When speaking of Shell & Tube Exchangers, we tend to break them into "standard" and "custom" shell and tube exchangers. When we talk of tolerances of flow nozzles and support locations, those manufacturers that belong to TEMA (Tubular Exchanger Manufacturers Association) are expected to build each heat exchangers to within those accepted tolerance called out in TEMA.
See link below for TEMA Tolerances brochure.
Having published tolerances is most important for both the customer and the manufacturer, especially when speaking of "custom" heat exchangers as they are built to a fabrication drawing, without the use of a manufacturing "jig" or "fixture". Without the use of a jig or fixture, the skilled welder relies on measuring tools, which is fairly precise to the naked eye, but when measured exactly, the dimensions will not exact each time that part is manufactured. Building shell & tube exchangers with nozzle tolerances of +/- ¼” don’t tend to be an issue for process plant or system integrator customer’s as long as it is not more than the noted tolerance. In that instance it would need to be corrected, especially, for a TEMA Shop.
“Standard” heat exchangers tend to be built for OEM customers that rely on exacting dimensions for each delivery of the same shell & tube exchanger. In order to maintain quality assurance of each unit, the use of a jig or fixture to assist the skilled welder is a must. This will ensure each and every part, that is welded together, to make a shell & tube exchanger will have the very same dimension each time it is made. This allows customers to use a Thermal Products heat exchanger, with precision and speed in their product.
Having shell & tube exchanger's built to precise measurements is also import when looking to replace a heat exchanger in kind. In this case a Drop In Replacement tube bundle or complete heat exchanger is easiest for plant maintenance personal, hospital or school facility engineers, to install. It assures them that they will not need to make any required piping modifications on either the tube side or shell side.
Thermal Products offers Drop in Replacement heat exchanger and tube bundles for a wide range of heat exchanger manufactures. In most cases, Thermal Products will have the needed equipment to manufacturer a NEW heat exchanger or tube bundle that will fit right into place of the old heat exchanger you are removing. If we don’t, we will advise you during the quoting phase and include freight, in our proposal, for you to ship your old heat exchanger to us for duplicating.
If your heat exchanger is custom and can’t ship it to our facility for duplicating, but have a fabrication drawing, we can offer and build a NEW heat exchanger to your fabrication drawing. Please see our latest Drop In Replacement heat exchanger shipment below.
A New England Food company approached Thermal Products, Scott Robinson and our partner Advantage Engineering to assist them in designing a new process cooling system to cool a new low protein food being manufactured and then packaged.
At first review the (3) process cooling loads were deemed to be in the neighborhood of 100 tons total, depending on product batch temperatures. The initial design fell well above the customers budget for this project and forced us to review other avenues.
During the site visit, Thermal Product’s Scott Robinson, noted that the incoming city water temperature was within a temperature range to handle two of the three processes and recommended using the city water to send to the existing Plate and Frame heat exchangers that were isolating the cooling water from the process food, affording Thermal Products and Advantage Engineering to offer a revised proposal to handle 80% less cooling load. This not only reduces the capital costs of the chiller, substantially, but also lowered the operating costs significantly from what was originally thought.
Scott determined the remaining third process, did require 6.5 gpm of 36°F cooling water to be supplied prompting a revised proposal for a 20 Ton Advantage Engineering Air Cooled Chiller Model OACS-20 with a close approach Plate and Frame exchanger, again to isolate a 30% Propylene Glycol and Water mixture from water heading to an existing heat exchanger with process food on the other side. Scott needed to “de-rate” the chiller to the 9.75 ton load thereby needing 20 tons. The industry design standard for chillers has been a base design of 50°F chilled water temperature @ 95°F ambient temperature. When a lower cooling temperature is required, as Scott did in this application, a higher nominal ton capacity is needed to reach 36°F. The final chiller included some of the equipment below.
• Air Cooled Condensed R407c refrigerant circuit
• Scroll compressors with hot gas bypass capacity control
• Crankcase heater for cold start-ups
• Discharge check valve
• Brazed Plate Heat Exchanger as the evaporator
• 3HP process pump
• NEMA 4 Control Cabinet
• Advantage Proprietary MI Microprocessor control instrument
• Plate and Frame Heat Exchanger, shipped loose for installation indoors
Thermal Products was able to further assist our customer’s tight delivery needs by doing a small customization of a stock chiller in order to have the chiller onsite in Massachusetts in 1 week from order.
The next step Scott says is to consider storing the approximately 10,000 gallons of elevated hot discharge water used daily by trimming those BTU’s off in one large insulated poly tank.
“I have a design in the works to recirculate and cool daily water by preventing it from costly one time use then down the drain”.
“Q3 and Q4 is the timeframe to look at this”
Please look for the follow-up article to wrap-up this application! Please contact Scott Robinson or any of the Thermal Products team to discuss your application
Scott has been with Thermal Products for over 7 years, but has more than 30 years’ experience in the HVAC and refrigeration industries, an easy shift to our line of heat transfer and related industrial products. Scott is an ASHRAE member and retains numerous state trade licenses. Scott is responsible for the New England trade areas.
Titanium TEMA Type AET ready for Shipment
Thermal Products was approached by a chemical company to design an Acetic Acid heater using 450 Thermal Oil. Heating Acetic Acid to a precise process temperature is key in the manufacturing insulated boxes.
Thermal Products designed a TEMA Type AET with a titanium tube side, meaning titanium tubes, titanium baffles and bundle supports, titanium tube sheets, titanium channel head, titanium reversing bonnet and titanium tube side connections.
A TEMA Type AET, is designed with a front channel head with channel cover, which enables the tube side of the heat exchanger to be cleaned without breaking or removing any of the piping. See figure "A" below.
The backend or rear bonnet was designed with a pull through floating head. This design takes into account thermal expansion and the ability to have a straight tube design with a removeable tube bundle. See Figure "T" above.
If you have an application that would require higher alloy materials, contact Thermal Products via phone, email, website inquiry form or chat feature on our website.
A local distributor was looking for three replacement tube bundles for Thrush Heat Exchanger Model S1848(2). Thermal Products offered our exact duplicate tube bundle Model TBU-18-48-2 with .049 wall copper tubes.
Thermal Products manufacturers drop in repalcement tube bundles for many shell and tube heat exchanger manufacturers, such as Armstrong heat exchangers, Taco heat exchangers, Bell & Gossett heat exchangers, Yula heat exchangers, Patterson Kelly heat exchangers, Basco heat exchangers, ITT heat exchangers, Xylem heat exchangers, Standard Exchange heat exchangers, American Standard heat exchangers and many more.
All Thermal Products replacement tube bundles meet OEM specifications and in many cases, surpass. Contact us today for your quote!
Above is a before and after picture of an old, tired heat exchanger and a new drop in replacement shell & tube exchanger that Thermal Products Inc designed and supplied as a drop in replacement heat exchanger to replace a modified Taco “E” BEU series heat exchanger. After meeting with the customer, a local state government, Thermal Products was able to offer one of our “Drop In Replacement” Heat Exchangers so piping changes would NOT be necessary. All critical center line dimensions were held.
Thermal Products offered a TPI-BEU-26-84-2, which is a 26” diameter shell, 84” tube length U-tube bundle, 2 pass tube side arrangement for steam to water application. We offered an all carbon steel constructed shell and head with ¾”, .049 wall copper tubes. The heat exchanger was built to ASME Code and stamped for 150 PSIG @ 375F. Higher temperature and pressure available upon request.
Although we supplied standard materials of carbon steel and copper tubing, Thermal Products, can readily supply Stainless steel shells and heads and stainless steel tubing, Cupro-Nickel tubing, admiralty tubing, Hastelloy, Titanium, AL-6XN among more.
If your shell and head or bonnet are in good condition, we can simply offer a replacement tube bundle instead. Replacing your tube bundle only with one of Thermal Products quality Drop In Replacement Tube bundles would make your project far less difficult and time consuming. In most cases, a Thermal Products replacement tube bundle comes with a .049 tube wall thickness, when most OEM tube bundles are supplied with .035 wall tubing, making your Thermal Products tube bundle more forgiving to tube side erosion from particulate in your water. Simply call your local Thermal Products office with your heat exchanger model number or picture of your heat exchanger nameplate and we’ll provide a quote to you, in most cases, the same day. All Thermal Products tube bundles come with gaskets.
All of our “Drop In Replacement” Heat Exchangers and Tube Bundles can fit identically to any of the heat exchangers made by Taco, Armstrong, Bell & Gossett, Thrush, ITT, Basco, Adamson, American Standard, Yula, Patterson-Kelly and many more, saving your company money and man hours. Contact us today!
HC Heat Exchanger
The Basco Type 500 and HC Series shell & tube heat exchanger offers the widest variety of options for utilizing water or water/glycol for many cooling applications such as cooling compressor lube oil, cooling compressed air, engine lube oil cooling, blow mold cooling, extruder cooling and CNC cutting oil cooling to name a few. It remains the industry standard in ultimate value and long-term reliability. The proven fixed tubesheet design shell and tube heat exchanger offers the cost effectiveness that comes with having a highly standard design, while easily providing for various options to meet specific application requirements. Multiple material options are available as well. This series includes seventeen models with air flow capacities from 75-1500 SCFM (2.12-42.48 SCMM) or oil flow from 7-105 GPM (27-397 LPM) and heat rejection from 14-281 HP (10.4-209.5 KW).
Preferred for new oil-water applications
Rugged steel construction
NPT, SAE O-Ring, SAE flange, or BSPP shell side connections available
End bonnets removable for servicing
Mounting feet included (may be rotated in 90° increments)
Optional material construction on tubes, tubesheets and end bonnets
Customer Focused and Driven
All catalog product is available with short lead-times
Expert application engineers are available to select and size the right product for your application
Custom designs are available
ASME Code Stamped available
Maximum Operating Pressure - Shell Side 300 PSI*
Maximum Operating Pressure - Tube Side 150 PSI
Maximum Operating Temperature 300°F
Tubes - Copper
Tubesheet - Carbon steel
Shell - Carbon steel
Baffles - Carbon steel
End Bonnets - Cast iron
Mounting Brackets - Carbon steel
Gaskets - Nitrile rubber/cellulose fiber
Nameplate - Aluminum foil
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Application Spotlight: Batch Process Water Heating
Thermal Products Inc was asked to design a Shell & Tube Heat Exchanger within a certain footprint as it needed to fit within our customer’s packaged heating system. We offered to design and build an all 316 Stainless Steel Shell & Tube Heat Exchanger, but our customer requested 304 Stainless Steel Shell & Tube Heat Exchanger instead. Our customer also requested the tube side connections of our shell & tube heat exchanger to be Tri Clamp connections for ease of cleaning the heat exchanger.
The design parameters for the project were to heat 300 gallons of process water from 60 degrees Celsius to 80 degrees Celsius in 15 minutes or less. Our customer’s control package needed to maintain tight temperature control with a +/- .5 degrees Celsius discharge temperature variance for their exacting process downstream. The circulating process water flow rate for each batch will be 120 gallons per minute (GPM)
The 304 Stainless Steel Shell & Tube Heat Exchanger was designed to be a 08024, Type BEU with 304 stainless steel tubes and a 2-pass tube side design. The thermal duty was achieved using 387 lb/hr of steam and was built to ASME Code Section 8, division 1 and TEMA C.
Thermal Products sales and design engineers can design a fully customized heat exchanger to your exacting specifications or an "off the shelf" design for quick shipment and installation. Thermal Products can supply the heat exchanger alone or integrate it into a skidded package with controls, valves and pump(s) on a skid enabling a more "plug and play" design, significantly reducing our customers installation costs.
Contact us today to discuss your application!
We understand the need for quick response times in all facets of the industrial and process market. As your local INDEECO Electric Process Heater expert, we are pleased to announce our ability to offer approval drawing in 1 week! Contact us today to discuss your application.
Thermal Products was approached by a regional Paper Mill to design a Semi Instantaneous Process Water Heater utilizing excess steam to trim heat process water for a new product line which required a slightly higher water temperature than what existed already.
Thermal Products designed a skid package that included the following equipment:
Skid package was then painted to custoemr specifications with a 2 part epoxy
Thermal Products can also offer the following equipment for a skid package to fit your specific application.
The use of a low finned tube within a shell and tube exchanger is an excellent solution for increasing efficiencies in the cooling or heating of gases and liquids. When space on your lube oil console or fuel conditioning skid is at a premium, see how Thermal Products can offer a smaller shell and tube exchanger design, using low finned tubes reducing the heat exchanger overall footprint and offering considerable potential to save in terms of materials and heat exchanger fill volumes.
The wide range of dimensions offered by Thermal Products Inc makes these products perfect for a broad scope of applications for oil/gas coolers in consoles, machinery and plant processes.
Low finned tubes increase that outside surface area. By having a finned tube in place, it increases the overall heat transfer rate. This then decreases the total number of tubes required for a given application which then also reduces overall equipment size and can in the long-run decrease the cost of the project.
Applications Thermal Products has designed low finned tubes within our shell and tube exchangers.
Benefits of Low Finned Tubes:
Contact our team today to discuss your application!