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STEP 1.
Plate log
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At first, the received plates will be identified, logged and visually inspected to be able to determine what next steps should be taken for the reconditioning process. The customer will be informed directly if major differences might occur.
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STEP 2.
Old gasket removal
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Now the best method for removal of the old gaskets will be selected. This depends on the application, the process and the connection of the gasket to the plate. Sometimes the removal will be done in a nitrogen bath, mainly when a mixed adhesive is used.
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STEP 3.
Plate cleaning
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After the all loose scaling and fouling is removed by high pressure water cleaning, the best cleaning method is determined. Depending on the material and the degree of contamination one or more solutions are chosen. Sometimes hours in an agitated acid solution has to be followed by hours or even days in a high temperature caustic solution.
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STEP 4.
Dye-penetrant test
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Through a dye-penetrant test all cracks and holes can be made perceptible under uv-light. Otherwise these or other causes of cross contamination are not visuable by sight. It is an important matter to check all plates, because one or more leaks can cause for a significant loss of production or production time which will generate more costs.
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STEP 5.
Cleaning dye-check fluids
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The plates are cleaned again to remove the fluids used in the dye-penetrate test. If necessary, plate cleaning needs to be repeated. |
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STEP 6.
Gasket groove preparation
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It is imperative that the gasket groove is prepared before applying new gaskets. A rolled groove is the primary cause for external leakage after regasketing. If a rolled groove is not identified the plate pack will not seal properly and cause costly down-time. With the WCR regasketing service program this type of deformation will be identified. In most cases WCR will be able to repress the plates. This can save up to 60% of the costs of the new plate and extend the life of the plate for years.
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STEP 7.
Gasket preparation
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Gaskets are cleaned and inspected to ensure proper bonding. |
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STEP 8.
Gasket application
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Gasket application using superior bonding adhesive is critical in the regasketing process. Selection of adhesive depends on the application and the operation conditions under which the plate heat exchanger will be in service. Media as well as temperatures and pressure steer which adhesive is selected. If the proper adhesive is not selected, the lifetime of the gaskets will be reduced dramatically. In fact, using improper adhesive can cause improper conformance of plate to gasket and result in rolled grooves, corrosion and even cracked plates during assembly.
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STEP 9.
Heat Curing
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All glued WCR gaskets get a 4 hour treatment in an industrial oven. This happens under a temperature between 135° and 155°C. This method leads to a ten times longer lifespan of the gasket in comparison to gaskets without this heat treatment.
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STEP 10.
Final quality control
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Before shipment every plate is carefully inspected for straightness, solid bonding, excess adhesive, deformations and plate pack sequence. If drawings are supplied, every plate pack will be returned in assembly order allowing for quick and easy installation.
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