Why Reverse Engineer Your Heat Exchanger?
When an industrial heat exchanger fails, ordering a generic off-the-shelf replacement creates a massive engineering nightmare. If the nozzle orientations, flange ratings, or saddle supports are off by even a few millimeters, your plant must undergo expensive and time-consuming piping modifications.
Furthermore, original Equipment Manufacturers (OEMs) often discontinue older models, lose original CAD drawings, or charge exorbitant markups for proprietary replacements.
- ✓ 100% Guaranteed Dimensional Match
- ✓ Upgraded Materials Available (e.g. switching from Carbon Steel to SS-316L)
Our 4-Step Replication Process
Dispatch to Ghaziabad
Simply dispatch your decommissioned or leaking heat exchanger directly to our Ghaziabad works. we reverse-engineer the design directly from your physical asset.
Precise Measurement & Mapping
Our engineers perform precise physical measurements. We accurately map nozzle orientations, flange ratings, baffle spacing, tie-rod placement, and tube pitch to generate a 1-to-1 3D mechanical model.
Design & Thermal Cross-Checking
Before fabrication, the reverse-engineered design is cross-checked against our proprietary HXM suite to ensure the new unit meets or exceeds original performance specs.
Drop-In Replacement
We fabricate the exact replacement. Since the nozzle coordinates and saddle supports are identical down to the millimeter, it drops perfectly into your existing plant piping.
Technical Reverse Engineering Scope
| Engineering Metric | PAL Engineers Retrofit Standard |
|---|---|
| Tubesheet Design | Exact thickness replication, pass-partition routing, and tube-to-tubesheet expansion/welding mirroring. |
| Nozzle & Flange Coordinates | Millimeter-accurate replication of Inlet/Outlet orientations, bolt-hole alignments, and ANSI/DIN ratings. |
| Baffle Pitch & Cut | Identical baffle spacing and cut ratios to guarantee identical pressure drops and fluid velocity. |
| TEMA Compliance | Full replication of TEMA Class R, C, or B designations (BEM, BEU, AEL, etc.). |
| Material Upgrades | Option to upgrade obsolete/corroded materials to high-grade SS-316L, Cu-Ni, or Titanium during fabrication. |
Ready to Replace Your Failing Heat Exchanger?
Send us the details of your decommissioned unit, and our engineering team will provide a timeline and logistics plan for reverse engineering.
Contact the Engineering Team
