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Replacement Tube Bundle for Floating Head Heat Exchanger | Custom Sizes

Tube bundle
July 03, 2025
Category Connection: Tube Bundle
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Tags:
#air cooler tube bundle #heat exchanger tube bundle #condenser tube bundle
Brief: This video frames the solution within typical operational contexts for clearer understanding. We demonstrate how a custom-sized replacement tube bundle can be configured to replace a floating head heat exchanger with a fixed tube sheet design. You'll see the key components and technical adaptations that make this possible, including thermal stress management and fouling mitigation strategies, providing valuable insights for refinery, power plant, and chemical processing applications.
Related Product Features:
  • Custom-sized tube bundles designed to replace floating head heat exchangers with fixed tube sheet configurations.
  • Constructed with corrosion-resistant materials including stainless steel 316L, titanium, copper-nickel alloys, or Inconel.
  • Features thick tube sheets that anchor tubes via welding, rolling, or expansion for rigid, leak-proof seals.
  • Includes segmental, helical, or rod baffles to direct shell-side flow and prevent vibration.
  • Designed to withstand high-pressure and high-temperature conditions up to 300 bar tube-side.
  • Offers cost efficiency by eliminating floating head components and reducing fabrication expenses.
  • Provides minimal leakage risk through welded tube sheets that eliminate gasket failures.
  • Suitable for applications with clean fluids, moderate temperature differences, and minimal fouling.
FAQs:
  • Why would I replace a floating head heat exchanger with a fixed tube bundle?
    Fixed tube bundles offer cost reduction by eliminating complex floating head assemblies, minimize leakage risk through welded tube sheets, and provide robust construction for high-pressure/high-temperature conditions where thermal stresses are manageable and maintenance requirements are minimal.
  • How are thermal expansion issues managed in fixed tube bundle replacements?
    Thermal stress is managed through installation of expansion joints like bellows or flanged joints on the shell, or by using shell and tube materials with similar coefficients of thermal expansion, particularly critical when temperature differences exceed 50-100°C.
  • What are the maintenance limitations of fixed tube bundles compared to floating head designs?
    Fixed tube bundles are not removable for mechanical cleaning, so maintenance is limited to chemical cleaning methods. This is mitigated through integrated CIP systems, wider tube pitch to reduce clogging, and anti-fouling tube coatings.
  • Which industries are best suited for fixed tube bundle replacements?
    These replacements are ideal for refineries (high-pressure gas coolers), power plants (feedwater heaters), chemical processing (non-fouling fluid exchangers), and HVAC systems (chillers with clean water circuits).
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