{"id":9175,"date":"2025-10-14T13:58:57","date_gmt":"2025-10-14T13:58:57","guid":{"rendered":"https:\/\/cicgroup.com\/nooter-eriksen\/?p=9175"},"modified":"2025-10-14T13:58:58","modified_gmt":"2025-10-14T13:58:58","slug":"case-study-tube-sheet-baffle-replacement-with-new-manway-installation","status":"publish","type":"post","link":"https:\/\/cicgroup.com\/nooter-eriksen\/2025\/10\/14\/case-study-tube-sheet-baffle-replacement-with-new-manway-installation\/","title":{"rendered":"CASE STUDY: Tube Sheet & Baffle Replacement with New Manway Installation"},"content":{"rendered":"\n

Project Overview & Customer Challenge<\/h2>\n\n\n\n

The unit\u2019s IP RAC was becoming a frequent source of maintenance headaches due to persistent tube-to-tube sheet joint leaks. These ongoing issues not only impacted system performance but also created reliability risks that required repeated attention from the plant\u2019s maintenance team.<\/p>\n\n\n\n

Over time, these leaks contributed to unplanned outages, increased maintenance costs, and reduced confidence in the unit\u2019s overall integrity. The plant was seeking a long-term solution to restore operational stability, reduce downtime, and improve serviceability of the affected section.<\/p>\n\n\n\n

Nooter Eriksen\u2019s Aftermarket team was brought in to provide a comprehensive solution that would not only address the immediate mechanical issues, but also improve accessibility for future inspections and repairs \u2014 aligning with the plant\u2019s broader asset management goals.<\/p>\n\n\n\n

Our Approach<\/h2>\n\n\n\n

Our team developed a solution centered on replacing the degraded internal components\u2014primarily the tube sheets and baffles\u2014with newly fabricated parts that matched the original OEM specifications. This ensured full compatibility and restored the mechanical integrity of the affected section.<\/p>\n\n\n\n

In addition to the replacement scope, we identified an opportunity to enhance long-term maintainability by incorporating a new tube-side manway into the component design. This access point would allow plant personnel to perform future inspections and maintenance more easily, improving outage efficiency and reducing manual labor requirements.<\/p>\n\n\n\n

To optimize quality and minimize onsite disruption, the tube-side section was carefully removed and shipped to a controlled shop environment for fabrication and manway installation. This off-site approach allowed for greater precision in fabrication, better welding conditions, and reduced field work hours during reinstallation. Once complete, the upgraded components were reinstalled, restoring the unit to full operation.<\/p>\n\n\n\n

Challenges & Results<\/h2>\n\n\n\n

Executing this type of upgrade presented a number of technical and logistical challenges that required detailed planning and experienced project management:<\/p>\n\n\n\n