Reformer Tubes Replacement
Products
Reformer Tubes Replacement
Reformer tube replacement is a highly specialized activity that ensures the safe and efficient operation of steam reformers used in hydrogen, ammonia, and methanol production plants. Over time, reformer tubes are subjected to extreme thermal stresses, carburization, and creep, which can lead to material degradation and reduced performance.
Metalok Industries provides complete reformer tube replacement services, including inspection, removal, installation, alignment, and welding of catalyst tubes and pigtails. Our experienced technicians use precision tools, lifting equipment, and thermal alignment techniques to ensure proper tube fit-up and dimensional accuracy during replacement.
All work is performed in accordance with ASME, API, and OEM standards, ensuring uniform tube installation, controlled welding parameters, and verified integrity through NDT and hydrotesting. Metalok’s proven expertise guarantees minimal downtime, enhanced reliability, and extended service life of reformer units in critical process plants.
- Inspect reformer tubes for signs of creep, bulging, or cracking.
- Isolate and depressurize the reformer safely before starting work.
- Remove old or damaged tubes using specialized lifting and extraction tools.
- Clean and inspect tube sheets, ferrules, and tube supports.
- Align and install new tubes with precise spacing and orientation.
- Perform welding as per qualified WPS/PQR and maintain controlled preheat/interpass temperature.
- Conduct non-destructive testing (RT, PT, or UT) on all weld joints.
- Install pigtails, supports, and insulation as per design requirements.
- Perform hydrostatic or pneumatic pressure testing to confirm integrity.
- Document all inspection, welding, and testing results for certification and handover.