Heat Exchanger Cleaning Tips

Fouling and debris limit heat exchanger effectiveness without frequent cleaning and, if left unchecked, can cause industrial equipment and processes to fail.

Shutdowns caused by heat exchanger failure can cost hundreds of thousands of dollars, far more than even the most elaborate cleaning methods. Heat exchanger cleaning, on the other hand, may increase performance and save money if done correctly.

Cleaning Heat Exchangers Using Ultra-High-Pressure Jetting

As it is effective and ecologically safe, remote and multi-lance ultra-high-pressure water jetting should be one of the primary choices for any heat exchanger cleaning program. It is feasible to remove deposits and scale from heat exchangers, tube bundles, and adjacent systems with only water. 

Using water instead of potentially toxic solvents and detergents eliminates the need for specialized disposal. This will also save cleaning and maintenance expenses by eliminating the requirement for hazardous chemical disposal services.

Finally, depending on the characteristics of your heat exchanger, some substances may degrade or destroy the materials employed by the heat exchanger makers in its construction. Titanium pipework, for example, which is often used in gas liquefaction facilities, is sensitive to acidic cleaning solutions and must be cleaned with either water or a mechanical process such as drilling.

Maintain Regular Cleaning Schedule for Heat Exchanger

Routine maintenance, as the name suggests, should be done on a regular basis. The proper scheduling of maintenance procedures may be prescribed by the manufacturer or set by the onsite maintenance crew, depending on the individual heat exchanger issue.

Cleaning on a regular basis will keep deposits and silt from building up to dangerous levels that might require the plant to shut down. Cleaning and inspection practices should be combined to guarantee that equipment is fully functional and fulfills regulatory requirements.

In-Situ Clean Process Heat Exchangers

Heat exchanger maintenance may now be conducted without disassembly thanks to robotic heat exchanger cleaning procedures. This is an excellent option for lant managers who want to reduce downtime and expenditures. 

Some professionals exclusively clean evaporator heat exchanger equipment at their own facilities, but most organizations can't afford the extra downtime. If your present contractor is unable to clean your heat exchanger in situ, get a second opinion from another service provider who may have an alternate cleaning process that can finish the job on-site, shortening the time it takes to complete the project.

Go 'Bare Metal'

When cleaning heat exchangers, all deposits and silt must be removed, and piping must be stripped down to the bare metal. If all fouling is not removed, the intended advantages will not be realized, and the return on investment in maintenance will be reduced.

Returning to bare metal extends the time between cleaning cycles by essentially restoring pipes and surfaces to factory-new condition. Plant efficiency will improve, as will the return on investment in advanced cleaning services if all scale and buildup are removed.

By eliminating many of the small flaws that serve as locations for new deposits to form, polishing the insides of pipes can assist enhance liquid flow. Request a video scope inspection once the cleaning is completed to ensure the quality of the work and the amount of cleanliness accomplished.

Clean the Outsides of Tube Bundles, Pipework, and Shells

Chemical deposits and buildups are more likely to impact tube bundles, inner pipework, and shell sides, thus cleaning these surfaces is a top concern. However, heat exchanger equipment's outside surfaces play a vital role in heat dissipation and effective functioning.

Cleaning the exterior surfaces of heat exchanger equipment should also be included in a routine maintenance schedule, not least because it makes visual inspections much easier. External heat exchanger cleaning should be considerably easier to schedule, with minimal, if any, downtime. Because the project is less urgent, you may be more flexible with the start date, making it much simpler to get the services of your favorite cleaning provider.

Clean Heat Exchangers with the Correct Equipment

Polymer deposits are especially difficult to remove, with some operators resorting to hammers, chisels, and chainsaws in an attempt to clean them. When working with precise equipment, employing generalist tools like these will almost always result in equipment damage and wasted employee effort.

Using a mix of ultra-high-pressure water jetting, band saws, and patience, plant equipment can nearly always be cleaned. The longer it takes to clean polymer deposits, the thicker they are. This underlines how important it is to clean and maintain your property on a regular basis.

Never Rely On Standard Cleaning Methods

Since "that's how it's always been done," many industrial service providers continue to employ the same limited set of cleaning approaches. Standard cleaning approaches are typically extremely successful, but they don't always account for advancements in heat exchanger technology, which makes the process more difficult.

Worse, traditional cleaning processes can be time-consuming and have inconsistent results, suggesting that your heat exchanger may not be fully cleaned. Because traditional water jetting procedures do not account for shell-side residue, up to 50% of deposits can be left behind once the cleaning process is completed. Standard cleaning approaches can only enhance heat exchanger performance by 50%. 

Shell-side deposits may be removed from heat exchangers using advanced cleaning procedures, emphasizing the necessity of not settling for ordinary services. Performance advantages will be substantially larger if both sides of the heat exchanger are clean.

Liaising with providers who produce unique solutions or combine proven cleaning processes are far better for your heat exchanger – and, eventually, your revenues. Newer approaches may be more successful and expedite the completion of cleaning jobs than traditional methods.

In conclusion, these suggestions will assist your company in reducing expenses and downtime while also ensuring that your heat exchangers are cleaned to the point of increasing profitability. Consider hiring a new provider if your present one fails to satisfy your needs. Obtain evidence of any provider's skills, such as client testimonials, while conducting your supplier research. You should also check to see if any possible cleaning supplier can help you save money on maintenance by integrating services like camera inspection and 3D modeling with cleaning cycles to do internal visual inspections. Alaqua is processing equipment such as evaporator, crystallizer, spray dryer, solvent recovery, distillation equipment, and heat exchanger equipment supplier worldwide based in the USA. They also offer installation and commissioning, personnel training, and various services for the processing equipment. Contact them today for any kind of queries regarding their processing equipment and services!