Heat Exchanger Tube Bundle Manufacturer in India –
Replacement and New Fabrication

xflowheatexchangers

Product Overview

X-Flow Heat Exchangers is a specialized tube bundle manufacturer in India, fabricating precision tube bundles for new shell and tube heat exchangers as well as direct replacement bundles for existing installed exchangers. When a heat exchanger's tube bundle wears out due to corrosion, erosion, fouling, or fatigue, replacing only the tube bundle — rather than the entire unit — is a highly cost-effective maintenance strategy. X-Flow's tube bundles are custom-fabricated to match original shell dimensions, tube specifications, pass arrangements, and baffle configurations, ensuring a perfect drop-in fit with leak-free operation and restored thermal performance. We work with all major tube materials including Carbon Steel, SS 304, SS 316L, Duplex Steel, Titanium, Hastelloy, Copper-Nickel, and Admiralty Brass — covering every process fluid and corrosion scenario.

Key Features

  • Exact-Match Replacement Manufacturing: Fabricated to match existing shell ID, tube OD, pitch, length, and pass arrangement – ensuring perfect fit without shell modification.

  • Wide Material Range: Tubes and tube sheets in CS, SS 304/316L/321, Duplex, Super Duplex, Ti Gr.2, Hastelloy C-276, Incoloy 800/825, Cu-Ni 90/10 and 70/30, Admiralty Brass.

  • Multiple Tube-to-Tube Sheet Joint Options: Hydraulic rolling, strength welding, or expansion + seal welding – selected per TEMA standards and service severity.

  • Precision Baffle Manufacturing: Segmental, double-segmental, and NTIW baffles machined to precise dimensions for proper shell-side flow distribution.

  • Anti-Vibration (AVB) Provision: Anti-vibration bars or support plates incorporated where tube vibration risk is identified.

  • Precise Tube Pitching and Drilling: CNC-drilled tube sheet holes ensure tight tolerances on tube hole diameter, tube pitch, and pass partition layout.

  • Complete Hydrostatic Testing: Each tube bundle is pressure-tested at 1.5x design pressure on the tube side after fabrication.

  • Upgrades Possible: While replacing, we can upgrade tube material, add more tubes, change pitch, or modify baffle arrangement to improve performance.

Types of Tube Bundles

1. Fixed Tube Sheet (FTS) Tube Bundle

Both tube sheets are welded directly to the tubes. The entire bundle is a rigid, permanent assembly installed in the shell. FTS bundles are the most economical and compact design for non-fouling services. X-Flow fabricates FTS bundles with welded-in impingement plates, pass partition plates, and tie rods as required.

2. U-Tube Bundle

Tubes bent into a U-shape with both ends connected to a single tube sheet. The U-bend end is free to expand thermally – ideal for high-temperature services and large temperature differentials. U-tube bundles are easily removable from the shell for shell-side cleaning. X-Flow provides precision U-bending with correct bend.

3. Floating Head Tube Bundle

One fixed tube sheet (front) and one floating tube sheet (rear) that is free to move axially. Allows unrestricted thermal expansion and complete bundle withdrawal for thorough cleaning.

4. Kettle / Reboiler Tube Bundle

Specially designed tube bundles for kettle reboiler and thermo syphon reboiler applications in distillation columns. Configured for full immersion in the boiling-side fluid with specific tube pitch and baffle arrangements to promote nucleate boiling and vapour disengagement.

Technical Specifications

Parameter Specification / Range
Bundle Type Fixed Tube Sheet, U-Tube, Floating Head (Removable Bundle Type)
Design Standard ASME Sec. VIII Div. 1
Shell ID Range 50 mm to 2,000 mm (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 Wall Thickness BWG 10 to BWG 22
Tube Length 400 mm to 6300 mm (custom lengths available)
Tube Pitch Triangular (30°), Rotated Triangular (60°), Square (90°), Rotated Square (45°)
Number of Tubes 7 to 5,000+ tubes per bundle
Number of Tube Passes 1, 2, 4, 6, 8 passes
Tube Material Copper, SS 304/316/321, Duplex, Hastelloy, Ti Gr.2, Cu-Ni, Brass, CS
Tube Sheet Material CS (IS 2062 / SA 516), SS 304/316L, Duplex, Ti, CS+SS Clad
Baffle Type Segmental (20-45% cut), Double Segmental, NTIW, Disc & Donut
Tube-to-TS Joint Hydraulic Rolling, Strength Weld, Expansion + Seal Weld
Design Pressure (Tube Side) Full Vacuum to 250 kg/cm²
Design Temperature -50°C to 450°C
NDE RT, DPT, UT, PMI, Hydro Test

Replacement Tube Bundle – Step-by-Step Process

  • Dimension Collection: Client provides original GA drawings, TEMA Sheet, or actual bundle dimensions from site measurement.

  • Material Verification: Original material is verified via PMI testing. We recommend upgrade materials where the original has shown premature failures.

  • Engineering Review: Our team checks tube layout, baffle spacing, tie rod arrangement, and pass partition for code compliance and improvement opportunities.

  • Fabrication Drawing Issue: A fabrication drawing is prepared and submitted for client approval before fabrication commences.

  • Precision Fabrication: CNC drilling of tube sheets, tube loading, expansion/welding, baffle installation, and full assembly at our Belgaum facility.

  • Testing and Documentation: Hydrostatic test at 1.5x design pressure, NDE as per client requirements, and complete documentation – test report, MTC, dimensional inspection report.

  • Dispatch and Installation Support: Bundle is carefully packed and dispatched. Technical support provided for installation if required.

Applications and Industries Served

  • Oil Refineries and Petrochemical Plants: Replacement tube bundles for crude oil preheaters, product coolers, overhead condensers, and reactor feed/effluent exchangers.

  • Fertilizer Plants: Replacement bundles for ammonia condensers, CO₂ coolers, urea process exchangers, and steam-heated process heaters.

  • Chemical and Pharmaceutical Plants: Upgrade tube bundles using SS 316L, Hastelloy, or Titanium for corrosive solvent, acid, or pharmaceutical process fluid services.

  • Power Generation: Replacement tube bundles for feed water heaters, LP/HP heat exchangers, oil coolers, and hydrogen coolers in thermal power plants.

  • Sugar and Distilleries: Juice heater bundles, syrup cooler bundles, condenser tube bundles, and reboiler bundles for sugar plant turnarounds.

  • Paper and Pulp Industry: Replacement bundles for chemical recovery heat exchangers, black liquor heaters, and blow heat condensers.

  • Food and Beverage Industry: Hygienic SS 316L tube bundles for pasteurizers, UHT systems, product coolers, and CIP heat exchangers.

  • Marine and Offshore: Seawater-resistant Cu-Ni or Titanium tube bundles for central coolers and lube oil coolers on ships and offshore platforms.