1. Assessment and Planning: 1.1 Inspection: Inspect the existing heat exchanger to confirm dimensions, plumbing layout and clearances to ensure that the replacement unit will fit in the footprint of the existing unit with minimal alterations to sludge piping. 1.2 Analysis: Analyze the heat exchangers performance data to understand its historical performance and efficiency. 1.3 Replacement Plan: Based on the inspection and analysis, develop a plan outlining the necessary steps and materials required for the complete removal and replacement of the heat exchanger. 2. Disasmebly and Cleanup: Fully evacuate and disassemble the existing unit and related gas, water, and electrical piping/conduit, remove / haul off unit, clean and prep the area and sludge piping for the installation of the new unit. 3. Installation and Testing: 3.1 Installation: Fully assemble and install the new unit ensuring the proper alignment of all related sludge, gas, water, and electrical piping/conduit. 3.2 Pressure testing: Conduct pressure tests to verify the integrity of the heat exchanger and its components. 3.3 Performance Testing: Conduct performance tests to ensure the heat exchanger is operating at its design capacity and efficiency. 4. Commissioning and Handover: 4.1 Commissioning: Commission the new heat exchanger, monitoring its performance under normal operating conditions. 4.2 Documentation: Prepare detailed documentation of the installation process, including test results and recommendations for ongoing maintenance. 4.3 Training: Provide training to the relevant personnel on the proper operation and maintenance of the new heat exchanger. 4.4 Handover: Handover the new heat exchanger to the client, along with all relevant documentation and maintenance guidelines.
