Methods for cleaning heat exchangers

During long-term operation of heat exchange equipment, scale, mechanical deposits, rust
and other contaminants are formed. As a result, the productivity of the equipment decreases
sharply, which leads to the need to clean it. For these purposes, periodic or unscheduled flushing
schemes are used, where, as a result, the calculated technical parameters of heat and power
devices are restored. Scale is the worst enemy of heat exchangers. During the heating process,
calcium salts and magnesium waste settle on the metal surface, and this leads not only to
deterioration in the operation of the equipment, but also to complete failure of the heat
exchangers. The liquid that passes through the circuits of the heating unit is not heated to the
required temperature, which, in turn, negatively affects the performance of heat supply and water
supply systems .

WHAT ARE THERE METHODS FOR CLEANING HEAT EXCHANGERS

Currently, there are three methods for cleaning heat exchange equipment. Each type of
cleaning depends on the degree of contamination of the unit and the technical parameters of the
equipment.
Mechanical method. The principle of mechanical action is used.
Chemical method. Removal of contamination is carried out using chemical reagents.
Combined method. The heat exchange unit is disassembled into its component parts, then
a chemical type of washing is applied.
The cleaning option is selected taking into account the technical characteristics of the
heating unit .
Mechanical flushing
In most cases, this method of cavitation and hydrodynamic washing is used in industrial
enterprises. The method has an expensive processing segment, since special heat exchange
equipment is used, designed to work for industrial purposes.
Manual method. The peculiarity of this cycle is that all parts of the heat exchanger are
completely disassembled. Locksmith's tools are used as tools. Next, using a scraper or a special
hard brush, contaminants are removed.
For a shell-and-tube heat exchanger, complete or partial disassembly of the equipment is
provided. Cleaning is carried out using sandblasting equipment. To clean dirt on pipes, use a
hollow rod in the form of a drill, cutter, or radial brush. The dirt is cleaned using a rotational-
forward movement, after supplying a reagent (washing liquid) to the cleaning site.
 Hydrodynamic jet cleaning. A jet is directed at the site of the scale under high pressure,
and a reagent can be added a little using an abrasive substance. For washing, special devices
operating under high pressure and technological nozzles are used to form a jet under pressure.
Cavitation method. Under slight pressure, liquid or fine vapor-gas bubbles are supplied to
places of contamination. Using local direction, shock microwave actions are formed. Due to the
microwave mechanism, it is possible to destroy the dirt and forcefully remove the formation.
Chemical cleaning of the heat exchanger
In this case, there is no need to disassemble the heat exchanger. Using a chemical
reagent, you can remove formations in the form of rust and scale. Disassembly of the heat
exchanger is not provided.
Disconnect the heating unit from the main power supply.
We connect the container and the flushing pump, and pre-load the chemical reagent into
the system.
We put the equipment into operation and carry out washing within 2-8 hours.
If the contamination is complex, it is possible to use up to 3-4 types of chemical reagents,
and each new reagent involves removing the old chemical composition from the system with
washing with running water.
At the final stage, we rinse the system with running water, check for leaks, test the
equipment and put it into operation.
Combined method for cleaning heat exchange equipment
The most labor-intensive way to clean a heating unit .
The unit is disassembled into its component parts.
The parts are soaked in baths containing a chemical reagent.
We remove contaminants under high pressure water jets.
We reassemble the equipment in the reverse order, check for leaks and put the system
into operation.
HOW TO DETERMINE THE CHOICE OF WASHING METHOD
Each washing method has its pros and cons. One of the types of cleaning has an
expensive option, the second is less expensive, but at the same time ineffective. For convenience,
we have compiled a table indicating the parameters of convenience and efficiency, ranking the
places of each method.
Convenience/
Way Efficiency/place
location

Mechanical 2 2

Chemical 1 3

Combined 3 1
In each specific case, it is necessary to take into account the financial and labor costs of
flushing heat exchange equipment.
 ADVANTAGES AND DISADVANTAGES OF HEAT EXCHANGER CLEANING
METHODS
The chemical method is considered convenient since human influence is minimal. All
you have to do is connect the equipment and complete the process. The downside is that it is
difficult to select a reagent, and not every chemical composition is able to cope with the removal
of the pollutant. The disadvantages include:
Perennial deposits cannot be removed using the in-place method;
the difficulty of selecting a chemical reagent in accordance with the intended purpose of
the thermal unit;
is required in a place specially designated for this purpose.
The mechanical method is less dangerous and does not pollute the environment. The
disadvantages include the procedure for disassembling the heat exchanger and possible
mechanical damage to some parts, which leads to the need to replace the element. This increases
the cost of the work. The disadvantages include:
complete disassembly of the unit is required ;
95% of manual labor is present ;
is possible ;
it is necessary to select the right plumbing tools and components for the mechanical
action of removing the pollutant.
The combined method is the most effective, since you can achieve 100% of the results.
The disadvantages include the need to disassemble systems and components, and the high cost of
work.
 HOW OFTEN DO YOU NEED TO WASH HEAT EXCHANGERS?
Manufacturers of heat exchange equipment recommend cleaning at least once a year. But,
as practice shows, manufacturers of heat exchange units do not take into account such factors as
the performance and operating mode of heat exchangers. Service centers recommend setting a
repair interval for equipment of up to one year.

It is recommended to clean the heating circuit in a boiler system once every 3 years. But
if the circuit is loaded with hot water, then cleaning is recommended at least once every 6
months.
Regulating automation will tell you whether the system is worn out and help you
determine when it is necessary to do at least a scheduled flush. If there is a malfunction of the
automation, and not due to the failure of their electronic components, the heat exchanger must be
flushed immediately, otherwise there is a risk of complete failure of the equipment.
Water does not have its own clear parameters, and if hardness softeners are not used,
scale can form very quickly. If the system supplies different water hardnesses, flushing the
circuits is necessary every 3 months.
In addition, factors have been identified when urgent flushing of the heat exchanger is
necessary:
 in the system dropped sharply;
there are signs of a sharp increase in thermal energy;
temperature conditions have unstable indicators, and over a certain period of time, that is,
in the range from 1 to 15 minutes, with a stably programmed heat exchanger operating system.