Retubing Services: Minimising Downtime for Shell & Tube and Air Cooled Heat Exchangers

Heat exchanger tube failures are a leading cause of unplanned shutdowns in process industries. When tubes fail in your shell and tube process exchanger or your air cooled cooling unit, operators face immediate pressure to restore operations.

The temptation is to rush toward complete unit replacement. But replacement isn't always the fastest or most economical solution.

Retubing offers a proven alternative that can return your heat exchanger to full performance in a fraction of the time, without the logistical complexity of removing and replacing large equipment.

At Spiro-Gills Thermal Products Ltd, we specialise in on-site retubing services for both shell and tube and air cooled heat exchangers. Our field service teams have restored critical units across oil refineries, petrochemical plants, and power generation facilities — often completing repairs while production continues.

Two Types, One Solution

Shell and Tube Heat Exchangers

Shell and tube units use plain tubes secured in tube sheets at each end of the cylindrical shell. The tube sheets separate shell-side and tube-side fluids. When tubes corrode, erode, or crack, retubing involves extracting damaged tubes and installing new ones to the tube sheets.

Air Cooled Heat Exchangers

Air cooled units use applied finned tubes that terminate at header plates (also called headers or tube sheets in some contexts). These are the finned tube bundles you see in cooling towers and remote process installations. When tubes fail, retubing replaces the finned tubes within the existing header and frame structure.

Both types can be retubed on-site — avoiding the need for complete unit replacement.

The Cost of Unplanned Shutdown

When a heat exchanger fails unexpectedly, costs accumulate rapidly:

• Lost production revenue
• Missed delivery commitments
• Emergency contractor premiums
• Rush shipping for replacement parts
• Demurrage for delayed vessels or shipments
• Reputational damage with customers

For critical path equipment, every hour of downtime has measurable financial impact. The priority is clear: restore operation as quickly as possible.

Why Retubing Beat Replacement for Emergency Repairs

When time is critical, retubing offers distinct advantages:

No Transport Logistics
Removing a large heat exchanger requires craneage, transport arrangements, and coordination with multiple contractors. Retubing eliminates this complexity — the unit stays in place.

Faster Turnaround
A complete retubing operation typically takes 3-7 days on-site. Replacement requires procurement of a new unit (weeks or months), removal, installation, and recommissioning.

Lower Cost
Retubing typically costs 30-50% less than equivalent replacement — crucial when emergency repairs strain maintenance budgets.

Material Upgrades
Retubing provides opportunity to upgrade tube materials for improved corrosion resistance. Replacing carbon steel with stainless steel, duplex stainless steel, or titanium can significantly extend service life.

On-Site Retubing: We Bring The Workshop To You

Spiro-Gills provides comprehensive retubing services at your facility for both shell and tube and air cooled units. Our mobile service teams perform complete retubing operations without removing your heat exchanger.

Shell & Tube Retubing

• Full retubing — complete replacement of all tubes
• Partial retubing — targeted replacement of damaged tubes
• Tube sheet repair — welding and remachining damaged ligaments
• Expansion and welding — tube-to-tube sheet joining to specification

Air Cooled Heat Exchanger Retubing

• Applied fin tube replacement
• Header plate repair and replacement
• Bundle recoring
• Structural frame repairs

Emergency Breakdown Response

Our field teams are available 24/7 for critical situations. We understand that production cannot wait — and we mobilise accordingly.

Pressure Testing

Comprehensive hydrostatic and pneumatic testing is performed on-site to verify integrity. Testing is conducted in accordance with ASME, ISO, or client-specified standards.

Certification

Full documentation and certification is provided, including material certificates, welding procedure specifications, and test reports.

The Retubing Process

A professional retubing operation follows rigorous engineering procedures tailored to the heat exchanger type:

Shell & Tube Process:

1. Inspection and assessment — verify retubing viability
2. Tube extraction — hydraulic removal of damaged tubes
3. Tube sheet preparation — cleaning and repair
4. Tube installation — precision fitting of replacement tubes
5. Tube-to-tube sheet joining — expansion, welding, or both
6. Testing and certification — hydrostatic testing and documentation

Air Cooled Process:

1. Inspection and assessment — evaluate tube and header condition
2. Finned tube removal — extract damaged applied fin tubes
3. Header plate preparation — clean and inspect headers
4. Finned tube installation — fit replacement applied fin tubes
5. Joint integrity — verify tube-to-header seals
6. Testing and certification — pressure testing and documentation

Capabilities for the Largest Units

Spiro-Gills handles heat exchanger bundles of all sizes:

• Comprehensive rigging and lifting equipment
• Complete lifting plans and method statements
• Full project management and coordination
• Experienced teams for complex installations

No bundle is too large for our field service teams.

Material Options

We work with the full range of heat exchanger tube materials:

• CARBON STEEL — Cost-effective for moderate environments
• STAINLESS STEEL — Corrosion resistance for chemical applications
• DUPLEX STAINLESS STEEL — Superior strength and corrosion resistance
• COPPER ALLOYS — Excellent thermal conductivity
• TITANIUM — Ultimate corrosion resistance for seawater
• NICKEL ALLOYS — High-temperature and corrosive service

Material selection is based on corrosion resistance, thermal requirements, and operating conditions.

Quality Assurance

Spiro-Gills operates under rigorous quality management:

• BS EN ISO 9001:2015 certified
• ASME U Certification for pressure vessel work
• Achilles UVDB certified supplier

All work is performed to ASME Boiler and Pressure Vessel Code Section VIII, EN 13445, or client-specified standards.

Industries We Serve

Our retubing services support critical equipment across:

• Oil refineries — crude preheaters, inter-stage coolers, air cooled condensers
• Petrochemical plants — process exchangers, cooling towers
• Power generation — feedwater heaters, turbine lube oil coolers, cooling systems
• Chemical processing — reactor coolers, distillation condensers
• Marine and offshore — seawater coolers, jacket water coolers

Book Your Retubing Work Today

Don't wait for the next failure. Proactive planning with Spiro-Gills ensures rapid response when you need it most.

📞 +44 (0) 1785 254 554
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