Gulf Engineering & Contracting Services (Pvt) Ltd. is your trusted partner in executing highly specialized services in boiler pressure parts fabrication and replacement, including water wall tubes, economizers, super heaters, and down comers, complete coils replacement & water wall panel replacement. With a seasoned team of certified welders, engineers, and QA/QC personnel, we ensure minimal downtime and maximum efficiency for your thermal and power plant assets.
ABOUT US
Boiler Pressure Parts & Water Wall Tubes Replacement
Boiler Tubes Replacement
Scope of Services
✅ Removal of old or damaged tubes
✅ Fabrication and supply of replacement tubes as per ASME/BS standards
✅ Tube finning, bending, and rolling
✅ Cutting and edge preparation of pressure parts
✅ Welding of new tubes with full compliance to WPS & PQR
✅ Replacement of headers, bends, and stub tubes
✅ Post Weld Heat Treatment (PWHT) as required
✅ 100% Radiographic Testing (RT) / Ultrasonic Testing (UT)
✅ Hydraulic testing up to design pressure or as specified
✅ Surface preparation and painting/coating of pressure parts
✅ Reinstallation of insulation and refractory as applicable
Complete Pressure Parts Coil Replacement
Gulf E&C provides end-to-end solutions for the complete replacement of boiler pressure parts coils, including economizer coils, superheater coils, and reheater coils. We undertake precise fabrication, bending, and welding of coils according to original equipment manufacturer (OEM) specifications and international standards.
- Design verification and material identification of existing coils
- On-site or workshop-based coil fabrication using CNC bending machines
- Header to coil welding with ASME qualified procedures
- Installation of spacer bars and supports for alignment
Water Wall Tube Panel Replacement
Our team specializes in the full replacement of water wall tube panels, ensuring thermal performance and boiler integrity are restored to optimum levels. We utilize advanced tools for panel cutting, replacement, and welding even in restricted and high-temperature zones.
- Dismantling and removal of damaged tube panels
- Bending and preparation of new tube panels as per boiler drawings
- Welding of membrane
- Welding of stub tubes and panel connections using GTAW/SMAW processes
- Installation of tube shields and anti-wear pads if required
- Weld quality inspection (RT/UT/MPI) and PWHT where applicable
- Alignment and leveling checks to avoid tube stress
- Hydrostatic pressure testing post-replacement
Our engineers conduct a thorough site assessment, followed by detailed planning using the latest CAD tools and industry standards (ASME Sec I, Sec VIII, TEMA, and IBR codes where applicable). We also assist in material selection and procurement through approved global vendors.
Engineering Excellence
Materials Expertise
- SA 192 / SA 210 Gr A1, C
- SA 213 T11 / T22 / T91
- DIN 17175 13CrMo44, 10CrMo910
- P1 / P5 / P9 / P11 / P22 / P91
- Customized metallurgical solutions for high-temp and corrosive environments
Quality Assurance
- Welder qualification per ASME Sec IX
- WPS, PQR, and WPQ documentation
- Non-Destructive Testing (RT, PT, MPI, UT)
- Dimensional checks, weld map preparation
- Third-party inspections (if required)
Safety & Project Execution
Safety is embedded into every activity. Our HSE policies ensure compliance with all site safety standards, PPE usage, and hazard controls. We plan our replacement and fabrication schedules with minimum plant shutdown periods, ensuring fast-track completion without compromising on quality or safety.
Industries Served
- Thermal Power Plants
- Sugar Mills & Process Industries
- Chemical & Fertilizer Plants
- Cement and Pulp Industries
- Refineries and Petrochemical Plants