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Plate Heat Exchanger Check: A Guide to Preventing Leaks
If you are having problems with your gasketed plate heat exchanger, you can determine the possible causes with our online troubleshooting service. It will help you determine if there is a leak outside, a leak inside the unit or an unexpected drop in pressure. If you need additional support, our experienced technicians are available on-site and remotely for immediate assistance. We find the causes of unplanned shutdowns and keep your equipment running as efficiently as possible. We also identify and prevent dangerous situations to improve working conditions for your staff.
Here are some of the most common problems with plate heat exchangers:
- Leakage
- Damage to gaskets
- Corrosion
- Clogging
- Improper use
If you notice one of these problems, it is important to contact a professional as soon as possible. Do not attempt to repair your plate heat exchanger yourself, as this can lead to even more damage.
Our technicians have extensive experience with plate heat exchangers and will be able to fix any problem quickly and efficiently. We will ensure that your plate heat exchanger is running in optimal condition, allowing you to avoid unplanned shutdowns and reduce maintenance costs.
Contact us today to learn more about our plate heat exchanger troubleshooting services.
Heat exchangers can experience a variety of leakage problems. Here are some tips to help you identify and fix these problems:
- Check the plates. The plates may be warped or damaged, which can also lead to leaks.
- Check the seals. The seals may be damaged or worn, which can lead to leaks.
- Check the connections. Connections may be loose or damaged, which can also lead to leaks.
If you cannot determine the cause of the leak, contact a professional.
Viravix Engineering can help you with your heat exchanger leak problems. We offer a wide range of services including:
- Parts replacement
- Remediation
- Visual conditioning
- Assessment
- Condition Audit
We ensure that you get a heat exchanger that will operate efficiently and safely.
Here are some additional tips for preventing heat exchanger leaks:
- Have your heat exchanger serviced regularly.
- Use the correct materials and fluids.
- Do not exceed operating pressures and temperatures.
- Clean dirt and debris from the heat exchanger.
If you follow these tips, you can prevent heat exchanger leaks and extend the life of your heat exchangers.
Possible causes of leakage:
- The gasket material has been damaged due to age or heat.
- An oxidizing agent is present in the process stream.
- Inappropriate or too concentrated cleaning fluid is used.
- NBR density in relation to ozone.
Recommended Solutions:
- If the cause of the leak is due to the age of the gaskets, they should be replaced. Check the compatibility of the new gaskets with the process fluid and upgrade the material if necessary.
- If the cause of the leak is CIP (cleaning in place), reconsider the cleaning method and the cleaning fluid used.
For future prevention:
- Replacing gaskets at recommended intervals will prevent failures due to age.
- In other cases, consider replacing with a different elastomer for media compatibility or changing the plate alloy to prevent corrosion.
- Hydraulic shock, swelling of the gaskets due to media incompatibility, or deformation of the gasket grooves.
- Loose plate pack.
- Clogging in combination with high pressure.
- Adhesive bond failure in conjunction with high pressure.
Recommended solutions:
- Re-seal the heat exchanger or change to an epoxy mounting system.
- Verify that gaskets are compatible with the process and ensure there is no deformation in the gasket grooves.
- Check startup procedures, process, pumps and valves.
To prevent future leaks:
- Follow the operating instructions for proper startup and shutdown procedures.
- When opening valves, open the exhaust first and then slowly open the intake. Be careful not to over tighten the heat exchanger and make sure the unit is tightened to the recommended size A to ensure metal to metal contact.
- The gasket is absorbing the media or cleaning fluid.
- The gasket is incompatible with the medium.
Recommended solutions:
- Replace the gasket with another elastomer suitable for the media.
- Reconsider the choice of cleaning media.
To prevent these problems in the future:
- Provide a media and water quality report prior to purchase to select the best "recommended" gasket material.
For glued units:
- Adhesive bonding failure
- Contamination of the plate gasket groove
- Contamination of the gasket
- Unsatisfactory curing of the adhesive
- Unsuitable adhesive for the process
- For unglued assemblies:
- Offset
- Incorrect assembly
Recommended solutions:
- Use repair adhesive on small parts, and for large parts, consider a complete plate pack rebuild using the correct adhesive and procedure.
- Properly install the glueless gasket in the slot, you may have to use tape to hold it in place and close it carefully.
To prevent these problems in the future:
- Be sure to clean the gasket, clean the gasket slot, follow the curing instructions and check that the gasket sits in the correct place.
- Check the type of adhesive.
- Make sure the gasket is in the gasket slot and close it carefully.
- Provide proper operator training.
- Redesign and Optimization: we can help you redesign and optimize your facility to improve its performance.
- Visual Condition Assessment: we can conduct a visual condition assessment of your equipment to identify any potential problems.
- Performance Audit: we can conduct a performance audit of your equipment to determine its actual performance and compare it to its estimated performance.
- On-site cleaning: we can perform an on-site cleaning of your equipment to remove any contaminants or deposits that may be reducing its performance.
- Parts replacement: we can replace any worn or damaged parts of your equipment to restore its performance.
- Condition Audit: we can re-audit the condition of your equipment after repairing or replacing parts to make sure it is working properly.
- Restoration: we can help you restore your equipment to its original condition.
- Inspection: we can inspect your equipment to ensure that it complies with all applicable standards and regulations.
- Training: we can provide you with training in the use and care of your equipment to help you maintain its performance over time.
To correct this problem, it is necessary to:
- Verify that the actual parameters match the parameters of the original heat exchanger design.
- If necessary, redesign or optimize the heat exchanger, reconsider channel plate wall shear stresses or plate pressing alternatives.
- Carefully evaluate during the design phase the best possible solution to account for temperature fluctuations throughout the year.
- Accumulation of undesirable substances on the surface of the heat exchanger.
- Low shear stress on the channel plate walls.
- Operating conditions different from design parameters.
Recommended solutions:
- Perform chemical or mechanical cleaning of the heat exchanger.
- Verify that the actual flow rate matches the design flow rate.
- Consider redesigning or removing plates, revising channel plate wall shear stresses, or alternative plate pressing options.
- Consider installing in-line filters.
To prevent these problems in the future:
- Perform cleaning-in-place (CIP) procedures on a regular basis as directed.
- Remove plates to increase load, increase heat transfer surface area, or consider different plate pressing depth options.
Recommended Solutions:
- Conduct a gas test with the plates installed in the unit.
- Consider replacing the plate material with other alloys. If the problem is due to seal material fatigue, check for surges or drops in operating pressure.
To avoid future leaks, avoid pressure surges and differential pressures and make sure the correct alloy is selected at the initial design stage.
- The size of solids in the fluid exceeds the press-in depth of the channel plates.
- Foreign particles are present in the flow.
Recommended solutions:
- Determine the largest size and number of solids in the filter media.
- Backwash the filter, install inline filters, or consider changing the depth of the plate press.
To prevent these problems in the future:
- Install port filters or strainers if particle size exceeds 50% of the free channel. Another option is to change to plates with a larger free channel (e.g., wide gap plates).
- Flush the pipes before starting the process (for the first time or after discontinuing system maintenance) to ensure that no foreign particles enter the PHE.
- Uneven flow distribution caused by operating conditions that differ from design parameters.
- Improper design.
Recommended solutions:
- Redesign the design to achieve more uniform flow distribution across parallel blocks (or remove one block).
- If this occurs in one block, replace it with a larger port size block or add another block in parallel.
To prevent these problems in the future:
Always carefully check actual conditions against design parameters.
- Improper plate assembly. Plates may be assembled incorrectly or in the wrong order after service.
- Improper manufacturing. Incorrect parts may have been used in manufacturing or the plates may not be assembled correctly.
Recommended solutions:
- Check the uniformity of the comb pattern on the side surface of the GPHE.
- Compare the heat exchanger specification to the documentation supplied with the heat exchanger.
- Open the heat exchanger and verify that the plates are installed in the same order as in the plate attachment list.
To prevent future errors:
- When servicing, mark the side of the plate pack with a diagonal line and/or number each plate in the correct order in which they hang in the heat exchanger.
- Always follow the service manual and the plate hanging list.
- Improper plate assembly. Plates may be assembled incorrectly or in the wrong order after service.
- Improper manufacturing. Incorrect parts may have been used in manufacturing or the plates may not be assembled correctly.
Recommended solutions:
- Check the uniformity of the comb pattern on the side surface of the GPHE.
- Compare the heat exchanger specification to the documentation supplied with the heat exchanger.
- Open the heat exchanger and verify that the plates are installed in the same order as in the plate attachment list.
To prevent future errors:
- When servicing, mark the side of the plate pack with a diagonal line and/or number each plate in the correct order in which they hang in the heat exchanger.
- Always follow the service manual and the plate hanging list.
- Assessment: We can assess the condition of your unit and determine which parts need to be replaced.
- Parts Replacement: We can replace any damaged parts on your unit.
- Training: We can train you on how to maintain and repair your unit to prevent further damage.
If you have any questions, feel free to contact us. We will be happy to help you keep your heat exchanger in good condition.
Damage
Plates and plate packs can be damaged due to the following causes:
- Plates may be dropped or bumped during transportation or during operation.
- Rust may be normal wear and tear depending on operating conditions and age.
- Some damage may not cause leakage (yet) and may not actually affect performance.
Solutions
Assess the risk and, if deemed safe, conduct a leak test at operating temperatures. If necessary, schedule service for the next service interval.
How to prevent future damage
To prevent future damage, handle the heat exchanger with care, use suitable tools and always follow the instructions in the operating manual.
How to prevent future damage
To prevent future damage, handle the heat exchanger with care, use suitable tools and always follow the instructions in the operating manual.
- Frame structures can fall or be struck by a truck or tool during transportation or site work.
- Rust may be normal wear and tear, depending on operating conditions and age.
- Some damage may not cause a leak (yet) and may not actually affect performance.
Solutions
If you notice any damage, fix it immediately and refer to the operating manual. Assess the risk and, if deemed safe, conduct a leak test at operating temperatures. If necessary, schedule service for the next service interval.
How to prevent future damage
To prevent future damage, handle the heat exchanger with care, use suitable tools and always follow the instructions in the operating manual.
- The gasket can be scratched during site work.
- Cracks or hardening can be normal wear and tear depending on the environment and age (ozone cracks).
- Some damage may not cause leaks (yet), and some damage may not greatly affect the performance of the unit (shortened life).
Recommendations:
- If you notice any damage, fix it immediately and refer to the user manual.
- Assess the degree of risk and, if deemed safe, perform a leak test at operating temperatures.
- If necessary, schedule service for the next service interval.
To prevent future damage, handle the heat exchanger with care, use suitable tools and always follow the instructions in the operating manual.