What can only one invisible to the eye crack in the heat exchanger lead to? How to detect it and how to avoid expensive equipment repairs?
For want of a nail the shoe was lost, For want of a shoe the horse was lost, For want of a horse the rider was lost, For want of a rider the battle was lost, For want of a battle the kingdom was lost, And all for the want of horseshoe nail
S. Marshak, "The Nail and the Horseshoe"
Green operation, safe and high performance are the main factors in the production of quality food
Heat exchangers operate in unstable, humid environments, exposed to extreme temperatures and chemical compounds. With age, the risk of imperceptible defects smaller than an air molecule increases. Untimely replacement of a damaged element negatively affects the quality of the product, inevitably leads to equipment failure and industrial injuries.
Plate-type heat exchangers' types of damage
wide range temperature difference,
aggressive chemical load.
a result of pitting corrosion not in time detected.
untimely opening or closing of valve members;
untimely start of pumps.
Plate damage due to water hammer shock.
the plate pack has not been tightened to the calculated value,
exceeding the maximum operating temperature of the PHE.
When pressure increases in the PHE circuits, one or more rubber seals are extruded out the plate pack.
How to detect a hidden equipment defect
Heat exchanger audit per section
Detailed report ready
Leak detection guarantee
Average cost per 1 section test
Gas testing technology without equipment disassembling
HOW DOES THIS WORK?
GasTest — no time or a quest!
CIP cleaning of heat exchangers.
Disconnecting product and utility piping.
One part of the heat exchanger is pumped with safe forming gas (hydrogen 10% + nitrogen 90%).
In the other part, a diaphragm pump provides air circulation in a closed circuit.
If there is damage in the plate, hydrogen molecules will penetrate the part with air mixture circulation at the leak point.
The device will fix the location and size of the defect, as well as the rate of hydrogen molecules leakage in the damaged plate.
Checking the seals of the heat exchanger over the entire surface.
Confirmation of the presence or absence of damage.
The size of the detected defects.
Photographic evidences of damages.
Recommendations for elimination of defects and further operation.
Why gas test is better than disassembly?
The equipment disassembly with subsequent visual inspection of the plate-type heat exchanger does not require large financial expenses.
However, when disassembling:
Downtime of the production process is inevitable (up to 3 days).
There is a high risk of damage to seals and plates.
It is necessary to change even appropriate seals (up to 7000 Euros per set).
A company personnel’ workforce costs increase.
Impossibility of microcracks detection.
Comparison table of test methods for heat exchangers
Hydraulic proof test
Gas test N2H2
< 30 microns
> 30 microns
GAS TEST 7 advantages
Reduces risks associated with product quality.
Detects a problem before the company incurs losses.
Uses environmentally friendly hydrogen at a safe concentration of 10%.
Has effective efficiency (9 times) compared to other tests without disassembling.
Eliminates migration of media and refrigerant coolant dilution.