1. Operation Condition Inspection
1. Check Operating Temperature
Regularly record the inlet and outlet temperatures of the heat exchanger to confirm whether the actual operating temperature meets the design requirements.
If the outlet temperature significantly deviates from the normal range, it may indicate insufficient heat transfer area, abnormal flow conditions, or internal fouling.
2. Check Flow Rate Conditions
Check whether the flow rates of hot and cold fluids remain stable to prevent reduced heat transfer performance caused by insufficient flow.
A decrease in flow rate may be caused by pipeline blockage, clogged filters, or contamination inside the heat exchanger.
3. Check Pressure and Pressure Drop
Monitor the inlet and outlet pressure and pressure drop of the heat exchanger regularly.
An increasing pressure drop usually indicates internal scaling, sediment accumulation, or flow channel blockage.
2. Visual Inspection of Equipment Condition
1. Check for External Leakage
Inspect the heat exchanger shell, flange connections, and sealing areas for liquid leakage or signs of corrosion.
Any leakage should be investigated immediately to prevent equipment damage or safety risks.
2. Check for Abnormal Vibration and Noise
A properly operating heat exchanger should run smoothly without excessive vibration or unusual noise.
Abnormal vibration or noise may be caused by fluid impact, installation problems, or internal component damage.
3. Check Insulation Condition
Inspect the insulation layer for damage, moisture, or falling-off parts.
Good insulation performance helps reduce heat loss and improves overall system efficiency.
3. Internal Cleaning Inspection
1. Check for Fouling and Scaling
Regularly inspect heat transfer surfaces for deposits such as scale, oil contamination, and biological fouling.
Fouling increases thermal resistance, reduces heat transfer efficiency, and may increase energy consumption.
2. Develop a Cleaning Plan Based on Operating Conditions
Plate heat exchangers can be cleaned through plate removal, mechanical cleaning, or chemical cleaning methods.
Shell-and-tube heat exchangers can be cleaned using high-pressure water cleaning, chemical cleaning, or mechanical methods.
3. Check Flow Channel Blockage
Ensure that internal flow passages remain clear to prevent reduced flow and poor heat transfer performance.
Systems using fluids containing particles or impurities should include proper filtration and regular flushing.
4. Seal and Connection Inspection
1. Check Gasket Condition
Inspect gaskets for aging, deformation, cracks, or loss of elasticity.
Damaged or deteriorated gaskets may cause leakage or mixing between hot and cold fluids.
2. Check Bolts and Fasteners
Inspect bolts and nuts for looseness, corrosion, or mechanical damage.
For plate heat exchangers, check the tightening dimension according to the manufacturer's requirements to ensure proper sealing performance.
3. Check Flange Connections
Inspect flange surfaces for damage, deformation, or sealing defects.
Proper flange conditions help maintain reliable and leak-free operation.
5. Corrosion and Material Inspection
1. Check Corrosion Conditions
Regularly inspect the shell, tubes, tube plates, and plates for corrosion damage.
Corrosion can reduce material thickness and may eventually cause leakage or equipment failure.
2. Evaluate Material Compatibility with Operating Media
Different fluids have different corrosion effects, so suitable materials must be selected according to the characteristics of the medium.
For example, environments containing chloride ions usually require more corrosion-resistant materials such as stainless steel or titanium.
3. Perform Non-Destructive Testing (NDT)
For critical equipment, inspection methods such as ultrasonic thickness measurement and dye penetrant testing can be used.
Non-destructive testing helps detect hidden defects and reduces operational risks.
6. Performance Testing and Record Keeping
1. Test Heat Transfer Performance
Evaluate heat exchanger performance by analyzing inlet and outlet temperatures, flow rates, and operating conditions.
Reduced heat transfer efficiency usually indicates the need for cleaning, repair, or operating optimization.
2. Maintain Detailed Maintenance Records
Record inspection dates, operating parameters, cleaning activities, replaced components, and repair history.
Complete maintenance records help determine future maintenance schedules and improve equipment management.
3. Analyze Operating Trends
Long-term data analysis helps identify performance changes and potential problems before failures occur.
Based on operating trends, preventive maintenance plans can be developed to reduce unexpected downtime.
7. Shutdown Maintenance Inspection
1. Preparation Before Shutdown Maintenance
Confirm that the heat exchanger has stopped operation and that all fluids have been drained and pressure has been released.
Maintenance work should never be performed under high-temperature or high-pressure conditions.
2. Inspect Key Components
Depending on the equipment type, inspect critical components such as plates, tubes, gaskets, tube bundles, and shells.
Replace or repair damaged components promptly to ensure reliable operation.
3. Inspection Before Restarting
Confirm that all components are correctly installed and that no tools or foreign objects remain inside the equipment.
Restart the system gradually and check for leakage, abnormal pressure changes, or unusual operating conditions.
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