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Troubleshooting a Blocked Plate Heat Exchanger and Symptoms to Look Out for
Ben Goodwin
Available 24/7 – Call Us Anytime for Emergency Support
Available 24/7 – Call Us Anytime for Emergency Support
Available 24/7 – Call Us Anytime for Emergency Support
Available 24/7 – Call Us Anytime for Emergency Support
Ben GoodwinIndustrial gasketed plate heat exchangers are widely used in many industries for various purposes. An underperforming, blocked heat exchanger could be the result of several factors.
The most common reason for an underperforming PHE is the unit becoming blocked, which could wreak havoc on your production line or other industrial processes.
Troubleshooting a blocked plate heat exchanger can be tricky, but with this guide, you will know exactly what to look for and how to fix the issue quickly.
Gasketed heat exchangers are essential equipment in many crucial industrial processes, so it is vital to keep them running smoothly.
A PHE is used to transfer heat between two fluids. The fluids pass through separate plates, which are then in close contact. This allows the heat to be transferred efficiently between the two fluids.
Note: In our experience, we’ve found that brazed plate heat exchangers (BPHE) offer several advantages over their gasketed counterparts. For instance, brazed plate heat exchangers are remarkably efficient with heat transfer due to their high thermal conductivity, more compact and lightweight, and higher resistance to pressure and temperature extremes. Additionally, maintenance is generally more straightforward because no gaskets require replacement. However, the critical factor that makes them a standout choice is their longevity – these devices are brazed together, essentially eliminating the risk of leaks, which are a common issue with gasketed designs. If you’re interested in exploring the benefits of these systems further, we recommend checking out the selection of SWEP brazed heat exchangers on offer. These units perfectly illustrate the potential advantages of this technology.
While PHEs are highly effective, they can become blocked if not maintained properly. When this happens, it can cause a decrease in efficiency or even a complete shutdown of the unit.
An industrial PHE
Knowing the signs of a blocked gasketed heat exchanger is the first step in troubleshooting the issue and possibly avoiding problems and costly repairs. Know more about the principles of PHE servicing.
By understanding the signs that your system is not performing as it should, you can take steps to prevent further damage and keep your production line running smoothly.
When troubleshooting a blocked plate heat exchanger, it’s crucial to inspect the plate heat exchanger plates for any signs of damage or debris that might be causing the obstruction.
A blocked shell and tube heat exchanger
If you notice any of these symptoms within your system, it is important to take action immediately.
A blocked PHE can quickly lead to more serious problems.
So now you know what to look out for, but what causes a PHE to become blocked in the first place so that you can avoid the same problem in the future?
If left unchecked, a blockage can cause severe damage to the unit and lead to costly repairs and disruption to your process. Read more about how to keep plate exchangers running at their best.
There are a few things that you can do to help prevent your gasketed heat exchanger from becoming blocked.
Cleaning a PHE can help remove blockages
The first step is to clean your heat exchanger. Stripping down the PHE and giving all the parts a good clean is the best way to remove any build-up causing a blockage and determine if there is any damage.
While the heat exchanger is stripped down, you can assess the plates and gaskets for any signs of wear and tear.
If there is significant damage, you might need to replace some or all of the plates and gaskets.
If you are uncomfortable doing this yourself, consult with a professional (like ourselves) to help clean a plate heat exchanger.
A few different chemicals can be used to clean and flush the sludge from a blocked heat exchanger.
The most common chemicals used are;
Cleaning your heat exchanger is a simple and effective way to troubleshoot symptoms.
dye penetrant being applied to check for cracks and other damage
Worn or damaged gaskets are one of the most common causes of why a gasketed plate exchanger becomes blocked.
If a gasket fails, it is easy to spot. Fluid drips out of the PHE because the pressure forces it through the leak.
To fix your PHE, you will need to disassemble it.
Take out the plate with the failed gasket and another plate next to it (so the flow pattern is not disrupted).
Next, if you have replacement parts available, swap them out, reassemble your PHE according to the specifications, and put it back into service.
heat exchanger plates with new gasket installed
WCR UK specialises in gasketed heat exchangers and can help with all your blocked PHE problems.
We have a wide range of replacement parts and cleaning and repair services for all major brands of heat exchangers.
