For Spliethoff, we received a CAT C32 plate heat exchanger at our workshop for maintenance. The unit consists of 61 titanium plates and was delivered complete with frame.
Before we start a refurbishment, we first determine the condition of the heat exchanger. We look at contamination, the condition of the plates and seals, and check relevant measurements. Based on this, we determine which work is required. Additional work or inspections can be carried out in consultation with the customer, depending on the findings.
No leakage was visible on this heat exchanger, but after opening the plate pack, clear contamination was found. In addition, the starter plate turned out to be damaged.
First inspect, then determine what is needed
Not every plate heat exchanger that arrives at our workshop automatically receives exactly the same treatment.
The condition of the unit determines the approach. That is why we first inspect the plate pack and the various components. Among other things, we look at contamination, damage, gaskets and connections, and record relevant measurements before dismantling.
This prevents work from being carried out as standard when there is no technical reason to do so. At the same time, the inspection may reveal issues that were not known beforehand. When additional work is required or advisable, this can be discussed with the customer.
On this CAT C32, the gasket grooves were in good condition and no leakage was observed on arrival. However, clear deposits were visible on both the water side and the other side of the plates. Contamination was also present around the portholes. During the inspection, a damaged starter plate was also identified.
All 61 titanium plates cleaned
To remove the contamination properly, the plate pack was completely dismantled and the existing gaskets were removed.
All 61 titanium plates were then cleaned. Both high-pressure cleaning and chemical cleaning were used. This allowed deposits to be removed from the profiled flow channels and around the portholes.
The difference can clearly be seen in the before-and-after photos. Before cleaning, parts of the plate surface were covered by a brown layer of deposits. After treatment, the original plate pattern and flow channels are clearly visible again.
Components replaced where necessary
Cleaning alone was not sufficient for this heat exchanger.
The existing seals were replaced with 61 new NBR clip-on gaskets. Four new liners were also installed. The starter plate that was found to be damaged during the inspection was replaced with a new one.
Here too, we do not replace components without reason. The technical condition of the unit determines which components can be reused and which need to be replaced.
Reassembly and inspection
After cleaning and replacing the required components, the plate pack was reassembled.
We do not only look at the correct sequence of the plates, but also at the compression of the plate pack. Before dismantling, a pack dimension of 215 mm was recorded. After refurbishment, the plate pack measured 214 mm.
By recording these measurements before and after the work, the heat exchanger can be reassembled in a controlled manner rather than relying solely on visual inspection.
Pressure test as final inspection
Once the heat exchanger has been fully reassembled, the final inspection follows.
For this unit, three sections were pressure tested at 2 bar for 30 minutes. The test was completed successfully. This allowed us to verify that the refurbished heat exchanger was correctly sealed after reassembly.
A pressure test is therefore part of the inspection of the work carried out. Other inspections or tests are not automatically performed on every heat exchanger. Which checks are required is determined based on the condition, the technical situation and any agreements made with the customer.
The result
The CAT C32 plate heat exchanger for Spliethoff left our workshop fully refurbished. All 61 titanium plates had been cleaned, the gaskets and liners had been renewed, and the damaged starter plate had been replaced. After reassembly, the unit was successfully pressure tested.
This case clearly shows why we do not approach a refurbishment as a fixed checklist. First inspect and measure, then determine what is needed. This allows us to carry out the work that is technically relevant for the specific heat exchanger and, where necessary, discuss additional work with the customer.
Maintenance for a plate heat exchanger?
The condition of a plate heat exchanger cannot always be fully assessed from the outside. By opening the unit and inspecting the plate pack, it becomes clear which cleaning, components and inspections are actually required.
Blue Orange takes care of the entire process, from inspection and dismantling to cleaning, refurbishment, reassembly and final inspection.
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