Novelty Steel Fabricates Carbon Steel and Stainless Steel Shell and Tube Heat Exchangers
for Various Industries.
3. Advantages of Tubular Heat Exchangers over Plate Heat Exchangers
In summary, plate exchangers offer advantages in terms of compactness, heat transfer efficiency, and design flexibility, while tube exchangers, particularly shell-and-tube, provide strength and stability for high-pressure and high-temperature applications.
4. Fabrication of Shell & Tube Heat Exchangers
- Define the heat exchanger requirements based on application, fluid properties, temperature, and pressure conditions.
- Develop detailed engineering drawings and specifications.
- Choose materials for the tubes, shells, headers, and other components based on the operating conditions and compatibility with the fluids involved.
- Cut tubes to the required lengths.
- Expand or roll the tubes to ensure a tight fit within the tube sheets.
- Fabricate tube sheets, which are usually made of a material compatible with the tubes.
- Drill holes in the tube sheet to accommodate the tu
- Insert the tubes into the tube sheet, ensuring a secure and leak-tight fit.
- Weld or mechanically bond the tubes to the tube sheet.
- Fabricate the shell or casing that will house the tubes.
- Weld or connect the shell components.
- Install baffles inside the shell to direct the flow of fluid and enhance heat transfer.
- Baffle design depends on the specific requirements of the heat exchanger
- Insert the assembled tube sheet and tube bundle into the shell.
- Secure the tube bundle in place, ensuring proper alignment.
- Install headers or manifolds at the ends of the tubes to facilitate fluid inlet and outlet.
- Weld or connect the headers securely.
- Perform additional welding to ensure the integrity of the heat exchanger.
- Inspect welds for quality and perform any necessary finishing processes.
- Conduct pressure tests to ensure the heat exchanger can withstand the specified operating pressures.
- Check for leaks and structural integrity.
Apply any required surface treatments, such as painting or coating, for corrosion resistance.
Perform quality control inspections at various stages of production to ensure compliance with design and safety standards.
Generate documentation, including “as-built” drawings, material certifications, and test reports.
Package the heat exchanger for transportation and dispatch.
5. Materials used in Tubular (Shell & Tube) Heat Exchangers
Tube heat exchangers are designed to handle a variety of fluids and operating conditions, and the materials used in their construction depend on factors such as the type of fluids, temperature, pressure, and corrosion resistance requirements. Here are some common materials used in tube heat exchangers:
- Tubes:
- Copper: Excellent thermal conductivity and corrosion resistance. Commonly used in HVAC and small-scale applications.
- Aluminum: Lightweight, good thermal conductivity, and corrosion resistance. Used in automotive and air-cooled applications.
- Stainless Steel: Offers corrosion resistance and is suitable for a wide range of fluids. Various grades are available, such as 304, 316, and duplex stainless steel.
- Tube Sheets:
- Carbon Steel: Often used for tube sheets in less corrosive environments.
- Stainless Steel: Used when corrosion resistance is a critical factor.
- Shell:
- Carbon Steel: Commonly used for the shell in less corrosive environments.
- Stainless Steel: Used when corrosion resistance is required.
- Baffles:
- Carbon Steel: Provides structural support.
- Stainless Steel: Used for corrosion resistance.
- Gaskets:
- Rubber: Commonly used for sealing purposes in less demanding applications.
- Nitrile, EPDM, or Viton: Used for higher temperature and chemical resistance.
- Expansion Joints:
- Stainless Steel Bellows: Provides flexibility to accommodate thermal expansion and contraction.
- Headers and Nozzles:
- Carbon Steel or Stainless Steel: Depending on the application requirements.
- Insulation:
- Mineral Wool or Fiberglass: Provides thermal insulation to minimize heat loss.
It’s important to note that material selection depends on the specific conditions of the application. For example, corrosive environments may require the use of corrosion-resistant alloys, and high-temperature applications may necessitate materials with good thermal stability. Additionally, considerations for factors like cost, manufacturability, and ease of maintenance play a role in material choices for tube heat exchangers.
FAQ
Each fabricated heat exchanger comes with comprehensive documentation, including:
- Material Certificates: For all materials used in manufacturing, ensuring compliance with specifications.
- Test Reports: For pressure testing, thermal performance, and non-destructive testing (NDT) results.
- Quality Control Documentation: Detailing all inspections, measurements, and certifications that the heat exchanger has passed.
We offer warranties on the heat exchangers we fabricate. Warranty periods vary based on factors like material selection, design complexity, and application conditions. The warranty typically covers:
- Material defects
- Workmanship
- Performance issues (if the unit fails to meet agreed-upon specifications)
Specific warranty details are provided in the contract, ensuring full transparency and peace of mind.
Yes, we understand that client needs may evolve during the manufacturing process. We offer flexibility in design modifications, but changes may affect the overall timeline and cost. Any adjustments to the design will be discussed with you in detail to ensure alignment with your new requirements and to avoid delays.
We understand the importance of timely delivery, and we prioritize meeting deadlines for every project. To ensure this, we:
- Provide detailed project timelines and milestones from the start.
- Use advanced project management tools to track progress and stay on schedule.
- Maintain close communication with clients to address any concerns or changes promptly.
- Have streamlined production processes and established relationships with suppliers to avoid delays in material procurement.
The cost depends on various factors, including:
- Type of heat exchanger (shell and tube, plate, etc.)
- Materials used
- Design complexity
- Quantity ordered
- Testing and certifications required
We offer competitive pricing and will provide a detailed quote after understanding your specific requirements.
Yes, we have the capability to handle both small and large-volume production runs. Whether you need a single unit for a specialized application or a bulk order for industrial use, we can scale our manufacturing process to meet your needs.
Yes, we can fabricate heat exchangers using a variety of materials, depending on the application requirements, including:
- Stainless Steel
- Nickel Alloys
- Titanium
- Carbon Steel
We can also incorporate coatings and treatments to improve corrosion resistance and extend the lifespan of the heat exchanger.
The timeline for manufacturing depends on several factors, such as design complexity, material sourcing, and quantity. Generally, it can take from a few weeks to several months. We provide a detailed timeline after assessing the scope of the project and required specifications.
