Tube Sheet Flange

A Tube Sheet Flange is a specialized component used primarily in heat exchangers,boilers,condensers,and other shell-and-tube equipment where the secure and precise attachment of tubes to the system is critical.This flange integrates the functions of a tube sheet—a plate drilled with holes to hold tubes in place—and a flange to connect the entire assembly to the piping or vessel system.It ensures structural integrity,pressure containment,and thermal efficiency in demanding industrial applications.

Key Features and Benefits

Dual Functionality

Combines the tube sheet(for tube support and sealing)and flange(for system connection)into a single,robust component,simplifying design and reducing potential leak points.

High-Pressure and Temperature Resistance

Engineered to withstand extreme operational conditions,including high pressure,temperature fluctuations,and thermal cycling,ensuring reliability in critical processes.

Precision Engineering

Features accurately drilled holes to maintain tube alignment,pitch,and spacing,which is essential for optimal heat transfer efficiency and fluid flow.

Leak-Proof Seal

Tubes are expanded or welded into the tube sheet holes,creating a secure seal that prevents fluid mixing between shell and tube sides.The flange connection itself is designed with gaskets(e.g.,ring-type joint)for additional leak prevention.

Material Compatibility

Fabricated from materials resistant to corrosion,erosion,and fouling,such as carbon steel,stainless steel,alloy steels,or clad materials(e.g.,stainless-clad carbon steel),tailored to the service environment.

Customization

Designed to meet specific project requirements,including size,thickness,hole pattern,and facing type(e.g.,raised face,flat face),complying with standards like ASME Section VIII,TEMA,and DIN.

Technical Highlights

Manufacturing Process:

Machined from forged or rolled plates to ensure dimensional accuracy.

Holes are drilled,reamed,or gun-drilled with tight tolerances(±0.1 mm).

Grooves may be added for seal welding or tube expansion.

Surface finishing(e.g.,machining)ensures flatness and smoothness for gasket sealing.

Common Materials:

Carbon Steel:SA-516 Gr.70,SA-285 Gr.C.

Stainless Steel:SA-240 Type 304/316,SA-182 F304/F316.

Alloy Steels:SA-387 Gr.11/22(chrome-moly).

Clad Materials:Explosion-bonded or weld-overlay clad for corrosion resistance.

Connection Types:

Welded Tubes:Tubes are seal-welded to the tube sheet for high-pressure applications.

Expanded Tubes:Tubes are mechanically expanded into holes for lower-pressure services.

Flange Faces:Raised face(RF),ring-type joint(RTJ),or flat face(FF)to match piping standards.

Design Standards:

ASME Boiler and Pressure Vessel Code,Section VIII.

Tubular Exchanger Manufacturers Association(TEMA)standards.

DIN EN 13445 for pressure vessels.

Applications

Ideal for:

Shell-and-tube heat exchangers(e.g.,condensers,evaporators).

Boilers and steam generators.

Nuclear and fossil fuel power plants.

Chemical and petrochemical processing equipment.

HVAC and refrigeration systems.

Marine and offshore heat exchange units.

Summary

The Tube Sheet Flange is a critical engineered component that ensures the efficiency,safety,and reliability of heat exchange and pressure vessel systems.Its integrated design reduces complexity while providing superior tube retention and system connectivity.Precision manufacturing,material versatility,and compliance with international standards make it indispensable in industries where thermal management and pressure integrity are paramount.By enabling optimal performance in harsh environments,this component supports the continuous operation of essential processes in energy,chemical,and manufacturing sectors.