Operation Guide for Summer Maintenance of Electrophoresis Tank Heat Exchanger

The electrophoresis‑tank heat exchanger is critical equipment in coating production lines. It maintains the electrophoresis bath temperature within the suitable range of 28‑32 °C. The high‑temperature and high‑humidity conditions in summer impose higher operating demands on heat exchangers. Maintenance frequency and service intensity shall be enhanced to guarantee efficient and stable equipment operation.

Key Challenges for Heat Exchangers in Summer

• High‑temperature and high‑humidity conditions accelerate scaling and corrosion of equipment and degrade the performance of sealing materials.

• Increased cooling load requires continuous high‑efficiency operation to stabilize bath‑liquid temperature.

• Frequent circulation facilitates deposition of impurities and microorganisms on plate surfaces, raising scaling risks.

Maintenance Procedures

Cleaning Maintenance (Core Operation)

Combine chemical cleaning and physical cleaning:

Cleaning frequency shall be raised in summer. Cleaning necessity can be judged from pressure‑drop variation. Immediate cleaning is required when the pressure drop exceeds 5 psi.

Inspection and Replacement of Sealing Gaskets

Inspection items: Check sealing gaskets for aging, deformation, damage or leakage.

Replacement criteria: Replace gaskets mandatorily if leakage persists even after tightening bolts to the minimum compression dimension.

Replacement steps:

1. Strip off the old gasket.

2. Soak the seal groove in gasoline to remove residual adhesive; clean and dry thoroughly.

3. Apply a thin coat of 801 high‑strength adhesive inside the groove and on the back of the new gasket.

4. Fit the gasket in place and compress it evenly all around.

5. Allow a 72‑hour curing period before reassembly and commissioning.

Operating‑Parameter Monitoring (Daily / Weekly Mandatory Inspection)

Mandatory daily / weekly inspection items:

• Temperature monitoring: Keep electrophoresis‑bath temperature at 28‑32 °C; cooling‑medium temperature at 5‑15 °C.

• Pressure monitoring: Monitor inlet‑outlet pressure difference. An abnormal rise indicates scaling or blockage.

• Flow‑rate monitoring: Guarantee minimum circulation flow (4 times bath volume per hour is suggested).

• Record‑keeping: Maintain operation‑parameter archives for trend comparison and analysis.

Anti‑Corrosion Treatment

• External anti‑corrosion: Coat equipment surfaces with anti‑corrosive paint to isolate air and moisture.

• Internal anti‑corrosion: Strictly control medium pH value; add corrosion inhibitors where necessary.

• Periodic inspection: Check plates for corrosion. Repair or replace components upon local corrosion detection.

• Ambient control: Ensure good ventilation around equipment to cut ambient temperature‑humidity and prevent attack by corrosive gases.

Pipeline‑System Inspection

• Air‑release valve: Verify proper function to vent trapped air, which would otherwise degrade heat‑transfer performance.

• Filter cleaning: Clean filters regularly to keep the filtration system unobstructed.

• Pipeline sealing: Inspect all joints for leakage. Pay special attention to hidden seepage under thermal insulation (check for dampness or discoloration of insulation layers).

Preventive Maintenance Schedule

Summer Operating Precautions

• Start‑up sequence: Where hot‑ and cold‑side pressures differ, slowly open the low‑pressure‑side valve first, then the high‑pressure‑side valve.

• Shutdown sequence: Slowly shut off high‑pressure‑side fluid first, then low‑pressure‑side fluid.

• No over‑temperature / over‑pressure operation: Operate strictly within equipment‑specified temperature and pressure limits.

• Avoid hydraulic shock: Operate valves gently to preserve sealing integrity.

• Insulation‑layer check: High summer humidity calls for insulation integrity checks to prevent dew‑induced internal corrosion.

Special‑Risk Prevention in Summer

Maintenance Record Sheet (Recommended Format)

Establish inspection records containing the following fields:

• Inspection date, inspector

• Readings of inlet‑outlet temperature, pressure and flow rate

• Cleaning / maintenance activities performed

• Sealing‑gasket replacement history

• Abnormal conditions and corrective actions taken

Complete records serve as valuable references for problem analysis and traceability, and form the foundation of preventive maintenance.