When Is Retubing Necessary?

Retubing is typically required under the following conditions:

• Tube leakage due to corrosion, erosion, or cracking

• Heavy scaling or fouling inside the tubes

• Loss of thermal efficiency

• Tube wall thinning detected during inspection

• Multiple tube failures, beyond practical repair via plugging

Replacing damaged tubes helps restore heat transfer efficiency and extends the service life of the heat exchanger.

Step-by-Step Retubing Procedure

1. Disassembly

• Drain and isolate the exchanger

• Remove covers, channel heads, and baffles

• Disconnect piping from the shell and tube sides

2. Removal of Old Tubes

• Cut or pull out damaged tubes

• Break mechanical expansion or weld joints if necessary

• Clean and inspect tube sheet holes for reuse

3. Preparation of New Tubes

• Cut new tubes to required length

• Deburr and clean ends

• Perform pre-installation surface treatment (e.g., pickling or passivation)

4. Tube Insertion

• Carefully insert new tubes into the tube sheet

• Maintain correct tube projection and alignment

5. Tube Expansion or Welding

• Mechanical expansion (rolling) to create a tight seal

• Or welding the tube-to-tube sheet joints for high-pressure or critical applications

• Ensure strong, leak-free connections

6. Hydrostatic Testing

• Pressurize the unit with water

• Inspect for leaks and structural integrity

• Perform non-destructive testing (NDT) if required

7. Reassembly

• Reinstall channel heads, gaskets, and covers

• Reconnect piping and restore the system to operation

• Document all procedures and test results

Quality and Safety Considerations

• Follow ASME, TEMA, or customer-specified standards

• Use certified materials that match original specifications

• Perform NDT methods like PT (penetrant testing) or RT (radiographic testing) for weld inspection

• Keep records for traceability and compliance

Benefits of Professional Retubing Services

• Restore heat exchanger performance to near-original levels

• Extend the overall lifespan of your equipment

• Minimize downtime and reduce operational risks

• Improve plant energy efficiency

Conclusion

Heat exchanger tube replacement is a critical maintenance task that requires precision, expertise, and compliance with industry standards. Whether you need partial retubing or full replacement, choosing an experienced service provider can help ensure optimal performance and safety.

If you are looking for professional shell and tube heat exchanger retubing services, feel free to contact us. We offer customized solutions, high-quality materials, and fast turnaround to minimize your downtime.