Heat Exchanger Retubing
Specialists in shell-and-tube heat exchanger retubing under TEMA and ASME standards in Venezuela.
In short: Heat exchanger retubing is one of the most in-demand services in the Venezuelan process industry. INCALCA has retubed heat exchangers with more than 3,000 tubes in a single intervention, working on a 24-hour continuous basis to meet the client's maintenance window. We master the complete process: bundle extraction with Aquadyne extractor, tubesheet inspection and recovery, ASTM certified tube installation, precision rolling, ASME Section IX tube-to-tubesheet seal welding and certification hydrostatic testing.
Heat exchanger retubing is one of the most in-demand services in the Venezuelan process industry. INCALCA has retubed heat exchangers with more than 3,000 tubes in a single intervention, working on a 24-hour continuous basis to meet the client's maintenance window. We master the complete process: bundle extraction with Aquadyne extractor, tubesheet inspection and recovery, ASTM certified tube installation, precision rolling, ASME Section IX tube-to-tubesheet seal welding and certification hydrostatic testing.
Bundle Extraction
INCALCA uses the Aquadyne hydraulic extractor for uniform hydraulic pressure extraction of the complete bundle without damaging tubes, shell or baffles.
- Disassembly of heads, flanges and channel cover
- Bundle extraction with Aquadyne hydraulic extractor
- Bundle transport to work area (shop or field zone)
- Shell cleaning with high-pressure hydrojet
- Shell inspection: corrosion, erosion, deformations
Bundle Inspection and Repair
INCALCA performs a complete inspection of all bundle components to determine which can be reused and which must be replaced.
- Individual tube inspection: UT thickness, LP on ends
- Tubesheet check: holes, corrosion, flatness
- Baffle and tie rod inspection
- Tubesheet repair: plugging of damaged holes or machining
- Baffle and tie rod replacement if damaged
- Total or partial retubing decision with client
Tube Installation and Rolling
New tubes are installed with the same or superior ASTM specification to the original design, and mechanically expanded with calibrated tools.
- Tubes ASTM A-179, SA-179, A-214 or special specifications
- MTR certificates verified by INCALCA prior to installation
- Sequential tube insertion into tubesheets
- Precision rolling with torque and roll depth control
- TIG (GTAW) seal weld under ASME Section IX procedure
- Liquid penetrant verification of the joint
Hydrostatic Test and Delivery
The hydrostatic test verifies the tightness of all tube-to-tubesheet joints and the shell. INCALCA delivers the equipment with a complete quality dossier.
- Hydrostatic test of tube side and shell side separately
- Test pressure per TEMA and client specification
- Verification of zero leaks at tube-tubesheet joints and gaskets
- Thermal insulation reinstallation if applicable
- Quality dossier: MTR, procedures, rolling and test records
Need this service?
Contact us to request a quote for our specialized services.