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Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box

The rear wall of the header box serves as a tubesheet in heat exchangers of double plate header box. Tube-to-tubesheet welding must be performed using orbital Gas Tungsten Arc Welding (GTAW) with a head extension, which is passed through the corresponding hole in the front wall (plugsheet) of the he...

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Autores principales: García González, José, Hernández-Ortega, Juan José, Jiménez-Ballesta, Ana-Eva, Pedreño, Rosendo Zamora
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8746155/
https://www.ncbi.nlm.nih.gov/pubmed/35009407
http://dx.doi.org/10.3390/ma15010261
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author García González, José
Hernández-Ortega, Juan José
Jiménez-Ballesta, Ana-Eva
Pedreño, Rosendo Zamora
author_facet García González, José
Hernández-Ortega, Juan José
Jiménez-Ballesta, Ana-Eva
Pedreño, Rosendo Zamora
author_sort García González, José
collection PubMed
description The rear wall of the header box serves as a tubesheet in heat exchangers of double plate header box. Tube-to-tubesheet welding must be performed using orbital Gas Tungsten Arc Welding (GTAW) with a head extension, which is passed through the corresponding hole in the front wall (plugsheet) of the header box, where the welding machine is supported. In this project, the effect of parallelism deviations between the plugsheet and the tubesheet of carbon steel header box is analyzed to evaluate its influence on the quality of the tube-to-tubesheet welding. Welded tube (SA-210 Gr. A1) to tubesheet (SA-516 Gr. 70) coupons are manufactured simulating the parallelism deviations previously analyzed in two double plate header boxes of air-cooled heat exchangers using two different preheating temperatures. Macrographic analysis is performed in order to evaluate the weld penetration (minimum leak path) and length of the weld leg in tube-to-tubesheet joints. The results obtained show important variations in those parameters when the parallelism deviations are equal to or greater than −1 mm over the theoretical distance as well as when the distance approaches +1 mm or more. Finally, the incorporation of dimensional controls prior to the welding process is discussed and the implementation of improvements in orbital GTAW equipment is recommended as an optimal solution for this kind of heat exchangers.
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spelling pubmed-87461552022-01-11 Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box García González, José Hernández-Ortega, Juan José Jiménez-Ballesta, Ana-Eva Pedreño, Rosendo Zamora Materials (Basel) Article The rear wall of the header box serves as a tubesheet in heat exchangers of double plate header box. Tube-to-tubesheet welding must be performed using orbital Gas Tungsten Arc Welding (GTAW) with a head extension, which is passed through the corresponding hole in the front wall (plugsheet) of the header box, where the welding machine is supported. In this project, the effect of parallelism deviations between the plugsheet and the tubesheet of carbon steel header box is analyzed to evaluate its influence on the quality of the tube-to-tubesheet welding. Welded tube (SA-210 Gr. A1) to tubesheet (SA-516 Gr. 70) coupons are manufactured simulating the parallelism deviations previously analyzed in two double plate header boxes of air-cooled heat exchangers using two different preheating temperatures. Macrographic analysis is performed in order to evaluate the weld penetration (minimum leak path) and length of the weld leg in tube-to-tubesheet joints. The results obtained show important variations in those parameters when the parallelism deviations are equal to or greater than −1 mm over the theoretical distance as well as when the distance approaches +1 mm or more. Finally, the incorporation of dimensional controls prior to the welding process is discussed and the implementation of improvements in orbital GTAW equipment is recommended as an optimal solution for this kind of heat exchangers. MDPI 2021-12-30 /pmc/articles/PMC8746155/ /pubmed/35009407 http://dx.doi.org/10.3390/ma15010261 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
García González, José
Hernández-Ortega, Juan José
Jiménez-Ballesta, Ana-Eva
Pedreño, Rosendo Zamora
Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box
title Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box
title_full Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box
title_fullStr Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box
title_full_unstemmed Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box
title_short Analysis of Tube-to-Tubesheet Welding in Carbon Steel Heat Exchangers of a Double Plate Header Box
title_sort analysis of tube-to-tubesheet welding in carbon steel heat exchangers of a double plate header box
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8746155/
https://www.ncbi.nlm.nih.gov/pubmed/35009407
http://dx.doi.org/10.3390/ma15010261
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