Shell and Tube Calorifier Bundle Replacement for NHS client
Heatxforce was contacted by a long-standing NHS client experiencing ongoing issues with one of their shell and tube calorifiers. The existing tube bundle had become heavily scaled and inefficient, resulting in poor domestic hot water recovery performance and concerns around long-term system reliability.
Due to the critical nature of the building and the importance of maintaining reliable hot water services, the client required a fast and effective engineering solution that would restore system performance while minimising operational disruption.
What Was The Problem?
The client had experienced a significant decline in domestic hot water performance across the building. The shell and tube calorifier was no longer able to meet peak heating demands, causing reduced temperatures and slower hot water recovery times.
As part of our initial investigation, Heatxforce engineers carried out a full assessment of the steam and condensate system, including:
- Temperature control valve operation
- Steam flow through the primary circuit
- Condensate drainage performance
- General calorifier operation
These checks confirmed that the wider steam and condensate system was operating correctly and that the issue was internal to the calorifier bundle itself.
Following inspection and removal of the bundle, extensive limescale deposits and internal deterioration were identified across the heat transfer surfaces. The scale build-up had created a thermal barrier around the tubes, severely reducing heat transfer efficiency and preventing the calorifier from achieving the required domestic hot water demand.
The bundle was deemed beyond economical repair and had reached end-of-life condition.
How Did Heatxforce Help?
Following a detailed engineering assessment, Heatxforce delivered a complete shell and tube bundle replacement solution.
Our team carried out:
- Full calorifier isolation and drain down
- Removal of associated pipework and access covers
- Safe extraction of the existing tube bundle
- Internal inspection and cleaning of the calorifier shell
- Reverse engineering and manufacture of a new copper tube bundle
- Reinstallation of the replacement bundle into the existing vessel
- Pressure testing, recommissioning, and operational testing
Due to restricted plantroom access and the size of the assembly, careful lifting and handling procedures were implemented throughout the project to ensure safe removal and installation.
The newly manufactured replacement bundle was designed to match the existing calorifier shell configuration and operational duty requirements, allowing the client to retain the original vessel while fully restoring system performance.
Following recommissioning, the calorifier successfully returned to full operation, achieving the required domestic hot water temperatures and recovery rates.
Heatxforce continues to support the client with ongoing steam, condensate, and mechanical system improvements to maintain long-term efficiency and reliability.
Existing Calorifier Tube Bundle
Manufacturing a replacement Calorifier Tube Bundle
The Replacement Calorifier Tube Bundle
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Codes, Standards & Certifications
Heatxforce build pressure equipment in accordance with PD5500 and ASME VIII Pressure vessel codes whilst conforming to the European Pressure Equipment Directive (PED) and UKCA Pressure Equipment Safety Regulations (PESR), which are mandatory inspection requirements applicable to pressure vessels and systems.
Our welding procedures are in accordance with ISO 15614-1 and ASME IX.
Welder qualifications are in accordance with ISO 9606-1 and ASME IX.
All of our welding related qualifications are certified by TUV Nord.
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