In the field of industrial heat energy conversion, fully welded plate heat exchangers have become the core equipment for many enterprises to achieve efficient heat transfer and energy conservation, thanks to their outstanding performance advantages. However, scientific and standardized installation is a prerequisite for them to exert their best performance. The following detailed step-by-step guide will help you accurately control the installation process, fully unleash the potential of fully welded plate heat exchangers, and inject strong impetus into the production and operation of enterprises.

In-depth Understanding of the Unique Advantages of Fully Welded Plate Heat Exchangers

The structural and performance advantages of fully welded plate heat exchangers are the key to their outstanding performance in complex working conditions. Their fully welded structure abandons traditional rubber gaskets and achieves sealing through precise plate welding technology. This design endows the equipment with the excellent performance of long-term stable operation without leakage in high-temperature and high-pressure environments. The wide-channel design is a major highlight, especially suitable for handling complex media containing solid particles, fiber impurities, and high viscosity, significantly reducing the risk of blockage and scaling, and reducing the frequency of equipment maintenance.

In terms of heat transfer efficiency, the optimized corrugated structure can form a strong turbulent flow during the fluid flow process, greatly enhancing the heat exchange effect. Compared with shell-and-tube equipment, the heat transfer efficiency is increased by more than 20%, saving a large amount of energy costs for enterprises. In terms of material selection, it covers a variety of highly corrosion-resistant materials such as stainless steel, titanium alloy, nickel-based alloy, and 254SMO. Whether in strongly acidic or strongly alkaline working conditions, it can be accurately matched to ensure the long-term stable operation of the equipment.

In addition, the equipped “Smart Eye ™” intelligent monitoring system can be regarded as the “digital brain” of the equipment, which can real-time monitor key parameters such as temperature and pressure drop. Through intelligent algorithms, it can achieve automatic early warning and energy efficiency optimization, keeping the equipment operation status under control and escorting safe production and efficient operation.

Step-by-step Explanation of the Installation of Fully Welded Plate Heat Exchangers

Preliminary Preparation: Laying a Solid Foundation for Installation

- Site Survey and Planning: Before installation, a comprehensive survey of the site should be carried out to ensure that there is sufficient installation space and it meets the requirements of the equipment dimensions. The site should have good ventilation conditions, be far away from high-temperature, humid, and corrosive gas environments, and avoid interference from vibration sources. At the same time, plan the operation space and maintenance access around the equipment to facilitate later maintenance and repair.

Equipment Inspection and Inventory: After the equipment arrives, carefully check the packing list to ensure that all equipment components are complete and there is no damage or deformation to the appearance. Focus on checking the welding quality of the plates, and check whether the welds are uniform and continuous, and whether there are defects such as pores and cracks. If there are any abnormalities, communicate with the supplier in a timely manner to deal with them to ensure that the equipment quality meets the standards.

Tool and Material Preparation Prepare all kinds of tools required for installation, such as wrenches, hoisting equipment, and levels. At the same time, according to the installation requirements, prepare auxiliary materials such as sealant and gaskets to ensure that the material quality meets the requirements of the equipment operation.

Equipment Positioning and Foundation Installation

Accurate Positioning: Determine the exact installation position of the equipment on the installation site according to the design drawings and process flow. Use tools such as a level to ensure that the levelness error of the equipment installation plane is within the specified range to avoid uneven fluid flow caused by installation inclination, which affects the heat exchange effect.

Foundation Construction: The equipment foundation should have sufficient strength and stability to withstand the weight and vibration of the equipment during operation. The surface of the foundation should be flat and smooth. When embedding anchor bolts or installing the base, strictly control their position and elevation to ensure accurate matching with the equipment installation holes. After the foundation construction is completed, carry out curing, and the equipment can be installed only after the strength reaches the requirements.

Equipment Hoisting and Positioning

Hoisting Plan Formulation: According to the weight, size of the equipment, and the conditions of the installation site, formulate a scientific and reasonable hoisting plan. Select appropriate hoisting equipment and lifting tools to ensure the safety and reliability of the hoisting process. During hoisting, avoid collisions and extrusions of the equipment, and protect the surface and welding parts of the equipment.

Smooth Positioning: During the hoisting and positioning process of the equipment, slowly adjust the position of the equipment to make it accurately fall on the foundation anchor bolts or base. Use a level to detect the levelness of the equipment again. If there is a deviation, make fine adjustments by adjusting the gaskets and other methods to ensure that the equipment is installed horizontally and firmly.

Pipeline Connection and Sealing Treatment

Pipeline Installation: Install the pipelines according to the design requirements to ensure that the pipeline routes are reasonable and the layout is neat. When connecting the pipelines to the equipment, avoid forced alignment to prevent the pipeline stress from being transmitted to the equipment, affecting the safe operation of the equipment. For high-temperature and high-pressure pipelines, necessary compensation devices should be set up to absorb the displacement generated by the thermal expansion and contraction of the pipelines.

Sealing Treatment: The sealing of the connection between the pipeline and the equipment is of vital importance. Use high-quality sealant or gaskets and install them according to the specified sealing process. The sealant should be applied evenly and in an appropriate amount, and the gaskets should be installed flat and without wrinkles. Tighten the connecting bolts evenly to ensure the sealing effect and prevent medium leakage.

Electrical and Instrument Installation

Electrical Connection: According to the electrical drawings of the equipment, connect the power cables, control cables, and other electrical lines. Ensure that the electrical connections are firm and the wiring is correct, and the laying of the electrical lines complies with relevant specifications. After the installation is completed, debug the electrical system to check whether the electrical performance of the equipment is normal.

Instrument Installation: Install monitoring instruments such as temperature, pressure, and flow rate to ensure that the installation positions of the instruments are reasonable and easy to observe and maintain. The instrument connections should be accurate and error-free, and the signal transmission should be stable. After the installation is completed, calibrate and debug the instruments to ensure that the measurement data is accurate and reliable.

System Debugging and Acceptance

Single-machine Debugging: After the equipment installation is completed, carry out single-machine debugging. Start the equipment and check whether the equipment runs smoothly and whether there are any abnormal noises or vibrations. Monitor the operation parameters of the equipment, such as temperature, pressure, and flow rate, to ensure that all parameters meet the design requirements. If there are any abnormalities, stop the machine in time to troubleshoot the faults until the equipment runs normally.

Joint Debugging: On the basis of qualified single-machine debugging, carry out system joint debugging. Simulate the actual production working conditions and run the entire system to check the collaborative working conditions between the equipment and other system equipment. Observe the stability of the system operation and detect whether the heat exchange efficiency reaches the design index. Rectify the problems found during the debugging process in a timely manner to ensure the reliable operation of the system.

Acceptance and Delivery: After the debugging is completed, organize relevant personnel to accept the equipment. Carry out a comprehensive inspection and evaluation of the equipment installation quality, operation performance, safety protection, and other aspects according to the acceptance standards. After the acceptance is qualified, sign the acceptance documents, and the equipment is officially delivered for use.

Operation and Maintenance Points After Installation

Strictly Control the Working Conditions

Temperature Management: During operation, it is strictly prohibited for the equipment temperature to exceed the design upper limit to avoid thermal fatigue cracking of the welds caused by excessive temperature. Monitor the temperature change of the equipment in real-time, set a reasonable temperature alarm threshold, and take cooling measures in time when the temperature is abnormal.

Pressure Control: Ensure that the operating pressure of the equipment is within the specified range to prevent the failure of the welds due to excessive pressure. Install a pressure monitoring device to monitor the pressure in real-time. When the pressure fluctuates abnormally, promptly investigate the cause and make adjustments.

Temperature Difference Control: Reduce the temperature difference impact between hot and cold media to avoid fatigue of the plate welds caused by excessive thermal stress. During the start-up and shutdown process of the equipment, reasonably control the flow rate and temperature change rate of the hot and cold media to achieve a smooth transition.

Strengthen the Management of Fluid Media

Control of Corrosive Media: For corrosive media, regularly detect their pH value to ensure that the media characteristics match the welding material of the equipment. For example, in high-chlorine working conditions, select equipment made of C – 276 material. According to the corrosiveness of the media, formulate reasonable anti-corrosion measures to extend the service life of the equipment.

Treatment of Particle Impurities: When handling media with high impurity content, a filter must be installed, and the filtration accuracy should meet the requirements of the equipment operation. At the same time, according to the characteristics of the media, select equipment with a wide channel to reduce the risk of blockage. Clean the filter regularly to prevent the normal operation of the equipment from being affected due to the blockage of the filter.

Cleaning Specifications: It is strictly prohibited to use cleaning agents containing chloric acid to clean the equipment. Improper cleaning will lead to pitting and perforation of the welds. Formulate a scientific cleaning plan, and select appropriate pickling, alkali washing, or physical flushing methods according to the characteristics of the media and the operation conditions of the equipment. The cleaning cycle is recommended to be once a year or every 6 – 12 months of operation. After cleaning, promptly detect the pressure, flow rate, and heat exchange efficiency of the equipment to ensure that the equipment performance returns to normal.

Combine Intelligent Operation and Maintenance with Daily Maintenance

Enable the Intelligent Monitoring System: Give full play to the role of the “Smart Eye ™” intelligent monitoring system to achieve all-weather real-time monitoring and early warning of parameters such as the temperature, pressure drop, and efficiency of the equipment. Through the data analysis of the system, promptly discover potential faults and performance degradation problems of the equipment, quickly locate the fault points, and provide remote guidance for maintenance to improve the operation and maintenance efficiency of the equipment.

Daily Inspection and Maintenance: Establish a daily inspection system for the equipment, and regularly check the operation status of the equipment, including the appearance of the equipment, the connection parts, and the instrument readings. Check whether there are any abnormal situations such as leakage, abnormal noise, and vibration in the equipment, and deal with the problems found in a timely manner. Regularly clean and maintain the equipment to keep the surface of the equipment clean and prevent the accumulation of dust and impurities from affecting the heat dissipation and operation performance of the equipment.

Technical Measures to Prevent Weld Failure

Control of Temperature Fluctuation: Avoid severe temperature fluctuations of the equipment to reduce thermal fatigue of the welding area. Optimize the production process, reasonably arrange the start-up and shutdown time of the equipment, and reduce the impact of temperature changes on the welds.

Ensuring Welding Quality: Select a qualified welding process and construct it strictly in accordance with the welding process specifications. Carry out non-destructive testing (such as X-ray flaw detection) on the welding parts to ensure that the welding quality meets the requirements. In the case of corrosive fluid, select matching welding wires and materials to prevent the generation of stress corrosion cracks.

Stress Relief: During the installation of the equipment and the connection of the pipelines, take measures to release the stress of the equipment and pipelines to avoid damage to the welds caused by stress concentration. For example, reasonably set up pipeline supports, compensators, etc. to absorb the stress generated by the thermal expansion and contraction of the pipelines.

Formulate Equipment Life Extension Strategies

Spare Parts Management: Design a redundant spare parts strategy, and configure spare plate bundles or modules according to the operation status of the equipment and the replacement cycle of vulnerable parts. Ensure that in case of equipment failure, spare parts can be replaced in a timely manner, reducing the downtime waiting time and ensuring the continuity of production.

Maintenance Planning: Scientifically plan the equipment maintenance cycle. It is recommended to conduct a comprehensive regular inspection once a year, and for heavy-duty systems, an inspection should be carried out every six months. Formulate a detailed maintenance plan, conduct a comprehensive inspection, maintenance, and repair of the equipment, and promptly discover and deal with potential problems to extend the service life of the equipment.

Operation Specification Management: Strengthen the training of operators to enable them to master the methods of adjusting the pressure and temperature of the equipment and the ability to judge abnormal data. Formulate strict equipment operation procedures, standardize the behavior of operators, and avoid equipment damage caused by improper operation.

Environmental Optimization: Strengthen the management of the equipment installation environment, take measures to reduce the impact of vibration sources on the equipment, and ensure that the equipment is installed firmly. Do a good job in moisture-proof and anti-corrosion measures, protect the equipment from environmental factors, and create a good operating condition for the equipment.

Conclusion

As the core equipment for efficient heat transfer in the industrial field, the installation quality and operation and maintenance of fully welded plate heat exchangers are directly related to the equipment performance and the production efficiency of enterprises. By following the above scientific and rigorous step-by-step installation guide and meticulous operation and maintenance points, the stable and efficient operation of fully welded plate heat exchangers in harsh working conditions such as high temperature, high pressure, easy corrosion, and easy blockage can be ensured, helping enterprises to achieve the goal of “safe operation + cost reduction and efficiency improvement”.

Shanghai Heat Transfer Equipment Co., Ltd., as a leading provider of heat exchanger solutions in the industry, with rich experience and a professional technical team, can provide you with customized solutions for fully welded plate heat exchangers and comprehensive expert technical support. Whether it is equipment selection, installation guidance, operation and maintenance, or fault handling, we will wholeheartedly serve you. If you need further information or assistance, please feel free to contact us:

Email:

zhanglimei@shphe.com

qiuying@shphe.com

WhatsApp /  Cell:＋86 15201818405

WhatsApp /  Cell: +86 13671925024