Heating Bundle Maintenance and Repair
britannia:jahco provides tube bundle maintenance and repair services for shell and tube heat exchangers. Services cover eddy current testing, tube plugging, partial and full re-tubing, chemical and hydroblast cleaning, and complete replacement bundle fabrication.
Key Highlights
Eddy Current Testing and Bundle Assessment
britannia:jahco uses eddy current testing (ECT) to assess tube wall condition without removing individual tubes. ECT detects wall thinning, pitting, and cracking and produces a tube-by-tube condition map that guides the repair or replacement decision.
Tube Plugging and Partial Re-tubing
Individual leaking or degraded tubes can be plugged and left in service. Where plugging is not practical or the tube count exceeds the acceptable limit, partial or full re-tubing restores bundle integrity without replacing the shell.
Full Bundle Replacement
britannia:jahco fabricates replacement tube bundles to client-supplied drawings or to drawings prepared from the original unit. Replacement bundles are available in the same tube material and configuration, or upgraded to a different alloy or tube gauge where the service conditions have changed.
Chemical and Hydroblast Cleaning
Fouled tube bundles are cleaned by high-pressure hydroblasting or chemical methods depending on the deposit type and tube material. Cleaning restores heat transfer area and reduces pressure drop across the bundle
Code-Compliant Repair and Documentation
All repair and replacement work is carried out under ISO 9001 quality processes certified through LRQA. All repairs are hydrostatically pressure tested in accordance with AS4037. A copy of the hydrostatic test report is supplied with every job.
Drawings for Non-Standard Bundles
Where no original drawings exist, britannia:jahco measures and draws the bundle before work begins. This is common for older exchangers where documentation has been lost.
Why Choose Our Tube Bundle Maintenance Services?
Tube bundle maintenance is most effective when the repair scope is based on measured condition data rather than visual inspection alone. Eddy current testing gives a tube-by-tube wall thickness map before any decision is made, which avoids unnecessary full replacements and identifies tubes that need attention before they leak.
Britannia Jahco assesses each bundle against the original design specification and the current service requirements. Where the service has changed, such as higher fouling rates, a different process fluid, or a revised flow rate – the replacement bundle – can be redesigned to suit the new conditions rather than simply duplicating the original. Fabrication is in-house at Dandenong South, which gives direct control over tube material, wall thickness, and tube-to-tubesheet joint quality.
Signs You Need Heating Bundle Maintenance
Consider our services if you need:
Our Process
Bundle Removal and Inspection
The bundle is removed from the shell and visually inspected for fouling, corrosion, mechanical damage, and tube-end condition before testing begins.
Eddy Current Testing and Condition Assessment
ECT is carried out on every tube to produce a tube-by-tube wall condition map. Results are assessed against the original wall thickness and the minimum acceptable wall for the design pressure.
Repair or Replacement Decision
The assessment report sets out the condition of the bundle, the number and location of defective tubes, and the recommended action: cleaning, tube plugging, partial re-tubing, full re-tubing, or replacement bundle fabrication.
Repair, Re-tubing, or Replacement Fabrication
Approved work is carried out to AS 3992, AS 1554, and TEMA standards. Replacement bundles are fabricated in-house. Tube-to-tubesheet joints are roller-expanded or welded to the specification required by the design code.
Hydrostatic Testing and Performance Verification
Hydrostatic pressure testing to AS 4037 confirms pressure envelope integrity after repair or replacement. Shell-side and tube-side circuits are tested separately before reassembly.
As-Left Documentation and Condition Report
Every job is completed with an as-left condition report, ECT data, hydrostatic test records, and weld records where applicable. This documentation supports in-service inspection programs under AS/NZS 3788 and API 510.
Partner with britannia:jahco and experience the difference in performance, transparency, and client service.
Why Choose britannia:jahco?
britannia:jahco combines tube bundle assessment, in-house fabrication, and code-compliant testing in one workshop. We hold ISO 9001 certification through LRQA and have been fabricating and repairing shell and tube heat exchanger bundles for decades.
Replacement bundles are fabricated to the same standards as new equipment: tube materials carry CMTRs, welding is under qualified WPS and PQR records, and every bundle is hydrostatic-tested before dispatch. Where the original drawings are unavailable, we measure and draw the bundle before fabrication begins.
Safety in Our Heating Maintenance Services
All tube bundle repair and replacement work is carried out under a documented quality plan. Hydrostatic testing at the design test pressure confirms pressure envelope integrity before the bundle re-enters service. Where the exchanger is registered under AS 1210, repair work is documented to the standard required for the registration record. Weld repairs are carried out under qualified procedures and inspected by NDE methods appropriate to the joint type and service.
Industries We Serve
The britannia:jahco team goes where others cannot follow. From custom-engineered heat exchangers to pressure vessels, and air receiver solutions we design to global standards using cutting-edge software to exceed expectations.
Confidence built. Peace of mind ensured.
Ready to Discuss Your Project?
We are experts in design, development, and delivery, and work with diverse markets. britannia:jahco delivers. Your requirements. On time. Every time. Visit our local factory. See it built. Feel at home.
We look forward to learning how we can help you.
