Heat exchangers in Russia

Heat exchangers are important equipment widely used in industries such as industry, energy, and chemical industry in Russia. They are used to achieve energy conversion through heat transfer between two fluids. Whether in oil refining, chemical reactions, or air conditioning and refrigeration systems, heat exchangers play a vital role. This article will discuss in detail the construction, manufacturing, cleaning, maintenance, and after-sales service of plate heat exchangers and shell and tube heat exchangers to help users fully understand the use and management of the equipment.

1. Structure of heat exchangers

The structure of heat exchangers has many types according to different applications and design standards. The main common types of heat exchangers in the Russian heat exchanger market include shell and tube heat exchangers, plate heat exchangers, air coolers, etc. The following is a brief introduction to several common heat exchangers:

1.1 Shell and tube heat exchanger

The shell and tube heat exchanger is the most common one and is widely used in fields such as petrochemicals and thermal power generation. It consists of an external shell, an internal tube bundle, and a variety of connectors. The coolant and the heating agent flow through the shell and the pipe respectively, and the heat is conducted through the pipe wall to achieve heat exchange between the two fluids.

1.2 Plate heat exchanger

The plate heat exchanger is made of multiple thin steel plates spliced ​​together by welding, pressing and other processes, and a series of narrow flow channels are formed between the plates. Compared with the shell and tube heat exchanger, the plate heat exchanger has higher heat transfer efficiency and compact structure, which is suitable for occasions with small flow but high efficiency heat exchange.

1.3 Air cooler

The air cooler is a heat exchanger that uses air as a cooling medium and is widely used in units, engines and some refrigeration equipment. Its structure usually consists of a set of heat dissipation fins and a fan. The air dissipates heat through the fins and takes away the heat.

2. Manufacturing of heat exchangers

The manufacturing process of heat exchangers involves multiple steps, and the quality control of each step directly affects the performance and service life of the equipment. Generally speaking, the manufacturing process includes the following links:

2.1 Material selection

The material selection of heat exchangers is very important. Common materials include stainless steel, carbon steel, titanium alloy, etc. These materials must not only have good thermal conductivity, but also have good corrosion resistance, high temperature resistance and mechanical strength, especially in chemical corrosion and high temperature and high pressure environments.

2.2 Processing Technology

During the manufacturing process, the processing technology of the heat exchanger is crucial. Common processing methods include stamping, welding, cutting, etc. For example, in the manufacture of plate heat exchangers, steel plates need to be formed by stamping, and then multiple sheets of plates are pressed together by a press to form a fluid channel. In shell and tube heat exchangers, the connection between the pipe and the shell is usually welded to ensure sealing and structural stability.

2.3 Assembly and Inspection

After manufacturing, the assembly of the heat exchanger needs to ensure the tight connection of each component to prevent leakage or excessive wear. In order to ensure the quality of the equipment, strict pressure testing and leak detection are usually carried out to ensure that the heat exchanger meets the design standards before it is put into use.

3. Cleaning of heat exchangers

Cleaning of heat exchangers is a vital part of maintenance work. Regular cleaning can maintain the efficient heat exchange performance of the equipment. Cleaning work usually includes the following aspects:

3.1 Necessity of cleaning

Over time, the pipes or inter-plate flow channels of the heat exchanger are prone to accumulate dirt, grease or scaling substances. These deposits will lead to a decrease in heat transfer efficiency and may even cause system failure. Therefore, regular cleaning can remove these deposits and restore the heat transfer performance of the equipment.

3.2 Cleaning methods

The cleaning method of the heat exchanger depends on the type and location of the scale. Common cleaning methods include:

• Chemical cleaning: By using acidic or alkaline cleaning agents to dissolve the scale, it is suitable for scale, grease and other soluble substances.

• Mechanical cleaning: Use a brush, spray gun or ultrasonic cleaning equipment to remove dirt on the inner wall of the pipe, which is suitable for harder deposits.

• Water flushing: Suitable for minor scale accumulation, flush the inner wall of the pipe through high-pressure water flow.

The cleaning process requires special attention to avoid damage to the heat exchanger body, especially the erosion of its sealing and material surface.

4. Replacement of heat exchanger

Although the heat exchanger can run for a long time after good maintenance and cleaning, in some cases, the heat exchanger still needs to be replaced. Common reasons for replacement include:

4.1 Material aging and corrosion

Because the heat exchanger is in high temperature, high pressure and corrosive environment for a long time, the material may age, corrode or wear. At this time, the heat exchange efficiency of the equipment will drop significantly, and even leakage will occur, which needs to be replaced in time.

4.2 Structural damage

During long-term operation, the heat exchanger may suffer structural damage due to fluid scouring or vibration, affecting its sealing or stability, resulting in inability to use normally.

4.3 Technology upgrade

With the advancement of technology, new heat exchanger designs often have higher thermal efficiency, lower energy consumption or are easier to maintain. Enterprises may choose to replace old equipment based on production needs and technology upgrade requirements.

5. Maintenance of heat exchangers

The key to maintaining heat exchangers is to extend their service life and ensure their efficient operation. Regular inspection and maintenance are steps that cannot be ignored. The following are common measures for heat exchanger maintenance:

5.1 Regular inspection

Regularly check the appearance of the equipment to check for leaks, corrosion, wear and tear. Focus on checking consumable parts such as pipes, joints, and sealing parts. Use technologies such as infrared thermal imaging or vibration analysis to detect potential faults in a timely manner.

5.2 Cleaning sediments

Regularly clean the sediments in the heat exchanger to avoid scaling, oil stains, etc. that affect the heat transfer effect. Filter the fluid to prevent impurities from entering the heat exchanger.

5.3 Replacement of aged parts

During the inspection process, if gaskets, washers, pipes and other parts are found to be aged or damaged, they should be replaced in time. Delayed replacement may cause equipment failure and accidents.

6. After-sales service of heat exchangers

The after-sales service of heat exchangers includes equipment installation, commissioning, maintenance, training and other aspects, which is an important link to ensure the long-term stable operation of equipment. Heat exchanger manufacturers in Russia usually provide the following after-sales services:

6.1 Installation and commissioning

The after-sales team will install and commission according to the specific conditions of the user's site to ensure that the equipment is in the best operating state when it is put into use.

6.2 Technical training

The manufacturer will provide relevant technical training to help users understand the operating principles, daily maintenance methods and troubleshooting techniques of the equipment.

6.3 Repair and maintenance

The after-sales team usually provides regular repair and maintenance services according to user needs. Regular maintenance can ensure the efficient operation of the equipment and reduce the occurrence of sudden failures.

6.4 Fault handling

When a heat exchanger fails, the manufacturer will respond quickly and provide solutions, including on-site repairs or remote technical support.

7. Conclusion

As an indispensable and important equipment in industrial systems, each link of the heat exchanger's structure, manufacturing, cleaning, maintenance and after-sales service directly affects the performance and service life of the equipment. Through scientific design, high-quality manufacturing and effective maintenance management, the heat exchanger can work stably in various harsh environments and provide efficient heat energy conversion services for all walks of life. Users should choose appropriate equipment according to their own needs and perform regular maintenance and care to ensure that the heat exchanger is always in the best working condition.

 

Plate Heat Exchanger Maintenance Manual Link