BOILER PRESSURE PARTS Superheater Coils: Super heater coils are used in a boiler to generate saturated steam.

The super heater

coils are specially used in Boilers of Power plant.

Economiser Coils: Economizer coils are used in downstream of Boiler bank to preheat the feed water
absorbing heat from hot exhaust gases. Economizers are always water tube type. Economizers have different types of Tubes depending upon the application. Bare tubes in Economizers are widely used in Industrial boilers and for applications like Heat recovery boilers in Sulfuric acid plants, gilled tubes are employed. Finned tubes are popular in HRSG applications. Feed water can be heated up to a level about 20 - 30 C below saturation temperature of the boiler.

Studded Tubes / Studded Coils: An electric current is applied by

contacts on the stud and tube and the resistance in this circuit produces the heat necessary for welding. Maximum resistance and therefore maximum heating occurs at the interface between the Stud and the tube. Pressure to forge the Stud and the tube together at the point of maximum heating is applied by various forms of tooling. These resistance welding processes produce a strong metallurgical bond between the stud and the tube while minimizing the heat affected zone (HAZ) in the tube. The use of pressure to forge the fin and the tube together helps to minimize the heat input necessary to make the weld. This Product is used in Fired Heaters under Very High Pressure & Temperature mainly in Petroleum refineries

Water Wall Tubes: These are tubes in the Boiler where water is
evaporated to steam and are also called Steam Generating Tubes. These Tubes also form the Walls of the Boiler and are hence called Water Walls or Water Wall Panels. These Tubes have very complicated shapes to allow Inspection openings and burner throats and fabrication require intricate binding on CNC programable bending Machines and checking on 3D layouts. Tubeweld can supply these tubes with ends swaged/reduced to smaller diameters or expanded to higher diameters. Ends can be supplied fully ground and annealed to facilitate Expansion or bevelled to weld to Header Stubs. The Water Wall Panels are High frequency tube to tube welded and then bent on Panel Bending Machines or the Gas tight panel can be made by welding Fins to tubes using Low Temperature Automatic Welding Machines using CO2 and Filler wires .

Heat Exchangers:

For pressure vessels and reaction vessels in M.S., Al, Monel, Inconel, Cupronickel, etc., Tube Weld employs the latest techniques for expanding tube ends into tube sheets. High pressure tests are always carried out on these heat exchangers before they leave the factory. Brass, copper, M.S. and S.S. tube sheets are used. Tube sheets are also made out of mild steel, alloy steel or stainless steel and baffle plates are made out of mild steel or stainless steel. Tube Weld fabricates U Tube heat exchangers which are used in fertilizer plants, petrochemical and power project complexes. Fabrication of U-Tubes for Heat-Exchangers Spans at extremely Short Delivery time, even Extra long (23 mts.) is Tube Weld specialty. Tube Bending as per TEMA. Tubes to any specification and any length can be supplied in extremely short time due to our wide Mother Tube Stocks.

Headers form an important part of all types of

boilers. Steam from the generating tubes is collected in headers which are therefore always under pressure. This pressure may vary from 300 psi to 2000 psi. Since headers are always under pressure, the utmost care is taken by us while fabricating them. Depending on the generating capacity of the boiler the header sizes fabricated by us vary from 100 mm to 600 mm NB. The stubs of various sizes are very carefully welded to the main body of the header to provide the desired openings from the header. Bevelling and weld preparation of stubs duly tack-welded to the main body of the header are first shown to Chief Inspector of Boilers for his approval and once again the stubs fully welded with main body are shown to Chief Inspector of Boilers under hydraulic pressure, varying from 1000 to 3000 psi as required by the specifications. The headers are stamped by Chief Inspector of Boilers before they leave our manufacturing plant. We also weld skubolets and weldolets in place of stubs

WATER WALL PANEL:

Water wall panels are used in Waste Heat recovery boilers. We can manufacture 100 MT /Month of panels with required accuracy. HELICAL & SPIRAL STEAM COILS Single start or Multi start Helical coil with required PCD on semi-automatic machine with material. PCD up to 4 meter and height up to 4 meters in carbon steel, alloy steel or stainless steel are manufactured by us. SAMPLE COOLER Sample Coolers are an economical means of reducing high temperature liquids to safe, usable levels. Sample coolers are used to check sample on-line in refineries & Chemical industries by cooling the sample. Temperature of steam / Hot Water is brought to a level that is compatible with the down stream equipment. Sample cooler is a heat exchanger that condenses / reduces temperature of steam by passing through a helical coil housed in a cylindrical shel

Helically Wound Finned Tubes

G Fin (Embedded Fin) The G fin strip is wound into a machined groove and securely locked into place by back filling with base tube material. This ensures that maximum heat transfer is maintained at high tube metal temperatures. Maximum operating temperature for this fin type is 450C. Fin material: Aluminum or copper Tube materials: Carbon steel, Cr.-Mo. steel, stainless steel. L Fins L Fin strip material is subjected to controlled deformation under tension giving the optimum contact pressure of the foot of the fin onto the base tube thus maximizing the heat transfer properties. The foot of the fin considerably enhances the corrosion protection of the base tube. Maximum operating temperature for this fin type is 150C. Fin material: Aluminum or copper. Tube materials: Carbon steel, Cr.-Mo. steel, stainless steel Crimped Fins This fin type (crimped fin) is a non taper fin wrapped under tension around the base tube. The finning process results in a crimp forming at the foot of the fin. Fin is then welded to the base tube at the strip ends. Maximum operating temperature for this fin type is 250C. Fin material: Carbon/stainless steel or copper. Tube materials: Carbon/stainless steel

Boiler Bank Tubes: Boiler bank tubes connect Steam and Mud drums in a boiler. Natural circulation occurs with
out the aid of any external down comers. First 20-30% rows act as risers and the rest act as down comers. Membrane division wall separates the boiler bank and the furnace. Drum coil heaters are provided in the lower drum to preheat the feed water before sending it to Economizer.

Waste Heat Boilers: Studded tubes are used in Reheaters in refineries and in the Fluidised Bed of an FBC
Boiler. The tubes are securely welded with studs to increase the surface area for better heat-transfer. Tube weld can give very closely studded tubes in High Alloy Steels using Automatic Stud Welders. The studs are welded both by an Automatic Drawn Arc Process and by Resistance Welding. On Alloy Steel Pipes Studded with Carbon or Alloy or Stainless Steel Studs both Pre & Post weld heating is carried out on line using state of the art technique. Details

Tube Size - OD x Thickness x Length Tube Specification - (can give Studding on 5 CP 1/2 M, 9 CP, Mo to S.S.Tubes.) Studded Length Unstudded Length at both end Stud Size - Dia x Length x (after weld) Stud Material - can give similar and dissimilar studs right upto 5 CP 1/2 Mo, 9 CP 1/2 Mo to S.S.Tubes Stud Pitch * Circumfereniral No. of pev. plan (pp) or angular pitch or * Linear Pitch No. of Stud planes per metre (ppm) * OR Total No. of Studs per tube.