditions, strainers should be flushed once a year on both the primary and secondary sides. The operator should be prudent in flushing the system.

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