Case Study: Custom Surfacing Tube Sheets for Boilers Delivered to Japan

Surfacing tube sheets play a crucial role in the efficient and reliable operation of boilers. These critical components act as sturdy foundations for heat exchange tubes, ensuring optimal performance and safety. In a recent project, our company successfully delivered six custom-made surfacing tube sheets to a prestigious customer in Japan. With exacting standards and stringent quality requirements, this project demanded exceptional precision and expertise.

The Manufacturing Process of Surfacing Tube Sheets

The production journey of these custom-made surfacing tube sheets encompassed various stages, each meticulously executed to ensure superior quality and performance. Here is a breakdown of the manufacturing process:

1. Incoming Material Inspection:
   To ensure the highest level of quality, the initial step involved a comprehensive inspection of the raw materials. Metallurgical properties, chemical composition, and mechanical characteristics were carefully assessed to guarantee material integrity and suitability.
2. Cutting:
   Using advanced cutting techniques, the raw materials were precisely shaped into the desired dimensions. Attention to detail and accuracy were paramount, as even minor deviations could impact the final product's performance.
3. Surface Overlaying:
   One of the critical phases in the manufacturing process was the surfacing or cladding of the tube sheets. A special alloy was meticulously applied to the surface, ensuring a strong bond and exceptional resistance to high temperatures, corrosion, and wear.
4. Non-Destructive Testing (NDT):
   To verify the integrity of the surfacing, non-destructive testing techniques such as ultrasonic testing, radiography, and magnetic particle inspection were employed. These tests guarantee that the surfacing meets the customer's strict quality requirements.
5. Heat Treatment:
   Heat treatment is essential to enhance the mechanical properties of the surfacing and improve its resistance to stress, fatigue, and deformation. The tube sheets were subjected to carefully controlled heating and cooling processes to achieve the desired material characteristics.
6. Sandblasting:
   To ensure a clean and uniform surface, the tube sheets underwent sandblasting, which effectively removes impurities, oxides, and any residual contaminants. This process prepares the surface for subsequent operations and enhances the adhesion of protective coatings.
7. Drilling:
   Precise drilling of holes on the tube sheets was executed accurately, adhering to the customer's strict aperture requirements. The drilled holes are instrumental in securing the heat exchange tubes, facilitating smooth heat transfer, and optimizing boiler performance.
8. Quality Inspection:
   At various stages throughout the manufacturing process, rigorous quality inspections were performed to ensure compliance with the customer's stringent requirements. Aperture accuracy within ±0.05mm and cladding thickness accuracy within ±0.2mm were meticulously verified to guarantee a flawless end product.
9. Packaging:
   Upon successful quality inspection, the custom-made surfacing tube sheets were carefully packaged, ensuring protection during transportation and delivery to the customer in Japan.

Benefits of Custom Surfacing Tube Sheets for Boilers

• Enhanced Performance: Custom surfacing tube sheets are tailored to meet the specific requirements of each boiler, optimizing heat transfer efficiency and overall performance.
• Corrosion and Wear Resistance: The application of special alloy cladding significantly enhances the tube sheets' resistance to corrosion, erosion, and wear, extending their lifespan and minimizing maintenance costs.
• Improved Efficiency: The precise aperture accuracy and cladding thickness achieved in the manufacturing process ensure optimal alignment and contact with heat exchange tubes, maximizing heat transfer efficiency and reducing energy consumption.
• Reliable and Safe Operation: Custom surfacing tube sheets undergo rigorous quality inspections and testing, ensuring their structural integrity and reliability, which are crucial for safe and uninterrupted boiler operation.

As a leading provider of high-quality tube sheets and other metal components, our company has a proven track record of delivering outstanding results for customers worldwide. With a solid commitment to precision, expertise, and customer satisfaction, we specialize in custom metal fabrication solutions that meet even the most demanding requirements.

If you are in need of custom-made surfacing tube sheets or any other metal components, we invite you to get in touch with our team. We are dedicated to collaborating closely with our customers to deliver tailored solutions that exceed expectations. Contact us at yuki.zhou@openex.com.cn today to discuss your project requirements and experience the difference between working with a trusted industry partner.