Plate heat exchangers are an important element of heating systems. They are efficient, compact and durable, but they are not immune to wear and tear. Working with hot, aggressive or dirty environments leads to a gradual deterioration of the condition of the plates and seals. To avoid critical failures, it is important to recognise the signs of malfunction in time and respond before the problem escalates into an accident.

Decreased heat transfer efficiency

One of the first signs is a gradual decline in efficiency. If the system does not reach the desired temperature or requires more energy, this is a reason to check the heat exchanger. The reasons may be:

• accumulation of deposits or scale on the plates;
• partial blockage of channels;
• reduction in thermal conductivity due to corrosion.

Such processes rarely manifest themselves abruptly — they accumulate slowly, so it is important to periodically check the system parameters.

Leakage between plates

Tightness is a critical factor. Visual signs of leakage:

• the appearance of drops or streaks at the joints between elements;
• increased humidity around the equipment;
• a strong smell or change in colour of the working environment.

In 90% of cases, the cause is worn or incorrectly installed seals. Less commonly, microcracks or plate deformations are the cause.

Mixing media

If you have a dual-circuit system and the coolants have started to mix, this is a sign of serious damage. The main causes are:

• damage to the plate (crack, puncture);
• critical wear of seals;
• insufficient clamping force of the frame.

In such a situation, it is necessary to stop the heat exchanger before diagnostics — further operation is dangerous.

Visual signs of wear

Even if there are no leaks, it is worth paying attention to the appearance of the parts. The following should raise alarm bells:

• cracks, hardening or loss of elasticity of seals;
• rust spots or darkening on the plates;
• displacements or irregularities in connection nodes.

Such defects are grounds for preventive replacement, even if the equipment is still working.

Increased intervals between servicing

If the heat exchanger appears to be operating steadily but its efficiency is declining, this may indicate hidden wear and tear. Sometimes operators do not notice gradual changes. Signs that it is time to call for service:

• the system takes longer to reach operating mode;
• temperature is unstable;
• frequent short stops.

Thus, longer intervals between services are not always a positive sign.

Why replace spare parts on time?

Timely replacement of plates or seals allows you to avoid higher costs in the future. Main advantages:

• reduction of the risk of accidents and downtime;
• stable system performance;
• extension of equipment service life;
• lower energy and repair costs.

Replacing components is an investment in stability, not an unnecessary expense. A complete replacement of the heat exchanger is always more expensive than timely replacement of parts.

Our capabilities

We specialise in plate heat exchangers and offer:

• supply of spare parts for brands: Alfa Laval, GEA, Schmidt, SPXFlow, Kelvion;
• seals and plates compatible with original equipment;
• service maintenance: diagnostics, cleaning, replacement of parts, restoration of operability.

We work quickly, efficiently and with consideration for the specifics of each production.

Heat exchanger wear is an inevitable but controllable process. Timely diagnostics, replacement of seals and plates, and regular maintenance are the key to stable and safe equipment operation. If you notice the signs described above, do not delay. Contact specialists and ensure the reliability of your system for years to come.