In seawater desalination, tube sheets and baffles play a critical role in ensuring the efficient transfer of heat between saltwater and freshwater. Tube sheets are typically circular or rectangular plates with holes drilled in them to hold the tubes, while baffles are used to direct the flow of the water through the tubes. In a recent project, Openex was tasked with manufacturing 292 tube sheets and 216 baffles made of S32304 duplex stainless steel. The dimensions of each plate were 2000mm wide and 5800mm long, with 14,389 holes on each plate.
The project presented a significant challenge due to the high precision and tight delivery time requirements of the customer. The traditional machine tools and processes of ordinary processing companies could not meet the customer's needs. To overcome this challenge, Openex relies on its advanced CNC drilling machines and rich experience in tube sheet manufacturing. We had 42 CNC drilling machines, including 11 sets of deep-hole drilling machines and 31 sets of CNC multi-hole drilling equipment from Italy Innse, Korea Daeyang, Shenyang Zhongjie, Wu Chong, etc.
To ensure the smooth implementation of the project, we convened the tube and plate manufacturing department, technical department, quality assurance department, and other related departments to create a perfect production plan. They coordinated the arrangement of staff and equipment to ensure that the 508 pieces of tube sheets and baffles were produced with high quality, efficiency, and delivered on schedule. 20 sets of CNC multi-drilling equipment were involved in the production at the same time.
The manufacturing process of tube sheets and baffles requires high precision and attention to detail. The first step is to prepare the duplex stainless steel plates and cut them into the required size Then, the plates are loaded onto the CNC drilling machines, where the holes are drilled according to the specified pattern. The holes must be precise in size and spacing, and the depth must be accurate to ensure that the tubes and fins fit perfectly.
After the holes were drilled, the tube sheets and baffles were then heat treated. This process was necessary to improve the strength and toughness of the material. The final step was to inspect the tube sheets and baffles for quality assurance. This was done using a variety of methods, including visual inspection, ultrasonic testing, and dye penetrant testing.
The production of 508 pieces of tube sheets and baffles required a significant amount of resources and expertise. The company's ability to deliver high-quality tube sheets and baffles in large volumes is a testament to its advanced technology, skilled workforce, and commitment to customer satisfaction. The use of CNC drilling machines and the coordination of various departments ensured that the project was completed within the tight deadline and met the customer's expectations.
Overall, the production of custom duplex stainless steel tube sheets and baffles in large volumes is a complex undertaking that requires advanced technology, skilled workforce, and coordination between various departments. This project case showcases our capability to supply high-quality tube sheets and baffles that meet the customers' precise requirements.
Openex is a leading metal fabricator with rich experience in heat exchanger components, including tube sheets, baffles, and other related products. With over 20 years of experience in the industry, we have established a reputation for delivering high-quality products that meet the most stringent customer requirements. Our advanced CNC drilling machines and skilled workforce enable us to produce custom tube sheets and baffles in large volumes, ensuring timely delivery and customer satisfaction.
If you have any questions or inquiries about tube sheets and baffles or any other metal fabrication services, please do not hesitate to contact us at yuki.zhou@openex.com.cn. We look forward to working with you.
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