Reformer Tube Replacement

August 5, 2026

  • Client: HMEL Mittal Energy Limited
  • Duration: 06 Days
  • Scope: Reformer Tube replacement as per SOW in Reformer Train-1 (511-F-101) during TA'25/26 at HMEL
  • Challenges:
  • The tubes were lodged inside the heater sleeves due to process expansion, making its removal challenging without risking damage
  • Limited Crane Access: Constraints in handling due to restricted crane movement.
  • Ensuring precise fit-up and alignment
  • Execution in a structurally complex environment in view of poor joint access for cutting and welding.
  • Solution & Implementation:
  • Structural Adjustments: Temporary support and spool locking arrangements to facilitate easy access for execution
  • The sleeves securing the expanded tubes were cut to facilitate tube removal.
  • Highly qualified welder and grinders were selected to ensure proper execution
  • Outcome:

Despite unforeseen challenges, the project was successfully completed within the timeline by adapting innovative tools and modifying structures.

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