»
Technical Inspection
Critical importance of heat exchanger inspection
Engineer inspects spiral heat exchanger in petroleum industrial plant .
Heat exchangers play an essential role in industrial operations , facilitating the efficient transfer of thermal energy across various sectors . From oil refineries to chemical processing plants , power generation facilities to
HVAC systems , these critical components enable sustainable and energy efficient processes . However , their continuous exposure to extreme conditions including high temperatures , corrosive substances , and highpressure fluids makes them susceptible to various forms of degradation .
By Omari Hussein Sabuni , Mechanical Engineer , Kinyerezi Power Plant
The necessity for rigorous inspection protocols cannot be overstated . As heat exchangers operate in increasingly demanding environments , the risk of performance degradation , efficiency losses , and potential failures grows significantly . This article delves into the crucial aspects of heat exchanger inspection , offering insights into inspection frequencies , scheduling strategies , essential tools , and both in-service and shutdown inspection procedures . By understanding and implementing these practices , organizations can significantly enhance their maintenance strategies , optimize operational efficiency , and prevent costly failures .
Understanding inspection frequency requirements Routine inspection protocols The foundation of effective heat exchanger maintenance lies in daily and weekly monitoring procedures . Operating personnel must conduct
regular temperature differential monitoring across the exchanger using calibrated instruments , as unexpected variations often serve as early indicators of developing problems such as fouling or reduced heat transfer efficiency . Alongside temperature monitoring , pressure differential analysis forms a critical component of routine inspections . By establishing baseline measurements and tracking deviations , operators can quickly identify potential blockages or flow restrictions that might impact system performance . The verification of consistent fluid flow rates is equally important , as maintaining designed flow parameters ensures optimal heat transfer efficiency throughout the system . External visual inspections constitute another vital aspect of routine monitoring . Qualified personnel should thoroughly examine the equipment ’ s exterior for any signs of leakage , which might manifest as drips , stains , or dampness around joints and connections . They must also pay close attention to vibration patterns and noise levels , as changes in these parameters often indicate developing mechanical issues . Surface corrosion indicators require careful observation , particularly around joints , supports , and areas exposed to harsh environmental conditions . The integrity of insulation materials must also be verified to maintain system efficiency and prevent energy losses .
Periodic inspection requirements Semi-annual to annual inspections demand a more comprehensive evaluation approach that begins with sophisticated non-destructive testing methods . Ultrasonic thickness measurements
50 Heat Exchanger World March 2025 www . heat-exchanger-world . com