Heat Exchanger Maintenance & Overhaul
Complete inspection, repair and overhaul of heat exchangers — workshop or site, planned or emergency — by the team that builds them.
Why This
Matters
The wrong specification here doesn't show up on day one — it shows up as downtime, contamination or wasted energy later.
Asset protection
Deferred exchanger maintenance converts a planned week of work into an unplanned month — leaks, seized bundles and failed tubesheets escalate fast once deterioration passes a certain point.
Process integrity
A leaking exchanger cross-contaminates streams and can shut down an entire unit; found at overhaul, it is a line item — found in service, it is an incident with safety and environmental consequences.
Operational efficiency
Fouled and degraded exchangers silently tax energy consumption every hour; overhaul restores design approach temperatures and the duty the plant was actually built around.
Where It's
Used
Heat Exchanger Maintenance & Overhaul in service — sector by sector, application by application.
Oil & Gas
Planned overhaul programmes and emergency exchanger repair.
View Oil & GasPower & Energy
Condenser and cooler overhaul during unit outages.
View Power & EnergyPetrochemicals
Bundle pulling, cleaning and repair inside turnaround windows.
View PetrochemicalsWater & Desalination
Condition assessment and staged refurbishment of desal trains.
View Water & DesalinationMarine & Offshore
Dockside and offshore cooler overhaul campaigns.
View Marine & OffshoreFood & Beverage
Plate pack reconditioning and pasteuriser service.
View Food & BeverageHow It Works
A structured overhaul takes an exchanger from as-found condition to documented, tested, design-performance service — with engineering judgement at every gate.
- 1
As-found inspection and performance review establish scope before anything is dismantled.
- 2
Bundle extraction, cleaning (hydrojetting or chemical) and full visual inspection.
- 3
NDT — eddy current or IRIS tube testing, PT/MT of welds — quantifies remaining life.
- 4
Repairs executed: tube plugging or replacement, tubesheet refacing, gasket surface restoration, coating.
- 5
Reassembly with new gaskets, hydrostatic test, and a documented condition report with reinspection interval.
Configurations
We Offer
Every variant Dolphin builds — each engineered for a specific duty, not a catalogue default.
Workshop Overhaul
- Best For
- Deep repairs needing machine tools and controlled conditions.
- Advantage
- Full facility capability — machining, welding, PWHT, testing under one roof.
Site Overhaul
- Best For
- Large exchangers and short windows where transport is impractical.
- Advantage
- Mobile crews with pulling, cleaning and testing equipment mobilise to site internationally.
Emergency Response
- Best For
- Unplanned failures threatening production.
- Advantage
- 24/7 mobilisation from Mussafah — hours, not weeks.
How to
Choose
| Criterion | Guidance |
|---|---|
| As-found condition | Tube test results decide repair versus retube versus replace — we quantify before recommending. |
| Window duration | Scope is engineered to the outage: what must be done now versus next turnaround. |
| Location constraints | Bundle transportability and site access determine workshop versus site execution. |
| Performance targets | If duty has degraded, overhaul scope includes thermal review — not just mechanical repair. |
Key
Benefits
What sets heat exchanger maintenance & overhaul from Dolphin apart, in specific and measurable terms.
- 01
Single accountable contractor
From inspection through tested return to service.
- 02
Quantified remaining life
Eddy current / IRIS tube testing — no guesswork.
- 03
Code repair capability
ASME R-stamp capability for code repairs.
- 04
Fleet condition database
Documented condition reports build an asset-life record.
- 05
24/7 emergency response
Emergency mobilisation from Abu Dhabi around the clock.
- 06
Manufacturer-backed decisions
Overhaul by a manufacturer — repairs backed by design engineering.
Technical
Specifications
Design codes, materials and testing scope confirmed for every heat exchanger maintenance & overhaul order.
| Equipment covered | Shell & tube · plate · air-cooled · coolers · condensers |
| Inspection | Eddy current · IRIS · PT/MT · visual · hydrotest |
| Repair scope | Plugging · retubing · tubesheet refacing · welding · coating |
| Code repairs | ASME R-stamp |
| Response | Planned programmes · 24/7 emergency callout |
Why Dolphin for
Heat Exchanger Maintenance & Overhaul
Manufacturer-grade repair
The same engineers who design exchangers assess yours — repairs are engineered, not improvised.
Speed from Mussafah
Workshop, spares and crews in Abu Dhabi collapse repair timelines that overseas OEMs measure in months.
ADNOC-inducted crews
Field teams carry the inductions, certifications and HSE record that major operators require.
Frequently Asked Questions
Yes — overhaul scope is independent of original maker; we service all brands and types.
Crews mobilise from Mussafah within hours for UAE sites, with 24/7 availability during client turnarounds.
Eddy current or IRIS results plus thermal margin: typically beyond about 10% of tubes plugged, retubing becomes the economic answer.
Every overhaul closes with a documented report — as-found condition, work performed, test results and recommended reinspection interval.
Yes — ASME R-stamp repairs and alterations with updated documentation.
Yes — mobile crews perform bundle pulling, cleaning, testing and reassembly at site, internationally.
Yes — thermal review is part of scope; re-baffling, tube upgrades or enhanced surfaces can recover or increase duty.
Contact us with unit details and your outage window; we scope the work in advance so the window is spent executing, not discovering.
Talk to an Engineer About Heat Exchanger Maintenance & Overhaul
Send your duty requirements or existing datasheet — our engineers will confirm the right configuration and get you a quote.