Unison Process Solutions

When a heat exchanger starts losing performance, the impact can extend beyond the equipment itself. Heating and cooling become less consistent, production schedules come under pressure, and an unresolved problem can lead to an unplanned shutdown.

Regular servicing helps identify issues and determine what action is needed. For maintenance and production teams, the starting point is understanding how the equipment normally performs, recognising changes and arranging support before those changes become a bigger problem.

At Unison Process Solutions, we support customers with heat exchanger servicing, inspection, cleaning and refurbishment. Here, we explain what servicing can involve and when to arrange an assessment.

Recognising common heat exchanger problems

A heat exchanger does not always stop working when a problem develops. Changes may appear gradually, making routine monitoring useful.

• Reduced heating or cooling performance
  If the equipment struggles to achieve its expected outlet temperature under comparable operating conditions, it needs investigation. Deposits on heat transfer surfaces can reduce performance, although changes in flow rates or operating conditions may also be responsible.

• Increased pressure drop
  An increase in the pressure difference between the inlet and outlet can indicate fouling or restricted flow. Comparing current readings with normal operating data helps establish whether something has changed.

• Visible leakage
  Leaks around a plate pack or connections should be assessed. On gasketed plate heat exchangers, possible causes include gasket deterioration, displacement or damage to sealing areas.

• Problems that return after cleaning
  If performance improves briefly and then deteriorates again, it is worth reviewing both the equipment and the cleaning process. Repeating the same cleaning procedure may not address the underlying cause.

These signs provide a reason to investigate, rather than a diagnosis on their own. Understanding the cause helps determine whether cleaning, replacement parts, refurbishment or another intervention is appropriate.

What does heat exchanger servicing involve?

The work required depends on the exchanger’s design, application and condition. For a gasketed plate heat exchanger, servicing may include several stages.

·Inspection and assessment

An assessment establishes the equipment’s condition and the scope of work. Where the unit is opened, plates and gaskets can be examined for damage, deformation and sealing problems.

Operating information is also valuable. Temperature readings, pressure trends and previous maintenance records help explain how the unit has been performing.

·Cleaning

Keeping heat transfer surfaces clean is essential to maintaining performance. The cleaning method must suit the deposits present and the materials used in the exchanger.

Cleaning-in-place may be appropriate where deposits can be removed without opening the unit. More severe fouling may require dismantling and manual cleaning. Cleaning chemicals and procedures should follow the relevant equipment guidance.

·Gasket replacement and refurbishment

Where gaskets are no longer suitable for service, replacement may be required. The gasket material must be compatible with the process conditions and cleaning chemicals.

Inspection may also identify damaged plates or other components requiring attention. Refurbishment should address the condition found rather than assume every unit needs the same work.

·Testing

Integrity testing and pressure testing can form part of the assessment or service programme. The appropriate test depends on the equipment and the purpose of the investigation.

Testing helps inform maintenance decisions, while further inspection or repairs may be needed where a defect is identified.

When should you arrange an inspection?

Arrange an assessment when you notice unexplained leakage, deteriorating temperature performance, an increased pressure drop or recurring problems despite cleaning.

However, maintenance should also be planned before symptoms appear. There is no single service interval suitable for every heat exchanger. The application, operating hours, process conditions, manufacturer’s guidance and previous findings all influence the schedule.

Reviewing equipment condition ahead of a planned shutdown gives you time to discuss the work required and organise parts and access. Keeping a record of inspections and repairs also helps inform future maintenance.

Preparing for a service visit

When contacting your service provider, have the equipment make, model and identification details available where possible.

Explain what has changed, when the issue began and whether it followed a process adjustment, cleaning cycle or previous repair. Share relevant operating readings and service records, and discuss the available shutdown window and site access requirements.

This information helps the service team prepare for the assessment.

Heat exchanger servicing with Unison

At Unison, we provide routine maintenance, emergency repairs and refurbishment for heat exchangers across dairy, food, beverage, chemical and pharmaceutical processing.

We offer on-site support for customers in Ireland, and plate packs can also be sent to our Limerick service centre for inspection and refurbishment.

Contact our team to discuss a performance issue or plan your next heat exchanger service.