Updated 3 months ago
By David Chen
Safety Warning
- Ensure proper chemical handling procedures and PPE when using cleaning chemicals
- Verify equipment is properly isolated and depressurized before opening
- Be aware of potential hazardous material exposure from process residues
- Ensure proper ventilation when working with cleaning chemicals
Equipment Information
This SOP applies to the following equipment
Equipment Type
Heat Exchanger
Applicable Models
Shell & Tube, Plate, Spiral, Air Cooled
1
Preparation and Isolation
Safely isolate and prepare the heat exchanger for cleaning
60-90 minutes
Tools: Blind flanges, Lockout/tagout kit, Drain containment system, Gas detection equipment
- Obtain necessary work permits and review cleaning procedure
- Isolate exchanger by closing and blinding all process connections
- Depressurize and drain both sides of exchanger to appropriate containment
- Verify zero energy state and install lockout/tagout devices
2
Opening and Initial Inspection
Open the exchanger and perform visual inspection
2-3 hours
Tools: Torque wrench, Hydraulic bolt tensioner, Bundle extractor, Digital camera
- Remove channel cover or end plates following proper bolt removal sequence
- Extract tube bundle or open plate pack as applicable
- Perform initial visual inspection to identify fouling type and severity
- Document condition with photographs and inspection notes
3
Chemical Cleaning
Perform chemical cleaning to remove fouling
4-8 hours
Tools: Circulation pump, Chemical resistant hoses, pH meter, Temperature probes, Chemical test kit
- Select appropriate cleaning solution based on fouling type
- Prepare cleaning solution according to chemical supplier recommendations
- Circulate cleaning solution at specified temperature and flow rate
- Monitor pH, temperature, and solution strength during cleaning
4
Mechanical Cleaning
Perform mechanical cleaning as required
3-6 hours
Tools: Tube cleaning equipment, High pressure water system, Inspection lights, Tube brushes
- Use appropriate tube cleaning tools based on fouling type and tube material
- Clean tubes systematically, ensuring complete coverage
- For plate exchangers, use high-pressure water cleaning on individual plates
- Inspect cleaning effectiveness and repeat as necessary
5
Post-Cleaning Inspection
Verify cleaning effectiveness and inspect for damage
1-2 hours
Tools: Inspection mirror, Borescope, Ultrasonic thickness gauge, Digital camera
- Visually inspect all surfaces for remaining fouling
- Check for signs of corrosion, erosion, or mechanical damage
- Perform thickness measurements on critical components
- Document post-cleaning condition with photographs
6
Reassembly and Testing
Reassemble the exchanger and prepare for return to service
2-4 hours
Tools: Torque wrench, New gaskets, Pressure testing equipment, Bolt lubricant
- Install new gaskets and seals as required
- Reassemble exchanger following proper torque sequence
- Perform pressure test to verify integrity
- Remove isolation blinds and prepare for startup