Industrial boiler retubing of firetube and watertube boilers is still a common repair, even with the advances in water treatment equipment and monitoring. The build up of scale, often down to the water in the area, causes tube corrosion and pitting which eventually leads to tube repairs being necessary. Tube replacements helps extend the life of a boiler and increase its efficiency.

McEwen Boilermaker's team are highly skilled in undertaking tube repairs and replacements, often working around the clock to ensure the boiler is not out of action for a long period of time.  All our engineers hold the relevant certification required ,such as confined space entry and coded welding qualifications. We supply all the relevant documentation in advance of the repair commencing, which includes Risk and Method Statements, Material Certification Certificates and Weld Procedures.

Industrial Boiler Retubing Procedures

Boiler tubes must endure extreme variations of temperature and pressure and are prone to scale build up and cracking over long periods. Most boiler retubing projects can be completed by our skilled engineers on-site. Typically, the procedure is as follows:

• Boiler Inspection – Qualified inspectors conduct visual inspections and Non-Destructive Testing (NDT) to identify areas of boiler tube pitting and cracking. This detailed examination aims to determine the extent of degradation and its underlying causes.
• Tube Extraction – Damaged boiler tubes are removed from their housing for replacement or repair. If a tube end has repairable faults that can be safely restored to full operation, approved repair methods are utilised.
• Tube Installation – New boiler tubes are purchased and then prepared in our workshop according to specifications and standards. Tubeplates, which connect the tubes between the combustion chamber and smokebox, are cleaned, and repaired in readiness for the fitting of the new tubes. The new smoke tubes are then installed into the boiler and are power expanded. They along with stay tubes are seal welded by our in-house coded welders.
• Boiler Testing & Accreditation – Certified inspectors oversee the repair process, conducting several staged inspections and tests from both a visual and NDT standpoint. These tests culminate with a final hydrostatic test, normally to 1 ½ times the design pressure of the boiler or vessel. We supply all the relevant documentation in advance of the repair commencing, which includes Risk and Method Statements, Material Certification Certificates and Weld Procedures.

The Long-Term Benefits of Retubing

Retubing offers benefits beyond the immediate need for repair. By revitalising the boiler’s core components, retubing enhances operational reliability, safety, and efficiency. The key benefits of retubing include:

• Improved Performance: Retubing restores the boiler to its optimal operating condition, ensuring consistent and reliable performance over time. By replacing worn or damaged tubes, heat transfer efficiency is maximised, leading to better steam generation and energy utilisation.
• Enhanced Safety: Worn or damaged tubes pose serious safety risks, including leaks, ruptures, and potential boiler failures. Retubing eliminates these risks by replacing compromised tubes with new, structurally sound ones, ensuring a safer working environment for personnel and equipment.
• Energy Efficiency: Optimal heat transfer achieved through retubing enhances energy efficiency, reducing fuel consumption and operating costs. Improved efficiency also contributes to environmental sustainability by lowering emissions and resource usage.
• Regulatory Compliance: Retubing ensures that the boiler meets or exceeds regulatory standards and safety requirements. Compliance with industry regulations not only avoids penalties but also demonstrates a commitment to maintaining high safety and environmental standards.
• Cost Savings: While retubing involves upfront investment, the long-term cost savings outweigh the initial expenses. Reduced energy consumption, minimized downtime, and extended equipment lifespan contribute to significant cost savings over the boiler's lifecycle.