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Steel Tube

Heat Exchanger Tube Sheet

A tube sheet is usually made from a round flat piece of plate,sheet with holes drilled to accept the tubes or pipes in a accurate location and pattern relative to one another.The tube sheets are used to support and isolate tubes in heat exchangers and boilers or to support filter elements. Tubes......
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A tube sheet is usually made from a round flat piece of plate,sheet with holes drilled to accept the tubes or pipes in a  accurate location and pattern relative to one another.The tube sheets are used to support and isolate tubes in heat exchangers and boilers or to support filter elements. Tubes are attached to the tube sheet by hydraulic pressure or by roller expansion.

 

A tubesheet may be covered in a cladding material which serves as a corrosion barrier and insulator. Low carbon steel tube sheets can include a layer of a higher alloy metal bonded to the surface to provide more effective corrosion resistance without the expense of using the solid alloy,which means it can save a lot of cost.

 

drilling-of-tube-sheet

Perhaps the best known use of tube sheets are as supporting elements in heat exchangers and boilers. These devices consist of a dense arrangement of thin walled tubes situated inside an enclosed, tubular shell. Tubes are supported on either end by sheets which are drilled in a predetermined pattern to allow the tube ends to pass through the sheet. The ends of the tubes which penetrate the tube sheet are expanded to lock them in place and form a seal.

 

The tube hole pattern or “pitch” varies the distance from one tube to the other and angle of the tubes relative to each other and to the direction of flow. This allows the manipulation of fluid velocities and pressure drop, and provides the maximum amount of turbulance and tube surface contact for effective Heat Transfer.

 

Tube-sheet-designing-for-heat-exchanger

In cases where it is critical to avoid fluid intermixing, a double tube sheet can be provided. The design of tube sheets is a fairly precise and complex process; the exact number of tubes needs to be established and a pattern of holes calculated to spreads them evenly over the tube sheet surface. Large exchangers may have several thousand tubes running through them arranged into precisely calculated groups or bundles. Sheet design and production is largely automated these days with computer software (like CAD) performing the calculations and the tube sheet drilling done on computer numerical control (CNC) machines.

 

In this design, the outer tube sheet is outside the shell circuit, virtually eliminating the chance of fluid intermixing. The inner tube sheet is vented to atmosphere so any fluid leak is easily detected.

Flange Surface :Anti-rust oil, clear lacquer, Black lacquer, Yellow lacquer, hot-dipped Galvanized, electrical galvanized

Technical: Forged, Casting

Flange Heat Treatment:  Normalizing, Annealing, Quenching+Tempering

Material:  We use CNC machining equipments to produce many kinds of tube plates, mainly focused on Nickel alloy, Monel, Hastelloy, Titanium, Aluminum, Stainless steel and copper alloy tube plates, the tube shapes include round, oval, square, inclined and special ones, with the hole dimension accuracy to 0.01mm, hole wall roughness Ra0.6, and the tube plate's sealing side roughness Ra0.4. The accuracy of positioning of the holes can reach 0.002mm, and the hole dimension can be any of that above 1mm.    

Size: Customized


Type of materials      Technical requirements

Duplex Stainless Steel      ASTM/ASME SA182 F44, F45, F51, F53, F55, F60, F61

Stainless Steel ASTM/ASME SA182 F304,304L,F316,316L, F310, F317L, F321, F347

Carbon Steel    ASTM/ASME A105, A350 LF1, LF2, A266, A694, A765 Gr.2

Alloy Steel         ASTM/ASME SA182 F1, F5, F9, F11, F12, F22, F51, A350-LF3

Non Ferrous      

Titanium          ASTM/ASME SB381, Gr.1, Gr.2, Gr.5, Gr.7, Gr.12, Gr.16

Copper Nickel  ASTM/ASME SB151, UNS 70600(Cu-Ni 90/10), 71500(Cu-Ni 70/30)

Brass, Al-brass         ASTM/ASME SB152 UNS C10100, C10200,C10300,C10800,C12200

Nickel Alloys     ASTM/ASME SB169,SB171, SB564, UNS 2200, UNS 4400, UNS 8825

UNS 6600, UNS 6601, UNS 6625

Alloy 20    ASTM/ASME SB472  UNS 8020

Hastelloy ASTM/ASME SB564, UNS10276 ( C 276 )

Claded materials     ASTM/ASME SB898, SB263, SB264 or closer

explosion cladding, making materials of 2 in 1 or 3 in 1.

Titanium- Steel, Nickel-Steel,Titanium- Copper,

Stainless Steel- Carbon Steel, Alloys- Steel etc.


Ti 6Al-4V, Grade 5 alloy (UNS R56400) is the most widely used titanium grade. It is a two phase α+β titanium alloy, with aluminum as the alpha stabilizer and vanadium as the beta stabilizer. This high-strength alloy can be used at cryogenic temperatures up to about 800°F (427°C). Ti 6Al-4V, Grade 5 alloy is principally used in the annealed condition.

 

As in other titanium alloys, Ti 64 alloy's corrosion resistance is based on the existence of a consistent and continuous oxide layer which is formed spontaneously upon exposure to oxygen.  It has excellent resistance to corrosion in seawater making it a good choice for use in offshore and subsea oil & gas operations where seawater corrosion and weight are concerns.


Ti 6Al-4V is resistant to general corrosion but may be quickly attacked by environments that cause breakdown of the protective oxide layer including hydrofluoric (HF), hydrochloric (HCl), sulfuric and phosphoric acids. Ti 6Al-4V resists attack by pure hydrocarbons, and most chlorinated and fluorinated hydrocarbons provided that water has not caused formation of small amounts of hydrochloric and hydrofluoric acids.


Ti 64 alloy is produced by primary melting using vacuum arc (VAR), electron beam (EB), or plasma arc hearth melting (PAM). Refining is achieved by vacuum arc remelting.  Like other titanium alloys, Ti 64 has a modulus of elasticity of 107 Gpa (16.5 x 103 ksi), roughly half that of carbon steels.


Advantages of Titanium 64:

• Good corrosion resistance in seawater applications

• Low density/ high strength-to-weight ratio

• Low modulus of elasticity

• Low thermal expansion

• Non-magnetic

• Good fatigue resistance

• Good high temperature mechanical properties


ype of materials Technical requirements

 * according to

Duplex Stainless Steel      ASTM/ASME SA182 F44, F45, F51, F53, F55, F60, F61

Stainless Steel ASTM/ASME SA182 F304,304L,F316,316L, F310, F317L, F321, F347

Carbon Steel    ASTM/ASME A105, A350 LF1, LF2, A266, A694, A765 Gr.2

Alloy Steel         ASTM/ASME SA182 F1, F5, F9, F11, F12, F22, F51, A350-LF3

Non Ferrous      

Titanium          ASTM/ASME SB381, Gr.1, Gr.2, Gr.5, Gr.7, Gr.12, Gr.16

Copper Nickel  ASTM/ASME SB151, UNS 70600(Cu-Ni 90/10), 71500(Cu-Ni 70/30)

Brass, Al-brass         ASTM/ASME SB152 UNS C10100, C10200,C10300,C10800,C12200

Nickel Alloys     ASTM/ASME SB169,SB171, SB564, UNS 2200, UNS 4400, UNS 8825

UNS 6600, UNS 6601, UNS 6625

Alloy 20    ASTM/ASME SB472  UNS 8020

Hastelloy ASTM/ASME SB564, UNS10276 ( C 276 )

Claded materials     ASTM/ASME SB898, SB263, SB264 or closer

explosion cladding, making materials of 2 in 1 or 3 in 1.

Titanium- Steel, Nickel-Steel,Titanium- Copper,

Stainless Steel- Carbon Steel, Alloys- Steel etc.


We are specialized in precision engineered components and the supply of Tube Sheets and Heat Exchanger Plates, forged flange and rolled tube Heat Exchanger Plates, primarily for use in the heat exchanger industry, pressure vessels of petroleum, chemistry and boiler, power station equipments; forgings and flanges for ship building and machinery manufacturing, as well as other forging products.


Tube Sheets & Plates

Exceptional tube sheet design is complex, precise, and essential for heat exchange.

We utilizes the most state-of-the art manufacturing to produce defect-free copper tube sheets and plates. Our sheets are drilled in predetermined patterns to allow the tube ends to pass through the sheet. These tube ends are then expanded to lock in place and form a seal.

 

Admiralty tube sheet arrangements are masterfully drilled to client specifications and drawings by our team of expert machinists. Once installed, they form a contained unit which is then bolted to flanges inside the shell creating a chamber that is used for liquid or gas heat exchange in boilers, heat exchangers, and other applications. Large exchange chambers can contain up to several thousand tubes that must be arranged into precisely calculated bundles.

 

Given the intricate nature of chamber and plate design, and to prevent any galvanic action between tubes and tube-sheets, the best option is to use the same material for both. However, this solution can be costly for many of our clients. These “second choice” materials must be as similar as possible in the galvanic series to ensure satisfactory performance by using coatings or cathodic protection.

 

STANDARD ALLOYS

ASTM B171 C46200,ASTM SB171 C46200, ASTM B171 C46400,ASTM SB171 C46400 ,EN 1653 CuZn38AlFeNiPbSn

 

Tube Sheet Referance Specification

Type Lap-Joint Flange (LJ), Socket-welded Flange (SW), Slip-on Flange (SO),

Welding-Neck Flange (WN), Threaded Flange (TH), etc.

American Series       CLASS 150, CLASS 300, CLASS 400, CLASS 600, CLASS 900,

CLASS 1500, CLASS 2500

European Series       PN 2.5, PN 6, PN 10, PN 16, PN 25, PN 40, PN 63, PN 100,

PN 160, PN 250, PN 320, PN 400

Standard  HG20592, ASME16.5-2009, DIN2633, ANSI, JIS, etc

Applications range  Widely used for pipe,heat exchanger,boiler,pressure vessels,heater,etc

Packaging     Wooden Cases or wooden pallet or as per customers

requirement


Others

1. Special design available according to requirement

2. anti-corrosion and high-temperature resistant with

black painting

3. All the production process are made under the

ISO9001:2000 strictly.

 

Duplex Stainless Steel      ASTM/ASME SA182 F44, F45, F51, F53, F55, F60, F61

Stainless Steel ASTM/ASME SA182 F304,304L,F316,316L, F310, F317L, F321, F347

Carbon Steel    ASTM/ASME A105, A350 LF1, LF2, A266, A694, A765 Gr.2

Alloy Steel         ASTM/ASME SA182 F1, F5, F9, F11, F12, F22, F51, A350-LF3

Titanium          ASTM/ASME SB381, Gr.1, Gr.2, Gr.5, Gr.7, Gr.12, Gr.16

Copper Nickel  ASTM/ASME SB151, UNS 70600(Cu-Ni 90/10), 71500(Cu-Ni 70/30)

Brass, Al-brass         ASTM/ASME SB152 UNS C10100, C10200,C10300,C10800,C12200

Nickel Alloys     ASTM/ASME SB169,SB171, SB564, UNS 2200, UNS 4400, UNS 8825

UNS 6600, UNS 6601, UNS 6625

Alloy 20    ASTM/ASME SB472  UNS 8020

Hastelloy ASTM/ASME SB564, UNS10276 ( C 276 )

Claded materials     ASTM/ASME SB898, SB263, SB264 or closer

explosion cladding, making materials of 2 in 1 or 3 in 1.

Titanium- Steel, Nickel-Steel,Titanium- Copper,

Stainless Steel- Carbon Steel, Alloys- Steel etc.


Packing Material (General)

Name  Effect

Plastic Mat Protection from compressional deformation for Fin Tube itself

Dimension:5mm(Thick)*100mm(Width)

Waterproof Paper   Protection from water in shipping

Plywood   For packing wall

8mm(Thick)

Square Steel  For packing frame

2.7mm(Thick)*80mm(Width)*40mm(Height)

2.7mm(Thick)*30mm(Width)*60mm(Height)

Our CNC machine tools allow us to offer tube sheets, baffles, and flanges. Tubesheets are available in any machineable shape or configuration. Products can be machined to TEMA industry standards or as specified by customer.


Materials:       

Cu, CuNi, Br, Al, SS, CS, Ni, Ti

Diamater Range:     72.0″ Max OD

Shape Range:  60.0″ x 120.0″ Rectangular Max

 

Fixed Tube Sheet Heat Exchanger

A Fixed Tube Sheet heat exchanger is the most common type heat exchanger in all Industries. Fixed Tube Sheet Heat Exchanger used in higher-pressure and Higher Temperature applications. Fixed tube Sheet heat exchangers are the one that are very much used in process chemical industries and refinery services, as there is absolutely no chance for intermixing fluids. This type heat exchanger is employed where even slightest intermixing fluids can not be tolerated. Fixed Tube Sheet Heat Exchanger has straight tubes that are secured at bothends to tubesheets welded to the shell. The construction may have removable channelcovers , bonnet-type channel covers tubesheets. The principal advantage the Fixed Tube Sheet Heat Exchanger construction is its low cost because its simple construction. In fact Fixed Tube Sheet Heat Exchanger is the least expensive construction type, as long as no expansion jointis required.

 

Specifications :

The Fixed tube-sheet heat exchanger are that shell pass cannot be cleaned with the mechanical method and the maintenance is difficult.

The Fixed tube -sheet heat exchanger is applicable to all services where the temperature difference between the shell and tube is small.

In the event a large differential temperature between the tubes and the shell, thetubesheets will be unable to absorb the differential stress, making it necessary an expansion joint.

Applications :

The Tube sheets at both ends the fixed tube-sheet heat exchanger are connected and fixed with the shell by means the welding method.

Fixed tube-sheet type heat exchanger features simple and compact structure, and low manufacturing cost for the same diameter shell, the biggest number caladria is available in tubular heat exchangers is widely applied in engineering.

the temperature difference is slightly great but the pressure shell pass is not high with media in the shell pass not easy to scale

The shell pass can be cleaned with chemical method after the scaling is formed.


Advantages :

Advantages are that the tubes can be cleaned mechanically after removal thechannel cover or bonnet, leakage the shellside is minimized since thereare no joints.

A disadvantage this design is that since the bundle is to the shell and cannot beremoved, the outsides the tubes cannot be cleaned mechanically.

Its applicationis limited to clean services on the shellside. However, if a satisfactory chemical clean-ing program can be employed.

Construction may be selected for foulingservices on the shellside.

This takes away the advantage low cost to a significant extent.


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