In large industrial facilities—like chemical plants and refineries—equipment often uses bundles of tubes to transfer heat between fluids. When one of these tubes gets damaged, it’s crucial to replace it. However, replacing a tube in this tightly packed system is risky, time-consuming, and can damage surrounding parts. The traditional workaround is to “plug” the damaged tube instead of replacing it, but this reduces performance and increases strain on the remaining tubes.
The
Innovation
This invention introduces a smarter, safer method to fully replace damaged tubes in heat exchangers without compromising the equipment. It allows technicians to remove a faulty tube and slide in a new one—even when space is tight and parts are misaligned. A temporary connection is made between the old and new tube, using a strong weld. As the new tube is pushed in, the damaged one is pulled out.
What Makes
It New
Unlike previous methods that use fragile or incomplete connections, this approach uses a full, strong, butt-to-butt weld between the new and old tube, ensuring a robust link. It avoids breaking or bending during the process, and the new tube is inserted as a single solid piece—without any weak welded sections inside.
Tangible Benefits
- Faster and safer maintenance
- No need for bulky or special tools
- Keeps system performance high
- Prevents overload on the remaining tubes
Broader
Impact
This method can improve uptime and reduce maintenance costs in critical infrastructure like power plants, chemical reactors, and hydrogen production units. It promotes safety, sustainability, and efficient use of industrial resources.