Extending Equipment Life Through Strategic Heat Exchanger Refurbishment

Industry

Gas Processing

Application

Industrial Equipment

Technology

BASCO Type ES

Modernizing Reliability Without Full Replacement

The BASCO® team successfully completed a refurbishment project on a Type ES-style heat exchanger originally manufactured in 1995. After nearly 30 years of reliable service, the unit required modernization to maintain performance and operational efficiency while minimizing cost and downtime.

Requirements

Restore thermal performance and operational efficiency of the existing Type ES-style heat exchanger.
Minimize customer downtime during refurbishment and installation.
Maintain compatibility with existing system layout, connections, and site-specific dimensions.
Provide a cost-effective alternative to full heat exchanger replacement.
Upgrade and modernize critical components to support long-term reliability and continued service life.

BASCO® Refurbishment Solution Extends Service Life of Legacy Unit

The customer needed to restore the performance of an aging heat exchanger without incurring the high cost, long lead times, and operational disruption associated with a full unit replacement. Maintaining existing system compatibility, such as site-specific sizing and connections was also a critical requirement.

BASCO® implemented a targeted refurbishment strategy designed to maximize value and extend equipment life:

Replaced the bundle and heads to restore thermal performance
Verified and re-used the existing shell, ensuring it met design and thickness requirements
Issued a U-2 form for replacement parts, maintaining compliance and documentation standards
Minimized disruption by reducing both downtime and overall project lead time

To ensure long-term reliability, BASCO® provides a full range of refurbishment and evaluation services, including:

Shell thickness inspection and verification
Refinishing of existing components where applicable
Repair or full replacement when required
Engineering-driven bundle redesigns and performance upgrades

The Results

Driving Long-Term Value Through Smarter Refurbishment

Cost Savings

Reduced total project cost
Refurbished the existing unit
Avoiding unnecessary capital expenditures

Performance Improvement

Restored and enhanced thermal performance through replacement of the bundle and heads
Optional upgrades such as advanced materials, extended surface tubing, and optimized tube diameters

Extended Equipment Life

Extended the service life of a nearly 30-year-old heat exchanger
Maximizing the value of the customer's existing asset while ensuring long-term reliability