Heat Exchanger Repair vs. Replacement
A leaking or underperforming shell-and-tube heat exchanger does not automatically need to be replaced. Depending on the condition of the shell, tubes, tubesheets, heads and other pressure-retaining components, repairing or rebuilding the existing exchanger may provide many additional years of service. Perry Products can evaluate existing equipment and help determine whether the most practical solution is a repair, complete retube, replacement tube bundle, material upgrade, or new heat exchanger. The right choice depends on the condition of the equipment, the cause of failure, process requirements, expected service life, downtime and overall project cost.
Repair or Rebuild May Make Sense When:
- The shell and channels are in good condition
- Tube failures are the main issue
- Existing unit still meets thermal duty
- Maintaining the existing footprint is valuable
- The metallurgy can be upgraded
Replacement May Be the Better Choice When:
- Significant shell or component thinning exists
- Tube failures are widespread
- Too many tubes have been plugged
- Process conditions have changed
- Existing materials are no longer suitable
Retube
When the pressure-containing components remain serviceable but the tubes have reached the end of their useful life, a complete retube can restore heat transfer surface and extend exchanger life.
Replacement Tube Bundle
For removeable-bundle exchangers, Perry Products can manufacture a new tube bundle to fit the existing shell. A spare bundle can also be supplied to help reduce downtime during future outages.
Material Upgrade
Replacing tubes, tubesheets or other components with different materials can address corrosion, erosion or changes in service conditions and provide better long-term performance.
Our team can review available information and evaluate the condition of your exchanger including:
✓ Shell and channel thickness (UT results)
✓ Tube condition (eddy current testing, pressure testing)
✓ Tubesheet condition
✓ Tube-to-tubesheet joints
✓ Thermal performance and fouling
✓ Failure mechanism and history
✓ Current operating conditions
✓ Whether the equipment meets current process requirements
Not Sure Where to Start?
Send us your exchanger drawing, nameplate photo, inspection report or whatever information you have available. Our team will review the information and help you determine the best next steop.