FFC Tube Bundle Reflux Condenser W fixed and floating header

Time:2025-06-14 22:59:28

Detail Introduction

FFC Tube Bundle Reflux Condenser W fixed and floating header

Description&Subject: Engineering, Designing, drawings, manufacturing, data sheet, inspection, testing, packing and shipping of reflux condenser;

01 Engineering Designing drawings manufacturing datasheet Reflux condenser

Supply and fabrication of FFC Tube Bundle Reflux Condenser heat exchanger with fixed and floating header as per attached drawings. Coil sour services NACE-MR-0175-98 special Chemistry on Plate Material ASME Section VIII Division-1 Design-API 661

02 inspection testing packing shipping reflux condenser

Equipment Parameters

Model: ZJPE-4-38-4800
Design Temperature: 150℃ Design Pressure: Tube Side 1.0MPa, Shell Side Atmospheric Pressure
Number of Tubes: 37/38 tubes Tube Arrangement: 4 rows
Material: Φ25×2-57, carbon steel rolled aluminum sheet, fins made of aluminum, the rest is carbon steel
Tube Length: 4800 mm Connection Pipe Diameter: DN100

Manufacturing Standard: GB/T14296-2008 "Air Coolers and Air Heaters"

03 Coil sour services NACE MR 0175 98 special Chemistry ASME VIII API 661

The following is the supply and manufacturing plan for the FFC tube bundle (reflux condenser), strictly adhering to relevant standards and drawing requirements:

Core Parameter Confirmation
Project Parameter
Model SZGL-4-38-4800
Design Temperature 150℃
Design Pressure Tube side 1.0MPa / Shell side atmospheric pressure
Tube Bundle Configuration 4 rows × 37/38 tubes (approximately 150 tubes in total)
Tube Specification Φ25×2-57 (1" tube), carbon steel rolled aluminum finned tube
Tube Length 4800mm (actual tube length 4877mm)
Connection Pipe Diameter DN100 (4" and 6" connections)
Manufacturing Standard GB/T 14296-2008
Special Standard NACE MR0175-98 (acidic environment)
ASME VIII Div.1

API 661

04 carbon steel rolled aluminum sheet fins made aluminum

Key Materials List (classified by BOM)

I. Main Structural Materials (total weight approximately 1,964kg)

No. Component Description Material Weight (kg) Remarks
1 Tube Sheet PL20x213x2210 SA-516-70M 295.62 Fixed/floating end tube box
2 Upper Head Plate PL14x166x2210 SA-516-70M 161.27
4 Heat Exchange Tube Φ25×2 L=4877mm SA-179 1084.60 Carbon steel base tube + rolled aluminum fins
11 14" Channel Steel Frame SA-36 230.03 Side support structure

15 3" I-Beam (HN100) SA-36 62.16 Main beam reinforcement

II. Tube Box Accessories (total weight approximately 45kg)

No. Component Description Material Weight (kg)
3 CHO Plate PL14x121x181 SA-516-70M 9.63
20 Partition Baffle PL14x121x181 SA-516-70M 30.25

12 Tube Box Pressure Plate 1/4"PL SA-516-70N 8.26

06 Pressure Tube side 1MPa Shell side atmospheric pressure

III. Connection Pipes and Flanges
No. Component Description Material Weight/Quantity
8 4"-Sch.100 Connection Pipe (114.3×10) SA-105B 7.68 kg
25 6"-Sch.80 Connection Pipe (168.3×11) SA-105B 5.97 kg
7 4"-150# RFWN Flange SA-105N 2 sets

24 6"-150# RFWN Flange SA-105N 1 set

07 Tube Bundle Configuration 4 rows 3738 tubes

IV. Seals and Connectors
No. Component Description Material/Type Quantity
5 1-1/8" Hex Plug SA-105N 300 sets
6 1-3/8" Gasket SOFT ROH 300 sets
9/10 1"/3/4" Threaded Joint + Plug SA-105N 2 sets each
13/22 1/2" Bolt and Nut Set SA-325 22 sets

Manufacturing and Inspection Focus

Material Compliance

All carbon steel materials provided with NACE MR0175 certification report for acidic environments (hardness ≤ HRC 22).

Finned Tube Process: Carbon steel tube with rolled aluminum fins (thickness ≥ 0.3mm), bonding strength ≥ 35MPa (GB/T 14296).

08 carbon steel rolled aluminum finned tube

08 carbon steel rolled aluminum finned tube

Key Structural Points

Floating Tube Box Design: Ensure sliding end has reserved thermal expansion displacement (API 661 requirement).

Tube Sheet Drilling Tolerance: Hole spacing ±0.3mm, hole diameter tolerance +0.1/-0 mm (GB/T 14296).

Finned Tube Installation: Expansion length ≥ 50mm, air tightness test pressure 1.5MPa.

Welding and Non-Destructive Testing

Pressure-bearing welds 100% RT inspection (ASME VIII Div.1).

Welds on the inner surface of the tube box smoothed, Ra ≤ 3.2μm (to reduce corrosion risk).

Pressure Testing

Tube side: 1.5MPa water pressure (holding pressure for 30 minutes).

Shell side: 0.02MPa air tightness test (atmospheric pressure verification).

Scope of Supply

Complete tube bundle assembly: including tube box, finned tube bundle, frame, flange connections, etc.

Accessories: plugs, gaskets, bolts, nameplate brackets (including stainless steel nameplate).

Document Package: Material certificates (MTC), NACE report, ASME data sheets, completion drawings.

Note: The pipe length in the BOM is 4877mm (including the expansion joint length at both ends), ensuring a net length of 4800mm after installation. The flange is supplied according to 150# grade; although the shell side is at normal pressure, it meets the requirements for the tube side at 1.0MPa plus a safety margin.

09 Floating Tube Box sliding end reserved thermal expansion displacement API 661

10 Finned Tube Installation Expansion air tightness test pressure

I Bill of Materials kg
1 "Tube & Plug Sheet PL20x213x2210
SA-516-70M" 295.62 kg
2 "Header Upper Plate PL14x166x2210
SA-516-70M" 161.27 kg
3 "CHO Plate PL14x121x181
SA-516-70M" 9.63 kg
4 Tube 1''x1/10'', L=4877mm, SA-179 1084.60 kg
8 4''-Sch.100( Pipe x 5-7/8'' LG, SA-105B (114.3x10) 7.68 kg
11 [14'' channel x 1/4'' thk, c/w 3'' flang x 15'-9-1/4'' LG-Side frame, SA-36 230.03 kg
12 1/4'' PL x 8'' x 8-1/2'' LG front&rear header clipes, SA-516-70N 8.26 kg
14 L2''x2''x1/4'' thk x 7'-1''LG-Lipped brace,SA-36 28.89 kg
15 3'' I-Beam, HN100,SA-36 62.16 kg
16 #12 GA. PL formed angle 3''x4''x7'-1-1/2'' LG.,SA-36 8.95 kg
17 #12 GA. PL formed angle 3''x2''x7'-1-1/2'' LG.,SA-36 6.39 kg
18 #12 GA. PL formed angle 4''x4''x7'-1-1/2'' LG.,SA-36 10.23 kg
19 #12 GA. PL formed angle 3-1/2''x2''x7'-1-1/2'' LG.,SA-36 7.16 kg
20 1/2'' PL x 5'' x 7'-2'' LG, pass plate (frount header), SA-516-70M 30.25 kg
21 Name Plate bracket C/W S.S. Thermo tech Name plate, SA-516-70 5.00 kg
23 1/4'' thk x 2-1/4'' x 6'' LG-Brace bolt plate 1.65 Kgs
25 6''-Sch.80( Pipe x 5-1/2'' LG, SA-105B (168.3x11) 5.97 Kgs
Subtotal 1,964 Kgs

II Bill of Materials set
5 1-1/8'' OD x 3/4'' LG Hex Shoulder Plug, SA-105N 300 set
6 1-3/8'' OD x 1-1/8'' ID x 1/16''L Gasket, SOFT ROH 300 set
7 4''-150# RFWN FLG(SCH.150 SORF) SA-105N 2 set
9 1''-1000# MPT scro. Full coupling c/w plug - CIA/B, SA-105N 2 set
10 3/4''-1000# MPT scro. Full coupling c/w plug - C2A/B, C3A/BSA-105N 2 set
13 1/2'' Dia. X 1-1/2'' LG hex Bolts C/w nuts, SA325 14 set
22 1/2'' Dia. X 1-1/2'' LG hex Bolts C/w nuts, SA325 8 set
24 6''-150# RFWN FLG(SCH.150 SORF) SA-105N 1 set

Why Jiashe Power FFC Tube Bundle Reflux Condenser ?


Reliable and Customized Designs	Cutting Edge Designing Process	Free Online Price System	Easy Bolt-by-number Assembly

Over Two Decades of Experience	Value For Money	Unmatched in Quality and Craftmanship	Excellent Customer Service

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