CASE STUDY: Precision Heat Exchanger Replacement
IDI Services Delivers Specialist Contract Lifting for Norfab at Roseisle Distillery
Client Profile
Norfab, a leading specialist in process engineering and fabrication for the distilling industry, required the replacement of critical heat exchangers at Roseisle Distillery. As part of essential maintenance and upgrades to the distillery’s processing systems, Norfab needed a lifting partner with the technical expertise and specialised equipment to safely remove existing units and install replacement heat exchangers within the operational distillery environment—all whilst maintaining the strict safety standards and minimal disruption requirements essential to active whisky production facilities.
The Challenge
The Roseisle Distillery heat exchanger replacement presented multiple complex challenges that demanded IDI Services’ specialised expertise:
Operational Environment Constraints
- Work conducted within an active distillery facility requiring strict adherence to safety protocols and operational procedures.
- Heat exchangers located within existing process systems necessitating careful disconnection, removal, and reconnection sequences.
- Limited access routes through the distillery’s infrastructure requiring precise equipment selection and movement planning.
- Confined working spaces within the plant room environment demanding compact yet capable lifting solutions.
- Coordination with Norfab’s installation team and distillery operations to minimise production disruption.
Technical Complexity
- Heat exchangers are precision-engineered vessels with specific handling requirements to prevent damage to sealed components and connection points.
- Multiple units requiring replacement, each with individual specifications, weights, and positioning requirements.
- Tight tolerances for positioning replacement units to align with existing pipework and connection interfaces.
- Protection of sensitive process equipment and instrumentation throughout the lifting operations.
- Load distribution considerations within the existing building structure and floor loading capacities.
Equipment and Access Requirements
- Indoor lifting operations requiring equipment capable of manoeuvring within confined industrial spaces.
- A-frame gantry system needed for controlled vertical movement of heat exchangers within restricted headroom.
- Hiab-equipped truck required for transport and precision positioning of replacement units.
- Specialised rigging configurations for safe handling of sealed pressure vessels.
- Ground protection systems to preserve distillery flooring during heavy equipment operations.
Safety and Coordination
- Compliance with distillery safety regulations, including hot work permits, isolation procedures, and confined space protocols.
- Coordination between IDI Services lifting team, Norfab installation engineers, and distillery operations personnel.
- Sequential operations requiring precise timing to maintain process system integrity.
- Weather-independent indoor operations allowing consistent progress regardless of external conditions.
The Solution
IDI Services designed a comprehensive contract lifting solution leveraging our 45+ years of industry experience:
Phase 1: Pre-Project Planning and Assessment
Our team conducted detailed surveys and planning sessions to ensure seamless execution:
- Site surveys documenting access routes, headroom restrictions, floor loading capacities, and equipment positioning requirements.
- Detailed assessment of heat exchanger specifications, including weights, dimensions, lifting points, and handling sensitivities.
- Coordination meetings with Norfab engineering team to understand disconnection sequences, installation requirements, and quality control procedures.
- Development of comprehensive method statements and risk assessments specific to distillery environments and heat exchanger handling.
- Selection of appropriate lifting equipment combinations to address both transport and precision positioning requirements.
- Establishment of communication protocols between all parties to ensure coordinated operations throughout the project.
Phase 2: Specialised Equipment Mobilisation
IDI Services deployed a carefully selected combination of lifting equipment suited to the project’s unique requirements:
Hiab Truck Services:
- Specialist hiab-equipped truck providing both transport capability and precision lifting functionality.
- Hydraulic crane system offering controlled load handling for positioning heat exchangers within the facility.
- Compact vehicle configuration allowing navigation through distillery access routes and positioning within plant rooms.
- Experienced hiab operators with distillery sector knowledge and confined space lifting expertise.
A-Frame Gantry System:
- Portable gantry structure (Porta-Gantry system visible in operations) providing stable lifting framework within confined spaces.
- Adjustable height configuration accommodating various heat exchanger dimensions and positioning requirements.
- Wheeled base allowing repositioning of the gantry system for multiple unit replacements.
- Load capacity rated for heat exchanger weights with appropriate safety factors.
- Integrated chain hoists and rigging points for controlled vertical movement.
Specialised Rigging Equipment:
- Custom sling configurations designed for heat exchanger geometry and lifting point locations.
- Load monitoring systems ensuring safe working loads throughout all lifting operations.
- Protection materials for heat exchanger external surfaces and connection points.
- Spreader bars and lifting beams for balanced load distribution during lifts.
Safety and Support Equipment:
- Comprehensive PPE for all personnel meeting distillery safety requirements.
- Communication systems for coordination between lift teams and operations personnel.
- Ground protection materials preserving distillery flooring during equipment movement.
- Lighting and access equipment for safe working conditions within plant rooms.
Phase 3: Heat Exchanger Removal Operations
The initial phase involved systematic removal of existing heat exchangers:
Preparation and Isolation:
- Coordination with distillery operations and Norfab engineers to ensure proper system isolation and de-pressurisation.
- Verification of disconnection completion and lifting point accessibility.
- Installation of A-frame gantry system in optimal position for first unit removal.
- Final safety briefings and pre-lift checks with all personnel.
Controlled Removal:
- Rigging of existing heat exchangers using appropriate sling configurations and lifting points.
- Controlled vertical lift using A-frame gantry system, carefully extracting units from their installed positions.
- Precise manoeuvring to clear surrounding pipework, instrumentation, and structural elements.
- Transition of removed units to transport positions using coordinated lifting sequences.
- Protection and securing of removed units for transport or disposal as directed by Norfab.
Phase 4: Replacement Unit Installation
The critical installation phase required millimetre-precision positioning:
Transport and Positioning:
- Delivery of replacement heat exchangers to the distillery facility using hiab-equipped truck.
- Strategic positioning of the hiab truck within the plant room for optimal access and load path.
- Coordination between hiab operations and A-frame gantry system for seamless load transfer.
- Careful manoeuvring of new units through access routes and into the installation area.
Precision Installation:
- Rigging of replacement heat exchangers using specialised lifting configurations.
- Controlled positioning using the A-frame gantry system for precise vertical and horizontal alignment.
- Millimetre-accurate placement to align connection flanges with existing pipework interfaces.
- Incremental adjustments under guidance from Norfab installation engineers to achieve perfect positioning.
- Temporary support and stabilisation whilst connection work proceeded.
- Sequential installation of multiple units following the same meticulous process.
Phase 5: Project Completion and Handover
The final phase ensured complete project delivery:
- Systematic demobilisation of lifting equipment following successful installation of all replacement units.
- Removal of ground protection materials and site reinstatement.
- Comprehensive documentation of all lifting operations with photographic records.
- Final coordination meeting with Norfab and distillery management confirming successful completion.
- Verification that all heat exchangers were correctly positioned and ready for Norfab’s commissioning activities.
The Results
The Norfab heat exchanger replacement at Roseisle Distillery was completed with exemplary outcomes:
Safety Performance
- Zero safety incidents throughout all removal and installation operations within the active distillery environment.
- Full compliance with distillery safety protocols, Norfab requirements, and industry regulations.
- Comprehensive risk management addressing confined space operations, overhead lifting, and coordination challenges.
- Seamless integration with distillery operations maintaining facility safety standards throughout.
Operational Excellence
- On-time completion meeting Norfab’s installation schedule and distillery operational requirements.
- No damage to heat exchangers during removal, transport, or installation phases.
- Minimal disruption to distillery operations through careful scheduling and efficient execution.
- Perfect positioning of all replacement units achieving precise alignment with existing system interfaces.
- Successful coordination between hiab truck operations and A-frame gantry system demonstrating equipment versatility.
Technical Achievement
- Millimetre-precision positioning of heat exchangers ensuring proper alignment for connection and commissioning.
- Successful navigation of confined space constraints and limited access routes within the facility.
- Effective use of combined lifting solutions, including hiab truck and A-frame gantry, for optimal results.
- Complete protection of surrounding process equipment and distillery infrastructure throughout operations.
Client Satisfaction
- Seamless partnership with Norfab engineering team throughout planning and execution phases.
- Professional execution maintaining the high standards expected in distillery environments.
- Flexible coordination accommodating Norfab’s installation requirements and distillery schedules.
- Comprehensive documentation supporting Norfab’s project records and quality assurance processes.
Client Testimonial
“IDI Services demonstrated exceptional capability in managing the heat exchanger replacements at Roseisle Distillery. Their combination of hiab truck and A-frame gantry systems provided exactly the lifting solutions we needed for this confined space operation. The team’s understanding of distillery environments, coordination with our installation engineers, and precise execution ensured the project proceeded smoothly from start to finish. Their professionalism and safety-first approach align perfectly with the standards we expect on all our projects.”
— Project Manager, Norfab
The IDI Advantage
This successful project exemplifies IDI Services’ core strengths in the distillery and process engineering sectors:
Specialist Distillery Experience
- 45+ years of experience serving Scotland’s distilling industry across all major facilities.
- Understanding of distillery operations and the critical nature of process equipment replacements.
- Compliance expertise with distillery safety protocols, regulations, and operational procedures.
- Established relationships with leading distillery contractors and equipment suppliers.
Versatile Equipment Solutions
- Hiab truck services providing combined transport and precision lifting capabilities.
- A-frame gantry systems offering stable, controlled lifting in confined spaces.
- Comprehensive rigging equipment suited to heat exchangers, pressure vessels, and process equipment.
- Flexible configurations allowing optimal solutions for diverse lifting challenges.
Technical Excellence
- Precision positioning achieving millimetre-accurate placement for complex installations.
- Confined space expertise managing operations within existing plant rooms and facilities.
- Load engineering ensuring safe working loads and structural integrity throughout operations.
- Quality assurance maintaining equipment protection and operational standards.
Collaborative Approach
- Seamless coordination with engineering contractors, facility operators, and multiple stakeholders.
- Flexible scheduling accommodating operational requirements and installation sequences.
- Clear communication throughout planning, execution, and completion phases.
- Reliable delivery meeting critical project timelines and technical specifications.
Distillery Sector Specialisation
Scotland’s distilling industry requires lifting partners who understand the unique challenges of working within operational facilities producing world-class spirits. IDI Services brings proven capabilities:
Process Equipment Expertise
- Heat exchangers, condensers, and cooling systems.
- Stills, column systems, and distillation equipment.
- Tanks, vessels, and storage systems.
- Pumps, motors, and mechanical equipment.
Facility Environment Understanding
- Active production requirements and minimal disruption protocols.
- Stringent safety standards and regulatory compliance.
- Access constraints within existing buildings and plant rooms.
- Protection of sensitive equipment and quality control environments.
Complete Service Portfolio
- Contract lifting using diverse equipment configurations.
- Transport services, including specialised hiab truck operations.
- A-frame gantry systems for confined space applications.
- Plant shifting, equipment relocation, and installation support.
Why Choose IDI Services for Distillery Lifting Projects
The distilling industry demands lifting partners who combine technical expertise with operational understanding and unwavering safety standards. IDI Services delivers:
- Specialist distillery sector experience across Scotland’s leading facilities.
- Versatile equipment solutions, including hiab trucks, gantry systems, mobile cranes, and specialised rigging.
- Safety-first culture with zero-incident performance record in distillery environments.
- Technical precision achieving exact positioning for complex process equipment.
- Collaborative partnerships with engineering contractors and facility operators.
- Proven reliability delivering critical projects on time and to specification.
Whether your project involves heat exchanger replacements, still installations, tank positioning, or any process equipment handling within distillery environments, IDI Services delivers the expertise, equipment, and execution excellence that industry leaders like Norfab depend on.
For more information on how IDI Services can support your distillery lifting and equipment handling requirements, contact our team today.
