A shell and tube heat exchanger consists of a shell, heat transfer tube bundle, tube sheet, baffle plate (baffle), and channel. The shell is mostly cylindrical with a tube bundle inside, and the two ends of the tube bundle are fixed on the tubesheet. There are two types of heat transfer fluids: hot fluid and cold fluid. One is the fluid inside the tube, called the tube side fluid; Another type is the fluid outside the pipe, called the shell side fluid.

 

 

1. What is Shell?

The shell serves as the outer housing of the heat exchanger. It contains one of the fluid streams and is typically constructed from materials such as carbon steel, stainless steel, or other alloys depending on the application and operating conditions.

 

2. What is Tube Bundle?

The tube bundle is the core component of the heat exchanger where heat transfer occurs. It consists of a series of tubes through which one fluid flows while the other fluid flows around the outside of the tubes. The tubes can be straight or bent, and they are usually made of materials such as copper, stainless steel, or titanium.

 

3. What is Tubesheet?

The tubesheet is a thick metal plate located at both ends of the tube bundle. It serves to support and secure the tubes in place, providing a leak-proof seal between the tube bundle and the shell.

 

4. What are Baffles?

Baffles are plates or spacers placed inside the shell to direct the flow of the shell-side fluid. They promote turbulence in the fluid flow, which enhances heat transfer efficiency by increasing the mixing of the fluid. Baffles also help to support the tubes and prevent vibration.

 

5. What is Baffle Plate?

The baffle plate is a large plate attached to the inner wall of the shell. It supports the baffles and helps to guide the flow of the shell-side fluid through the heat exchanger.

 

6. What is Front Channel and Rear Channel?

These are the spaces between the baffles where the shell-side fluid flows around the tube bundle. The front channel is located near the inlet of the shell-side fluid, while the rear channel is located near the outlet.

 

7. What is Tube Side Connection?

These are the inlet and outlet connections for the fluid flowing through the tubes. They allow the tube-side fluid to enter and exit the heat exchanger.

 

8. What is Shell Side Connection?

These are the inlet and outlet connections for the fluid flowing around the outside of the tubes. They allow the shell-side fluid to enter and exit the heat exchanger.

 

9. What is Vent?

The vent is an opening on the shell of the heat exchanger used to remove trapped air or gases during startup or operation. It ensures proper operation and prevents air pockets from interfering with heat transfer.

 

10. What is Drain?

The drain is an opening on the shell or tubesheet used to remove liquid from the heat exchanger. It is typically used for maintenance purposes or for draining the system during shutdowns.

 

11. What is Expansion Joint?

An expansion joint is a flexible element installed in the shell or tube bundle to accommodate thermal expansion and contraction. It prevents damage to the heat exchanger caused by temperature fluctuations.

 

12. What are Heat Exchanger Legs?

Legs are support structures attached to the bottom of the heat exchanger to elevate it above the ground or other surfaces. They provide stability and facilitate installation and maintenance.

 

13. Lifting Lug?

Lifting lugs are welded to the shell of the heat exchanger and used for lifting and handling during installation or maintenance.

 

14. Reinforcing Pad?

Reinforcing pads are additional material welded to the shell or other components to strengthen areas subjected to high stress or pressure, such as nozzle connections.

 

These components work together to facilitate efficient heat transfer between the two fluid streams while ensuring structural integrity, reliability, and safety of the heat exchanger. 

 

Wuxi Changrun has provided high-quality tube sheets, nozzles, flanges, and customized forgings for heat exchangers, boilers, pressure vessels, etc. to many well-known petrochemical enterprises at home and abroad. Our customers include PetroChina, Sinopec, Chevron, Bayer, Shell, BASF, etc. Send your drawings to sales@wuxichangrun.com We will provide you with the best quotation and the highest quality products.

What is a forged tube sheet?

Forging is a process of manufacturing components by plastic deformation of metal. During the forging process, the metal is pressed to the desired shape. A forged tubesheet is commonly made from a round disc forging with holes drilled to accept the tubes or pipes in an accurate location and pattern relative to one another. The advantages of forging tube sheets are high density, high strength, and good toughness. However, due to the high temperature and specialized equipment required for forging, the cost is relatively high.

 

A forged tube sheet is a critical component in shell-and-tube heat exchangers. It serves as a support for the heat exchanger tubes and provides a sealed barrier at the ends of the tubes to prevent leakage between the tube-side and shell-side fluids, ensure effective heat transfer or to support filter elements. In shell and tube heat exchangers, two plates support the tubes, one on each end. They are in contact with both fluids on the shell side and the tube side, so they must be corrosion resistant and sealed tightly. Many heat exchanger design codes and standards require forged tubesheets.

 

 

 

Forged Tube Sheet Production Standards:

The production standards for forged tube sheets can vary depending on the specific industry and application. However, some common standards that may be followed include:

 

1.ASME (American Society of Mechanical Engineers) Standards: ASME Boiler and Pressure Vessel Code (BPVC) provides guidelines and standards for the design, fabrication, and inspection of pressure vessels, including heat exchangers. ASME standards ensure that the equipment meets safety and performance requirements.

 

2. ASTM (American Society for Testing and Materials) Standards: ASTM specifications provide guidelines for the materials used in the fabrication of tube sheets. Different grades of materials are specified based on factors such as temperature, pressure, and corrosion resistance.

 

 

Material of Forged Tube Sheets:

The choice of material for forged tube sheets depends on the specific requirements of the application. Common the material include: carbon steel tube sheets, stainless steel tube sheets, alloy steel tube sheets. A tubesheet may be covered in a cladding material which serves as a corrosion barrier and insulator which is weld overlay tube sheets. (Know more about welding overlay tube sheet)

 

 

Forgings for manufacturing tube sheets need to meet the following performance requirements:

1. High strength: able to withstand high pressure and impact loads, ensuring the stability and safe operation of the tube sheet.

2. Good corrosion resistance: It can resist the corrosion of the medium and extend the service life of the tubesheet.

3. Good sealing: Ensure the normal operation of the tube plate and prevent medium leakage.

4. Good processability: Easy to process into complex shapes to meet the design requirements of tubesheets.

 

 

Forged tube sheets find applications in various industries, including:

1. Petrochemical Industry: For heat exchangers in refineries and chemical processing plants.

2. Power Generation: In boilers and steam generators.

3. Oil and Gas Industry: For heat exchangers in oil refineries and offshore platforms.

4. Chemical Processing: In chemical reactors and processing equipment.

 

 

Forged tube sheets are crucial components in heat exchangers, manufactured through a forging process to achieve specific mechanical properties. They adhere to industry standards and are chosen for their strength, durability, and resistance to corrosion in various industrial applications. Wuxi changrun specialized in forged tube sheet manufacture.

 

What is a tube sheet for heat exchanger?

One of the most common heat exchangers in service within industrial process applications is the “Tube Sheet Heat Exchangers”. They are available in many shapes, sizes and have been used in industry for over 150 years. In this exchanger group are various sub design types: Fixed, U-tube and Floating tubes heet. Variations of all can be denoted as type “E”, “F”, “G”, “H”, “J”, “K” or “X”. The main applications are where high pressure/temperatures are key considerations. Loosely, general designs consist of the/an outer shell in which resides a tube bundle (these can be configured as finned, plain etc) sealed at each end by a tube sheet which isolates the tubes and the outer shell.

 

 

How does a heat exchanger work?

Tube Sheet Heat Exchangers have the capability to transfer large amounts of heat at low(er) costs. This, in principle, down to both design simplicity and effectiveness – large tube surface for reduced weight, volume of liquid and importantly floor space.

 

Whilst there is a wide variety to choose from there are certain key components similar in all. Tube sheets have tubes attached to them within the body or “shell” of the heat exchanger. The tubes allow the movement of a given medium (gas/fluid) through the shell chamber stopping it mixing with a second fluid medium that lies outside these tubes. As long as there is a temperature difference between these, in effect, the two flow past one another exchanging heat without ever mixing. Tube sheets can be fixed or floating dependent on the application the heat exchanger is designed for.

 

 

 

The role of tube sheets in heat exchangers

Tube sheets are a critical component of the final design. There are a multitude of materials they can be manufactured from. Material selection is made after careful consideration as it is in contact with both fluids. It must therefore have the necessary corrosion resistance, electromechanical and metallurgical properties associated for its given working environment.

 

The tube sheets themselves contain holes drilled into them. This, in a given, very specific design configuration, at very precise locations with critical tolerances. The amounts of holes can range from a few to thousands. These pattern or “pitch” holes are relative to each other tube sheet within the shell. This pitch changes tube distance, angle and flow direction. These parameters have been varied to maximize the heat transfer effectiveness.

 

Tube Sheet Heat Exchangers of the big advantages of using a shell and tube heat exchanger is that they are often easy to service, particularly with models where a floating tube bundle where the tube plates are not welded to the outer shell is available. Fixed Tube Sheet Heat Exchangers used on fixed tube sheet heat exchangers. 

 

Tube Sheet Heat Exchangers the right choice of materials they can also be used to cool or heat other mediums, such as swimming pool water or charge air. Fixed Tube Sheet Heat Exchangers ideal cooling solution for a wide variety of applications. One of the most common applications is the cooling of hydraulic fluid and oil in engines, transmissions and hydraulic power packs.

 

 

How does wuxi changrun work?

Because these tube sheets are the main, critical，Wuxi changrun manufactures directly to OEM drawings issued as DXF files. The in house Delcam FeatureCam CAD reading capabilities mean the final product supplied from us is manufactured to the exacting specifications as designed, released and issued from you the client.

 

Wuxi changrun’s considerable experience in this highly specialized area means that whatever the requirement, whatever the timescale, we have the technical, in house experience and know-how to approach a given task, deliver on time and in budget. This is why the company is entrusted to manufacture to key, blue chip clients across the globe.

Tube sheets are commonly used industrial components, widely employed in industries such as chemical, petroleum, pharmaceuticals, and food processing. Tube sheet size standards refer to the standardized size specifications used in the design and manufacturing process to ensure interchangeability and universality of various pipeline equipment. This article provides a detailed introduction to tube sheet size standards.

 

Tube Sheet Overview

1. Tube Sheet Definition

A tube sheet is a device that connects multiple pipelines or equipment and consists of two flat surfaces, typically with numerous holes on the top surface, with each hole connecting to one or more holes on the bottom surface.

 

2. Tube Sheet Classification

Depending on different application scenarios and functional requirements, tube sheets can be categorized into the following types:

(1) Distributors: Divert one inlet into two or more outlets.

(2) Collectors: Collect two or more inlets into one outlet.

(3) Heat Exchangers: Achieve heat exchange through the transfer of heat between internal fluids.

(4) Reactors: Complete chemical synthesis or other chemical processes through internal reactions.

 

Tube Sheet Size Standards

1. Tube Sheet Hole Diameter: In the design and manufacturing process, international standards like ISO/TR 10400 or ASME B16.5 are typically used as standard specifications for tube sheet hole diameters. Both of these standards specify a range of hole sizes, ranging from 1/2 inch to 48 inches.

 

2. Tube Sheet Thickness: Tube sheet thickness refers to the distance between the top and bottom surfaces of the tube sheet. In the design and manufacturing process, standards such as ASME B16.5 or GB/T 9119 are typically used as standard specifications for tube sheet thickness. These standards specify a range of thicknesses, ranging from 3 millimeters to 100 millimeters.

 

3. Tube Sheet Hole Spacing: Tube sheet hole spacing refers to the distance between adjacent holes. In the design and manufacturing process, standards like ASME B16.5 or GB/T 9119 are usually used as standard specifications for tube sheet hole spacing. These standards specify a range of hole spacing sizes, ranging from 15 millimeters to 600 millimeters.

 

4. Tube Sheet Material: Tube sheet material refers to the type and variety of materials used in manufacturing the tube sheet. In the design and manufacturing process, standards such as ASME B16.5, GB/T 9119, or JIS B2220 are typically used as standard specifications for tube sheet materials. These standards classify and specify various material types and varieties.

 

 

 

Frequently Asked Questions

 

1. What is the purpose of tube sheet size standards?

The purpose of tube sheet size standards is to ensure the interchangeability and universality of various pipeline equipment, allowing pipeline equipment produced by different manufacturers to be compatible and work together.

 

2. What is the relationship between tube sheet hole diameter, thickness, and hole spacing?

There is no direct relationship between tube sheet hole diameter, thickness, and hole spacing. Different tube sheet size standards specify different ranges of hole diameter, thickness, and hole spacing sizes, and users can choose the appropriate specifications according to their needs.

 

3. What are the common types of tube sheet materials?

Common tube sheet materials include carbon steel, stainless steel, alloy steel, copper, aluminum, and more. Users can select the appropriate material type and variety based on their specific requirements.

 

 

 

Conclusion

Tube sheet size standards are crucial for ensuring the interchangeability and universality of various pipeline equipment and should be strictly followed during the design and manufacturing process. 

 

Wuxi Changrun has provided high-quality tube sheets, nozzles, flanges, and customized forgings for heat exchangers, boilers, pressure vessels, etc. to many well-known petrochemical enterprises at home and abroad. Our customers include PetroChina, Sinopec, Chevron, Bayer, Shell, BASF, etc. Send your drawings to sales@wuxichangrun.com We will provide you with the best quotation and the highest quality products.

 

904L alloy steel has the following characteristics:

904L is a highly alloyed austenitic stainless steel with low carbon content. This steel is designed for environments with harsh corrosion conditions. Initially, this alloy was developed for corrosion resistance in dilute sulfuric acid. This feature has been proven to be very successful through years of practical application. 904L has been standardized in many countries and has been approved for use in the manufacture of pressure vessels. 904L alloy, like other commonly used CrNi austenitic steels, has good resistance to pitting and crevice corrosion, high resistance to stress corrosion cracking, good resistance to intergranular corrosion, good processability, and weldability. The maximum heating temperature during hot forging can reach 1180 degrees Celsius, and the minimum stop forging temperature is not less than 900 degrees Celsius. This steel can be hot formed at 1000-1150 degrees Celsius. The heat treatment process of this steel is 1100-1150 degrees Celsius, and it is rapidly cooled after heating. Although this steel can be welded using universal welding processes, the most appropriate welding methods are manual arc welding and tungsten inert gas arc welding. When using manual arc welding to weld plates with a diameter not exceeding 6mm, the diameter of the welding rod shall not exceed 2.5mm; When the plate thickness is greater than 6 millimeters, the diameter of the welding rod is less than 3.2 millimeters. When heat treatment is required after welding, it can be done by heating at 1075-1125 degrees Celsius and then rapidly cooling. When using tungsten inert gas arc welding, the filler metal can be used with the same welding rod. After welding, the weld seam must be pickled and passivated.

 

 

904L metallographic structure

904L is a completely austenitic structure, and compared to austenitic stainless steels with high molybdenum content, 904L is not sensitive to the precipitation of ferrite and alpha phase.

 

 

Corrosion resistance of 904L

Due to the low carbon content of 904L (maximum 0.020%), there will be no carbide precipitation under general heat treatment and welding conditions. This eliminates the risk of intergranular corrosion that occurs after general heat treatment and welding. Due to its high chromium nickel molybdenum content and the addition of copper, 904L can be passivated even in reducing environments such as sulfuric acid and formic acid. The high nickel content results in a lower corrosion rate even in the active state. In pure sulfuric acid with a concentration range of 0-98%, the usage temperature of 904L can reach up to 40 degrees Celsius. In pure phosphoric acid with a concentration range of 0-85%, its corrosion resistance is very good. Impurities have a strong impact on the corrosion resistance of industrial phosphoric acid produced by wet process technology. Among all types of phosphoric acid, 904L has better corrosion resistance than ordinary stainless steel. In highly oxidizing nitric acid, 904L has lower corrosion resistance compared to high alloyed steel grades without molybdenum. In hydrochloric acid, the use of 904L is limited to lower concentrations of 1-2%. Within this concentration range. The corrosion resistance of 904L is better than that of conventional stainless steel. 904L steel has high resistance to pitting corrosion. Its resistance to crevice corrosion is also very good in chloride solutions. The high nickel content of 904L reduces the corrosion rate in pits and crevices. Ordinary austenitic stainless steel may be sensitive to stress corrosion in an environment rich in chloride at temperatures above 60 degrees Celsius. By increasing the nickel content of the stainless steel, this sensitization can be reduced. Due to its high nickel content, 904L exhibits high resistance to stress corrosion cracking in chloride solutions, concentrated hydroxide solutions, and environments rich in hydrogen sulfide.

 

 

904L Tube sheet 

A 904L tube sheet is a component used in various industrial applications particularly in heat exchangers and condensers. The 904L stainless steel tube sheet is specifically chosen for its superior resistance to aggressive environments, such as those containing sulfuric acid, phosphoric acid, and chloride solutions. It offers exceptional resistance to pitting, crevice corrosion, and stress corrosion cracking, making it highly suitable for applications in the chemical, petrochemical, and offshore industries. The use of 904L stainless steel tube sheets ensures the long-term reliability and performance of heat transfer equipment. Its corrosion resistance properties allow for extended service life and reduced maintenance requirements, resulting in cost savings and enhanced operational efficiency. Choose 904L tube sheets for superior corrosion resistance and reliable performance in demanding environments. Experience the benefits of this high-quality stainless steel alloy for your heat exchangers and condensers.

 

 

904L flange

904L flanges are commonly used in industries such as chemical processing, petrochemical, pharmaceutical, and offshore applications. Their resistance to corrosion makes them suitable for handling corrosive fluids and gases. Additionally, 904L flanges offer excellent strength, durability, and weldability, making them a reliable choice for critical applications. The use of 904L flanges can help ensure the integrity and longevity of piping systems by providing a robust and corrosion-resistant connection. They are available in various types, including slip-on, weld neck, blind, and threaded flanges, to suit different installation requirements. In summary, 904L flanges are specifically made from 904L stainless steel, which offers superior corrosion resistance in demanding environments. Their use can enhance the reliability and performance of piping systems, making them ideal for applications where corrosion resistance is paramount.

 

904L application areas:

904L alloy is a versatile material that can be applied in many industrial fields:

1. Petroleum and petrochemical equipment, such as reactors in petrochemical equipment.

2. Storage and transportation equipment for sulfuric acid, such as heat exchangers.

3. The flue gas desulfurization device in power plants is mainly used in the tower body, flue, door panels, internal components, spray systems, etc. of the absorption tower.

4. Scrubbers and fans in organic acid treatment systems.

 

 

Similar grades

GB/T	UNS	AISI/ASTM	ID	W.Nr
00Cr20Ni25Mo4.5Cu	N08904	904L	F904L	1.4539

 

 

904L chemical composition

C	Si	Mn	P	S	Cr	Ni	Mo	Cu	Fe
0.02	1	2	0.045	0.035	19-23	23-28	4-5	1-2

 

 

Mechanical properties

Tensile strength	Yield Strength	Elongation	Density	Melting point
RmN/mm	Rp0.2N/mm	A5％	8.0g/cm3	1300-1390℃

 

 

 

Wuxi Changrun has provided high-quality tube sheets, nozzles, flanges, and customized forgings for heat exchangers, boilers, pressure vessels, etc. to many well-known petrochemical enterprises at home and abroad. Our customers include PetroChina, Sinopec, Chevron, Bayer, Shell, BASF, etc. Send your drawings to sales@wuxichangrun.com We will provide you with the best quotation and the highest quality products.

 

Forging ratio is an indicator used to indicate the degree of metal deformation during the forging process, usually defined as the ratio of the cross-sectional area of the metal before and after forging.

 

The calculation method for forging ratio can be the elongation forging ratio or the upsetting forging ratio. The elongation forging ratio refers to the ratio of the cross-sectional area of the steel ingot or billet before elongation to the cross-sectional area after elongation. The upsetting forging ratio, also known as the upsetting ratio or compression ratio, refers to the ratio of the cross-sectional area of the steel ingot or billet after upsetting to the cross-sectional area before upsetting. The selection of forging ratio is crucial for ensuring the quality and performance of forgings, and factors such as different metal materials, forging performance requirements, process types, and the shape and size of forgings need to be considered. For example, alloy structural steel ingots typically require a larger forging ratio, while electroslag steel ingots have better quality and require a smaller forging ratio.

 

The size of the forging ratio directly affects the mechanical properties and forging quality of the metal. Increasing the forging ratio is beneficial for improving the structure and properties of the metal, but excessive forging ratios may also lead to unnecessary waste and increased workload. Therefore, while ensuring the quality of forgings, it is advisable to choose a smaller forging ratio as much as possible.

 

 

1. Basic definition of forging ratio

The ratio of the cross-sectional area of a metal billet before and after forging is called the forging ratio. It represents the magnitude of forging deformation, and the forging ratio can be calculated using the following formula:

 

 

2. Calculation methods of forging ratio

Note:

(1) The forging ratio of chamfered steel ingots is not included in the total forging ratio;

(2) When continuously elongating or upsetting, the total forging ratio is equal to the product of the sub forging ratios;

(3) When there is elongation between two upsets and when there is elongation between two upsets, the total forging ratio is equal to the sum of the two sub forging ratios, and it is required that each sub forging ratio is not less than 2.

 

 

About us:

Wuxi Changrun has provided high-quality tube sheets, nozzles, flanges, and customized forgings for heat exchangers, boilers, pressure vessels, etc. to many well-known petrochemical enterprises at home and abroad. Our customers include PetroChina, Sinopec, Chevron, Bayer, Shell, BASF, etc. Send your drawings to sales@wuxichangrun.com We will provide you with the best quotation and the highest quality products.

 

 

Our company has 27 international and domestic first-class brand drilling equipment that have been put into use, including 11 deep hole drills. We have advantages such as large processing specifications (maximum diameter of 8.6m), batch production, mature process plans, and standardized quality control. The processed tube sheet products are widely used in industries such as seawater desalination, heat exchangers, pressure vessels, paper machines, petroleum refining, steam turbines, and nuclear power.

 

What are the tube sheet inspection and testing methods?

Tube sheet inspection and testing methods are used to ensure the integrity and safety of tube sheets, which are components used in heat exchangers and other types of equipment. There are several methods used for tube sheet inspection and testing, including:

 

Visual Inspection

This is the simplest method of tube sheet inspection, which involves a visual examination of the tube sheet surface for any visible cracks, corrosion, erosion or other signs of damage.

 

Dye Penetrant Test (PT)

This method involves applying a dye penetrant to the surface of the tube sheet and then wiping off the excess. The penetrant is then drawn into any cracks or other surface defects by capillary action. A developer is applied, which draws the penetrant out of the cracks and makes them visible.

 

Magnetic Particle Test (MT)

This method involves applying a magnetic field to the tube sheet and then applying ferromagnetic particles to the surface. Any surface cracks or defects will cause the magnetic field to be distorted, making the particles cluster at the location of the defect, which can then be visually detected.

 

Ultrasonic Testing (UT)

This method uses high-frequency sound waves to detect defects in the tube sheet. A probe is placed on the surface of the tube sheet, which emits sound waves that travel through the material. Any defects in the material will cause some of the sound waves to be reflected back to the probe, which can be detected and analyzed.

 

Eddy Current Testing (ECT)

This method involves passing an alternating electrical current through a coil, which induces eddy currents in the tube sheet. Any defects in the material will cause changes in the eddy currents, which can be detected and analyzed.

 

These methods can be used individually or in combination to provide a comprehensive inspection and testing of tube sheets. The choice of method(s) used will depend on the type of equipment, the material of the tube sheet, and the level of sensitivity required for defect detection.

 

Wuxi Changrun has provided high-quality tube sheets, nozzles, flanges, and customized forgings for heat exchangers, boilers, pressure vessels, etc. to many well-known petrochemical enterprises at home and abroad. Our customers include PetroChina, Sinopec, Chevron, Bayer, Shell, BASF, etc. Send your drawings to sales@wuxichangrun.com We will provide you with the best quotation and the highest quality products.