Applus+ in Indonesia supports heat exchanger integrity assessment during turnaround maintenance

Heat exchangers play a vital role in petrochemical processing facilities, where equipment performance and operational continuity depend on the integrity of tube bundles. Over time, corrosion, erosion, fouling, and other degradation mechanisms can affect tube condition, creating potential risks to efficiency, safety, and production. During the planned turnaround, the operator required a detailed inspection of multiple heat exchangers to assess tube condition, identify potential defects, and support informed maintenance decisions within a tightly controlled shutdown schedule.

To meet these requirements, Applus+ implemented an integrated inspection programme combining several advanced NDT techniques. Remote Field Testing (RFT) was used to detect corrosion, wall loss, and defects in ferromagnetic tubes, while the Internal Rotary Inspection System (IRIS) provided highly accurate thickness measurements and quantitative data on tube integrity. These activities were complemented by boroscope inspections, enabling visual examination of internal tube conditions and areas that required further assessment. By combining these technologies, Applus+ delivered a comprehensive evaluation of equipment condition and reliability.

One of the project's primary challenges was completing a high-volume inspection scope within the limited turnaround window while maintaining strict safety, quality, and reporting requirements. Applus+ addressed this through detailed planning, effective coordination with the client, and the deployment of experienced Asset Integrity and NDT specialists supported by specialized inspection equipment. This approach ensured efficient execution of inspection activities while maintaining the accuracy and consistency of data collection throughout the campaign.

The integration of multiple inspection techniques provided the client with reliable and actionable information on the condition of critical heat exchanger tubes. The inspection results supported maintenance and repair decisions, enabled the identification of areas requiring attention, and contributed to the safe and efficient restart of plant operations following the turnaround.

The project was completed successfully, demonstrating Applus+ in Indonesia's capability to deliver advanced heat exchanger inspection solutions during complex turnaround campaigns. By combining technical expertise, proven inspection methodologies, and efficient project execution, Applus+ helped the client enhance asset integrity management and support the long-term reliability of critical petrochemical infrastructure.