Heat Exchanger Maintenance Checklist for Plate & Shell-and-Tube Units
A printable heat exchanger maintenance checklist for routine inspection of plate and shell-and-tube units — daily, monthly and annual tasks, gasket and tube checks, cleaning triggers and record-keeping.
How to use this maintenance checklist
This checklist helps facility managers and maintenance engineers keep plate and shell-and-tube heat exchangers running at design performance. Group tasks into daily/weekly, monthly/quarterly and annual intervals, and log every reading so you can spot a trend before it becomes a failure. Adjust the frequency to your own fouling rate, medium and duty cycle — dirty or high-temperature services need tighter intervals. Print this page or copy it into your CMMS as a recurring work order.
Daily and weekly checks
• Record inlet and outlet temperatures on both sides and compare against the design datasheet. • Record inlet and outlet pressures and calculate pressure drop across each side. • Walk the unit and check for leaks at gaskets, connections, tie-bars and tube-sheet joints. • Listen and feel for abnormal vibration or noise (pumps, flow-induced vibration). • Confirm no visible corrosion, staining or insulation damage. • Check that isolation and vent valves are in the correct position.
Monthly and quarterly checks
• Trend the thermal performance: a falling temperature approach or rising pressure drop signals fouling. • Verify tightening dimension (A-measure) on gasketed plate packs is within the plate manufacturer's min/max range. • Inspect and clean strainers and filters upstream of the unit. • Check gasket condition for hardening, cracking or creep at accessible edges. • Verify water treatment / dosing is on-spec (pH, chlorides, biocide) for the cooling or process water. • Confirm cathodic protection or sacrificial anodes (where fitted) are intact.
Annual and shutdown maintenance
• Open gasketed plate units and inspect every plate for fouling, pitting, cracking and gasket bonding; replace glued gaskets that have failed. • For shell-and-tube units, inspect and clean the tube bundle, check for tube erosion/corrosion and pull test plugs or eddy-current test where required. • Clean plates or tubes mechanically and/or with CIP chemistry matched to the deposit (see our cleaning-chemicals guide). • Pressure/leak test after reassembly before returning to service. • Replace worn tie-bars, bearing plates and studs; re-torque to spec. • Update the equipment history record with plate/gasket lot numbers and cleaning results.
When to clean or re-gasket
Clean when pressure drop rises roughly 1.5–2× above the clean baseline, when the temperature approach widens beyond design, or when throughput falls off. Re-gasket when gaskets are hardened, cracked, leaking, or at the plate maker's recommended service life. Persistent fouling despite cleaning usually points to water-treatment or flow-distribution problems rather than the exchanger itself — see our guides on preventing fouling and cleaning chemistry.
Record-keeping and spare parts
Keep a log of temperatures, pressures, pressure drop, cleaning dates, chemicals used and parts replaced for each unit. Trends in this log are the earliest and cheapest warning of fouling or gasket failure. Hold critical spares — a plate/gasket set or tube plugs — for units on essential duty. Jiangxing supplies replacement plates, gaskets and spare parts for our units and common plate heat exchanger models; send your nameplate data or a plate sample and we will match them.
Need help or replacement parts?
For a maintenance plan, replacement plates and gaskets, or an on-site fouling assessment, contact Evan at jxmike@shheatex.com or message +86 173 1725 8304 on WhatsApp. Send your unit model, medium and operating conditions and our engineering team will recommend intervals and matched spare parts.
Frequently asked questions
How often should a heat exchanger be serviced?
Do daily/weekly performance and leak checks, monthly to quarterly gasket and water-treatment checks, and a full open-and-clean inspection at least once a year. Fouling-prone, high-temperature or dirty services need tighter intervals — let trended pressure drop and temperature approach drive the schedule.
What are the signs a plate heat exchanger needs cleaning?
A pressure drop roughly 1.5–2 times the clean baseline, a widening temperature approach, or reduced throughput all indicate fouling. Trend these readings against the design datasheet so you clean before performance is badly affected.
When should heat exchanger gaskets be replaced?
Replace gaskets when they are hardened, cracked, leaking, or have reached the plate manufacturer's recommended service life. Always inspect gasket condition when a gasketed plate unit is opened for cleaning.
What should a heat exchanger maintenance log include?
Record inlet/outlet temperatures and pressures, calculated pressure drop, cleaning dates, chemicals used, gasket and plate lot numbers, and parts replaced. This history is the earliest warning of fouling or gasket failure and supports warranty and compliance.
Send your working conditions to Evan
Share your medium, temperatures, flow rate and pressure — Evan will return a thermal selection and indicative pricing after reviewing the available data.