Leak Repair
Diagnosis and repair of leaks in boilers, heat exchangers and pressure vessels under ASME code in Venezuela.
In short: A leak in a boiler or heat exchanger is an operational emergency that can force an unplanned plant shutdown with enormous economic losses. INCALCA responds to these emergencies 24/7 with the experience accumulated over 36 years resolving all types of leaks: tube-to-tubesheet leaks, boiler tube bundle leaks, shell and dome leaks, and flange leaks. Precise diagnosis is the first step: INCALCA identifies the origin and cause of the leak before proposing a solution, to ensure the repair is permanent, not just a temporary patch.
A leak in a boiler or heat exchanger is an operational emergency that can force an unplanned plant shutdown with enormous economic losses. INCALCA responds to these emergencies 24/7 with the experience accumulated over 36 years resolving all types of leaks: tube-to-tubesheet leaks, boiler tube bundle leaks, shell and dome leaks, and flange leaks. Precise diagnosis is the first step: INCALCA identifies the origin and cause of the leak before proposing a solution, to ensure the repair is permanent, not just a temporary patch.
Leak Types and Diagnosis
Each type of leak has a different cause, damage mechanism and technical solution. INCALCA has experience with all types of leaks that occur in industrial pressure equipment.
- Tube-to-tubesheet leaks: due to failed mechanical expansion or seal weld
- Tube body leaks: corrosion, erosion, thermal fatigue or pitting
- Exchanger shell leaks: external corrosion or mechanical damage
- Flange leaks: gasket failure, misalignment or flange deformation
- Boiler shell or dome weld leaks
- Nitrogen test or bubble test for precise leak location
Tube-to-Tubesheet Leak Repair
Tube-to-tubesheet leaks are the most frequent in in-service heat exchangers. INCALCA resolves them by tube plugging or by replacing the affected tube.
- Tube plugging: installation of TEMA certified plugs in leaking tubes
- Re-rolling of leaking tube if tubesheet is in good condition
- Seal weld repair: removal, cleaning and TIG re-welding
- Tube replacement if damage is extensive (perforation, corrosion)
- Inspection of adjacent tubes to detect similar latent damage
Shell and Boiler Dome Leak Repair
Shell or dome leaks in a boiler require welding under ASME R stamp with National Board Authorized Inspector supervision.
- Removal of corrosion-damaged material by grinding or air-arc
- Damage scope evaluation by UT thickness and LP
- Repair welding with qualified WPS under ASME Section IX
- Post-weld heat treatment (PWHT) if required
- Verification hydrostatic test with Authorized Inspector (AI) present
- NBIC R-1 form and boiler record update
24/7 Emergency Response
Leaks in critical process equipment cannot wait. INCALCA is available 24/7 for industrial emergencies.
- Immediate response: teams available 24 hours a day, 7 days a week
- Deployment of ASME welders, detection equipment and materials within hours
- Coordination with plant safety team for work permit (PTW)
- Emergency repair under ASME code with complete documentation
- Continuous work until equipment operation is restored
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