Tube sheets Manufacturers & Suppliers
Tube sheets are crucial components in various heat exchangers, boilers, and condensers. They serve as the primary support structure for the heat transfer tubes, ensuring their proper alignment and spacing. These sheets are typically made of high-strength materials, such as carbon steel, stainless steel, or titanium, to withstand the harsh operating conditions and high pressures encountered in these systems.
At N-Pro Engineers India, we take pride in being the foremost Tube Sheets Manufacturer and Supplier in India, offering an extensive range of top-quality tube sheets tailored to meet the diverse needs of our valued customers. Our commitment to excellence is reflected in the wide array of tube sheets we provide, available in various sizes, specifications, standards, materials, and types. This diversity allows our customers to select the perfect tube sheet that precisely aligns with the unique requirements of their projects. Whether it’s the dimensions, materials, or specific industry standards, our tube sheets are crafted with precision and expertise to guarantee reliability and longevity.
As a leading Tube Sheet Manufacturer, we prioritize delivering products that not only meet but exceed the expectations of our clients. We stand as a trusted partner for industries seeking top-tier tube sheets, providing unmatched quality, durability, and customization options. With our unwavering commitment to customer satisfaction and adherence to international standards, we strive to be the preferred choice for all tube sheet requirements in the ever-evolving industrial landscape.
What are Tubesheets?
Tubesheets play a crucial role in the construction and operation of heat exchangers, condensers, boilers, and other pressure vessels. A Tubesheet acts as a support element, holding the tubes or pipes in place within the shell of these devices. It facilitates the transfer of heat between the tube-side and shell-side fluids while providing mechanical stability.
Tubesheets and Heat Exchanger
The tubesheet is a critical component that plays a vital role in the functionality and performance of the heat exchanger. It serves as a support structure for the tubes or pipes that carry the fluids involved in the heat exchange process.
Typically a flat plate, often circular or rectangular in shape, and is positioned at one or both ends of the heat exchanger. It is responsible for holding the tubes or pipes in place within the shell of the heat exchanger, ensuring proper alignment and preventing movement or vibration during operation.
The primary function of the tubesheet is to create a sealed boundary between the tube-side and shell-side fluids within the heat exchanger. It ensures that the fluids flow through their respective channels without mixing, while facilitating efficient heat transfer between them.
The tubesheet must be designed to withstand the pressure and temperature conditions of the heat exchanger, as well as any mechanical stresses or vibrations that may arise during operation. It is typically made of materials such as carbon steel, stainless steel, alloy steel, copper alloys, or titanium, depending on the specific requirements of the heat exchanger and the fluids being processed.
The tubesheet contains precisely positioned holes or bores through which the tubes or pipes are inserted and secured. These holes must be accurately aligned to allow for proper fluid flow and efficient heat transfer. The arrangement and pattern of these holes in the tubesheet, known as the tube bundle layout, are carefully designed to optimize the heat exchange process.
Tubesheets Commonly Manufactured In
At Npro Engineers India, we specialize in manufacturing Tubesheets in various materials, ensuring optimal performance and durability. Some commonly used materials for Tubesheet manufacturing include:
Carbon Steel: Offering excellent strength and cost-effectiveness, carbon steel Tubesheets are widely used in various applications.
Stainless Steel: Known for its corrosion resistance and high-temperature capabilities, stainless steel Tubesheets are ideal for demanding environments.
Alloy Steel: Tubesheets made from alloy steel offer enhanced strength, durability, and resistance to extreme temperatures.
Copper Alloys: Copper Tubesheets are preferred for their excellent thermal conductivity, making them suitable for heat exchangers and condensers.
Titanium: Offering exceptional corrosion resistance and low weight, titanium Tubesheets are popular in marine and chemical industries.
Specifications of Tubesheets
| Product | Tube Sheets |
| Outer Diameter (OD) | 40-6000mm |
| Thickness | 5mm – 300mm |
| Dimensions | Conform to Customer Drawing |
| External Shape | Circular or Round Shapes |
| Typical Hole Patterns | Triangular Pattern, Rotated Triangular Pattern, Square Pattern, Rotated Square Pattern |
| Materials | Stainless Steel, Duplex Steel, Carbon Steel, High Nickel Alloy, Copper, Aluminium, Brass |
Types of Tubesheets
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Applications of Tubesheets
Tubesheets find extensive application in various industries due to their critical role in heat exchange processes. Some notable applications include:
Chemical Industry: Tubesheets are essential in chemical reactors, distillation columns, and condensers, enabling efficient heat transfer in the manufacturing of chemicals.
Oil and Gas Industry: Heat exchangers and condensers in oil refineries and offshore platforms rely on Tubesheets for effective cooling and heating of process fluids.
Power Generation: Tubesheets are integral to boilers and steam generators, facilitating the transfer of heat between combustion gasses and water to generate electricity.
HVAC Systems: Heat exchangers in heating, ventilation, and air conditioning systems employ Tubesheets to regulate the temperature and ensure efficient heat transfer.
Food and Beverage Industry: Heat exchangers used for pasteurization and sterilization processes in the food and beverage industry rely on Tubesheets for effective heat transfer.
Why Choose Npro Engineers India?
As a leading manufacturer and supplier of Tubesheets, Npro Engineers India stands out for several reasons:
Extensive Expertise: With years of experience in the industry, we possess comprehensive knowledge and expertise in Tubesheet manufacturing.
High-Quality Standards: We adhere to stringent quality control measures throughout the manufacturing process, ensuring exceptional quality Tubesheets that meet international standards.
Diverse Material Options: We offer Tubesheets in a wide range of materials, allowing us to cater to diverse industrial requirements.
Customization: We understand that every project is unique. Hence, we offer customization options for Tubesheets, tailoring them to specific dimensions, hole patterns, and material grades.
Timely Delivery: We prioritize timely delivery of Tubesheets, ensuring that your projects stay on schedule.
Competitive Pricing: Our commitment to providing cost-effective solutions makes us an ideal choice for Tubesheets without compromising on quality.
Choose Npro Engineers India for your Tubesheet requirements, and experience unparalleled quality, reliability, and customer satisfaction.
Working Principle of Shell and Tube Heat Exchanger
- The operation of a shell and tube heat exchanger is straightforward.
- One fluid flows inside the tubes, while the other circulates through the shell.
- Heat exchange occurs as the cold fluid gains heat from the hot fluid.
- The cold fluid enters the inlet nozzle (shell or tube side) and exits as hot fluid from the outlet nozzle.
- The heat transfer efficiency depends on the surface area, determined by the number of thermally conductive metal tubes.
- Fluid flow within the heat exchanger can be parallel or cross-flow.
- The inlet and outlet nozzles for the channel side are typically located on the front header.
- This design usually involves an even number of tube passes but can include an odd number, in which case the channel side’s outlet nozzle is on the rear header.
- Increasing the number of tube passes enhances the heat transfer coefficient.
- Turbulators and baffles are installed inside tubes and shells to boost fluid turbulence and improve heat transfer between the fluids.
Basic Components of Shell and Tube Heat Exchanger
Typically a Shell and Tube Heat Exchanger consists of two-compartment /sections one is shell side and the other is channel/tube side
- The shell side section consists of the following components: Shell, Cover, body flange, Nozzles, and Saddle support.
- Channel / Tube side section consists of the following components: Channel, Cover, Body Flange, Nozzles, Tube Sheet and Tubes (Tube Bundle)
Tube Bundle of Shell & Tube Heat Exchanger
Tube Bundle consists of the following components
-Tube-sheet
- Tubes
- Baffles
- Tie rods
- Spacers Sliding strips
- Tube bundles are removed during maintenance. Standard practice is to flow corrosive fluid inside the tubes so that if corroded they can be easily replaced or repaired
Tube Pattern inside shell & tube heat exchanger
Tube Pitch
- The tube placement requires a minimum center-to-center distance of 1.25 times the outside diameter of the tube.
- When mechanical cleaning of the tube is specified, a minimum cleaning lane of 6.4 mm must be provided.
Baffles
- Baffles are strategically placed within the shell of the shell and tube heat exchanger.
- They serve to enhance turbulence within the system, extending the flow path for improved heat exchange.
- Baffles play a crucial role in supporting the tubes, minimizing the risk of tube damage and vibration.
Types of Shell and Tube Heat Exchanger
There are two types of TEMA heat exchangers: shell and tube. In accordance with TEMA (Tubular Exchanger Manufacturers Association), Shell and Tube Heat Exchangers can be divided into the following types:
- Class R Exchangers – Refinery and Petrochemical Application
- Class C Exchangers – General Process Application
- Class B Exchangers – Chemical Process Application
TEMA Shell and Tube Heat Exchanger Applicable Criteria
- Inside diameter less than 2540 mm (100 inch)
- Product of nominal diameter (mm) and design pressure (kPa) of 17.5 x 106
- Design pressure of 3000 psig (20684 KPa)
Shell and Tube heat exchanger types based on construction
Depending on various construction and configuration parameters following types of shell and tube heat exchangers are widely used in industries.
Fixed Tube Sheet Heat Exchanger
- The tube sheet is securely fixed within the shell using welding, earning this design the name “fixed tube sheet exchanger.”
- This straightforward and cost-effective construction permits the cleaning of tube bores through mechanical or chemical methods.
- When a significant temperature difference exists between the materials in the shell and the tubes, an expansion joint is typically installed within the shell.
Floating Head Heat Exchanger
- In a floating head heat exchanger, the rear header has the flexibility to float or move because it isn’t welded to the shell.
- This design allows for the easy removal of the tube bundle during maintenance, enhancing accessibility and simplifying maintenance procedures.
Stationary Tube sheet with removable tube bundle
U-tube Heat exchanger
- U-tube heat exchangers belong to the category of shell and tube heat exchangers.
- The distinguishing feature of these heat exchangers is the tube bundle, which consists of continuous tubes bent into a “U” shape.
- The bend side of the U-shaped tubes is free-floating, which allows for thermal expansion without the need for expansion joints.
- It’s important to note that the design, while beneficial for thermal expansion, presents challenges when it comes to cleaning due to the bends in the tubes.
Shell and Tube Heat Exchanger Material of Construction
The following materials are the most common as Shell & Tube Heat Exchanger MOC.
- Carbon steel and Cladding Plates
- Stainless Steel
- Duplex Stainless steel
- Tubes – Carbon steel, Stainless steel, Duplex stainless steel, Exotic material such as copper, Inconel, Titanium
Maintenance of Shell and Tube Heat exchangers
Regular maintenance of shell and tube heat exchangers is essential to ensure their continued functionality. They should be inspected at specified intervals, following both user experience and manufacturer guidelines. These heat exchangers can experience failures due to various factors, including:
- Improper Design: Ensuring that the heat exchanger is correctly designed from the outset is critical to its long-term performance.
- Excessive Fouling: The accumulation of deposits on the heat exchanger surfaces can reduce efficiency. Periodic cleaning helps prevent this issue.
- Air or Gas Binding: Inadequate piping installation or a lack of proper vents can lead to air or gas entrapment within the system, affecting heat transfer. Correcting these issues is crucial.
- Excessive Clearances: Corrosion can result in increased clearances between baffles, the shell, or the tubes, affecting heat transfer efficiency.
- Operating Conditions Deviation: When operating conditions differ significantly from the design conditions, it can impact the heat exchanger’s performance.
- Maldistribution of Flow: Uneven distribution of fluid flow within the unit can lead to inefficiencies. Addressing flow issues is essential.
To enhance the performance and longevity of shell and tube heat exchangers, the following preventive maintenance steps are recommended:
- Regular Cleaning: Periodically clean the heat exchanger surfaces to prevent fouling, ensuring efficient heat transfer.
- Tube Inspection: Inspect the condition of the tubes to identify any signs of wear, corrosion, or damage that may impede heat exchange.
- Gasket Replacement: Gaskets should be periodically replaced to maintain a proper seal and prevent leaks.
- Leak Repair: If any leaks are detected during inspections, they should be promptly repaired to prevent loss of efficiency and potential damage to the system.
By adhering to these maintenance steps at regular intervals, the risk of equipment failure can be reduced, and the overall performance of the shell and tube heat exchanger can be improved.
Application of Shell and Tube Heat Exchangers
Shell & Tube Heat Exchangers find their application in the following Industries
- Refinery and Petrochemical
- Fertilizer
- Oil and Gas
- Chemical
- Power Plants
Kettle Reboiler Type Heat Exchanger
- Kettle reboilers are known for their simplicity and reliability in industrial processes.
- In some cases, they may require the use of pumps to transfer the liquid from the bottom of the column into the kettle. Alternatively, there may be enough liquid head to naturally deliver the liquid into the reboiler.
- In this type of reboiler, steam is introduced into the tube bundle, flows through it, and exits as condensate.
- The liquid from the base of the tower, often referred to as the “bottoms,” is directed through the shell side of the reboiler.
- A retaining wall or overflow weir separates the tube bundle from the reboiler section. This ensures that the reboiler section, where the reboiled liquid (known as the bottom product) is withdrawn, keeps the tube bundle adequately covered with liquid.
- Kettle reboilers are favored for their reliability and ability to handle high vaporization rates, often reaching up to 80%.
- Liquid from the bottom of the tower is directed through the tube bundle, where it undergoes vaporization and exits as condensate.
- To control the liquid level over the bundle, a restraining device, often in the form of a baffle, is employed.
Specifications :
- Proper reboiler operation is crucial for the efficient functioning of a distillation process.
- In a traditional distillation column setup, all the vapor responsible for driving the separation process originates from the reboiler.
- The reboiler is responsible for receiving a liquid stream from the bottom of the column. It may then either partially or fully vaporize this liquid stream.
- Typically, the heat needed for this vaporization process is supplied by steam.
Applications:
- The significant level of vaporization in reboilers makes them susceptible to fouling, and these reboilers tend to be expensive due to their large shell size and maintenance requirements.
Advantages :
- Reboilers are a type of heat exchanger commonly employed to supply heat to the base of industrial distillation columns.
- Their primary function is to boil the liquid originating from the bottom of a distillation column, resulting in the generation of vapors.
- These vapors are then reintroduced into the distillation column to facilitate the separation process.
Established in 1983, N PRO ENGINEERS INDIA is an ISO-certified company based in Pune, specializing in manufacturing and supplying high-quality steel products globally.
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