Cold gas exchanger
Project
Cold gas exchanger for acid plant
84’ long x 16’ wide x 16’ tall (one piece construction
Weight: Approx. 260,000lbs
304, 304H, and 316L stainless steel parts
Lopes’ largest single-piece fabrication in company history
GO BIG OR GO HOME
The Cold Gas Exchanger is Lopes’ first production of a shell-and-tube heat exchanger and we did not start small. This was the largest single-piece fabrication in Lopes history as of 2016.
This project is a testament to the quality and accuracy of fitting and welding performed at Lopes due to the many constraints imposed by the great size and weight of the vessel. Lopes worked with client-supplied, raw and machine finished, 304 and 316L stainless steel parts which included a total of 1,674 50’ long tubes that were pushed into the vessel through several perfectly aligned tubesheets and baffles. Using a scaffolding stage system our shop was able to push upwards of 400 tubes in a single shift. The sheer weight and size of the exchanger, complete with tubes, meant long-term planning was required from the project kick-off.
A complete and detailed work methodology of all steps of fabrication was developed before touching any material. Consideration of the final shipment was an integral part of planning from the very start. Due to the sheer weight of the exchanger, it could not be lifted while in shop, so the final tube pushing and vestibule installations were performed while the main shell was stationary on stilted saddles 4’ off the ground. This allowed a transport trailer to pick up the vessel from underneath as well as being perfectly aligned for the subsequent crane lift that floated it smoothly into position at its final destination. With our skill and in-depth planning, Lopes was able to under take a while new type of project for the first time and deliver it safely, on budget, and on time.
Image of the final Cold Gas Exchanger