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Heat exchanger

The conversion of fossil energy carriers to electricity takes place via a power plant. These plants burn coal and oil – as well as biomass and wood as alternative sources of energy – to produce hot steam. In these boiler systems, smooth-tube or finned tube heat exchangers serve as air pre-heaters. Heat exchangers are also found in oil and gas, as well as nuclear industry. ​

 

 1. Heat exchanger plate                     

 

​Heat exchanger plates

The nuclear heat exchangers are operating on a high pressure which means that the heat exchanger plate (HEP) thickness is around 600 – 800 mm (23.622 –31.496 inch). The material used for these applications is a combination of low carbon steel and ISO S cladding or low carbon steel and stainless cladding.

 

 

 

 

 

 

  1. ​Deep hole machining with CoroDrill® 808      
  2. Short hole drilling with
    CoroDrill® 870      
  3. CoroTurn® 107 and T-Max® P

​Deep hole machining process

The deep hole machining process in heat exchanger plates (HEP) is used for the mounting of the tubes in the tube sheet. This is the thickest part of the heat exchanger, reaching out up to 800 mm (31.496 inch). It is also here where the heat source (primary side) intersects with the water in the heat exchanger vessel (secondary side).

The nuclear heat exchangers are operating at a high pressure which means that the HEP thickness is around 600 – 800 mm (23.622 –31.496 inch). The material used for these applications is a combination of low carbon steel and ISO S cladding or low carbon steel and stainless cladding. The cladding is applied by explosion or welding.

This is done with Single Tube System (STS) machine tools. These machine tools are configured with one or more spindles. The drilling is done horisontally so that means that the HEP is lying on the side. The heat source can be of different types like fossil fuels , recycled material or nuclear fusion reactors. The normal breakdown is non-nuclear and nuclear.

The non-nuclear heat exchangers are normally operating at low pressure which means that the HEP thickness is around 300 mm (11.811 inch). For these types of application a uniform material such as plain low carbon steel and stainless steel are used.

For these types of operations on the STS, we recommend CoroDrill® 808.

Learn more about STS system here.

Machining challenges

  • True and straight holes with minimal deviation
  • Acceptable surface finish
  • Predictable tool life
  • Ability to drill predictably straight holes

Solution with CoroDrill® 808

  • Excellent chip breaking thanks to T-land geometry
  • Acceptable surface finish
  • Predictable tool life
  • Traceability
 

​Short hole drilling

              

The short hole drilling process in heat exchangers is used for the support of the tubes on the vessel side. These support plates are around 30 mm (1.181 inch) thick. The drilling is normally done as stack drilling. The most common material is stainless steel due to a strong corrosion resistance needed.

For this type of operation we recommend CoroDrill® 870.

Learn more about general drilling here.

Machining challenges

  • Reliable process
  • Maximum number of plates in stack
  • Poor tool life

Solution with CoroDrill® 870

  • Reliable and secure process
  • Easy handling and secure tip changing
  • Optimized chip control and evacuation
  • Long predictable tool life and high productivity
  • Low cost per hole and excellent hole quality  

Heavy turning

 

A typical heavy turning application is turning of large components with uneven surfaces in combination with very large and varying cutting depth. It is performed in order to remove the forging or casting skin and other defects from the components surface. Wtih the clean surface the component is ready for further processing.

For this type of operations, we recommend using bot T-Max® P and CoroTurn® 107 with positive and negative inserts.

Learn more about heavy turning here.

Machining challenges

  • Reliable process
  • Maximum number of plates in stack
  • Good tool life

Solution with T-Max® P
and CoroTurn® 107

  • Reliable and secure machining, even in roughing applications
  • Full range of clamping and coolant systems for all materials and applications
  • Possibility to optimize by using dampened tools
 
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