Phe Maintenance Service Cleaning Disassembly And Assembly Services

The required time for cleaning, disassembling, and assembling plate heat exchangers is influenced by various factors, and the specific duration needs to be comprehensively evaluated based on equipment specifications, scaling degree, cleaning process, and site conditions. The following is a detailed analysis:

 Core influencing factors and proportion of time consumption

1. Equipment specifications and structural complexity

Plate heat exchanger size:

Small equipment (with less than 100 pieces of board): The overall time is about 4-8 hours, of which the dismantling and cleaning process accounts for 60% (2.5-5 hours), and the assembly and debugging process accounts for 40% (1.5-3 hours).

Large equipment (plate quantity ≥ 500 pieces): The time consumption can be extended to 1-3 days, and disassembly and cleaning need to be carried out step by step (such as batch cleaning of plates). During assembly, strict control of bolt torque is required, and the proportion of time consumption can be increased to 50% (6-12 hours).

Structural design:

Detachable heat exchanger: The conventional disassembly and cleaning process is more efficient; If special tools are required to disassemble welded or semi welded heat exchangers, an additional 2-4 hours may be required.

2. Types and severity of scaling

Mild scaling (such as scale, thin rust):

Using cyclic acid washing and high-pressure water flushing, the cleaning time is about 2-3 hours, without the need for deep disassembly, with a total time of 6-10 hours (including assembly and debugging).

Severe scaling (such as hard scale, polymer deposition):

It is necessary to extend the pickling soaking time (30 minutes to 2 hours) or cooperate with mechanical assisted cleaning (such as ultrasonic cleaning). The cleaning process alone takes 4-8 hours, and the total time can reach 1-2 days.

3. Cleaning process and technical solution

Conventional chemical cleaning+manual disassembly and cleaning:

Suitable for common scale, with a total time of 8-12 hours (including preparation of chemicals, cyclic cleaning, and manual wiping of plates).

Efficient combination process (such as acid washing+robot cleaning):

Automated equipment can shorten dismantling and cleaning time by 30% -50%, and the total time consumption of large equipment can be compressed to within 1 day, but it requires early equipment debugging (an additional 1-2 hours).

4. On site conditions and auxiliary work

Shutdown preparation and safety measures:

Equipment shutdown, pressure relief, power outage, and isolation treatment require 1-3 hours. If high-risk working conditions (such as flammable and explosive media) are involved, gas detection and protective measures need to be added, which will extend the time by 2-4 hours.

Wastewater treatment and environmental protection requirements:

Neutralizing and cleaning wastewater to meet discharge standards takes 1-2 hours. If there are no pre-treatment facilities on site, additional transportation of wastewater may be required, which may add 0.5-1 day.

Optimization measures to shorten time consumption

Preprocessing and rapid detection:

Before cleaning, analyze the scaling composition through endoscope or sampling, and prepare chemicals in advance to reduce on-site waiting time (1-2 hours can be saved).

Modular disassembly and cleaning process:

For large equipment, "group disassembly and cleaning" (such as grouping every 100 pieces) is used to simultaneously clean and assemble, shortening the overall cycle by 30% -40%.

Application of automation equipment:

Using board cleaning robots (2-3 times more efficient than manual labor) and automatic torque wrenches (reducing assembly time by 50%), suitable for emergency repair scenarios.

Precautions

Do not blindly compress time: Excessive pursuit of efficiency may lead to incomplete cleaning (such as acid residue) or assembly errors (such as uneven bolt stress). It is recommended to reserve 10% -20% buffer time.

Advance communication requirements: If the service needs to be completed within the shutdown window, it is necessary to confirm the equipment parameters with the service provider in advance and develop an urgent plan (such as multi team parallel operations).