Client: Synthite Ltd
The Brief
Synthite Ltd is a chemical manufacturer based in Wales. We were contacted to resolve an issue with boiler tubes, which were found to be extensively cracked within the combustion chamber.
The Solution
Cracked tubes inside combustion chambers need to be addressed ASAP, as they can lead to secondary damage to other components, as well as release carbon monoxide. We reviewed the damage and understood the job at hand – a full boiler retubing repair.
Work Completed
- To safely remove the tubes without compromising the surrounding material, we carried out a trepanning technique using specialist J-prep tooling.
- Following tube removal, both the front and rear tube plates were subjected to full magnetic particle inspection (MPI), a non-destructive testing (NDT) method to confirm no cracking or defects remained before retubing the boiler. A third-party PNC Level 2 NDT technician followed this critical step to ensure long-term integrity and compliance.
- New tubes were then installed, welded and expanded.
- The NDT technician carried out post-weld NDT to confirm that all work was acceptable to the industry standards.
The Finished Project
By retubing a boiler using controlled trepanning techniques, third-party PCN Level 2 NDT inspections and precision coded welding and tube expansion, DK Welding Services Ltd helped restore the combustion chamber to safe, compliant and efficient operating conditions.
Our end-to-end approach, from careful tube removal and detailed inspection through to installation, welding and final NDT verification, ensured the integrity of the pressure components while minimising risk and downtime for the client’s critical plant equipment.
