Plate Heat Exchanger Check:
A Guide to Preventing Leaks

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.

We hope these services will help you eliminate your equipment’s performance problems and improve its efficiency. If you have any other questions, contact us by phone or mail.

• 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.