QSK60 Plate Heat Exchanger

Coolant System

Session 21 - QSK60 Plate HX

L:\custsupp\Training\documented_files\cm_hhp_products\2006_05q_hhp_marine_engine_troubleshooting_course\development_files\instructor_guide
\powerpoint_files\day_3\session_21_qsk60_plate_hx 16 March 2006
 QSK60 Plate Heat Exchanger
Coolant System

Expansion
Tank

Plate Heat
Exchanger

Sea Water
Pump
 QSK60 Plate Heat Exchanger
Coolant System

Plate Heat
Expansion Exchanger
Tank

Alternator
Guard Trunnion
Grease Fitting
Damper Hose
Guard (with
Sea Water
all mounting
Pump
hardware)
Front Front Engine
Trunnion Support

FRONT VIEW
 QSK60 Plate Heat Exchanger
Coolant System

JW 75% Hot
Bypass

JW Cold
Bypass

2 into 1
Bypass to JW
Pump

JW 25% Into
Heat
Exchanger
JW 25%
Return to
Pump
 QSK60 Plate Heat Exchanger
Coolant System

LTA, Cooled,
Heat
Exchanger
Out

LTA
Return to
Pump

Sea Water
Sea Water Pump Out to
Outlet Heat
Exchanger

Sea Water
Inlet
 QSK60 Plate Heat Exchanger
Coolant System
LTA Water Pump for a keel cooled system
 QSK60 Plate Heat Exchanger
Coolant System

Top Tank and JW Out

Bracket Removed Manifold

JW 25% Into
Heat
Exchanger

Alternator frame
size 33SI used in
option EE8144

Mercer
Connection
Sea Water
Outlet
 QSK60 Plate Heat Exchanger
Coolant System

LTA to Heat Top Tank and Bracket

Exchanger Removed
Inlet
QSK60 Plate Heat Exchanger
Coolant System

Fuel Manifold
Balance Hose

Left Front
Fuel Drain
Block
Trunnion Grease
Hose

Sea Water
Pump Support
Bracket
 QSK60 Plate Heat Exchanger
Coolant System

LTA to Heat
Exchanger
Fuel Drain Inlet
Tube,
(routes
behind fan
bracket)

Fuel
Manifold
Balance
Hose

Sea Water
Outlet
Support
Bracket
 QSK60 Plate Heat Exchanger
Coolant System

Jacket water heat

exchanger bypass
(75% of flow)

LTA supply
to RB
aftercoolers

Jacket water
supply to heat
exchanger
(25% of flow)
LTA supply to
heat
exchanger
Jacket water
thermostat Jacket Water
bypass Seawater supply to
outlet coolant pump
 QSK60 Plate Heat Exchanger
Coolant System

LTA supply
to LB
aftercoolers

LTA supply to
thermostat
Sea housing
Water
Supply LTA
thermostat
bypass

LTA heat exchanger

outlet to LTA coolant
pump
 QSK60 Plate Heat Exchanger
Coolant System

The plate heat exchanger consists

of a pack of corrugated metal plates
with portholes for the passage of the
two fluids between which heat
transfer will take place.

The plates are fitted with a gasket

which seals the inter-plate channel
and directs the fluids into alternate
channels.

The number of plates is determined

by the flow rate, physical properties
of the fluids, pressure drop, and
temperature program.
 QSK60 Plate Heat Exchanger
Coolant System
The plate corrugations promote fluid turbulence and
support the plates against differential pressure.
Working Principle

Channels are formed between

the plates and the corner ports
are arranged so that the two
media flow through alternate
channels.

The heat is transferred through

the plate between the channels,
and complete counter-flow is
created for highest possible
efficiency.

The corrugation of the plates

provides the passage between
the plates, supports each plate
against the adjacent one and
enhances the turbulence,
Flow principle of a plate heat exchanger
resulting in efficient heat transfer.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Removal

Disconnect all plumbing for the front and rear

of the heat exchanger:

Seawater tube

Jacket water tube

LTA tube.

Install a lifting eye into the heat exchanger

front plate at location (11).

Install a lifting eye into the heat exchanger

rear plate at location (12).
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Removal

The nylon strap used to remove the heat exchanger

must have a capacity of 140 kg [300 lb].

Insert a nylon strap through the lifting eyes.

WARNING
This component weighs 23 kg [50 lb] or more.
To reduce the possibility of personal injury, use a
hoist or get assistance to lift this component.

Remove the capscrews from the heat exchanger bracket.

Remove the heat exchanger.

 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Removal

Remove the eight capscrews that hold the shroud to the
heat exchanger assembly.

The ends of the shroud will possibly have to be bent

outwards to clear it from the sides of the heat exchanger.

Draw a diagonal line across the top of the plate pack

with a paint marker or a wide marker.

The diagonal line will aid in assembly

 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Dismantle

Remove spacer capscrews (9) and (10).

Remove the inserts the spacer capscrews

were routed through.

Remove the service spacers from the front

cover.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Dismantle

Thread the service spacers into the side alignment spacers

until they bottom out.

The plate pack clamping capscrews must be loosened in

sequence and in small increments to keep the front and back
covers within 12 mm [½ in] variance from parallel.

Loosen the plate pack clamping capscrews in sequence and

small increments until they can be removed from the assembly.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Dismantle

Remove the plate clamping capscrews and front cover.

Keep the plates in the order they were removed in

when disassembling the plates.

This will aid in the assembly of the heat exchanger.

Remove the plates from the assembly.

 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Inspection and

Cleaning

Observe the orientation of the gasket for assembly accuracy.

Remove each gasket from the plate one at a time.

Clean the plate with a soft brush and running water.

CAUTION

Incorrect orientation of the gaskets can cause

overheating and sea water to enter the cooling system.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Inspection and

Cleaning

If incrustation deposits are present that are difficult to

remove, spray the plate with a high pressure water hose.

If brushing and high pressure water does not properly

clean the plates, the deposits on the plates can
be evaluated.

Use the information in the following lists to determine

what solvents to use.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Inspection and

Cleaning

Use the information in the following lists to determine what solvents to use.

Incrustation

Calcium carbonate (corrosion products - clean with nitric acid).

Calcium sulphate (metal oxides - clean with sulfamic acid).

Silicates (silt - clean with citric acid, alumina - clean with phosphric acid,
diatomic organisms and their excrement of various colors - clean with
complexing agents EDT, A, and NTA).
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Inspection and

Cleaning

Biological Growth

Slime - Clean with alkaline cleaning agents.

Bacteria - clean with sodium hydroxide.

Nematodes - Clean with sodium hydroxide.

Protozoa - Cleaning effect can be considerably increased by the

addition of small quantities of hypochlorite or agents for the
formation of complexes and surfactants. Concentration maximum:
Four Percent.
Temperature maximum: 60°C [140°F].
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Inspection and

Cleaning

Solvents That Can Not be Used

Ketones (acetone, methyletylketone, methylisobutylketone)

Esters (ethylacetate, butylacetate)l Halogenated hydrocarbons (chloro-thene,

carbon tetrachloride, freons) Aromatics (benzene, toluene).

Inspect the gaskets for swelling, cracks,

and deformation.

Replace the gaskets swollen, cracked or

deformed.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Reassemble

Insert the service spacers into the side

alignment spacers.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Reassemble

WARNING
The plates can have sharp edges. To reduce the possibility of cuts, wear gloves when handling the
plates.

CAUTION
Incorrect orientation of the gaskets can cause overheating and sea water to enter the cooling system.
 QSK60 Plate Heat Exchanger
Coolant System
QSK60 Heat Exchanger Reassemble
Place the gaskets back onto the plates one at a time.
Make sure the tabs are locked into the slots and
orientated correctly.

Insert cleaned plates against the rear cover in the

correct order.

Refer to the exploded view for the plate installation order.

After the plates are assembled in the engine, make sure

the profile shows a honey comb pattern and the gasket
tabs alternate position.

If the pattern is not a honey comb pattern throughout the

entire plate pack, the plates must be rearranged.
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Reassemble

Install the front plate making sure the aligning shroud

groove is on the same side (top) as the alignment groove
on the rear cover.

Install capscrews (1) through (8). When tightening the

capscrews, keep the front and back covers
within 12 mm[½ in] variance from parallel.

Tighten the capscrews in the sequence shown in

the graphic.

Once the cover is completely against the eight

spacers, tighten the capscrews in the sequence
shown in the graphic.

Torque Value:
15 n.m [120 inlb]
Torque Value:
135 n.m [100 ftlb]
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Reassemble

Remove the service spacers.

Install the inserts and the side alignment capscrews

into locations (9) and (10).

Tighten the capscrews.

Torque Value:
The ends of the shroud will possibly need to be bent
to fit over the heat exchanger.

Install the shroud onto the heat exchanger.

Install the eight shroud capscrews.

Tighten the capscrews.

 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Reassemble

Install a lifting eye into the front plate at location (11).

Install a lifting eye into the rear plate at location (12).

The nylon strap used to install the heat exchanger

must have a capacity of 140 kg [300 lb].

Insert a nylon strap through the lifting eyes.

 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Reassemble

Place the heat exchanger onto the bracket.

Insert the bracket capscrews that attach the bracket to

the heat exchanger.

Tighten the capscrews.

Torque Value:
45 n.m [33 ftlb]

Remove the nylon strap.

Connect all plumbing for the front and rear of the

heat exchanger:

Seawater tube
Jacket water tube
LTA tube.

Tighten all capscrews.

Torque Value:
45 n.m [33 ftlb]
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Reassemble

Install the expansion tank. Refer to Procedure 008-052.

Connect the batteries or air starter supply line.
Fill the cooling system. Refer to Procedure 008-018
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Testing

Heat Exchanger Testing

Hydrostatic test procedure:

Testing is performed after final assembly.

Testing is done on one side at a time with the other side open to
atmosphere.

Hydrostatic pressure is limited to 40 psi.

This pressure is held for a minimum of 10 minutes.

 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Testing

Detecting Faults and Failures

Heat exchanger failures fall into one of two groups:
Performance Failures
Mechanical Failures
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Testing

Performance Failures:
Immediate:
Different operating conditions
Incorrectly connected piping
Plate Pack problem

Cyclic:
Variations in flow rate
Pump problems

Gradual Reduction:
Fouling on engine coolant side
Fouling on sea water side
Plugging of port area
 QSK60 Plate Heat Exchanger
Coolant System

QSK60 Heat Exchanger Testing

Mechanical Failures
External Leakage:
Gasket failure (dislocation, crushing, scars, ageing)
Plate Failure (under-tightening, deformation)

Internal Leakage:
Corrosion – chemical imbalance
Erosion – high velocity and concentration of sand or
sharp particles

Fatigue – variations in temperature and/or pressure

Water Hammer – unbalanced pressure shocks