PHE spares & gasket services in India

A leading process manufacturing company in South India was facing recurring issues with their Plate Heat Exchangers used across cooling, heating, and heat recovery applications. The facility operated multiple PHE units across three major production divisions, each division running several heat exchangers under varying temperatures and pressure conditions.

Despite regular internal maintenance, the plant continued to experience frequent gasket leakages, pressure drops, cross-contamination risks, and unplanned shutdowns. Incorrect gasket material selection, inconsistent tightening practices, and delayed spare replacement resulted in rising maintenance costs, increased energy consumption, and production losses. This situation severely affected operational reliability and forced frequent emergency stoppages.

We implemented a structured on-site PHE Spares & Gaskets management solution, designed to deliver consistent sealing performance and long-term reliability across all divisions.

1. Dedicated On-Site Teams
   Each production division was assigned a specialised Ram Engineering team in partnership with Adhiam. Each team consisted of:
   • One PHE Service Technician: Responsible for dismantling PHE units, inspecting plates and gaskets, replacing worn-out spares, and ensuring correct reassembly as per OEM standards.
   • One Gasket & Spare Monitoring Specialist: Tasked with monitoring gasket conditions, identifying early signs of wear or chemical degradation, ensuring accurate spare compatibility, and tracking replacement cycles for each PHE unit.
2. Centralised Supervision
   All divisional teams operated under a senior Ram Engineering Supervisor, coordinating with Adhiam, who acted as the single point of contact for the client. This ensured uniform service quality, correct material selection, consistent tightening practices, and seamless coordination with the plant’s maintenance and production teams.
3. Integrated Service Delivery
   The continuous on-site presence enabled proactive gasket replacement, correct spare inventory management, immediate response to leakage risks, and smooth integration with planned shutdown schedules, eliminating emergency interventions.

The Result:

Through this dedicated and systematic PHE Spares & Gaskets management approach, Ram Engineering delivered outstanding operational improvements:

• Eliminated Leakage-Related Shutdowns by Over 90%:Proactive gasket replacement and correct material selection virtually eliminated unplanned stoppages caused by leaks and sealing failures.
• Extended Gasket Service Life by More Than 40%: Application-specific gasket compounds and proper tightening practices significantly increased gasket durability.
• Improved Heat Transfer Stability: Consistent sealing ensured stable pressure and temperature differentials across all PHE units.
• Reduced Maintenance Costs: Emergency repairs and repeated gasket replacements were eliminated, resulting in substantial annual savings.
• Optimised Client Maintenance Resources: The client’s internal teams were relieved from repetitive troubleshooting and could focus on critical process improvements.
• Enhanced Operational Reliability: Heat exchanger performance became predictable, safe, and consistent across all divisions.