Heat exchangers are the unsung heroes of several industrial processes and as such they are usually taken for granted - nobody enjoys paying for what's commonly viewed to be unnecessary care. Heat exchanger Tubes supply responsibility for such a long time, that when they begin to fall in efficacy, it is usually a slow process that goes mostly unnoticed - until their functionality has deteriorated sufficiently to be a problem. Afterward, it actually is a problem - and one requiring urgent attention. What aggravates the situation is the heat exchanger which has not ever been cleaned properly, coupled with the commercial need to be sure that it stays on-line. When the decision is made to carry out cleaning, often nobody knows what the operation of the exchanger is supposed to be, either as the drawings are lost, or no record of any advancement was made after the original cleaning.
While these days Seamless Tubes are widely used everywhere in the industries. When the exchanger finally is opened up to assess the extent of the defiling, it's not surprising to find it's so serious that cleaning takes a lot more than planned. Any advantage that may have been obtained by a speedy traditional clean is offset by the prolonged cleaning length and costs - and, needless to say, lost production. Bear in mind that this is the kind of situation specialist cleaning companies see every week if this seems like a nightmare scenario. Having to make 'finger in the wind' forecasts clearly is not a way that is sufficient to plan care.
There's possible to result in a significant development in heat exchanger availability and 'cleanability', by working closely with the individuals who fabricate industrial plants and design Heat Exchanger Tubes.
Better design would lead to improved cleaning - where enhanced means safer, cleaner and quicker, maybe in situ or even on-line and with better waste containment. It'd then be quicker and simpler to clean exchangers back to bare metal to return them to duty and their design performance. Plants ordered and are usually set on the cornerstone of not availability throughput and ease-of-cleaning. Providers are happy to comply with this and so tend to design heat exchanger Tubes with 30-40% extra capacity to make certain that they'll continue to supply obligation, even when rather commonly defined.
If a plant is optimized for cleaning, nearly full production may be maintained through the cleaning procedure. Relatively minor mechanical changes, like adding isolating valves to exchangers, means that every exchange, or bank of exchangers, can be taken down and cleaned while the others remain on-line. A redesign of the exchanger so that a header could be removed means it may afterward be cleaned in a number of hours instead of several days to the standard high pressure water jetting, with a different system.
Now, typical service periods have become stretched to three and even four years in some instances, but the clear working savings are actually a false market. As they're getting longer run times, while competing refineries have little choice but to play the same match or lose millions during more frequent shutdowns investors are really joyful. Four years down the line, but the plant must come down for leading cleaning and care and it'll experience a far higher capital replacement cost than in the past.