/ News & Press / Video / Time-lapse manufacturing of large shell and tube heat exchangers

Time-lapse manufacturing of large shell and tube heat exchangers

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Kind: captions
Language: en

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For nearly 40 years HRS has been designing and manufacturing heat exchangers ...
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... for a wide variety of industries such as environmental, industrial, food and pharmaceutical.
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Every HRS heat exchanger is designed specifically to the client's demands, from small units to large ones.
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Our largest heat exchangers are designed to the smallest detail...
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... to make sure they fit perfectly within the customers’ planned installation.
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Let’s take a closer look at a unit recently manufactured by HRS and a time-lapse of how it was made.
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This unit is designed for a gas heat recovery application and fully manufactured in stainless steel ...
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... with HRS's reknown high quality for arduous duties.
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For gas applications, small pressure drops are often required.
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This leads to large tube bundles...
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... such as this one.
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Here we have 2900 tubes inserted within this shell ...
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... one by one.
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With almost 21Km of tubes fitted inside this shell ...
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... the tubes are carefully expanded and welded into the tube sheet, ...
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... to give a high level of resistance to thermal and mechanical stresses.
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Impingement rods are carefully spaced and placed at the shell inlet, ...
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... absorbing kinetic charge of the incoming flow and preventing unwanted tube vibrations.
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Inside the shell, segmental baffles are placed for supporting the large tube bundle...
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... and improving the thermal efficiency.
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The inlet nozzles are designed to meet strict dimensional specifications.
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Otherwise, this 14 tonnes monster would not connect to the pipework at the customer's facilities.
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Lifting logs are fitted to the 1.5m diameter and 7m long shell ...
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... to ensure safe transportation during its manufacturing, transport and finally the installation.
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Expansion bellows are fitted to absorb thermal dilations which take place between the inner tubes and the shell.
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The gas flow in this heat exchanger can reach up to 500ºC.
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Fixing supports are installed for reinforcing the bellows ...
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... during the handling of the unit prior to startup.
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Stainless steel plate is rolled for the fabrication of the heat exchanger shell.
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The shell sections are joined together.
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On the left hand side, the baffle cage is being prepared.
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The expansion bellows are point welded to the shell.
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The shell section is complete, measuring 7 meters in length.
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The baffle cage reaching its completion.
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Working around the clock to meet the promised delivery date.
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The baffle cage is placed in the shell.
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The first tubes are inserted one by one.
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Only the first tube plate is welded at this time.
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Positioning of the second tube plate.
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The remaining tubes are inserted.
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When all the tubes are inserted they are point welded to the tube plate.
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Now the orbital welding and roller expansion work can begin.
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Two operators begin the orbital welding.
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Tubes are welded in a zig-zag pattern to avoid tension on the tube plate.
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The tubes are roller expanded assuring a perfect fit.
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The unit has been pressure tested and is prepared for transportation.
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Specially manufactured saddles are used to support the unit on the truck.
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A 16 ton lift.
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Job done!

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