SERVICES
Heat exchanger overhaul
Complete refresh. Maximum performance. Lifetime extended.
A heat exchanger that is showing wear delivers less heat transfer, loses capacity and increases your risk of failure. Think leaks, corrosion, deformed plates, corroded tubes or damaged gaskets. When cleaning is no longer sufficient, overhaul offers the most durable solution.
At Blue Orange we overhaul heat exchangers completely according to professional standards: disassemble, clean, test, repair and rebuild. In our workshop or – where possible – on site.
Your installation will perform almost like new again after this.
When do you choose to overhaul a heat exchanger?
Overhaul is necessary when a heat exchanger has structural or recurring problems, such as:
leaks that keep coming back
cracks, deformations or metal loss
severe corrosion
worn or hardened gaskets
damaged plates or contaminated bundles
pressure loss or abnormal flow
performance loss that cleaning cannot solve
Overhaul extends life by 3-10 years on average, depending on exchanger type and operating conditions.
What does revision entail? Our approach step by step
Blue Orange works according to a transparent and technically sound revision process.
1. Diagnosis & technical examination
We always start with a thorough inspection:
visual inspection of plates, tubes, bundles and gaskets
penetrant test (crack detection)
pressure test (hydrostatic test)
measurement of flow/pressure drop
analysis of efficiency and temperature differences
checking for corrosion and material deformation
With this, we determine exactly what needs to be replaced, cleaned or repaired.
2. Disassembly
We completely or partially disassemble the heat exchanger:
take apart record packages
pull out bundles
remove end caps
remove gaskets
inspect couplings and flanges
Everything is securely packed, labeled and prepared for cleaning.
3. Cleaning (chemical or ultrasonic).
Part of any overhaul is deep cleaning.
We choose the best method based on contamination and material:
✔ Dry cleaning
For scaling, sludge, rust, water/glycol contamination.
✔ Ultrasonic cleaning
For CACs, air coolers, oil coolers, delicate plates and marine coolers.
After cleaning, all parts are completely clean, degreased and free of deposits
4. Repair & replacement
Depending on the state:
gaskets replaced
replace plates in case of deformation or cracks
repair or renew bundles
Welding or splicing (if permitted)
sanding/repairing end covers
renew gaskets and seals
correcting plate direction
build up plate packages in correct pressure/order
We use high-quality, brand-independent parts (GEA, Kelvion, Alfa Laval, NRF, etc.).
5. Precision Construction
We completely rebuild the heat exchanger to OEM specifications:
correct gasket tension
plate position and flow patterns
proper compression of record package
correct assembly of bundle and end covers
6. Testing & final inspection
We test and validate everything:
pressure test
leak tightness test
flowtest
final inspection of all parts
performance measurement before and after overhaul
Reporting & advice for your heat exchanger overhaul
After the overhaul, you will receive a complete and clear overhaul report.
This will tell you exactly what the condition of your heat exchanger is and what performance you can expect.
You will receive, among other things:
A complete overhaul report with all work performed
before and after photos, so you can see exactly what has been repaired and cleaned
test results of pressure tests, flow measurements and final inspections
an honest maintenance recommendation, tailored to your installation and operating load
a recommended maintenance interval so that you avoid breakdowns and downtime
recommendations for future cleaning or inspection, based on the findings during the overhaul
Any areas of concern that may pose future risks
advice on gaskets, plates or bundles that will last for years to come – or will need attention in the foreseeable future
This gives you all the information you need to keep your plant safe, efficient and operating – without unexpected surprises.
Sectors
Recognizable for your industry?
How do we proceed?
Every project at Blue Orange goes through the same clear structure. So we work quickly, precisely and completely transparently, from intake to completion.
Analysis & inspection
We check the heat exchanger for wear, corrosion, leaks and cracking.
This allows you to see immediately what needs to be repaired or replaced.
Disassembly & cleaning
We completely disassemble the heat exchanger and clean all parts:
ultrasonic for fine or marine fouling
chemical for lime, sludge or water side scale
Everything becomes clean and ready for recovery.
Recovery & construction
We replace worn gaskets, plates or tubes and repair damaged parts.
Then we rebuild the heat exchanger to OEM specifications.
Testing & Reporting
We perform a pressure test, leak tightness test and final inspection. You will know exactly how much capacity has been restored.
You will receive a clear overhaul report with photos, test results and a maintenance recommendation.
If desired, we also provide transportation or scheduling for subsequent inspections.
Specifically, what does an overhaul provide?
life extension of 3-10 years
restored cooling capacity
lower temperatures in process or engine
less energy and fuel consumption
optimal flow and pressure
no leaks or malfunctions
installation meets technical requirements
lower cost than replacement
Why?
Choosing Blue Orange?
Because every minute of downtime counts, and every detail makes a difference.
Active 24/7
we respond quickly, even outside office hours
Rapid intervention:
often operational again within 48 hours
Measurable result
up to 30% more efficiency
Longer lifespan
up to 25% more years of use
Get your heat exchanger overhauled
Request an inspection or overhaul recommendation:
Get in touch – our specialists are standing by.
When cleaning is no longer sufficient, or when structural problems occur such as leakage, corrosion, deformation or pressure loss.
Repair focuses on one component. Overhaul is a complete technical refresh including inspection, cleaning, repair and testing.
On average once every 5-10 years, depending on sector, load and maintenance.
Plate changers: 1-3 days.
Shell & tube: 2-7 days.
Marine coolers: depending on bundle & contamination.
Yes, a complete overhaul requires disassembly to inspect and repair every part.
Yes, we work with high-quality OEM equivalent parts and replace all gaskets and damaged plates.
Yes, on gaskets, labor and parts. Duration depends on type of exchanger and usage.
Small cracks are often weldable, but for severe damage we replace the plate for optimum safety.
Depends on type, size, contamination and damage. Often 50-70% cheaper than complete replacement.
Yes, that is even standard in our approach.
Yes. We are brand independent and overhaul all makes and types.
Cleaning sometimes yes; complete overhaul usually in our workshop because of equipment and testing facilities.