Product Description
Manufactured in our specialized metallurgical casting foundry in Jingjiang, our Central Tube Sheet Support is a heavy-duty, high-temperature cast alloy intermediate tube support plate engineered to maintain tube alignment and prevent sagging across horizontal tube banks inside convection sections of petrochemical fired heaters and boilers. Leveraging 26 years of metallurgical casting experience and certified under ASME "U" and "S" standards, we cast each Central Tube Sheet Support using heat-resistant chromium-nickel alloy steels formulated to withstand direct exposure to flue gas temperatures exceeding 870°C. By adhering to international design rules that limit tube unsupported spans to 35 times the tube outer diameter (or a maximum of 6 meters), this rugged Central Tube Sheet Support prevents tube bowing, mechanical strain on end tube sheets, and localized refractory damage, providing fired heater manufacturers and refinery maintenance teams with an essential structural component built for long-term continuous service.
Applications
Fired Heater Convection Sections: Supporting horizontal convection tube passes, finned tubes, and shock rows inside crude heaters, reformers, and crackers.
Heat Recovery Steam Generators (HRSG): Providing intermediate structural support for horizontal economizer and evaporator tube banks.
Industrial Waste Heat Recovery Units: Operating as internal support dividers inside high-temperature flue gas ducts and convection boxes.
Convection Section Retubing & Overhauls: Supplying replacement cast intermediate support plates during scheduled plant turnarounds.
Technical Specifications
|
Design & Fabrication Standards |
API 560 / ISO 13705, ASTM A297, ASME Section VIII Div. 1 |
|
Casting Process |
Precision sand casting and static mold casting with controlled directional solidification |
|
Material Grades (Cast Heat-Resistant Alloys) |
25Cr-35Ni (ASTM A297 Grade HP / HP40) for severe flue gas temperatures 25Cr-20Ni (ASTM A297 Grade HK / HK40) for medium-to-high temperature zones 25Cr-12Ni (ASTM A297 Grade HH) for moderate temperature zones |
|
Design Temperature Rules |
Sized for contact flue gas temperatures plus 55°C (100°F) in convection sections; Maximum design temperature up to 950°C |
|
Corrosion Allowance |
Minimum corrosion allowance of 1.3 mm (0.05") for austenitic alloys; 2.5 mm (0.1") for ferritic alloys |
|
Maximum Flue Gas Gradient |
Designed to accommodate flue gas temperature gradients across the plate without exceeding 222°C (400°F) |
|
Maximum Tube Unsupported Span |
Spaced strictly within 35 times the tube outer diameter, not exceeding 6.0 meters (20 feet) between adjacent supports |
Customization Capabilities
Tailored Tube Hole Arrays: Custom hole diameters, pitch layouts (triangular, rotated triangular, inline, or square), and edge clearances engineered to match convection tube bundles.
Replaceable Segmented Configurations: Engineering multi-segment split designs that allow individual support plate sections to be replaced during maintenance turnarounds without dismantling surrounding furnace tubes.
Metallurgical Grading by Temperature Zone: Selecting specific cast alloy grades (HP, HK, or HH) matched to local flue gas temperature gradients, optimizing material costs while ensuring structural integrity.
Integrated Mounting Lugs & Stiffeners: Casting reinforced mounting feet, structural perimeter flanges, and stiffening ribs directly onto the support plate for secure attachment to furnace casing frames.
Zero MOQ Flexibility: Supporting single replacement castings for turnaround repairs as well as complete multi-plate sets for new furnace construction projects.
Quality Control
Tailored Tube Hole Arrays: Custom hole diameters, pitch layouts (triangular, rotated triangular, inline, or square), and edge clearances engineered to match convection tube bundles.
Replaceable Segmented Configurations: Engineering multi-segment split designs that allow individual support plate sections to be replaced during maintenance turnarounds without dismantling surrounding furnace tubes.
Metallurgical Grading by Temperature Zone: Selecting specific cast alloy grades (HP, HK, or HH) matched to local flue gas temperature gradients, optimizing material costs while ensuring structural integrity.
Integrated Mounting Lugs & Stiffeners: Casting reinforced mounting feet, structural perimeter flanges, and stiffening ribs directly onto the support plate for secure attachment to furnace casing frames.
Zero MOQ Flexibility: Supporting single replacement castings for turnaround repairs as well as complete multi-plate sets for new furnace construction projects.
FAQ
Q: How do you determine the correct cast alloy grade for intermediate tube supports?
A: Material selection is governed by API 560 guidelines based on calculated flue gas temperatures at the support location. For flue gas temperatures above 750°C, 25Cr-20Ni (HK40) or 25Cr-35Ni (HP) is used; for intermediate temperatures between 600°C and 750°C, 25Cr-12Ni (HH) provides dependable performance and cost efficiency.
Q: What is the typical production lead time for custom cast intermediate tube sheets?
A: Production typically requires 3 to 4 months from pattern tooling approval and material confirmation to final machining and inspection.
Q: What warranty coverage do you provide for international deliveries?
A: We provide an 18-month warranty from site arrival or 12 months from commercial operation (whichever comes first), backed by responsive technical engineering support.
Q: What payment terms and currencies do you accept for export contracts?
A: We support EXW and FOB shipping terms. Our standard commercial milestones are 30% advance deposit, 40% manufacturing milestone payment, and 30% balance prior to factory dispatch, payable in USD, EUR, or RMB.
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