Onsite Service – Heat Exchanger Replacement Project
InKorr were recently approached to perform an onsite service project to replace a failed Heat Exchanger at a Hazardous Substances site. There were many hurdles to overcome with this project, however with our previous experience in these types of projects we were able to meet and overcome these on all levels.

– Project planning –
We worked with the client both onsite & remotely to put together a step by step calendar/plan of all stages of the project including offsite pre-works, On the day job steps of works to be completed, and follow up works to be performed.
– Acquisition of parts & personnel –
An important part of completing this sort of project is ensuring you have all the right parts and people to complete each stage. Following site inspection, stock checks and job assessment, we provided & assisted with the procurement of all necessary parts/spares & trades for specific tasks.
– Works Prior to onsite project –
As well as our onsite capabilities, InKorr can perform extensive in house service works which we utilized in this case, performing a complete refurbishment of the clients spare plate pack including disassembly, initial inspection, tagging & engraving plate sequence, chemical cleaning, hydro-blasting & mechanical cleaning, Dye penetrant crack testing, minor panel beating/reforming repairs, regasketting, re-ordering and assembling pack for easy onsite installation.


– Safety Precautions –
As with all jobs InKorr undertakes, personnel safety is of the highest importance. This being a hazardous substances site it was all the more important to ensure all safety requirements were met and in place during the project. Including careful planning of plant shutdown and isolation’s, balancing and draining of process fluids, correct PPE and equipment available and used at each stage.
– Performing the Onsite Service –
Working together with the site technicians and contracted trades, following all setup stages of the project, it was time to get to work. Plant pipework was disassembled and removed and the failed Heat Exchanger was lifted out of the skid to be disassembled and later inspected further. At the same time, a complete new Frame with the refurbished plate pack was being assembled. One plate in the old unit was required for the build of the new unit. So onsite refurbishment and testing of this plate was performed. Given the all clear it was added to the new build, the new unit assembly was completed to design specifications and readied for installation. The new unit was lifted into position, pipework reattached and the unit was prepped for pressure and performance testing.


– Testing & Sign-off of works –
Following the successful completion of the service project, the unit underwent pressure and performance testing to ensure all components were in working order and ready for operation. No external or cross-flow leaks were found, pressure and flow testing were successful. Our clients plant was once again ready to operate. As with all of our jobs, a detailed service report and testing certificates are supplied to our client and included in our records for the future and ongoing planned maintenance we will provide.
– Follow-up works –
With the onsite component of this project now completed it is time for us to further analyze the failed exchanger to try determine a reason for failure & put in place processes to avoid this happening again in the future. Back at our workshop we will also perform refurbishment works on the old plate pack to determine its condition and possible use again in future. Cleaning, crack testing, regasketting and sequencing works will be performed and if its in reusable condition, will be readied for use again as a part of the new scheduled preventative maintenance program.

Our team is available for any job, including emergency shutdowns and maintenance work on short notice. Please contact us on the lines below for more information.
E = inkorr.service@inkorr.com.au
Ph = (03) 9800 4118