Shell and Tube Heat Exchanger Manufacturer in India

xflowheatexchangers

Product Overview

X-Flow Heat Exchangers is a trusted shell and tube heat exchanger manufacturer in India, delivering precision-engineered thermal solutions for demanding industrial applications. Our shell and tube heat exchangers (STHE) are built to TEMA and ASME standards using high-grade materials, ensuring reliable performance across wide ranges of pressure, temperature, and fluid conditions. Whether you require a fixed tube sheet, U-tube, or floating head design, X-Flow provides complete custom engineering — from thermal design and material selection to fabrication, testing, and dispatch. Our manufacturing facility in Belgaum, Karnataka, is equipped with advanced fabrication infrastructure to deliver quality heat exchangers to clients across India and abroad, serving industries such as oil and gas, chemical processing, pharmaceuticals, power generation, food and beverage, and fertilizers.

Key Features

  • TEMA and ASME Compliant Design: All units designed and fabricated as per TEMA Class R, C, or B and ASME Section VIII Div. 1 standards, ensuring safety, reliability, and code compliance.

  • Wide Material Range: Available in Carbon Steel, SS 304, SS 316/316L, Duplex Steel, Hastelloy C-276, Titanium, Copper-Nickel, and other exotic alloys to suit corrosive and high-temperature services.

  • Multiple Design Configurations: Fixed Tube Sheet, U-Tube, and Floating Head designs available to suit thermal expansion, fouling, and maintenance requirements.

  • High Thermal Efficiency: Engineered with optimized baffle spacing, tube pitch, and tube count to maximize heat transfer area and minimize pressure drop.

  • Custom Tube Sizes and Lengths: Available in 1/4", 3/8”, 1/2”, 5/8”, 3/4", 1", 1.25", and 1.5" OD tubes with lengths from 300 mm to 6300 mm and beyond based on process requirements.

  • Full Hydro test and NDE: Each unit undergoes radiography, dye penetrant, ultrasonic testing, and hydrostatic pressure testing before dispatch.

  • Nozzle and Flange Customization: Full flexibility on nozzle orientation, flange rating (ANSI 150# to 2500#), and connection type per client P and ID.

Types of Shell and Tube Heat Exchangers

1. Fixed Tube Sheet Heat Exchanger

The fixed tube sheet design is the most economical shell and tube configuration. Both tube sheets are welded to the shell, making it a rigid, compact, and cost-effective solution. Best suited for applications where shell-side fluids are clean, non-fouling, and the temperature differential between shell and tube is moderate. Widely used in process cooling, condensers, and preheaters.

2. U-Tube Heat Exchanger

In U-tube heat exchangers, tubes are bent into a U-shape and both ends are fixed to a single tube sheet. This allows free thermal expansion of the tube bundle, eliminating differential thermal expansion stresses. The tube bundle can be removed for shell-side cleaning. Ideal for high-pressure, high-temperature, and steam-heated applications where tube-side fouling is minimal.

3. Floating Head Heat Exchanger

Floating head heat exchangers allow the tube bundle to expand and contract freely inside the shell. The floating head can be fully removed for thorough mechanical cleaning of both tube and shell sides. This design is preferred for services involving heavy fouling, phase change, or corrosive fluids.

Technical Specifications

Parameter Specification / Range
Design Standard TEMA R / C / B, ASME Sec. VIII Div. 1, IS 4503
Shell Diameter 50 mm to 2000 mm (NPS 2" to 80")
Tube OD 1/4",3/8”,1/2”, 5/8”, 3/4”, 1", 1.25", 1.5" (6.35 mm to 38 mm)
Tube Length 300 mm to 6300 mm (custom lengths available)
Design Pressure Full Vacuum to 250 kg/cm²
Design Temperature -50°C to 450°C
Shell & Tube Materials CS, Copper, SS 304/316/316L, Duplex, Hastelloy, Ti, Cu-Ni
Configuration Fixed Tube Sheet, U-Tube, Floating Head (Removable Bundle Type)
Passes 1, 2, 4, 6, 8 tube passes
Heat Duty Range 1,200 kcal/hr. to 50,00,000 kcal/hr.
NDE / Testing RT, DPT, UT, PMI, Hydro Test, Pneumatic Test
Surface Finish Mill Finish, Sandblasted, Epoxy Coated, Hot-Dip Galvanized

Applications and Industries Served

  • Oil And Gas Refineries: Crude oil preheating, overhead condensers, product coolers, reboilers, and desalter heating.

  • Petrochemical And Chemical Plants: Process fluid heating/cooling, solvent condensers, acid coolers, and reactor feed/effluent exchangers.

  • Pharmaceutical Industry: WFI cooling, solvent recovery condensers, sterile process heating, and CIP circuit heat exchangers.

  • Power Generation: Feed water heaters, oil coolers, hydrogen coolers, and LP/HP heat exchangers for thermal power plants.

  • Food And Beverage: Pasteurizers, UHT systems, product coolers, and CIP heat exchangers in hygienic stainless steel.

  • Fertilizer Plants: Ammonia condensers, urea process exchangers, CO₂ coolers, and steam-heated process heaters.

  • Sugar And Distillery: Juice heaters, syrup coolers, evaporator condensers, and molasses coolers.

  • HVAC And Utilities: Water-to-water heat exchangers, chilled water systems, and plant utility cooling circuits.

Why Choose X-Flow Heat Exchangers?

  • In-House Thermal and Mechanical Design: Our engineering team performs complete thermal sizing, mechanical design, and TEMA calculations in-house — ensuring accuracy and faster project execution.

  • Quality-First Manufacturing: Every unit is manufactured with strict quality control — from raw material inspection and PMI testing to final hydrostatic pressure testing and documentation.

  • Pan-India and Export Supply: We supply to clients across all major industrial states of India and accept export orders with appropriate documentation and international compliance.

  • Comprehensive Documentation: GA drawings, Datasheets, Inspection certificates, Hydro test reports, and MTCs provided with every unit.