Key maintenance points and recommended intervals for core components of heating/heat exchange systems (core components)

The core actions involve cleaning the heat exchange surface and heating tubes, removing scale and impurities, preventing blockages, and ensuring heat transfer efficiency. For lightly polluted wastewater, it is recommended to clean once every 1-3 months. However, for highly scaled wastewater (such as high calcium and magnesium, high sulfate wastewater), the cleaning frequency should be shortened to once every 2 weeks to 1 month. For cleaning, it is preferable to use citric acid or a dedicated neutral detergent for cyclic cleaning. Direct immersion in strong acids or alkalis is strictly prohibited to prevent corrosion of equipment materials.

Vacuum system (vacuum pump + vacuum tank)

The focus should be on checking the oil level and quality of the vacuum pump, and replacing the vacuum pump oil according to the standard of running for 2000 hours. If the oil quality becomes turbid, emulsified, or blackened ahead of time, it must be replaced immediately. Weekly spot checks must be conducted on the vacuum level and the condition of the seals. An abnormal vacuum level can directly lead to an increase in the boiling point of wastewater and a surge in energy consumption. If the seals are aging, they must be replaced in a timely manner to avoid air leaks affecting the vacuum environment.

Pump assembly and piping (feed/discharge/condensate pump + piping valves)

Conduct weekly inspections on the operating pressure, noise, and leakage of the pump. Dismantle and clean the pipeline filters monthly to remove trapped impurities and prevent pipeline blockage or pump wear. Simultaneously, inspect the sealing and switching flexibility of each valve, and promptly repair or replace any valves found to be stuck or leaking.

Electrical and control system (PLC + sensor + instrument)

Conduct monthly inspections on circuits and wiring terminals to prevent loosening or short circuits; calibrate core sensors such as temperature, liquid level, and vacuum degree once every quarter. Regularly back up the PLC control program to avoid equipment malfunction due to program loss. Inaccurate sensors can cause loss of control over automatic feeding, evaporation, slagging, and other actions, and must be calibrated promptly.

Condensation and exhaust gas treatment system (condenser + activated carbon adsorption device)

Conduct monthly inspections on the condenser, clean the internal dirt, and ensure condensation efficiency; the activated carbon adsorption device should replace the activated carbon in a timely manner according to the adsorption saturation level to avoid excessive emission of exhaust gas odor. At the same time, check the condensate water recovery pipeline to ensure normal recovery of condensate water and improve water resource utilization.

The daily/per-shift operational checklist includes the following steps before startup: confirm that the power supply and cooling water supply are normal, the vacuum pump oil level meets the standard, all valves are in the correct state, and there are no leaks or pipeline blockages;

During operation: continuously monitor evaporation temperature, vacuum degree, feed rate, and concentration ratio, observe the quality of condensate water and slag discharge status, and make timely adjustments if any abnormalities are detected;

After shutdown: Drain the residual wastewater from the equipment, flush the pipelines and heat exchange surfaces with clean water, record the operational data for the day, and maintain a log for future troubleshooting.

Common maintenance pitfalls and avoidance suggestions Pitfall 1: Long-term failure to clean the heat exchange surface → Consequence: Decreased heat transfer efficiency, soaring energy consumption, and in severe cases, pipeline blockage leading to machine downtime;

Misconception 2: Long-term failure to replace vacuum pump oil → Consequence: Insufficient vacuum degree, resulting in the equipment being unable to evaporate normally at low temperatures;

Misconception 3: Neglecting wastewater pretreatment → Consequence: High scaling and highly corrosive components directly enter the equipment, accelerating equipment corrosion and blockage;

Avoidance advice: If the wastewater contains high concentrations of calcium, magnesium, sulfate, etc., softening or scale inhibition pretreatment must be carried out in advance.

In terms of maintenance costs and personnel requirements, mainstream low-temperature evaporators are fully automated with PLC control, eliminating the need for 24-hour on-site supervision. Only one employee is required to conduct regular inspections and perform maintenance tasks. The main consumable costs are vacuum pump oil, descaling agents, and activated carbon, which are relatively low. When maintenance is carried out according to standards, the equipment can have a service life of 8-10 years, significantly longer than equipment that is not maintained properly.