When a manufacturing facility discovered solvent contamination in its solvent recovery condenser system, the clock started ticking.
From risk to resolution: A turnkey heat exchanger replacement success story
A dangerous volume of flammable solvent had infiltrated the shell-side water system of a heat exchanger — turning a routine maintenance issue into a critical safety hazard. While plant staff suspected trouble with one unit, the full extent of the failure remained hidden — until Ward Vessel & Exchanger was called in.
What Ward uncovered underscored the value of fast, full-scope response. The company’s investigation exposed a broader risk — and highlighted the critical need for rapid, expert intervention.
"In an industry where uptime is critical and downtime is costly, turnkey specialists like Ward are redefining what it means to respond."
In an industry where uptime is critical and downtime is costly, turnkey specialists like Ward are redefining what it means to respond — delivering speed, safety and engineered precision when it matters most. The inspection and testing phase was complex, but it gave both Ward’s team and its customer confidence that every problem area had been identified — ensuring nothing was left behind. Close examination of the damaged tubes revealed signs of chloride stress corrosion cracking, shedding light on a deeper root-cause issue. That insight helped the customer make an informed decision to replace the exchangers rather than risk plugging or other temporary repairs.
Further testing revealed a far more urgent situation: all three heat exchangers were leaking extensively. Dozens of pinholes and cracks riddled the tubes, rendering the units unfit for continued operation. A basic tube-plugging repair wasn’t an option — it would have compromised both performance and plant safety.
Engineered for urgency: One week to full recovery
With production on pause and a tight restart window looming, Ward moved quickly. The team partnered closely with the client to define process demands and conducted a detailed thermal analysis to determine the right specifications. In just a few days, a custom, properly sized exchanger was fabricated to meet the plant’s operational requirements.
Ward’s field crew and crane mobilized rapidly to the site. The team removed all three damaged exchangers, modified the mounting structure to accommodate a single, larger replacement and installed the new unit. The scope of work also included rerouting and adjusting supply and return piping to ensure seamless function within the new configuration.
Less than a week after the faulty equipment was discovered, the plant was back online with a fully functional, thermally optimized exchanger and a clean, efficient piping layout. Most importantly, the hazardous flammable water issue was eliminated — restoring safe operations and peace of mind.
The plant avoided an estimated six weeks of downtime, saving over $1 million in lost production — and eliminated a major safety hazard in the process. This project illustrates Ward’s strength as a specialty turnkey provider — from initial inspection and thermal analysis through design, fabrication and installation. The company’s rapid response, engineering expertise and streamlined project execution highlights the advantages of working with a team built for complex process equipment challenges.
For facilities grappling with critical heat exchanger or process system issues, Ward offers a single-source solution with a proven record of fast, results-driven performance.
When vital equipment fails, there’s no time for trial and error. Trust Ward Vessel & Exchanger to deliver engineered answers — quickly, safely and reliably.
For more information, visit wardve.com, email at sales@wardve.com or call (713) 413-8416.
