Custom Large Forged Heat Exchanger Tubesheet with CNC Multi Drilling Machining

Product Highlights

• Large‑size open‑die forged heat exchanger tubesheet, multi‑material optional including carbon steel, alloy steel, stainless steel, duplex steel, nickel‑base alloy and titanium grades; compact grain flow eliminates casting shrinkage, porosity and slab segregation defects
• High‑precision CNC multi‑spindle simultaneous drilling service, supports triangular, square, rotated tube layout per TEMA specification; strict tolerance control for hole diameter, hole pitch, perpendicularity and surface roughness for tube expansion and strength welding
• Excellent through‑thickness mechanical performance, stable under cyclic pressure and temperature fluctuation for heavy‑duty shell‑and‑tube heat exchangers, condensers, reboilers and process pressure vessels
• Complete in‑house workflow: ingot forging, custom heat‑treatment, rough machining, multi‑axis CNC deep‑hole drilling, sealing groove / bolt hole processing and full non‑destructive testing
• Fully custom‑manufactured strictly according to customer CAD drawings, datasheet and project specifications; supports fixed‑tubesheet, floating‑head, U‑tube and clad overlay tubesheet designs
• Manufactured in compliance with ASME, TEMA and pressure‑vessel forging standards; third‑party witness inspection (SGS, TUV, BV) is available
• Long‑term reliable service for petrochemical, power generation, oil‑gas, seawater desalination, fine‑chemical and heavy‑industrial heat‑transfer equipment

Product Overview

This custom large forged tubesheet is the core pressure‑bearing component for heavy‑duty shell‑and‑tube heat exchangers. Starting from qualified steel ingot, the workpiece goes through multi‑direction upsetting and stretching open‑die forging to achieve homogeneous metallurgical structure across full thickness. After quenching‑and‑tempering, solution annealing or stress‑relief heat‑treatment, forgings are processed by heavy‑duty CNC equipment, including multi‑spindle simultaneous drilling for massive tube‑hole array, bolt holes, sealing grooves, locating steps and nozzle openings.

Different from flame‑cut rolled plate, forged construction guarantees consistent mechanical properties for extra‑large and heavy‑thickness sections. Precision multi‑drilling strictly controls aperture tolerance, hole‑pitch deviation and hole perpendicularity, ensuring high‑quality tube‑to‑tubesheet joints by expansion or welding. Widely used for large‑scale heat exchangers, condensers, evaporators and reboilers under high‑pressure, high‑temperature or corrosive operating environments worldwide.

Material Grade Characteristics – Optional Forged Grades for Large Tubesheet

• Carbon Steel(A105, SA‑516 Gr70, 16Mn):Cost‑effective pressure‑vessel grade, good comprehensive mechanical performance for non‑corrosive and moderate‑temperature service.
• Alloy Steel(42CrMo, F11, F22, 12Cr2Mo1):Cr‑Mo alloy steel with high‑temperature strength and creep resistance, suitable for high‑pressure & high‑temperature petro‑chemical process units.
• Stainless Steel(304/F304, 316L/F316L):Austenitic stainless steel for general‑to‑moderate corrosion media, widely adopted in pharmaceutical, food and fine‑chemical equipment.
• Duplex Steel(2205, 2507):High yield strength, outstanding resistance to chloride pitting, crevice corrosion and stress corrosion cracking for seawater and brine working conditions.
• Nickel‑base & Titanium(Inconel 625, Hastelloy C276, TA1/TA2):For severe corrosive media, strong acid, seawater and high‑temperature aggressive process conditions.

Representative Chemical Composition (Weight %)

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Representative Mechanical Properties (Heat‑Treated Forged Condition)

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Related Material Grades

• Carbon & Alloy Steel Forgings: A105, SA‑516 Gr70, 16Mn, 35CrMo, 42CrMo, F11, F22, F91
• Austenitic Stainless Forgings: F304, F304L, F316, F316L, F321, F347
• Duplex & Super‑Duplex Forgings: 2205, 2507
• Nickel‑Base Alloy Forgings: Inconel 625, Inconel 718, Hastelloy C276, Hastelloy B3
• Titanium Forgings: TA1, TA2

Key Advantages

1. High‑Integrity Forged Metallurgical Structure Multi‑step open‑die forging eliminates internal shrinkage, porosity and segregation; uniform grain flow through full thickness, far superior to rolled‑plate cutting for large‑diameter heavy‑thickness tubesheet.
2. Precision CNC Multi‑Spindle Drilling Capacity Heavy‑duty multi‑spindle simultaneous drilling equipment guarantees tight tolerance on hole diameter, hole‑pitch and perpendicularity; supports triangular / square / rotated layouts complying with TEMA for high‑quality tube expansion and welding joints.
3. Full‑Process In‑House Manufacturing Complete workflow covering forging, heat‑treatment, turning‑milling, multi‑drilling, groove processing and NDT; reduces intermediate links and ensures traceability for every forging piece.
4. Broad Customization Range Flexible dimension scope, multiple material options, support fixed‑tubesheet, floating‑head, U‑tube and clad overlay construction, fully adapted for various heat‑exchanger designs and working‑condition requirements.
5. Strict Pressure‑Vessel‑Grade Quality Assurance 100% non‑destructive inspection, batch‑by‑batch spectral analysis and mechanical testing; full material traceability to satisfy international pressure‑equipment codes for global energy and chemical projects.

Typical Applications

• Large petrochemical shell‑and‑tube heat exchangers, condensers and reboilers
• Thermal‑power plant high‑pressure auxiliary heat‑exchange equipment
• Oil & gas refinery process heat‑transfer pressure‑bearing components
• Seawater desalination and marine engineering large heat‑exchanger units
• Fine‑chemical, fertilizer and pharmaceutical heavy‑duty process heat exchangers
• New‑energy industry large‑size pressure vessels and heat‑exchange core parts

Processing Service

We provide integrated heavy open‑die forging, heat‑treatment and full precision machining services, produce finished tubesheet strictly according to customer CAD/PDF drawings:

• Premium ingot selection, multi‑upsetting & stretching open‑die forging
• Custom heat‑treatment: normalizing & tempering, quenching‑and‑tempering, solution annealing and stress‑relief
• Rough turning/milling to remove forging scale and surface defects
• Heavy‑duty CNC multi‑spindle simultaneous deep‑hole drilling for tube‑hole array
• CNC processing for bolt holes, sealing grooves, locating steps and special features
• Surface treatment: pickling, passivation, anti‑rust coating for storage & sea shipment

We supply custom large forged tubesheets with CNC multi‑drilling for heat‑exchanger and pressure‑vessel manufacturers worldwide across petrochemical, power‑generation, desalination and heavy‑chemical sectors.

Quality Assurance

• 100% UT Ultrasonic Testing for internal forging flaws complying with ASME and NB/T standards
• MT Magnetic‑Particle / PT Penetrant Inspection for surface and tube‑hole inner‑wall crack detection
• Tensile test, impact test & hardness measurement for mechanical‑property verification
• Spectrometer full‑spectrum chemical‑composition analysis per forging lot
• High‑precision CMM dimensional inspection for diameter, thickness, hole‑pitch and all critical tolerances

Mill Test Certificate EN 10204 3.1 can be provided together with shipment documents before delivery. Third‑party inspection witness is available upon request.

Packing & Delivery

Packing

• Inner packaging: waterproof anti‑rust plastic film; dedicated protective covers for machined sealing faces and all tube‑hole openings against scratch, dust and corrosion
• Outer packaging: reinforced fumigated heavy‑duty wooden case or high‑strength steel‑frame crate for long‑distance sea transportation
• Custom special packaging available on customer request for oversized and super‑heavy workpieces

Lead Time Normally 30‑50 working days after receipt of advance payment. Exact delivery time depends on forging dimension, weight, material grade, CNC multi‑drilling complexity and third‑party inspection schedule.