Shell & Tube Heat Exchanger Fabrication

We manufacture and document approved shell-and-tube exchanger scopes according to the confirmed code requirements. Common references include:

• • ASME Section VIII Div.1 / Div.2 with U or U2 stamp — the most common requirement for Americas, Middle East, and Southeast Asia projects
• • TEMA standards (R, C, or B class) for shell and tube mechanical design, combined with ASME pressure design
• • EN 13445 / PED 2014/68/EU with CE marking for European projects
• • GB 150 / GB 151 for Chinese domestic or dual-standard projects
• • API 661 for air-cooled heat exchangers in refinery and petrochemical service

If your project specifies a combination — e.g. ASME pressure design + TEMA mechanical + NACE MR0175 materials — please provide the approved datasheet and drawings so we can confirm whether ORL can manufacture and document the scope.

The fastest path to an accurate quotation is a filled-in datasheet (TEMA format preferred). If you don't have one yet, we need:

A rough spec sheet is enough only for initial screening. For budget or firm quotation, customer-approved datasheets and drawings are required so we can confirm manufacturing feasibility before commitment.

Material selection is one of the most consequential decisions in heat exchanger design. Our approach:

• • Carbon steel (SA-179 / SA-106): Standard for clean water, steam, light hydrocarbons below ~250°C — lowest cost, widest availability
• • Stainless steel 304L / 316L: Aqueous corrosive services, food/pharma, mild chloride environments
• • Duplex (2205 / 2507): High-chloride seawater or brine, combines strength with corrosion resistance
• • Titanium Gr.2 / Gr.12: Seawater coolers, chlorinated water, where stainless would pit — common in power plant condenser retrofit
• • Nickel alloys: Highly oxidizing acids, HCl, mixed acid service, chemical reactors
• • NACE MR0175 compliance: Required for any H₂S-containing streams above threshold — affects material certs, hardness limits, and PWHT

We can review material availability and fabrication suitability against the customer-approved datasheet. Process corrosion responsibility and final material selection should remain with the owner, EPC or design institute.

Practical manufacturing limits depend on confirmed design, dimensions, weight, material procurement, lifting capacity and transport route:

For ultra-high pressure, cryogenic service, oversized equipment or special alloys, send the datasheet and drawings first — we will confirm feasibility before quoting and will decline scopes outside our capability.

Fouling is the single largest cause of heat exchanger performance degradation. For manufacturing inquiries, fouling and cleanability should already be reflected in the approved design. General design points include:

• • Fluid allocation: The fouling fluid goes tube-side whenever possible — tubes are easy to clean mechanically; shell side is much harder to access. Exceptions: corrosive fluids that attack the shell, high-pressure fluids where thick shells are expensive
• • Velocity design: Tube-side velocity maintained above 1.5 m/s (liquids) to reduce particulate settlement; below 3 m/s for erosion-sensitive fluids
• • TEMA fouling factors: We apply TEMA Table RGP-T-2.4 fouling resistances as minimums; client-specified values used where provided
• • Bundle design for cleanability: Fixed tubesheet for clean service (cheapest, best heat transfer); removable U-tube or floating head for fouling service requiring hydroblast cleaning
• • Anti-fouling coatings: Available on tube OD for cooling water service — reduces biofilm attachment in open-loop cooling systems

Our standard NDT scope for ASME U-stamp units (additional tests available on request):

All NDT results are documented with inspector name, date, technique, and accept/reject criteria. Reports are included in the final documentation book.

Confirmed orders ship with a documentation dossier according to the agreed code and inspection scope. Typical contents may include:

• • ASME U-1 Data Report (or equivalent national report for other codes)
• • EN 10204 3.1 Material Test Reports for all pressure parts — shell, heads, nozzles, tubes, tubesheets, flanges
• • Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR)
• • Welder performance qualification records
• • NDT reports — RT films/digital files, PT/MT reports, UT scan records as applicable
• • Hydrostatic test certificate with date, pressure, hold time, and inspector signature
• • Dimensional inspection report
• • PWHT charts where required
• • As-built datasheet and drawings in PDF and DXF/DWG format
• • Operation and maintenance manual

Documents are provided in English as standard. Certified translations into other languages are available on request. Hard copies and digital (USB) delivery both available.

We welcome and actively facilitate third-party inspection. Our process:

• • ITP issued at order kick-off — Inspection Test Plan defines all witness (W), hold (H), review (R), and surveillance (S) points. Client signs off before fabrication starts
• • Advance notification — minimum 5 working days notice before each witness/hold point. We never spring tests on inspectors
• • Pre-inspection document packages — material certs, WPS, traveler, and dimensional drawings pre-staged for inspector arrival
• • Inspector access — unrestricted access to all manufacturing stages including supplier material receiving
• • Inspection agencies accepted: SGS, TUV Rheinland, Bureau Veritas, Lloyds Register, DNV, Intertek, and client-nominated agencies

Inspection costs (agency fees) are typically quoted as a separate line item so they are transparent. We can include them in the order if you prefer a turnkey delivery.

Lead times depend on complexity, size, and material lead times. Typical schedule from order confirmation:

Expedited delivery is possible for standard sizes with pre-purchased materials — contact us for urgent project scheduling.

Maintenance frequency is driven by service severity, not a fixed calendar. Our recommendations:

• • Clean services (steam, condensate, clean water): Inspect every 3-5 years during planned turnaround. Hydrostatic re-test every 10 years or per jurisdictional rules
• • Moderate fouling (cooling tower water, lube oil): Annual performance monitoring; clean when overall heat transfer coefficient drops 15-20% from design, typically every 1-2 years
• • Heavy fouling (raw river water, process streams with solids): Quarterly inspection; online performance tracking recommended with differential temperature monitoring
• • Corrosive service: Annual external inspection plus UT thickness measurement on shell; tube sample pulled and visually/UT inspected every 3-4 years

Maintenance intervals should be set by the plant owner or design institute based on actual service severity. ORL can supply spare tube bundles or tube sets when drawings and material specifications are available.