Plug-Type Header (Carbon Steel Or Stainless Steel), Used In Air-Cooled Heat Exchanger

Overview

Plug-Type Header is a specialized design of a fluid distribution header used on the tube side of air-cooled heat exchangers. It serves to distribute the process fluid evenly into the tube bundle or collect it from the tubes.

General Consideration And Requirements Of Plug-Type Header

• The Headers shall be Plug-type and shall be provided with plugs opposite the ends of each tube unless otherwise specified. 
• The pressure seal shall be maintained by means of a gasket between the plug flange and the plug plate. 
• The Plug holes shall be of sufficient size to allow roller expansion and cleaning of the tubes. 
• The plugs shall be cylindrical with hexagonal head. it shall have sufficient length to fill the plug sheet threads.

Key Features:

1. Design:

   • The header is essentially a cylindrical or rectangular chamber connected to the tube bundle.

   • It has several removable plugs (usually threaded or bolted) on its body.

   • These plugs provide access ports for:

     • Cleaning

     • Inspection

     • Tube maintenance or plugging

2. Function:

   • Acts as the inlet or outlet for the fluid on the tube side.

   • Distributes fluid evenly into the tube rows for optimal heat exchange.

   • Provides easy access for maintenance without disassembling the entire heat exchanger.

3. Construction:

   • Made from carbon steel or stainless steel depending on operating conditions.

   • Designed to handle the pressure and temperature of the process fluid.

   • The plugs are sealed with gaskets or welding to prevent leakage.

4. Advantages:

   • Maintenance friendly: Plugs can be removed individually, which allows for easy inspection and cleaning.

   • Flexibility: Allows quick plugging of leaking or damaged tubes without shutting down the whole system.

   • Compact: Takes less space compared to other header designs with multiple flanges.

Where is it Used?

• Common in air-cooled heat exchangers where fluid is cooled by air flowing outside the tubes.

• Useful when the tube side fluid needs regular inspection or cleaning.

• Often used in petrochemical, refinery, and power plant applications where uptime and maintenance are critical.

Visual Description

• Imagine a pipe or chamber connected to multiple tubes.

• Along the header’s body, you’ll see several circular removable plugs (like caps or covers).

• These plugs allow easy access to individual tubes inside the header.

Summary