Plate Heat Exchanger Servicing

HRSFUNKE offers a complete plate heat exchanger refurbishment program. Our engineers are available to attend site to open heat exchangers and remove the existing plates and gaskets. We would recommend using our rotating plate pack solution with this service. You can also return the complete plate heat exchanger to our works for refurbishment. This service will also include a full hydraulic pressure test, complete with test certificate, before the heat exchanger is returned to site.

Stage 1: Pre-Clean and Initial Inspection When the plates and gaskets arrive back at our works they are checked in against your specifications. After a visual inspection, the old gaskets are removed and the heat transfer plates are pre-cleaned using a pressure washer.

Stage 2: Chemical Clean The heat transfer plates are then dipped in a series of chemical baths to remove deposits and scale. They are then completely rinsed with clean water and visually inspected for a second time.

Stage 3: Dye Penetration Testing The cleaned plates are sprayed with a fluorescent dye and inspected with an ultra violet lamp, for pit corrosion, pin holes and cracks. To help reduce servicing costs, we first select a random percentage for testing. This allows us to efficiently identify any failure trends before the entire plate pack is tested.

Stage 4: Regasketing The heat transfer plates are regasketed with new gaskets and assembled in plate pack order ready for installation in the heat exchanger frame. During the regasketing process the gaskets are taped to the plates and stacked to minimize gasket movement, ready for the next stage.

Stage 5: Oven Cure Heat transfer plates with glued gaskets are placed inside a temperature controlled oven, for a specific time period. The curing is an important stage as it eliminates gasket movement during final assembly.

Stage 6: Final Assembly The heat transfer plates will be installed in the plate heat exchanger frame. This work is completed by trained service engineers, as each plate heat exchanger has a specific heat transfer plate arrangement. A full hydraulic pressure test will be carried out on all plate heat exchangers, which have been serviced at our works.

Rotating Plate Packs

If your heat exchanger is part of a critical application or if downtime for servicing must be kept to an absolute minimum we would recommend a rotating plate pack.

Minimised Downtime The old plate pack is removed to be cleaned, regasketed and held ready for the next service. When the heat exchanger is next serviced the process is repeated. The existing plate pack is removed and replaced with the refurbished plate pack so that downtime is kept to just a few hours rather than the one to two weeks that would normally be required to refurbish the plates. This method of plate pack rotation is particularly cost effective if you have several heat exchangers on site that have identical plate packs, as just one rotating plate pack can be used to service many heat exchangers.

Reduced Risk In critical applications unexpected heat exchanger failures can cost thousands of pounds for every day the heat exchanger is not running. Adopting the rotating plate pack system means you have a spare plate pack ready to install in the event that a heat exchanger fails unexpectedly. This can be vital, especially as the lead time for spare parts can be several weeks for some heat exchangers, particularly obsolete models.

Damage Limitation The normal plate cleaning process downtime may be kept to one week assuming all the plates pass the dye penetration test but what happens if some of the plates fail? If new plates are not available from stock your downtime can suddenly change from one week to several weeks with dramatic consequences. Having a rotating pack gives you precious time to replace any plates that have failed whilst keeping your heat exchanger in operation.

Prolonged Heat Exchanger Life Regularly refurbishing your heat exchanger plates will prolong their life in the long run. Deposits and scale left in a heat exchanger for long periods of time may damage the heat transfer plates, often rendering them useless even after the first service. Regular preventative maintenance will ensure consistently high efficiency and maximum heat exchanger life.

Plate Heat Exchanger Installation

If access is poor or your plate heat exchangers are simply too big to be installed in one piece, our engineers can flat pack them for ease of transporting and positioning. The heat exchangers are broken down in to their key components and palletised ready for transporting to the plant room. Following a site survey the flat packed heat exchanger is positioned in line with the plant room drawing, rebuilt and pressure tested. As the work is undertaken by our own engineers your 12 month warranty is not affected.

Service Contracts The performance of heat exchange equipment will steadily reduce from the first time it’s used. To maintain your water temperature you will have to adjust flow rates and boiler or chiller temperatures. This in turn will increase time, effort and more importantly costs. With a service contract you can be safe in the knowledge that your essential heat exchange equipment will be fully functional. Regular inspections enable us to identify any reduction in performance or mechanical problems early, reducing their impact and likelihood of a breakdown occurring.

How It Works During the annual contract period, you will receive a minimum of two visits. These can be either scheduled or used as an emergency visit. You will also benefit from discount on spare parts. After each visit you will receive a detailed service report on the condition of the equipment, this allows us to tailor the maintenance programme more accurately to your requirements.

Clients and Specifiers

capricole construction
wsp
jumeriah
masafi
wasl properties
command of militar work
almara
saudi binladin group
aecom
dssr