Equipment Condition Assessment for Shell & Tube Heat Exchangers

We conduct heat exchanger condition assessments scaled to the assessment opportunity — external assessment during normal operation, internal assessment during planned openings, and comprehensive assessment including tube testing during turnarounds. External assessment includes thermal performance analysis (temperature approach, UA degradation trending, pressure drop monitoring), external visual inspection (insulation condition, nozzle condition, support condition), and cathodic protection verification where applicable. Internal assessment (during opening) includes tubesheet face condition evaluation (corrosion, erosion, gasket groove condition), channel and cover condition inspection, gasket seating surface assessment, and accessible tube-end inspection. Tube integrity testing (during turnaround or planned tube test) includes full-length tube testing using the appropriate NDE method (ECT, IRIS, or RFT) with defect sizing and location mapping, tube plug verification, and statistical analysis of wall loss distribution. Baffle assessment (during bundle pull) includes baffle hole enlargement measurement, baffle plate corrosion and erosion, tie rod and spacer condition, and bundle-to-shell clearance evaluation. Each exchanger receives a condition report with tube condition mapping, remaining wall thickness statistics, corrosion rate calculation, fouling rate quantification, and recommendations with priority classification: continue operating, plan cleaning, schedule tube repair, plan bundle replacement.