How to Retube Exide Tubes: 4-Step Process Explained
X-ID tubes have transformed boiler efficiency — but repairing them requires a different process than standard tubes. Here's the exact four-step method used by professionals.
Ritchie Ware is joined by Stephen Hanley from Thomas Wilson and WARE technician Romie to walk through the correct four-step process for retubing X-ID fire tubes: flattening the ribbing, hydraulic cutting to 3/16 projection, rolling and beading, and final straight roll.
X-ID tubes are now common in high-efficiency fire tube boilers. Without the right technique and tools, techs risk improper seals, cracked welds, or damaged tube sheets — costly mistakes on equipment that's already doing more with less.
WARE uses X-ID tubes in its rental fleet to push boiler capacity from 350 HP up to 1000 HP in a trailer footprint. They stock Thomas Wilson tooling through BoilerWAREhouse and offer repair services directly.
Need X-ID tube repair tools or boiler service support? Visit boilerwarehouse.com or wareinc.com to talk to someone who actually does this work.
Timestamps:
0:00 - Introduction: What Are X-ID Tubes?
0:36 - Guest Intro: Stephen Hanley, Thomas Wilson
1:20 - How Exide Tubes Work and Why They're Efficient
3:04 - Why Standard Retubing Tools Don't Work
3:48 - Overview of the Four-Step Repair Process
5:40 - Step 1: Flatten the Ribbing with a 65 Expander
6:21 - Step 2: Cut Tube to 3/16 Projection
6:52 - Step 3: Roll and Bead with Combination Beading Expander
7:18 - Step 4: Final Straight Roll
7:30 - Recap, Tool Sources, and Wrap-Up
Related search terms:
X-ID tube repair, how to retube a fire tube boiler, boiler retubing steps, Thomas Wilson tube expander, X-ID tube flattening tool, fire tube boiler maintenance, boiler tube beading expander, 3/16 tube projection, SA 178 grade tube, boiler efficiency upgrade
Related Search Q&A:
What is an X-ID tube?
An X-ID tube is an SA 178 electrically resistance-welded fire tube with internal ribbing that creates turbulence in hot gases, increasing boiler efficiency by approximately 25%.
Why can't you use standard tools to retube X-ID tubes?
The internal ribbing on X-ID tubes prevents standard expanders and cutters from seating properly. The ribbing must be flattened first before standard tooling can be used.
What are the four steps to retube an X-ID tube?
Flatten the ribbing with a long-roll expander, cut the tube to 3/16 projection with a hydraulic tube cutter, roll and bead with a combination beading expander, then finish with a straight roll to snug the tube.
Why is 3/16 projection important when cutting boiler tubes?
Too much or too little projection prevents a proper bead from forming, which can lead to leaks or cracks at the tube sheet joint.
Where can I buy Thomas Wilson tube tools?
Thomas Wilson tools are available directly from Thomas Wilson, through authorized resellers worldwide, and through BoilerWAREhouse at boilerwarehouse.com.
Need boiler parts, valves, gaskets, or maintenance supplies? Visit BoilerWAREhouse: https://www.boilerwarehouse.com
Learn more about WARE boiler service, rentals, training, and support: https://www.wareinc.com
Want boiler training? Learn more about Boiler University and boiler operator education through http://www.boileruniversity.com
🔔 Subscribe for weekly boiler tips and deep dive technical content.
👍Like & share to help us elevate the steam industry.
👍If you found this helpful, like, subscribe, and leave your boiler questions in the comments.
© 2026 @wareboilers. All rights reserved. Unauthorized reproduction or distribution of this content is prohibited. Ware Boilers’ videos are intended for promotional purposes only and does not constitute professional advice. Please contact our boiler professionals via https://www.wareinc.com/ with specific questions or repair needs. You should not attempt any boiler repair or modification without first consulting with a licensed contractor and the manufacturer. Ware Boilers does not warrant the accuracy, completeness, or usefulness of information available on this YouTube page. Nothing contained in or provided in any of Ware Boilers’ videos is intended to constitute advice or to serve as a substitute for a licensed contractor’s inspection or manufacturer specifications. Any reliance you place on such information is strictly at your own risk.
Ritchie Ware is joined by Stephen Hanley from Thomas Wilson and WARE technician Romie to walk through the correct four-step process for retubing X-ID fire tubes: flattening the ribbing, hydraulic cutting to 3/16 projection, rolling and beading, and final straight roll.
X-ID tubes are now common in high-efficiency fire tube boilers. Without the right technique and tools, techs risk improper seals, cracked welds, or damaged tube sheets — costly mistakes on equipment that's already doing more with less.
WARE uses X-ID tubes in its rental fleet to push boiler capacity from 350 HP up to 1000 HP in a trailer footprint. They stock Thomas Wilson tooling through BoilerWAREhouse and offer repair services directly.
Need X-ID tube repair tools or boiler service support? Visit boilerwarehouse.com or wareinc.com to talk to someone who actually does this work.
Timestamps:
0:00 - Introduction: What Are X-ID Tubes?
0:36 - Guest Intro: Stephen Hanley, Thomas Wilson
1:20 - How Exide Tubes Work and Why They're Efficient
3:04 - Why Standard Retubing Tools Don't Work
3:48 - Overview of the Four-Step Repair Process
5:40 - Step 1: Flatten the Ribbing with a 65 Expander
6:21 - Step 2: Cut Tube to 3/16 Projection
6:52 - Step 3: Roll and Bead with Combination Beading Expander
7:18 - Step 4: Final Straight Roll
7:30 - Recap, Tool Sources, and Wrap-Up
Related search terms:
X-ID tube repair, how to retube a fire tube boiler, boiler retubing steps, Thomas Wilson tube expander, X-ID tube flattening tool, fire tube boiler maintenance, boiler tube beading expander, 3/16 tube projection, SA 178 grade tube, boiler efficiency upgrade
Related Search Q&A:
What is an X-ID tube?
An X-ID tube is an SA 178 electrically resistance-welded fire tube with internal ribbing that creates turbulence in hot gases, increasing boiler efficiency by approximately 25%.
Why can't you use standard tools to retube X-ID tubes?
The internal ribbing on X-ID tubes prevents standard expanders and cutters from seating properly. The ribbing must be flattened first before standard tooling can be used.
What are the four steps to retube an X-ID tube?
Flatten the ribbing with a long-roll expander, cut the tube to 3/16 projection with a hydraulic tube cutter, roll and bead with a combination beading expander, then finish with a straight roll to snug the tube.
Why is 3/16 projection important when cutting boiler tubes?
Too much or too little projection prevents a proper bead from forming, which can lead to leaks or cracks at the tube sheet joint.
Where can I buy Thomas Wilson tube tools?
Thomas Wilson tools are available directly from Thomas Wilson, through authorized resellers worldwide, and through BoilerWAREhouse at boilerwarehouse.com.
Need boiler parts, valves, gaskets, or maintenance supplies? Visit BoilerWAREhouse: https://www.boilerwarehouse.com
Learn more about WARE boiler service, rentals, training, and support: https://www.wareinc.com
Want boiler training? Learn more about Boiler University and boiler operator education through http://www.boileruniversity.com
🔔 Subscribe for weekly boiler tips and deep dive technical content.
👍Like & share to help us elevate the steam industry.
👍If you found this helpful, like, subscribe, and leave your boiler questions in the comments.
© 2026 @wareboilers. All rights reserved. Unauthorized reproduction or distribution of this content is prohibited. Ware Boilers’ videos are intended for promotional purposes only and does not constitute professional advice. Please contact our boiler professionals via https://www.wareinc.com/ with specific questions or repair needs. You should not attempt any boiler repair or modification without first consulting with a licensed contractor and the manufacturer. Ware Boilers does not warrant the accuracy, completeness, or usefulness of information available on this YouTube page. Nothing contained in or provided in any of Ware Boilers’ videos is intended to constitute advice or to serve as a substitute for a licensed contractor’s inspection or manufacturer specifications. Any reliance you place on such information is strictly at your own risk.
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