Checking the tightness of heat exchangers
Heat exchangers, integral components in food production, are subject to challenging conditions such as unstable and humid environments, extreme temperatures, and exposure to various chemical compounds.
Over time, the likelihood of imperceptible defects smaller than an air molecule increases, posing risks to the heat exchanger’s performance. Therefore, it becomes essential to periodically recheck the tightness of heat exchangers to identify any potential flaws. This re-verification process ensures that the heat exchangers remain in optimal condition, promoting the safety and efficiency of food production.
Neglecting the timely replacement of a damaged element in the heat exchanger can have detrimental effects on the quality of the final product. It may also lead to equipment failure and, in the worst-case scenario, result in industrial injuries. By emphasizing the importance of rechecking the heat exchanger for tightness, manufacturers can maintain high-quality standards and prevent potential accidents.
The engineering aspect of maintaining a green and efficient operation necessitates regular re-verification of heat exchangers to uphold their performance, guarantee food safety, and mitigate any risks associated with faulty equipment.
Plate-type heat exchangers' types of damage
How to detect a hidden equipment defect
per section
per 1 section test
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 integrity tester 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?
- 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
condition
fatigue
Microcrack
< 30 microns
Microcrack
> 30 microns
hole
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.
- Saves labor costs of own personnel by 95%.
- Does not require additional water consumption.
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