Heat exchanger leak detection
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Using the 3+1 conversion process of “Ⅲ,Ⅰ – Ⅳ,Ⅱ”, it has been determined that there is air leakage in heat exchanger No. IV; simple and effective methods for detecting leaks in heat exchangers are sought. Thank you
Add water to the shell, inflate it, and remove the floating head. Check where there is a leak in the containment layer.
The most effective and fastest method for detecting leaks is to remove the access covers at the bottom and top of the heat exchanger, and then seal off the openings from above and below using plugs that have been prepared in advance (fabricated according to the inner diameter of the heat exchanger’s heat exchange tubes). It is crucial to learn how to identify the tubes with internal leaks (these usually show signs of acid sludge). Workers working at the bottom should preferably use an oxygen torch to achieve incomplete combustion in order to locate such tubes (black smoke will be produced!) ! !
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When testing a heat exchanger for leaks, it is absolutely forbidden to use water
I agree with you; acidic sludge can turn into dilute acid when it comes into contact with water, thereby causing further corrosion of the pipes, and it may not be possible to detect this completely.
Can colored gases be used to pressurize the shell side?
The normal operation process can be determined through analysis； After stopping production, test directly with air.
Have you considered using hydrogen leak detection, as it’s very cost-effective?
By the way, do you have any experience using alkaline solution to clean heat exchangers?