Successful Delivery of Custom-Made Tube Sheets: Project Case

Project Introduction

In the pursuit of innovation and sustainability, well-known environmental protection enterprises are constantly seeking reliable partners to provide them with high-quality components. Recently, a well-known environmental protection enterprise partnered with us for the supply of custom-made tube sheets. These tube sheets, consisting of 10 pieces, with a diameter of 3197mm and a thickness of 30mm, were meticulously manufactured and successfully delivered to the customer.

Tube sheets play a crucial role in various industrial applications, particularly in heat exchangers, condensers, and boilers. These vital components provide support and secure the tubes in a fixed position, facilitating the efficient transfer of heat or fluid. Tube sheets are typically constructed using high-quality materials to withstand extreme conditions and maintain structural integrity over an extended period.

One important aspect of tube sheet manufacturing is the creation of accurately aligned holes for tube insertion. These holes must be precisely drilled to ensure a tight fit and optimal performance. We use advanced multi-hole CNC drilling machines, enabling us to achieve high efficiency and accuracy in hole production. The state-of-the-art machinery significantly reduces manufacturing time without compromising quality.

The Manufacturing Process of Tube Sheets

The manufacturing process of these custom-made tube sheets involved several intricate steps, each crucial in achieving the desired end product. Let us delve into the key stages:

1. Cutting: The initial step involved cutting the raw materials, typically high-quality steel, into the desired shape and dimensions. This precision cutting ensured the correct size and consistency of the tube sheets.
2. Beveling: Following the cutting process, beveling was performed to prepare the edges for welding. Beveling creates the necessary groove for the weld, ensuring a strong and reliable joint.
3. Welding: Submerged arc welding, a highly efficient and reliable method, was employed to fuse the tube sheets and achieve secure joints. This technique ensures excellent weld quality, providing optimal structural integrity.
4. Grinding and Planing: After welding, grinding and planing were carried out to smoothen and refine the surface of the tube sheets. This process aimed to eliminate any irregularities or imperfections, ensuring a flat and uniform surface.
5. Non-Destructive Testing (NDT): To guarantee the integrity and quality of the welds, NDT techniques, such as ultrasonic or radiographic testing, were employed. These non-destructive methods allow for comprehensive evaluation and identification of any potential defects or flaws.
6. Drilling and Machining: Multi-hole drilling equipment was utilized to create the required holes on the tube sheets. With precision drilling, we ensured accurate placement and alignment of the holes to facilitate the attachment of tubes.
7. Inspection: A meticulous inspection process was carried out to verify the dimensional accuracy, structural integrity, and overall quality of the tube sheets. This comprehensive inspection ensured that the end product met the stringent standards set by our company and the customer.

Quality Control Measures

Throughout the manufacturing process, stringent quality control measures were implemented to guarantee the highest standards of performance and reliability. The deformation of the leveling was closely monitored and controlled within a strict limit of 3mm to ensure optimal flatness. The utilization of submerged arc welding, combined with plasma gas planing for root cleaning, helped avoid weld carburization and preserve the mechanical properties of the welds. These measures played a crucial role in ensuring the longevity and efficiency of the tube sheets.

About Us

With extensive experience in custom manufacturing, we possess the expertise, advanced technology, and skilled workforce necessary to meet diverse customer requirements.

We specialize in the production of high-quality tube sheets, along with a wide range of other precision components, catering to various industries. Our commitment to innovation, strict quality control, and timely delivery have earned us a stellar reputation as a trusted partner in the manufacturing sector.

If you are in need of custom-made metal components or have specific project requirements, feel free to contact us today at sales3@openex.com.cn. Our dedicated team is ready to collaborate with you, providing tailored solutions to drive your business forward.