The spiral plate heat exchanger consists of two parallel thin plates that form two uniform spiral channels. Fixed-distance columns are welded between these plates to keep them at a consistent distance, which not only maintains structural integrity but also enhances the rigidity of the spiral plate. These heat exchangers allow two heat transfer media to flow fully in a counter-current manner, significantly improving heat exchange efficiency. Even with small temperature differences between the media, the device can achieve excellent performance. However, if a leak occurs, the entire unit may become irreparable. So, how should one address this issue?
When dealing with a leak, the first step involves identifying the location of the internal leak point. Once identified, begin cutting holes starting from the outermost layer of the heat exchanger corresponding to the leak point. The process moves progressively inward toward the layer containing the internal leak. The holes should be oval-shaped and slightly larger than the outer layers, gradually decreasing in size as they move inward—typically differing by about 40mm between each layer. If the leak is deeper, the initial cuts on the outer layers need to be larger.
After cutting the holes, thoroughly clean any oxidation residue left on each layer of the plate. This step is critical for ensuring a tight weld when attaching the patch plate. Use tools like chisels and small hand grinders to carefully trim and remove debris. Make sure to collect all the cleaned slag to avoid it falling into the heat exchanger.
Next, fit the patch plate. To ensure high-quality repairs, instead of reusing the original sheets from each layer, a new patch plate is fabricated. The patch plate must match the exact material and thickness of the heat exchanger’s spiral plates. The edges of the patch plate should extend 15–20mm beyond the cut-out sections of each layer, maintaining an oval shape that aligns with the curvature of the heat exchanger's layers.
Finally, address the internal leak points through welding. Carefully inspect the leak to determine whether it is a crack or a sand hole. In some cases, using a hand grinder may be necessary to clean the area and create grooves to facilitate better welding. Welding is performed using a J422 electrode with a diameter of 3.2mm, and the current should be controlled between 100–120A. Begin by welding the leak points first, followed by each refill layer, working outward from the innermost layer. This method ensures stability and effectiveness while repairing the damage.
If the heat exchanger continues to show signs of failure after these steps, it might be best to consider replacing the unit entirely. Regular maintenance and inspection can help prevent such issues from arising in the future. Proper care and attention to detail are essential in extending the lifespan of your equipment.
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