TPi May 2016

Case study #2 – a 2,220+ hole tubesheet flange

A process industry end-user had a project for a blue chip customer. The final delivery included complex special flanges within the final assembly. One of these flanges, when manufactured, had over 2,150 drilled holes at 25.2mm Ø; ten holes at 22.5mm Ø; and 68 holes on the PCD (32mm Ø). The stainless steel was 304/L, of European origin. Production began with a laser cut profile. This profile was then machined back to its final 36mm face and 13mm outer ring thickness, and the pitch configuration was drilled with just over 2,220 holes of differing diameters. Allan Roper, Alexander Comley Ltd’s QA director, commented, “We were delighted to deliver these highly technical flanges on time and in accordance with our customer’s drawings. The investment decision taken by the board to manufacture large diameter flanged product has taken the company on from strength to strength. It is a great opportunity to support this project and secure our standing as an end-user manufacturer.” Conclusion The humble flange, simple or complex, standard or bespoke, large or small, whether in a general piping system or deep within a piece of critical process equipment, is one of the most integral components to be found on- and off-shore, above- and sub-sea. Its flexibility, application diversity and ability to be designed and re-designed as bespoke means projects can be delivered no matter how stringent the design criteria may be. Alexander Comley has been trading since 1920 and the current board has over 100 years’ experience in the market sector. Day after day, year after year the company comes across new, more challenging requirements from old, new, domestic and international customers and their associated projects. In 2013, £500,000 was invested in a large vertical machining centre with live tooling, enabling the company to manufacture 2,000mmdiameter x 1,600mmheight.Whilst Alexander Comley is not a design company, the in-house Delcam Featurecam CAD reading software means almost any manufacture can be undertaken directly from DX files, eliminating the risk of human programming error. This has helped the company secure its place for the next decade onwards as a forward thinking one, striving to be at the forefront of flanged product with all its associated, manufacturing challenges. The investment level has been recognised by customers globally, and has already led to increased business levels from mainland Europe, Australasia, Southern America and Asia, as well as partnerships in countries to develop their national markets, most recently in Ghana.

Tubesheet, slotted face configuration, 345+ holes

Tubesheet, varied pitch configuration and diameters, some internally, fully threaded inners, some slight countersunk outer, 225+ holes o/a

resistance, electromechanical and metallurgical properties associated for its given working environment.

The tubesheets themselves have holes drilled into them. These are dependent on very specific design configurations, at very precise locations with critical tolerances. The quantity of holes can range from a few to thousands. These pattern or ‘pitch’ holes are relative to each other tubesheet within the shell. This pitch changes tube distance, angle and flow direction. These parameters have been varied to maximise the heat transfer effectiveness. Because these tubesheets are the main, critical, internal flanged component(s) they are manufactured directly to OEM drawings as issued to Alexander Comley Ltd as DX files. In-house Delcam Featurecam CAD reading software means the final product supplied is manufactured to the exacting specifications as designed, released and issued from a given client. Alexander Comley’s experience in this highly specialised area means that whatever the requirement, whatever the timescale, the company has the technical in-house experience and know- how to approach a given task, and to deliver on time and in budget. The company states that this is why it is entrusted to manufacture to key, blue chip clients across the globe.

Alexander Comley Ltd – UK sales@alexandercomley.com www.alexandercomley.com

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Tube Products International May 2016

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