Heat Exchanger Replacement

Location: Louisiana

Date Completed: 2011

Services Utilized

  • Construction Erection Services - Construction Means & Methods - Construction Processes & Phasing
  • Structural/Geotechnical Engineering - Plant Turnarounds & Expansions - Pipe Configurations & Support Systems - Process Evaluation

Challenges Encountered

  • develop the extraction means & method for a 33,000 lbs elevated heat exchanger
  • allow for the one-piece removal and later replacement installation
  •  could not cut or remove nozzles or module structural members

Solutions Provided

  • Huval devised a cantilevered beam extraction and exchanger sled 30 feet above grade with steel columns & tie rods to support it
  • then engineered a rolling hydraulic jacking system  to avoid nozzle conflicts with tight clearance issues

The client’s heat exchanger developed a tube sheet leak and required replacement. The two existing options available for the exchanger’s removal were not feasible. Those options were to either go with an original module installation, which would have required structural member removals to extract the exchanger in one piece or a time consuming exchanger disassembly.

Huval & Associates provided engineering services to develop the extraction means and method for the entire 33,000 lbs elevated heat exchanger that allowed for the one-piece removal and later replacement installation of the shop fabricated and tested exchanger without having to cut or remove nozzles or module structural members.

Our firm prepared the detailed Engineering Design Plans, Shop Drawings, Erection, Extraction, Insertion and Lift Procedures.  Within the design plans Huval & Associates devised a cantilevered beam extraction and exchanger sled 30 feet above grade with steel columns and tie rods to support it.  We also engineered a rolling hydraulic jacking system in order to avoid nozzle conflicts with tight clearance issues.

Services included:

  • Structural Steel Support Design
  • Fabrication Shop Drawings
  • Exchanger Sled Design
  • Hydraulic Jacking System Design
  • Erection/Extraction/Installation Procedures
  • Crane Lift Design