If you want your plant’s shell and tube heat exchangers to last as long as possible, then it is vital to keep them clean and corrosion free. When properly maintained, a quality shell and tube heat exchanger can last for 40 years or more.
A poorly maintained heat exchanger can be subject to increased fouling, tube blockages, leaking, and corrosion. Any of these issues can reduce the efficiency of your unit while causing expensive maintenance issues down the line.
See also: Features and Benefits of Shell and Tube Heat Exchangers
Proper Instrumentation
Proper maintenance requires you to have the correct instrumentation to start with. Ideally, this would include devices to measure flow rates, temperatures, and differential pressure.
Proper instrumentation allows you to track the life of the unit and troubleshoot it faster.
Cleaning
You should schedule a thorough cleaning every one to three years. If your unit gets heavy use, you may increase this schedule. You should also check the manufacturer guidelines: some heat exchangers require more frequent cleanings regardless of how they’re being used.
Different applications require different cleaning methods. Hydroblasting may be effective for biofouling, but many heat exchangers will require extra attention. Removing sediment and scaling is vital, which means you may need to use wire brushes or scrapers.
You can use chemical cleaning aids so long as they are compatible with your tube.
Inspection & Repair
Cleaning is often the best time for an inspection. Look for:
- Worn gaskets
- Leaks
- Corrosion
- Cracks
- Water pH
- Sacrificial anodes
If you find any of these issues, you should schedule repairs right away.
Testing
Periodic testing offers more opportunities to catch problems before they become unmanageable.
Schedule the following tests:
- Pressure testing, which helps you find weaknesses or leaks within the unit long before those issues are visible to the eye.
- Flow testing and balancing helps you verify flow rates are even and the unit remains efficient.
- Eddy current testing helps you check wall thickness and will alert you to the presence of cracks in the tube.
Record Keeping
Document both your maintenance activities and any performance data you’re collecting from the unit. This data can help you catch issues that you wouldn’t have caught otherwise. It can also help you plan maintenance in advance.
Use checklists to make sure you don’t miss anything.
Record keeping can also ensure that your team stays on top of maintenance activities, eliminating guesswork.
Need a new heat exchanger?
Even with the best maintenance in the world, heat exchangers eventually wear out.
When that happens, turn to Courtney and Nye.
We have a long history of serving industrial applications in the PNW and offer a wide variety of shell and tube heat exchanger options, including new, remanufactured, and quick-ship options.
Contact us, and we’ll help you find the right heat exchanger to meet your needs!