ASME U Stamp TEMA Class R team heat exchanger Tube Bundle for Steam Gland Condenser heat exchanger

ASME U Stamp TEMA Class R team heat exchanger Tube Bundle for Steam Gland Condenser heat exchanger

Our custom-engineered ASME TEMA Class R team heat exchanger Tube Bundle is designed and manufactured as a high-performance replacement bundle for critical oil refinery applications, specifically optimized for the Steam Gland Condenser heat exchanger at the Sasrah Refinery in Iraq. Engineered in strict compliance with ASME Section VIII Division 1 and TEMA Class R standards, this premium floating steam heat exchanger core is built to handle severe thermal duties, enhancing gasoline production and optimizing plant efficiency under rigorous downstream refinery operating conditions.

CORE COMPONENTS & MATERIAL SPECIFICATIONS

• Heat Exchanger Tubes: SA179 Seamless Carbon Steel Tubes layout designed to eliminate the potential for hydrogen-induced cracking and maximize heat exchanger thermal transfer area.

• Tubesheets: Fabricated from premium Forged Steel SA266 Grade 2 to provide dense microstructural integrity near joints, precision-machined with 20.4mm diameter holes.

• Baffles & Support Plates: Multi-segment internal support baffle plates machined from SA516 Grade 60 / ASTM A36 plates to control fluid direction and support the team heat exchanger assembly.

• Sliding Saddle Frame: Structural steel plates matched with integrated sliding saddles and sliding plates to accommodate calculated axial thermal expansion of the heat exchanger during operation.

• Fasteners & Gaskets: Heavy-duty high-tensile bolting connections calibrated to explicit ASME tightening torque limits to ensure zero process leakage at the shell-channel junction.

CORE TECHNOLOGY & MANUFACTURING ADVANTAGES

• TEMA Class R Structural Configuration: The overall design, baffle clearance spacing, and inner tube layouts conform strictly to TEMA Class R requirements for severe refinery environments, ensuring this team heat exchanger withstands regular turnaround cleaning.

• CNC Precision Tubesheet Boring: All tube holes for this heat exchanger are drilled using advanced CNC vertical boring machines to an exact diameter of 20.4mm, preventing early crevice corrosion and guaranteeing complete metal-to-metal tube expansion contact.

• Stress Relief & Simulated PWHT: All pressure-retaining forged plates and carbon steel sections undergo calculated Post-Weld Heat Treatment (Simulated PWHT) cycles to minimize residual stress across all heat-affected zones before assembling the team heat exchanger.

• Mechanized Tube Joint Execution: Tubes are precision-expanded and seal-welded or strength-welded to the SA266 forged tubesheet using automated expansion torque logs, guaranteeing a continuous airtight seal inside the heat exchanger bundle.

STRICT QUALITY CONTROL & TESTING

• Manufacturer Hydrostatic Testing: This completed team heat exchanger component is subjected to full-pressure hydrostatic holding tests at the manufacturer facility to visually and instrumentally confirm joint leak-tightness.

• Standardized Geometrical Verifications: All fabrication tolerances are verified under strict compliance with ISO 2768-mK and EN ISO 13920-BF standards to ensure precise dimension control and perfect fitment into the existing heat exchanger shell.

• Material Traceability Documents: Delivery includes a comprehensive, verified Technical Databook containing certified Material Test Reports (MTRs) for SA179 and SA266 metals, ASME qualified welding logs, and NDT examination reports.

INTERNATIONAL LOGISTICS & TARGET MARKET SUPPORT

• Anti-Corrosion Seaworthy Protection: All machined flange paths and tubesheet faces of the team heat exchanger are coated with temporary rust-inhibiting compounds and wrapped with heavy-duty weather barriers suitable for ocean freight.

• Structural Loading Layouts: The entire heat exchanger bundle is cradled onto heavy-duty steel support frames or skid assemblies to eliminate any direct weight loading on the SA179 heat exchanger tubes during transit and crane operations.

• Middle East Regulatory Customs Support: Full technical documentation package available to support strict customs clearance and import validation frameworks required for shipping industrial team heat exchanger machinery directly into Iraq and adjacent refinery sites.