HEXNOVAS provided a fully interchangeable replacement solution for existing VAHTERUS Plate & Shell® heat exchangers, helping the customer reduce purchasing cost, shorten delivery time, and avoid expensive site modification.
The customer’s existing equipment was originally supplied by VAHTERUS and had been operating on site for many years. During maintenance planning, the customer required a replacement unit that could be installed directly into the existing system.
Original layout reference for PSHE 4LL-154/1/1 replacement
Based on the original drawings and nameplate information, HEXNOVAS reproduced the key installation dimensions, nozzle positions, support arrangement, and connection layout.
Compact Plate & Shell heat exchanger replacement
Larger capacity Plate & Shell heat exchanger replacement
For replacement projects, dimensional accuracy is as important as thermal performance. Our engineering team focused on both.
We reviewed the original drawings, nameplate photos, nozzle arrangement, and installation constraints.
The replacement unit was designed with the same nozzle orientation, centerline, support height, and footprint.
Heat transfer area, pressure drop, operating pressure, and temperature conditions were recalculated.
The new unit could be installed directly with minimal shutdown time and no major site modification.
The main value of this project was not only the equipment itself, but the total saving in procurement, installation, and downtime.
Compared with sourcing original replacement units, the customized HEXNOVAS solution offered a more cost-effective alternative.
Reverse engineering and customized manufacturing helped reduce technical confirmation and production lead time.
With 1:1 interface design, the customer avoided cutting, welding, foundation changes, and support modification.
Direct replacement helped minimize installation time and reduce production interruption.
Critical dimensions including nozzle centerlines, shell size, support position, and installation height were controlled during design.
Thermal and mechanical calculations were reviewed to ensure the replacement unit met the original duty requirements.
| Item | Original VAHTERUS Unit | HEXNOVAS 1:1 Replacement |
|---|---|---|
| Equipment Type | Plate & Shell® Heat Exchanger | Customized Plate & Shell Heat Exchanger |
| Installation Size | Existing fixed site layout | Matched to original footprint |
| Nozzle Arrangement | Existing pipework already connected | Same nozzle orientation and centerline |
| Site Modification | Modification required if replacement dimensions differ | No major piping or foundation modification |
| Procurement Cost | Higher cost for original replacement | More economical replacement solution |
| Delivery Time | Longer lead time for imported spare unit | Shorter lead time through customized manufacturing |
These reference images were used to verify the replacement layout, model information, connection sizes, and installation dimensions.
1:1 replacement design based on original installation layoutHEXNOVAS successfully provided a 1:1 replacement solution for the customer’s existing VAHTERUS Plate & Shell heat exchangers. The replacement units were designed to match the original layout, allowing the customer to keep the existing piping, supports, and installation space.
This project demonstrates HEXNOVAS’ capability to replace imported plate & shell heat exchangers with customized, fully interchangeable units. For customers operating aging imported equipment, this approach can reduce total replacement cost, shorten delivery time, and minimize site construction risk.
Send us the nameplate, photos, drawings, and operating conditions. HEXNOVAS can help evaluate whether a drop-in replacement solution is possible for your existing plate & shell, welded plate, gasketed plate, or shell & tube heat exchanger.
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Original PSHE 4LL-76/1/1 nameplate
Original PSHE 4LL-154/1/1 nameplate
