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Heat Exchanger Machining Solutions
What is a Heat Exchanger?
A heat exchanger is a device built for efficient heat transfer from one medium to another.
Tube Sheets
The tube sheet is one of the main components in a shell & tube heat exchanger.
Depending on the tube bundle configuration, a heat exchanger can be equipped with one or two tube sheets.
These are usually made of low carbon steel material, with a varying thickness based on the fluid pressure.
Depending on the final application (petrochemical, nuclear, oil&gas, etc.) the tube sheet can be cladded with Stainless Steel or other Super Alloys or even be entirely made out Stainless Steel or Superalloys.
Typical Hole Patterns
The most common types of holes experienced in tube sheet drilling are triangular, rotated triangular, square and rotated square. Each hole pattern presents its own drilling challenges. See typical pattern types below.
Triangular Pattern
Triangular Tube Sheet Pattern Example
Rotated Triangular Pattern
Rotated Triangular Tube Sheet Pattern Example
Square Pattern
Square Tube Sheet Pattern Example
Rotated Square Pattern
Rotated Square Tube Sheet Pattern Example
Material Configuration
Baffles
The baffles are thin plates positioned for the entire length of the tube bundle.
They have two primary functions:
- Sustain the tube bundles
- Increase the heat-transfer by changing the flow of the fluid and generating turbulence
Baffles have generally a thickness between 10mm to 20mm and they are usually machined in stacks of 2 to 5 plates, making the drilling operation more complex.
Typical Baffle Geometries
Single Segmented Baffles
Double Segmented Baffles
Disc and Donut Baffles
Baffle Drilling
- Baffles are generally drilled in stacks from 2 - 5 plates
- Single plate thickness vary from 10mm - 20mm
- Welding the plates together can increase stability
Challenges in Baffle Drilling:
- Uneven surface
- Space between the plates
- Instability
- Disc generated at the hole exit between the plates
Proven Machining Operations
Drilling
Tubesheets have different sizes and a series of holes are done to create a place where the tube ends are welded.
Depending on the hole size and plate material, WIDIA can cover this application with TDMX, TC4 and VariDrill
Drilling of Stacked Plates
Baffles are generally machined in stacks of 2 to 5 plates. Common material is low carbon steel. To face this application with confidence WIDIA offers the TDMX Modular Drilling platform, in combination with the flat bottom insert geometry FPE
Hole Finishing
If necessary, WIDIA is capable of covering fine finishing operations with the TRF / TRM product series
Turning
To remove the surface impurity on tube sheets, these are machined with a turning operation. WIDIA offers a wide range of Heavy duty inserts, as well as ISO turning inserts to cover all the most common materials
Tooling Solutions
TDMX
Extra stable pocket seat design enables high feed rates even in tough conditions, resulting in an increase of productivity and decrease in cost per hole
TC4
Versatile Indexable drilling platform covering a wide range of materials and applications
VariDrill
Universal Solid Carbide Drilling portfolio, suitable for Steel, Stainless Steel and Super Alloys
