The internals that decide whether a shell-and-tube exchanger runs a full campaign or comes back open at the next shutdown — ferrules, plugs, tube sheets, baffles, dish ends and bellows, machined to the bundle drawing.
6 Products in this range
Almost nothing in this range is a stock item. A tube sheet is drilled to the pitch on your drawing, a ferrule is sized to the actual tube bore, a dish end is formed to the shell diameter and thickness the vessel was designed around. Send the drawing — or the old part — and we work from that.
We manufacture for shell-and-tube exchangers, air-cooled units, boiler banks, economisers, condensers and general pressure vessels. Where the code applies, material, forming and heat treatment follow ASME Section VIII Div. 1, TEMA and IS 2825 as the enquiry requires.
Six component families for heat exchangers, boilers and pressure vessels.
01
Thin-walled sleeves pushed into the inlet end of each tube, where turbulence and entry erosion do their damage. The ferrule takes that wear instead of the tube wall, and when it is worn out you replace a sleeve rather than re-tube the bundle. Standard lengths run 150–300 mm, longer where the inlet velocity is high.
02
When a single tube leaks mid-campaign, the plant does not want the bundle out — it wants that tube taken out of service by lunchtime. A tapered plug driven into both ends does exactly that. We machine them to the measured tube ID with a standard taper, in the same material as the tube so no galvanic couple is introduced.
03
Cold and hot formed heads for vessel, tank and exchanger shells — torispherical, ellipsoidal 2:1, hemispherical, conical and flat. The knuckle is the critical region: it is formed, then thickness-checked across the knuckle radius, because that is where forming thins the plate most.
04
Baffles do two jobs at once — they force the shell-side fluid across the bundle instead of letting it run straight through, and they carry the tubes so they do not sag or vibrate. Both jobs depend on hole position and hole clearance, so plates are CNC drilled from the bundle layout and de-burred on both faces before the tubes are ever pulled through them.
05
The single most demanding part of an exchanger. Every hole has to land on pitch and stay parallel through the full thickness, and the seating faces have to finish flat, or the joints leak on the first thermal cycle. We machine from plate or forged discs, drill on CNC, cut grooves where the design calls for them, and record the actual hole chart with the part.
06
Metallic bellows absorb the axial, lateral and angular movement a hot line or a fixed tube-sheet exchanger cannot avoid, and keep that movement out of the nozzles and anchors. Single or multi-ply convolutions are formed and welded in-house, then supplied with the tie rods, hinges or gimbal hardware the layout needs.
Chosen against the shell-side and tube-side media together — the fluid that attacks first decides the grade.
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| Component | Carbon & Low Alloy | Stainless | High Performance |
|---|---|---|---|
| Tube Sheets | SA 516 Gr 70, SA 266 Cl 2, SA 182 F11 / F22 | SA 182 F304 / F316 / F321 | Duplex F51, Inconel 625 clad |
| Dish Ends | SA 516 Gr 60 / 70, IS 2062, SA 387 Gr 11 / 22 | SA 240 304 / 304L / 316 / 316L | Duplex 2205, Monel 400, titanium Gr 2 |
| Baffle Plates | SA 516 Gr 70, IS 2062 E250 | SA 240 304 / 316 | Duplex 2205 |
| Ferrules | — | SS 304 / 316 / 321 | Inconel 600 / 625, titanium Gr 2 |
| Tube Plugs | SA 105, mild steel | SS 304 / 316 | Brass, Cu-Ni 90/10, Inconel |
| Bellows | — | SS 304 / 316L / 321 | Inconel 625, Incoloy 800 |
Plugs and ferrules are supplied in the tube material by default, so no dissimilar-metal couple is created inside the bundle.
Typical composition of the plate and forging grades used for these components, percent by weight.
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| Grade | C | Mn | Si | P max | S max | Cr | Ni | Mo |
|---|---|---|---|---|---|---|---|---|
| SA 516 Gr 70 | 0.27 max | 0.85–1.20 | 0.15–0.40 | 0.035 | 0.035 | — | — | — |
| SA 266 Cl 2 | 0.30 max | 0.40–1.05 | 0.15–0.35 | 0.025 | 0.025 | — | — | — |
| SA 387 Gr 11 | 0.05–0.17 | 0.40–0.65 | 0.50–0.80 | 0.035 | 0.035 | 1.00–1.50 | — | 0.45–0.65 |
| SA 387 Gr 22 | 0.05–0.15 | 0.30–0.60 | 0.50 max | 0.035 | 0.035 | 2.00–2.50 | — | 0.90–1.10 |
| SA 240 304 | 0.08 max | 2.00 max | 0.75 max | 0.045 | 0.030 | 18.0–20.0 | 8.0–10.5 | — |
| SA 240 316L | 0.030 max | 2.00 max | 0.75 max | 0.045 | 0.030 | 16.0–18.0 | 10.0–14.0 | 2.00–3.00 |
| SA 240 321 | 0.08 max | 2.00 max | 0.75 max | 0.045 | 0.030 | 17.0–19.0 | 9.0–12.0 | — |
| Duplex 2205 | 0.030 max | 2.00 max | 1.00 max | 0.030 | 0.020 | 22.0–23.0 | 4.5–6.5 | 3.0–3.5 |
| Inconel 625 | 0.10 max | 0.50 max | 0.50 max | 0.015 | 0.015 | 20.0–23.0 | 58.0 min | 8.0–10.0 |
SS 321 is stabilised with titanium and Inconel 625 carries niobium plus tantalum; the mill certificate states the actual heat analysis.
Minimum room-temperature values required by the governing specification.
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| Grade | Tensile Strength (MPa, min) | Yield Strength (MPa, min) | Elongation (%, min) | Hardness (HB, max) |
|---|---|---|---|---|
| SA 516 Gr 70 | 485–620 | 260 | 21 | 200 |
| SA 266 Cl 2 | 485–655 | 250 | 22 | 197 |
| SA 387 Gr 11 Cl 2 | 450–585 | 310 | 22 | — |
| SA 387 Gr 22 Cl 2 | 515–690 | 310 | 18 | — |
| SA 240 304 | 515 | 205 | 40 | 201 |
| SA 240 316L | 485 | 170 | 40 | 217 |
| Duplex 2205 | 620 | 450 | 25 | 293 |
| Inconel 625 | 827 | 414 | 30 | — |
Impact testing at the design minimum temperature and post-weld heat treatment are carried out where the code or the enquiry calls for them.
Where these components are put to work.
Nothing leaves the works untested.
Tube sheets and baffles are verified against the drilling layout, and the measured hole chart is issued with the part.
Formed dish ends are thickness-mapped across the crown and knuckle to prove the minimum design thickness after forming.
Positive material identification on alloy and stainless parts, plus magnetic particle inspection on ferritic welds.
Mill test certificates, heat-treatment charts, NDT reports and dimensional records travel with every consignment.
Tube layout, shell diameter, materials and quantity are enough for us to quote — a photograph of the worn part works too.
