High Pressure Regeneration Gas-Gas Hairpin Heat Exchangers

About Client

For a gas processing facility in the Netherlands, Heat Exchanger Service was selected to design and manufacture four high-pressure hairpin heat exchangers for regeneration gas service. The units play a key role in the heat recovery process and were designed for demanding operating conditions, including high pressures, elevated temperatures and cyclic operating loads.

Our Activities

Engineering, fabrication, testing and certification of four regeneration gas-to-gas hairpin heat exchangers.
555 m² heat transfer surface; 32,000 kg empty weight per unit.
Design conditions: 92 barg (shell & tube side), -30°C to +330°C.
Carbon steel shell side and 316L stainless steel tube side for high strength and corrosion resistance.

Challenge

A key challenge of this project was designing heat exchangers capable of operating under severe pressure and temperature conditions while being subjected to cyclic service.

The combination of pressure fluctuations, thermal cycling and demanding process conditions required careful consideration during both the design and fabrication phases to ensure long-term mechanical integrity and operational reliability.

In addition, the project combined multiple material grades within a single exchanger design, requiring strict quality control and manufacturing procedures throughout the production process.

Scope of work

Complete design and engineering
Fabrication of four hairpin heat exchangers
Supply and integration of carbon steel and stainless steel components
Non-destructive examination and pressure testing
PED Category IV certification
Final inspection, documentation and delivery
560 U-tubes per exchanger (Ø15.88 x 1.65 mm, straight length 9,300 mm)
Design pressure: 92 barg
Design temperature: -30°C to +330°C
Carbon steel shell side (SA516 Gr.70, SA333 Gr.6 and SA350 LF2)
Stainless steel tube side (316L)
Designed in accordance with EN 13445-3:2021, API 660, API 663, TEMA R and PED 2014/68/EU
Category IV Module G

The Result

The project was successfully completed with the delivery of four high-pressure regeneration gas-gas hairpin heat exchangers. With a combined fabricated weight of nearly 130 tonnes, a total of 2,240 U-tubes and a design specifically developed for cyclic operation, the exchangers provide a reliable and robust solution for long-term service in a demanding gas processing environment.

Questions? Our Experts Are Here to Help You!

Marco Reijngoudt

Business Unit Manager HES