Client:
Oil Processor – Tasmania
Application:
Shell-and-tube heat exchanger used for heating oil with steam
Challenge:
The existing heat exchanger suffered from severe internal fouling and declining thermal performance.
Maintenance teams were conducting frequent cleanings, often under urgent conditions, leading to:
- High labour costs (including penalty rates)
- Unplanned downtime
- Emergency part procurement
- Process disruption due to late production restarts
- In ability to cope with increased oil throughput ( overcame issues with performance redundancy)
The facility sought a solution that would extend runtime between cleaning intervals while improving overall heat transfer performance—without replacing the full exchanger.
Solution
Dimpleflo® Re-Tubing Upgrade
Teralba Industries proposed a re-tubing upgrade using Dimpleflo® high-efficiency tubes. This option preserved the existing shell, baffles, and tube sheets while replacing the internal tubes with Dimpleflo heat transfer enhancement.
Key Features of the Dimpleflo Tubes:
- Dimpled internal surface creates turbulence at lower Reynolds numbers
- Minimised boundary layer build-up, reducing fouling rates
- Improved thermal conductivity due to continuous agitation of the flow
- Compatible with existing shell dimensions for direct retrofitting
Implementation:
- Existing unit was isolated and de-tubed.
- Dimpleflo tubes were sized and fabricated to match the original unit geometry
- Tubes installed without modification to shell or piping
- Re-tubed unit pressure tested and recommissioned within standard maintenance window
Implementation:
- Existing unit was isolated and de-tubed.
- Dimpleflo tubes were sized and fabricated to match the original unit geometry
- Tubes installed without modification to shell or piping
- Re-tubed unit pressure tested and recommissioned within standard maintenance window
Outcome:
The Dimpleflo re-tubing solution delivered a fast return on investment by:
- Dramatically reducing downtime and maintenance cost
- Improving heat exchanger performance and energy efficiency
- Eliminating the need for emergency intervention and unplanned service work
This project demonstrated that re-tubing can deliver benefits far beyond simple restoration when augmented with Dimpleflo heat transfer technology. The anti-fouling properties of Dimpleflo tubing provided a step-change in reliability and efficiency, particularly valuable in oil and gas, and other industries where high uptime and stable performance are critical.
Client Feedback:
“Since the Dimpleflo heat transfer tubes went in, we’ve had zero unplanned stoppages, and our maintenance team isn’t constantly reacting to fouling issues. It’s been a game changer for the site.”
Teralba Industries