How a Shell and Tube Heat Exchanger is fabricated

A drawing for a shell and tube heat exchanger is drawn with a full dimension and specification of materials is specified.

Drawing of a Shell and Tube HEat Exchanger

The first process is to assemble the tube bundles together first before inserting it into the main shell. Below shows a fully assembled tube bundle.

A fully Assembled Tube Bundle

Next, the tubes are then fully welded into the tubesheet. Our welders are qualified welders with the necessary PQR, WPS and WQT qualifications.

Welding tube to tubesheet

After full weld, the tube bundle is then inserted into the shell body.

Shell and Tube Heat Exchanger

And then, the end caps on both sides are assembled together.

Assembly of end caps Shell and Tube Heat Exchanger

Again, the end caps are fully welded together after ensuring that all dimensions are according to the drawing as after full weld, the parts cannot be modified again.

Full Welding of Shell Side

Next, the nozzle inlet and outlets are then assembled and welded.

Assembly of Nozzle Shell and Tube Heat Exchanger

Finally, the end flanges at both ends are assembled and fully welded.

Flanges assembled and welded

Final dimension check after full weld then on to hydrostatic test. The pressure of test is according to the requirement of the customer as specified on the drawing specs.

Hydrostatic Test on the tube bundle side. This process is actually done before the assembly of end caps to the shell.