The main process to make a shell and tube heat exchangers consist of several steps. Here's a more detailed breakdown: Here's a more detailed breakdown:
1. Design and Engineering:
- Correlate the heat transfer needs by considering temperature ranges, pressure ratings, and flows. Where necessary, include special aspects.
- Tube number, tube diameter, tube length, shell diameter, baffle arrangement, and other specifications shall be chosen and indicated accordingly.
- CAD (computer-aided design) means that using the software program to create precise drawings and simulations we may fine-tune their performance.
2. Material Procurement:
- Source materials including the shell, tube, baffles, headers and gaskets of the heat exchanger are based on the process design requirements.
- The materials are selected considering the various parameters like operating conditions (temperature, pressure, fluid type), resistance to corrosion and affordability.
3. Tube Fabrication:
- Tubes as separate entity are produced using different processes such as extrusion and seamless rolling in other to meet with the size and the material requirements to meet the demands.
- To length, these tubes are cut to specific specs, then vary in processing such as bending, shaping, or end forming as the need is.
4. Tube Sheet Fabrication:
- The sheets are commonly made from materials used for the shell, and are held onto the shell by bolts, rivets, or welds. The thickness of the material is determined by the tubes that it supports.
- A hole of appropriate size is made through drilling, punching, or by the high-powered machinery. The holes in the tubes must be in line with the design to achieve an ideal assembly.
5. Shell Fabrication:
- The shell can be made as one piece or the multiple parts weld, depending on the chassis and particular design.
- The techniques of T (TIG- Tungsten Inert Gas) or M (MIG- Metal Inert Gas) welding that involve shell februations are widely used.
6. Assembly:
- A tube, its end flanges, and the tube sheet are assembled. They are then inserted again into the shell tube sheet at both ends of the shell.
- This is what the baffles are installed for, inside the envelope, to direct the conduct and improve the heat transmission.
- For the purpose of fluid inlet and outlet, I produced the closures in the form of heads that were attached to the end of the tubes.
- Sealing gaskets or O-rings are positioned on either side of creating a seal to stop the fluid leaks.
7. Welding and Brazing:
- This fusion welding process or brazing is used to join together various components like tubes to tube sheets, tube sheets to shell, or baffles to the shell individually through this fusion welding process or brazing.
- Well trained welders can guarantee strong, do not have any leakage of gases, and their method of welding must be following welding standards.
8. Testing and Quality Assurance:
- A large number of procedures also goes through the heat exchanger quality and performance tests such as pressure tests, leak tests, as well as non-destructive tests (NDT) like radiography or ultrasonic.
- Checks for quality control are implemented during the Shell and Tube Heat Exchanger Manufacturers process to assure that the dimensions are correct and that the material is intact as well as the specifications have been met.
9. Surface Treatment:
- Surface treatment methods such as painting, coating, or passivation comes into the play to shield the substance from corrosion or improve the thermal conductivity.
10. Final Inspection and Packaging:
- The conveyer belt leads to the last Quality assurance step in which the heat exchanger is checked by inspectors to ensure that it meets all specifications and standards.
Also Read: How To Manufacture The Shell And Tube Heat Exchanger
- After the inspection and final test, the heat exchanger is containerized for safe and secure shipping which can be accompanied by paperwork like inspection certificate and operating manual.
Swastik Hydraulic team work around the various engineering departments (design engineers, makers, quality control inspector), the production area and welding will support the production of an efficient shall and tube heat exchanger.