This custom-fabricated ASME TEMA Class R team heat exchanger finned tube bundle serves as the primary thermal core for the W-04A/B High-Temperature Process Condenser within a 400 Tons/Year Imidazoline Production Line. Designed to process utility water on the shell side through 7 single-segmental crossflow baffles while directing process oil through a 4-pass high-temperature tube circuit, this heat exchanger core handles a nominal design heat duty of 581 kW. The mechanical layout conforms to ASME Section VIII Division 1 parameters to withstand a minimum tube side operating fluid entry of 350.00°C.
Bundle Layout Pattern: 30-Degree Triangular Pitch Angle / 32.000 mm Pitch Spacing
Tube Passes / Baffle Type: 4 Passes Tube Side / 35% Diameter Cut Single-Segmental Baffles (7 Pieces, 400 mm Spacing)
Operating Parameters: Shell Side Inlet 45.00°C to Outlet 35.00°C / Tube Side Inlet 350.00°C to Outlet 190.00°C
Design Boundaries: Shell Side 1200.0 kPaG at 150.00°C / Tube Side 1000.0 kPaG at 200.00°C
Corrosion Allowance: Shell Side 1.000 mm / Tube Side 1.000 mm
Finished Components Weight: Dry Weight 2032 kg / Operating Weight 3057 kg / Removable finned tube bundle Weight 1126 kg
Process Connections: Shell Side Inlet/Outlet 100.00 mm (PN16 RFSO Flanged) / Tube Side Inlet/Outlet 80.000 mm (PN16 RFSO Flanged)
Internal Gasket Standard: PTFE or Spiral Wound Gaskets with Graphite Filler
All pressure-retaining parts, internal elements, and bounding structures of this team heat exchanger finned tube bundle utilize explicitly documented ASME Section II material standards:
Tubes Layout: 218 pieces of ASME SA-213 TP316L (SS316L) bright annealed seamless exchange tubes measuring 25mm OD x 2mm wall thickness x 3000mm length arranged in a 30-degree layout.
Tubesheets: Stationary and floating structural plates configured for a TEMA BES floating head assembly utilizing torque-controlled expanded and strength-welded tube-to-tubesheet joints.
Baffle & Support Plates: 7 cross-flow pieces of single-segmental carbon steel plates cut at a 35% diameter ratio and spaced at tight 400mm central intervals.
Shell Cylinder Sections: Heavy-walled carbon steel plate meeting ASME SA-516 Grade 70 / Q345R parameters providing a 1.000mm corrosion allowance.
Frame Internals: 6 carbon steel tie rods combined with 3 passlane seal rods and 1 pair of sealing strips positioned along the bundle perimeter to prevent fluid bypass.
Process Connection Flanges: Carbon steel RFSO flanged connections rated to PN16 standards for direct integration with external piping networks.
High-Temperature Thermal Expansion Accommodation: The TEMA BES horizontal multipass configuration isolates the finned tube bundle from the external shell structure, absorbing axial elongation down to the 350°C process inlet boundary.
Automated Expanded & Strength-Welded Joints: Automated orbital equipment executes structural strength welding of the SA-213 TP316L stainless steel tubes to the tubesheet, followed by secondary electronic torque expansion.
Integrated Fluid Bypass Control: Retaining 1 pair of mechanical sealing strips and 3 passlane seal rods restricts parallel shell-side water streams to a 0.055 crossflow window fraction.
Precision Segmented Baffle Layout: CNC milling machines establish a 400mm horizontal pitch spacing for the 7 single-segmental baffles, matching the shell interior clearance to 4.7625 mm.
Multi-Circuit Hydrostatic Holding Tests: Completely assembled team heat exchanger bundles undergo separate pressure retention tests at the manufacturing facility matching the 1200 kPaG shell and 1000 kPaG tube limits.
Volumetric and Surface Weld NDT: All pressure-boundary longitudinal and circumferential welding paths undergo 100% volumetric Radiographic Testing (RT) supplemented by Liquid Penetrant Testing (PT) on stainless-to-carbon steel transition joints.
Joint Integrity Helium Leak Audits: The complete matrix of 218 tube-to-tubesheet expanded joints undergoes helium mass spectrometer leak detection testing to isolate micro-porosity before final frame insertion.
Third-Party Regulatory Audits: Every phase of mechanical fabrication, material tracking to original mill certificates, and final dimensional geometry verification allows direct oversight by independent inspection agencies including Bureau Veritas (BV), SGS, or TÜV.
