Premium-grade replacement tube bundles custom-manufactured to extend the lifecycle of your existing shell & tube heat exchangers [1]. Engineered strictly to TEMA and ASME codes, we fabricate each bundle [1] using high-precision CNC tubesheet drilling, automated joint sealing, and corrosion-resistant alloys.
| Specification Parameter | Value / Standard Configuration |
|---|---|
| Product Type | Replacement Tube Bundle (Straight / U-Tube / Finned) [1] |
| Design Standard Codes | ASME Section VIII Div 1, TEMA Standards Class R/B/C |
| Tube Metallurgy | Stainless Steel (SS316L/SS304), Copper, Cupro-Nickel, Titanium |
| Tubesheet Materials | Carbon Steel (ASME SA516 Gr 70), SS, Brass/Bronze Clad |
| Maximum Tube Length | Up to 6000 mm (Custom fabricated to customer drawings) |
| Maximum Tube Count | Up to 1200 Tubes per bundle (Custom layouts available) |
| Water/Fluid Testing | Hydrostatic Pressure up to 45 Bar, Helium Leak, Eddy Current |
| Baffle Metallurgy | Carbon Steel, Stainless Steel, Brass/Bronze |
| Manufacturing Basis | Reverse-Engineered from Old Bundles or Custom Blueprints [1] |
Precision CNC Tubesheet Drilling: Our manufacturing plant utilizes advanced CNC drilling machinery to ensure exact tubesheet hole configurations, pitch tolerances, and baffle pass-partition alignments. This exact dimensional accuracy prevents shell-side fluid bypass, optimizes water velocities , and allows new replacement bundles to slide smoothly [1] into your existing exchanger shells without binding.
Advanced NDT-Inspected Joint Sealing: Tube-to-tubesheet joint interfaces are the primary source of process cross-contamination and fluid pressure drop. We perform automated orbital TIG welding or precise pneumatic torque expanding depending on design operating pressures. Every completed bundle [1] undergoes strict non-destructive testing (NDT), including hydrostatic testing up to 45 Bar, helium leak tests, or eddy current inspections.
Certified Corrosion-Resistant Alloys: Sourced strictly with premium stainless steel, cupro-nickel, brass, or solid titanium , our replacement bundles are engineered for maximum chemical compatibility with your aggressive process streams. This highly precise metallurgical selection minimizes material degradation, preventing premature tube failure and maximizing overall system lifetime.
Every replacement bundle is modeled with specific thermodynamic profiles. Below are the key engineering specifications built into our designs:
Our automated orbital TIG welding guarantees uniform, high-durability tube-to-tubesheet joint seals that withstand high thermal shock cycles.
If original manufacturing blueprints are unavailable, we can reverse-engineer custom replacement bundles directly from your old physical assets [1].
Every bundle undergoes strict hydro-testing at 1.5 times the design operating pressure, verifying leak-free structural integrity before dispatch.
