Replacement of Italian heat exchangers: development and turnkey delivery

Customer and project

The EuroChem company is implementing a large-scale project “EuroChem-North-West-2” in Kingisepp (Leningrad Region) – the construction of a new high-tech enterprise for the production of ammonia (1.1 million tons/year) and urea (1.4 million tons/year).

Our project:

Manufacture and supply of heat exchange equipment of finned tubes for installation of melt and granulation of urea with productivity 4000 t/day.

Task 

The customer planned to replace Italian-made heat exchange equipment, however, due to the manufacturer’s departure from Russia, there was a risk of disruption of supplies. It was necessary to find a solution that:

● would be completely consistent with the original by dimensions, connection dimensions, materials and characteristics;

● has been certified according to the requirements of TR CU 010 and TR CU 032;

● was accompanied by a complete package of documentation according to Russian standards.

Few companies have the competence to solve such problems due to stringent requirements for analog accuracy and the complexity of the matching process. However our company not only managed it, but also did it flawlessly.

Solution

We have carried out extensive work to search and verify a manufacturer capable of producing an ideal analogue of the original equipment:

✔ Careful selection of the manufacturer

● Analysis of experience, technical equipment and reference lists;

● Checking the quality of documentation and calculations;

● Assess the efficiency of interaction and correction of comments.

✔ Full control of production and testing

● Our specialists personally participated in the tests, identifying and eliminating the slightest inconsistencies.

✔ Certification and documentation

● Provided certification according to TR CU 010 and TR CU 032;

● Prepared 40 documents per heat exchanger, 6 units in total (drawings, passports, calculations, instructions).

✔ Guarantee of safety during transportation

● Developed individual packaging instead of the standard one to avoid damage during transportation.

As part of the project, we produced and supplied:

• Granulator air heater I

• Granulator air heater II

• Granulator air heater III

• Auxiliary air heater

• Granulator air heater

• Auxiliary air heater

Result

• The customer received a complete analogue of Italian equipment without loss of quality and deadlines;

• All requirements for dimensions, materials and characteristics were completed 100%;

• Equipment life – 25 years;

• Equipment fully certified and is accompanied by all necessary documentation.

Our company has confirmed its ability to quickly resolve unique engineering tasks, providing customers with high-quality equipment even in conditions of import substitution. We managed to solve this problem at such a high level thanks to:

♦ Deep expertise in the selection of manufacturers;

♦ Maximum detailed control at all stages;

♦ Ability to work with complex technical requirements.

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We we didn’t just find a replacement – we ensured reliability and compliance with all standards.

With wishes of a reliable partnership,

EnergoFront team #FrontProject