At Projectile, we specialize in high-quality heat exchanger retubing services for clients across a variety of industries. Whether you are operating in fossil or nuclear power generation, petrochemical processing, HVAC, or manufacturing, our team brings the knowledge and field-proven experience needed to deliver fast, efficient, and reliable retubing services. We handle both planned outages and emergency repairs, with the flexibility to work onsite or at our dedicated facility in Pennsylvania.
Why Retubing is Essential?
Over time, heat exchanger tubes degrade due to corrosion, scaling, pitting, thermal fatigue, and normal wear. These issues reduce system efficiency, drive up energy costs, and increase the risk of unexpected shutdowns. When these problems arise, plant managers often face a critical decision: retube the existing unit or replace it entirely.
In most cases, retubing is the smarter and more cost-effective choice. When the tubes are damaged, it is often the case that the heat exchanger tube sheets and support plates are still in good condition. Tube sheets and support plates are very expensive components and it typically makes financial sense to recycle these parts and only replace the tubes. Heat exchangers are typically placed in challenging areas where it’s difficult to remove the entire unit for a retube. This is another reason why it may make sense to keep the skeleton of the heat exchanger together and only replace the tubes. By replacing only the compromised tubes and preserving the rest of the exchanger, retubing can restore the unit to optimal working condition while avoiding the cost and lead time of purchasing a new exchanger. This approach not only improves performance and energy efficiency but also extends the service life of your equipment.
Our Retubing Process
Whether you need onsite support at your facility or prefer to ship your bundle to our shop in Pennsylvania, Projectile is fully equipped to manage your retubing project from start to finish. Many clients choose the offsite option for its convenience, controlled environment, and simplified logistics. Either way, we maintain high quality standards and keep you informed at every step of the process.
Here’s a breakdown of our proven retubing workflow:
Our technicians start with a detailed evaluation of your exchanger, including tube condition, wear patterns, and tube sheet integrity. This helps determine the scope of work and identify any additional issues early.
Crews carefully extract damaged tubes using industry-standard removal techniques to avoid damaging the tube sheet or surrounding components.
Then we clean, resurface, and prep the tube sheet to ensure a perfect seal with the new tubes. Proper tube sheet prep is essential for long-term reliability.
Next, we install high-quality replacement tubes—matched to your material and design specifications—using precision alignment to avoid deformation or misfit.
Tubes are mechanically expanded into the sheet to form a tight, leak-free seal. Depending on your design, we also perform rolling or welding as required. Projectile can also install TEMA grooves before tube expansion for extra sealing support.
After installation, the unit undergoes hydrostatic and/or pneumatic testing, along with visual inspections and quality control checks to verify design specifications and integrity of the heat exchanger.
Industries We Serve
Our heat exchanger retubing services are trusted across a wide range of industries:
- Power Generation: Fossil, nuclear, and hydroelectric plants
- Oil & Gas: Refineries and upstream/downstream operations
- Chemical Processing: Industrial chemical plants and terminals
- Food & Beverage: Sanitary heat exchangers and CIP systems
- Pulp & Paper: High-temp exchangers and black liquor heaters
- HVAC and Refrigeration: Chillers, evaporators, and condensers
Projectile only uses high-grade materials sourced from trusted suppliers. We match tube material to your application and environment to ensure long-term reliability. Options include:
- Stainless Steel
- Copper-Nickel
- Titanium
- Carbon Steel
- Exotic Alloys
We also handle a range of tube configurations, such as:
- Straight Tubes
- U-Tubes
- Finned Tubes
Whether your system requires a partial retube or a full bundle rebuild, we’re ready to deliver the solution you need.
Retubing offers several advantages over replacing the entire heat exchanger:
- Cost Savings: Reusing the shell, baffles, and tube sheet cuts material and manufacturing costs.
- Faster Turnaround: Retubing projects can be completed in days, not weeks or months.
- Less Disruption: There’s no need to re-pipe or reconfigure existing systems.
- Environmental Benefit: Retubing reduces scrap and waste compared to a full replacement.
In many situations, Retubing makes the most sense when the exchanger is still structurally sound but suffering from tube degradation. By replacing only the damaged tubes, you preserve the majority of the system while restoring function and performance.
Don’t wait for a system failure to take action. If you notice any of the following issues, it may be time to consider retubing:
- Decline in system efficiency or throughput
- Frequent leaks
- High percentage of tubes that are plugged – typically a heat exchanger should not have more than 10% of the total tubes plugged
- Tube-side fouling, corrosion, or scale buildup
- Rising operating costs or energy consumption
- Sudden outages or system downtime
- Pressure test failures or visible damage
Heat exchanger problems often happen when you least expect them. That’s why Projectile offers emergency retubing services to get your equipment back online quickly. Whether it’s during a planned outage, a last-minute maintenance window, or a weekend failure, we have mobile crews and tools ready to respond 24/7.
Why Choose Projectile?
Request a Quote or Consultation
Ready to restore your heat exchanger’s performance and extend its service life? Contact Projectile today for a free consultation or detailed project quote. Our team is here to answer your questions, review your system needs, and help you determine the best path forward.
Let’s keep your system running efficiently—with less downtime, more reliability, and a partner you can trust.