Boiler Retubing
Leaders in industrial boiler retubing in Venezuela. Restore the integrity and efficiency of your boiler to ASME standards.
In short: Industrial boiler retubing is the most critical major maintenance intervention that can be performed on a boiler: it involves extracting all or part of the deteriorated tubes and replacing them with new tubes certified to ASME standards. INCALCA has been performing fire-tube and water-tube boiler retubings in Venezuela for 36 years, serving the oil, petrochemical, sugar, food and energy sectors. Each retubing is performed under ASME Code with R Stamp, with welders qualified under ASME Section IX, ASTM certified material with full traceability, and documented hydrostatic testing.
Industrial boiler retubing is the most critical major maintenance intervention that can be performed on a boiler: it involves extracting all or part of the deteriorated tubes and replacing them with new tubes certified to ASME standards. INCALCA has been performing fire-tube and water-tube boiler retubings in Venezuela for 36 years, serving the oil, petrochemical, sugar, food and energy sectors. Each retubing is performed under ASME Code with R Stamp, with welders qualified under ASME Section IX, ASTM certified material with full traceability, and documented hydrostatic testing.
Inspection and Pre-Retubing Diagnosis
Every retubing intervention begins with a comprehensive technical inspection to determine the actual scope of work.
- Visual inspection of the firebox and tube bundle
- Tube thickness measurement by ultrasound (UT)
- Liquid penetrant testing (LP) on welds and tubesheets
- Tubesheet evaluation: wear, corrosion, oval holes
- Scope determination: total or partial retubing
- Diagnostic report with recommendations
Tube Extraction and Preparation
Safe extraction of the old tubes without damaging the tubesheet is a critical skill. INCALCA uses specialized tools developed over 36 years.
- Tube end cutting with saw or tube cutter
- Extraction with Aquadyne hydraulic extractor or mechanical extractor
- Tubesheet hole cleaning with special brushes and grinders
- Circularity and diameter check of tubesheet holes
- Repair of damaged holes by plugging or welding and re-machining
- Interior shell and flue gas chamber cleaning
Installation of New Certified Tubes
New tubes are specified, supplied and installed in accordance with the boiler's original construction code and ASME R stamp requirements.
- Tubes ASTM SA-179, SA-192, SA-210 per boiler specification
- MTR origin certificates verified by INCALCA
- Manual or assisted insertion of new tubes into the bundle
- Mechanical expansion (rolling) with calibrated tools
- Tube-to-tubesheet seal weld under ASME Section IX
- Roll depth and torque control
Hydrostatic Test and ASME Documentation
The final step of every ASME R stamp retubing is the hydrostatic test witnessed by an Authorized Inspector (AI).
- Hydrostatic test at 1.5x working pressure per ASME
- Authorized Inspector (AI) witness and signature
- Immediate repair of any leaks detected during testing
- National Board R-1 form completion
- Boiler data plate update
- Complete quality dossier delivered to client
Special Technical Capabilities
INCALCA can perform retubings in conditions that exceed the capabilities of most Venezuelan industrial maintenance companies.
- Retubing of large boilers: more than 1,000 tubes
- 24/7 operation to meet plant shutdown windows
- Cranes up to 80 ton for heavy bundle handling
- Confined space work with certified personnel
- Integrated service: material procurement + installation + testing
- Operations in oil, petrochemical, sugar and energy industries
Need this service?
Contact us to request a quote for our specialized services.