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The benefits of routine service and maintenance for Plate Heat Exchangers

What is the purpose of a Plate Heat Exchanger?

A plate heat exchanger is a type of heat exchanger that uses metal plates to efficiently transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because the fluid is spread out over the plates allowing maximum heat transfer efficiency.

Having plate heat exchangers regularly maintained and serviced allows for more efficient operation and prevents production downtime and expensive repairs.

Blocked or poorly maintained plate heat exchangers cost more to operate, slow production and compromise safe operation.

This report outlines the importance of regular and effective maintenance of plate heat exchangers.

Operational cost savings can be guaranteed, and downtime minimised with the effective maintenance of your plate heat exchangers. Heat Exchange Group Services Ltd can give expert maintenance support across the heat exchange sector.

Running to fail with critical equipment does not allow for cost effective operation of any plant. Utilising our dedicated team of engineers Heat Exchange Group Services can maintain, service and repair your plate heat exchangers ensuring a cost effective, strategic, and professional approach.

How a gasket Plate Heat Exchanger works

Plate Heat Exchangers (PHE) were first produced in the 1920’s and have since been widely used in a

great number of sectors.

A PHE consists of a series of parallel plates that are placed one above the other, so it allows the formation of a series of channels for fluids to flow between them.

The space between the two adjacent plates forms the channel in which the fluid will then flow.

Inlet and outlet ports are at the corners of the plates and allow hot and cold fluids through alternating the channels of the heat exchanger so that a plate is always in contact on one side with the hot fluid and the other with the cold.

Plates are usually corrugated to enable a turbulent flow of fluids giving a rise to very high heat exchange rates. The corrugations also give many thousands of contact points on each plate making each complete unit rigid when tie roads are tightened. Gaskets manufactured from several different components to suit the process separate to the plates.

The size of a plate ranges from a few square centimetres up to two or three square metres. The number of plates in a single exchanger can be as little as ten growing to several hundred.

Running to failure is a no go!

Many businesses operate their PHEs until they fail, thinking that this will allow for minimum operating costs. This strategy can lead to expensive repairs and unexpected and expensive downtime.

Consider some of the below:

Budget control – Heat Exchange Group Services can provide a regular maintenance package at agreed intervals with costed, plant-specific recommendations.

We have qualified and experienced engineers that are able to maintain units in our engineering workshops or in situ at your site. Our full overhaul service includes chemical cleaning of plates, NDT crack detection, rebuild with new gaskets (oven-baked for glue type units) and pressure testing.

Heat Exchange Group Services understands how unexpected breakdowns result in downtime and expensive callouts. Often repairs carried out in these situations can be a ‘quick fix’ and lead to bigger and more expensive failures in the future.

Production downtime – a reduction in performance and unit efficiency are one of the main reasons for callouts to our service centre. Spares on older PHE units sometimes need to be manufactured to order and this can lead to further delays. Identifying potential problems early (at a planned service visit) can ensure parts are available when needed or replaced at the next service visit.

Design – Heat Exchange group offer a full consultation and design service. We can diagnose underperforming units and redesign a suitable alternative or upgrade.

Inspections and surveys- our team of engineers are available to attend site to carry out a full survey of your heat exchange equipment and provide a detailed report that identifies any issues together with solutions to ensure you are operating at optimum efficiency.

Spares – we hold stock of plates and gaskets for all modern plate heat exchangers. We also have access to suppliers who stock plates and gaskets for older and less common units.

Maintenance engineers – most of our engineers are time served with many years operational experience. Some have qualifications that are site specific to customers who need to know their site regimes and health and safety have been accounted for.

Installation and repair – our service teams offer a fast response, and it is a 24/7 service!

Fouling – The fouling of heat exchangers may be defined as the accumulation of unwanted deposits on heat transfer surfaces. This layer imposes an additional resistance to heat transfer and the narrowing of the flow area. This is due to the presence of deposits resulting in an increased velocity for a given flow rate. The deposit usually extremely rough so that there is an increased resistance to the flow of the fluid across the plate surface. The consequences of fouling are a reduction in exchanger efficiency and excessive pressure drop across the whole unit.

Corrosion, Cracks and Pitting – Corrosion failures in plate heat exchangers are often related to equipment design, service conditions and materials of construction.

Plate heat exchangers are chosen over shell and tube heat exchangers for applications requiring superior heat transfer efficiency, compactness, lower weight, and volume.

Although materials used are often resistant, corrosion will occur over time. Some corrosion, including cracks and pin holes can occur due to chemical reactions or vibration, others due to general wear and tear. Corrosion can be made worse depending on what liquid and temperature the unit works at. Internal leaks produce cross contamination, external leaks can cause contamination and damage to plant.

Gasket Failure – Over a period all gaskets will degrade. This degradation can be exacerbated by the storage and quality of the environment that they have been manufactured and stored in. Life span of gaskets can also be reduced by excessive operating temperature and pressures.

Temperatures and pressure changes can affect the performance and lifetime of gaskets making it vital these are chosen correctly in the first instance and maintained at regular intervals. Exposure to UV light can also affect performance.

Gaskets are designed to operate within a specific temperature and pressure range. Operating outside these design parameters can lead to early gasket and sometimes plate failure. Regular inspection and maintenance will help prevent early plate and gasket failure.

Gasket Material Choice 

Rubber Type Applications Maximum Temperature
 

Nitrile Butadiene Rubber (NBR)

Compatible with oil and fats.

Low chemical resistance to acids and bases.

 

140°C

 

Hydrogenated Nitrile Butadiene

Better chemical resistance compared to NBR. Compatible with hydrocarbons, oils and fats  

160°C

 

EPDMP

 

Better chemical resistance to acids and bases.

 

180°C

 

FKMG

Strong chemical resistance and compatibility with oils.  

150°C

 

FKMT

Performance grade, especially for high temperatures. slightly lower chemical resistance than FKMG.  

180°C

 

Q (Silicone performance grade)

 

Medical grade, for applications with ultra-pure water.

 

100°C

 

Neoprene

 

Ammonia applications.

 

110°C

Our full PHE Service procedure…

  1. Book in and examine

Before any inspection and cleaning takes place, we book in each individual plate separately, determining what material the gasket is and looking for any date stamps to determine the age of the rubber gasket. We can then advise the costs for the service and replacement gaskets. If a full unit has arrived, we inspect all components including NDT of metal liners and offer a full inspection report to bring the unit back to new.

  1. Remove gaskets

Depending on the type of gaskets and length of service, these can be removed by hand safely and without damaging the plate itself. Some may have been exposed to high temperatures which have baked the gasket hard so some chemical immersion or heat may be needed to aid the removal.

  1. Pre-wash and chemical cleaning

Depending if any deposits or fouling are present on the plates, a prewash may be needed first to be sure not to damage the chemical tanks and weaken the mix. Each plate is immersed in chemical baths and closely monitored as to length of time needed depending on plate material and condition.

  1. Pressure jet cleaning

Plates are pressure washed to remove any chemicals remaining on the surface and any deposits not removed by the chemicals. These are then thoroughly dried before inspections begin.

  1. Visual examination

All Plates are inspected for any visual defects i.e. channel deformation, visual holes and parts damaged seen by the naked eye.

  1. NDT and crack detection

Ultraviolet and fluorescent dye penetrant are sprayed across each plate and left to fully immerse into any cracks. These are then examined under UV light to discover cracks and pinholes.

  1. Fitting new gaskets

All plates then have new rubber gaskets attached and if required, specialist glue is used to adhere these to the plates. Clip versions are often used for some duties which removes the need to glue.

  1. Oven Curing

Glued gaskets are oven cured to ensure a secure bond to the plate.

  1. Pressure Testing

If a complete PHE unit is received, this is reassembled to the same specification as it was received. The unit will be tightened to the correct tightening dimension based on the model, material, and thickness of each plate. The unit will then be pressure tested to the correct operating pressure.

  1. Quality Report and Certification

A final visual inspection of the unit or plates is undertaken, and all necessary documentation is issued. This will include a quality report, certificate of conformity and pressure test certificate.

Why use Heat Exchange Group Services?

Heat Exchange Group is the leading UK and worldwide supplier of the widest range of heat exchanger and industrial/marine boiler products and services. The group was formed in 2018, following the merger of Thornhill Heat Exchangers and Greens Power.

We have over 30 years of experience in the service and maintenance of plate heat exchangers and associated equipment. Our engineers have experience of working in many different industries.

Blocked and poorly maintained plate heat exchangers cost more to operate and slow production. Our full-service inspection process provides guaranteed, proactive maintenance of your heat exchanger preserving performance and keeps your operations running trouble free. It’s worth noting, PHE plates immersed in chemicals too long can actually reduce their life span!

Download our comprehensive guide to the benefits of routine service and maintenance of Plate Heat Exchangers.

Contact us now for great quality service fast response repairs…

+44 (0)300 124 0495 info@heatexchangegroup.co.uk

 

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Heat Exchange Group Services leads on PHE service

Heat Exchange Group Services (HEGS) has developed a comprehensive Plate Heat Exchanger (PHE) service package that systematically ensures customers equipment operates at optimal efficiency.

Our highly experienced and qualified team come to our customers’ site to undertake our six point HEGSagon of PHE Service

  1. Strip, inspect, identify and mark each plate
  2. Clean – high pressure steam and heated chemical dipping tanks
  3. 100% NDT testing of all plates for damage and distortion
  4. New gaskets fitted to serviced or new plates
  5. Reassembled and pressure tested
  6. Quality pack issued and service history logged

Discover more about the benefits of routine service and maintenance of PHE equipment .

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PHE Servicing and Maintenance for a range of industry sectors and applications

Our teams at our factory in Wakefield, our service centre in Prudhoe and our mobile service engineers who provide fast response to our customers’ PHE service, maintenance and repair requirements work across a range of industry sector including

Food

Drink

Chemical

Oil and gas

Power generation

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We probably do more than you think

We recently reviewed where our business had got to and what we had achieved so far and even we were surprised and impressed by what our teams have accomplished. To summarise it we put together this snapshot of where we are today and there is much much more to come!

 

 

 

 

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We service all makes and models of plate heat exchangers

We are UK’s leading provider for servicing, maintenance and reconditioning of all makes and models of plate heat exchanger (PHE), including our own Thornhill models. We provide a fully OEM compliant and guaranteed service for virtually all brands including Alfa Laval, Tranter, APV, GEA, Kelvion, Danfoss, Carrier, Fischer, Schmidt, Sondex, Swep, Vicarb, SAPHEX, Vahterus, UK Exchangers and Funke.

We have two sites in the UK – our service centre, which provides a fast turnaround service and our factory which manufactures larger heat exchanger products. Our service team is located throughout the UK meaning we can react extremely fast wherever our customers are based.

Our entire business (including our site teams) is covered by ISO45001 (Health and Safety), ISO14001 (Environmental) and our ISO9001 quality system. You can read more about our accreditations here.

Our OEM-trained heat exchanger service engineers offer a range of services that include cleaning, refurbishment, pressure testing and replacement PHE units.

Find out more about our plate heat exchanger services

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We are the leading service and maintenance provider for all types of heat exchangers

Heat Exchange Group repairs, services and manufactures a wide variety of heat exchanger applications and boiler products at our UK factory in Wakefield and service centre in Prudhoe as well as at customers’ sites.

To find out more about how we service heat exchanger equipment to help organisations across a range of sectors cut energy usage, reduce costs and improve efficiency, check out our short video.

 

Heat Exchange Video

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Our services for the offshore sector are first-rate

Over the last 6 months Heat Exchange Group’s offshore service and repairs operations have grown rapidly as a result of the investment we have made in our heat exchanger and boiler repair engineers to ensure they are BOSIET and CA-EBS trained and in our on and off-site equipment.

Recent projects include:

  • Inspection of two steam boilers that were both out of action, followed by refractory repairs, boiler flange repairs and burner service.
  • Full boiler retube of Hot Water boiler.
  • Refurbishment of eight plate heat exchangers including two Alfa Laval M30 unit as parts of an existing service agreement with an Aberdeen based operator/producer.
  • High pressure jetting, testing and repairs of a large crude oil heat exchanger.
  • Supply of replacement boiler safety valves and water level controls for steam boiler.

Our offshore team has doubled and comprises mechanical service engineers (incudes coded welding), burner service and automation engineers plus a comprehensive support team at our service centre.

We inspect, service, and repair all types, makes and models of heat exchangers and boilers, as well as pipework, coded welding, and spare parts supply. Work can be carried out by our team either offshore or in our dedicated service centre. This includes our 6 stage PHE refurbishment process (strip & inspect, clean, crack detect, gasket, rebuild, test).

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Showcasing Anna Borisova, Group HR Advisor

As part of National Careers Week 2024, we are putting our employees in the spotlight. Anna Borisova is Heat Exchange Group’s HR Advisor

Her role is generalist, meaning she is involved in a whole employee cycle from recruitment to leaving/retirement. At Heat Exchange Group every day is different and that’s what Anna likes about her job. It can include general queries from employees and managers, guidance and advice, one-to-one meetings, onboarding new employees, emails, calls, reports, policy reviews and updates and communication with stakeholders in and outside of the company.

Can you describe a particularly rewarding or fulfilling moment in your career that affirmed your chosen path?

Truly fulfilling moments in my career are when I successfully help employees overcome a difficult situation in the workplace. Seeing the positive impact of my efforts on individuals is incredibly fulfilling and rewarding.

Find out more about Anna and her career path to becoming Heat Exchange Group’s Group HR Advisor.

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Showcasing Tomasz Wnek, Engineering Manager (Design)

As part of National Careers Week 2024, we are putting our employees in the spotlight. Tomasz Wnek is Heat Exchange Group’s Engineering Manager (Design).

He is responsible for thermal, mechanical, and structural design of boiler equipment, heat exchangers and other equipment manufactured at Green’s, a Heat Exchange Group company. Tomasz works with a team carrying out sizing of heat exchangers and overall construction design, making sure all customer’s operational and installation requirements are considered. He is responsible for mechanical calculations to assure safe operation of the equipment and compliance with any necessary statutory and regulatory requirements.

What motivated you to pursue a career in your field, and how has it evolved?

My interest in engineering probably started with my childhood obsession with LEGO and creating my own designs out of limited amount of sets. Since then, I was always interested in physics and science, and wanted to understand how things work. Learning engineering at a University was a natural choice, followed by undergraduate placements in engineering companies to gain practical experience.

Find out more about Tomasz and his career path to becoming Heat Exchange Group’s Engineering Manager.

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Showcasing Shaun Duro, Service Manager – PHE & Rail

As part of National Careers Week 2024, we are putting our employees in the spotlight. Shaun Duro is Heat Exchange Group’s Service Manager.

He looks after the day to day running of the plate heat exchanger and rail departments. His role is to ensure the smooth running of works entering and leaving Heat Exchange Group’s facility and to a high standard. He also assists to ensure the company is up to date with all the correct QHSE standards and that all staff are trained to the current guidelines. Shaun has a role to ensure the company’s key account customers are looked after whether this be by phone, email or personal visits to their sites. He became qualified to assist with internal audits and fully trained for warehouse racking system inspections. He says that it’s important for him  set an example amongst colleagues and develop relationships to ensure everyone works efficiently.

What would you say to those considering a career in manufacturing or engineering?

  • Grab each opportunity by the grasp of your hands!
  • Do any training that can assist with your career path to enhance your own personal portfolio.
  • Listen to others and gain respect from your co workers as this will make performing work task more efficient and enjoyable.

Careers in this sector are amazing and rewarding!

Find out more about Shaun and his career path to becoming Heat Exchange Group’s Service Manager – PHE & Rail