Tube Bundle Manufacturer for Custom Fabrication and Replacement
Gelan manufactures custom tube bundles for new equipment and replacement projects.
We build based on your drawings, operating conditions, materials, and inspection requirements.
- Drawing-Based Custom Fabrication
- 8–10% Heat Transfer Recovery Potential
- Removable, U-Tube, Straight & Finned Options
- MTC, Inspection and Test Documents Available
Tube Bundles We Fabricate for Industrial Equipment
Different equipment needs different tube bundle designs. Gelan fabricates custom tube bundles for heat transfer, cooling, condensation, steam generation, and waste heat recovery projects.
Heat Exchanger Tube Bundle
For heating, cooling, condensation, and vaporization inside shell and tube heat exchangers.
Condenser Tube Bundle
For vapor condensation, cooling water service, and process cooling duties.
Reboiler Tube Bundle
For heating and vapor generation in refinery, petrochemical, and chemical units.
Air Cooler Tube Bundle
For air cooled heat exchangers where process fluid is cooled by ambient air.
Economizer Tube Bundle
For recovering exhaust heat and preheating boiler feedwater or process medium.
Boiler Tube Bundle
For industrial boilers and steam generation sections under pressure and temperature service.
HRSG Tube Bundle
For high-temperature exhaust gas heat recovery and steam generation projects.
Send your drawing, datasheet, or old bundle details. Gelan can review the structure, material, and replacement requirements before fabrication.
New Tube Bundle Fabrication and Replacement Tube Bundle Support
Whether you need a tube bundle for new equipment or an old unit replacement, Gelan can support fabrication based on your project data, drawings, and shutdown schedule.
For New Equipment Projects
New projects need tube bundles that match the full equipment design from the beginning.
Gelan fabricates custom tube bundles for heat exchangers, condensers, reboilers, air coolers, boilers, economizers, and HRSG units.
- Tube bundle fabrication based on approved drawings
- Tube sheet, baffle, tie rod, spacer, and support plate manufacturing
- Tube material selection based on pressure, temperature, and medium
- Tube-to-tubesheet welding, expansion, or welding plus expansion
- Inspection records and project document support
For Replacement and Revamp Projects
Old tube bundles often lose performance because of fouling, corrosion, leakage, vibration, or tube damage.
Gelan manufactures replacement tube bundles for existing equipment. We can work from old drawings, datasheets, site measurements, or sample bundle details.
- Heat exchanger tube bundle replacement
- Tube bundle replacement for shutdown maintenance
- Same-size replacement based on existing equipment
- Material upgrade for corrosion or high-temperature service
- Review of bundle structure, cleaning access, and replacement risk
- Delivery planning based on your maintenance schedule
Tube Bundle Design and Manufacturing Parameters
Each tube bundle is built around the equipment duty, medium, pressure, temperature, and maintenance needs. Gelan can customize the structure, material, and fabrication details based on your drawing or datasheet.
| Parameter | Common Options / Considerations |
|---|---|
| Tube Bundle Type | Straight tube bundle, U-tube bundle, floating bundle, fixed tubesheet bundle, removable tube bundle, finned tube bundle |
| Equipment Application | Shell and tube heat exchanger, condenser, reboiler, air cooler, boiler, economizer, HRSG, waste heat recovery equipment |
| Tube Material | Carbon steel, stainless steel, alloy steel, duplex stainless steel, high-temperature alloy, project-specified material |
| Tube Sheet Material | Carbon steel, stainless steel, clad plate, alloy steel, or customized material |
| Tube Form | Bare tube, finned tube, straight tube, U-tube |
| Baffle / Support Plate | Segmental baffle, support plate, customized baffle layout, carbon steel or stainless steel material |
| Tube-to-Tubesheet Connection | Expansion, welding, or welding plus expansion based on pressure, medium, and leakage risk |
| Cleaning and Maintenance | Removable design, cleaning clearance, inspection access, fouling control |
| Operating Condition | Customized by pressure, temperature, medium, flow rate, and heat transfer duty |
| Surface Treatment | Pickling, passivation, coating, or project-required treatment |
| Design Basis | Customer drawing, datasheet, sample bundle, existing equipment data, or project specification |
| Inspection Support | Dimensional check, material certificate, welding record, leakage test, pressure test, NDT if required |
| Document Package | Drawings, MTCs, inspection records, test reports, and handover documents |
*These are common tube bundle manufacturing options. Gelan can customize the bundle based on your drawings, datasheets, medium, pressure, temperature, and project requirements.
How Gelan Helps Your Tube Bundle Fit, Perform, and Last Longer
A tube bundle failure can lead to leakage, poor heat transfer, shutdown delay, or costly rework. Gelan supports your project from design review to fabrication, inspection, and delivery, so the final bundle fits the equipment and operating condition.
Meet Your Heat Transfer Duty
Poor tube layout or baffle spacing can reduce heat transfer and increase pressure drop.
Gelan support:
- Gelan checks tube size, tube count, tube sheet layout, baffle spacing, and bundle structure before fabrication.
Benefit:
- Lower installation mismatch risk.
Recover Heat Transfer Performance
Fouling, corrosion, and blocked tubes reduce heat transfer.
Gelan support:
- Gelan reviews tube layout, baffle spacing, material, and flow condition for replacement projects.
Benefit:
- Up to 8–10% heat transfer recovery potential in suitable cases.
Reduce Leakage Risk
Tube-to-tubesheet joints are key leakage points.
Gelan support:
- Gelan supports expansion, welding, or welding plus expansion based on pressure, medium, and temperature.
Benefit:
- Better sealing and lower early failure risk.
Match Corrosion and Temperature Duty
Wrong material can shorten tube bundle life.
Gelan support:
- Gelan selects tube, tube sheet, baffle, and support materials based on medium, temperature, pressure, and corrosion risk.
Benefit:
- Designed to support 3–5 years longer service life potential under proper conditions.
Make Review and Delivery Easier
Missing documents can slow down EPC review and site handover.
Gelan support:
- Gelan can provide MTCs, dimensional checks, welding records, leakage tests, pressure test reports, and handover documents.
Benefit:
- Smoother inspection, delivery, and project closeout.
Industries We Support with Custom Tube Bundles
Gelan supplies custom tube bundles for heat transfer, cooling, steam generation, and replacement needs in major industrial sectors.
Tube Bundle Fabrication Projects Support By Gelan
12 Air Cooler Tube Bundles for a Replacement Project in Algeria
Project characteristics
Gelan support:
- Supplied plug header type air cooler tube bundles to match the existing equipment structure
- Used SA516 Gr.70N / SA179 materials for tube box and tube requirements
- Fabricated embedded finned tubes with φ25.4 × 2.77 mm base tube and φ57.15 mm finned tube OD
- Used AL1060 fins, with 433 fins/m and 0.4 mm fin thickness
- Followed ASME VIII-1 and API 661 design and manufacturing requirements
- Supplied matching flanges, flange gaskets, connection bolts, nuts, plugs, and plug gaskets
- Prepared English and French documents for project review and delivery
Customer value:
This support helped the customer reduce mismatch risk during air cooler tube bundle replacement.
3 Boiler Tube Bundle Sets for an India Custom Project
Project background:
An India project needed custom boiler tube bundle supply for PH Boiler and AQC Boiler equipment.
Gelan support:
- Supplied 2 sets of PH Boiler tube bundles
- Supplied 1 set of AQC Boiler tube bundle
- Used SA210 Gr.A1 material for boiler service
- Supported heavy tube bundle supply with about 1,369 tons total weight
- Included frame-type packaging for large tube bundle shipment
- Production cycle: 180 working days after contract, advance payment, and drawing confirmation
- Designed and manufactured according to domestic standards for this project
Result:
Gelan helped the customer turn project data into a manufacturable supply scope, with material, quantity, packaging, and production schedule clearly defined before fabrication.
Related Equipment and Components for Tube Bundle
Review related Gelan products for complete equipment supply, tube bundle matching, or replacement parts.
Shell and Tube Heat Exchanger
Uses tube bundles as the main heat transfer core for heating, cooling, condensation, and vaporization.
Air Cooler
Preheats air, fuel, feed, or process medium before the main heating stage in heat recovery systems.
Finned Tube
Used to increase heat transfer area in air cooler, boiler, economizer, and waste heat recovery tube bundles.
Economizer
Uses tube bundles to recover exhaust heat and preheat water or process medium.
Waste Heat Boiler
Uses tube bundles for high-temperature waste heat recovery and steam generation.
FAQ About Tube Bundles
1. Can Gelan manufacture custom tube bundles for my equipment?
Yes. For customers looking for a tube bundle manufacturer, Gelan can support custom tube bundle fabrication within our wider industrial equipment and component manufacturing scope.
We can build tube bundles based on your drawing, datasheet, old bundle details, material requirement, pressure, temperature, medium, and inspection standard.
2. What information do I need to provide for a tube bundle replacement?
- Existing drawing or datasheet
- Tube size, tube length, and tube quantity
- Tube sheet size and material
- Baffle type and spacing
- Operating pressure and temperature
- Process medium
- Required inspection documents
- Shutdown or delivery schedule
3. Can Gelan make a heat exchanger tube bundle separately?
Yes. Gelan can supply a heat exchanger tube bundle as a separate component or as part of complete heat exchanger equipment.
This is useful when your shell is still usable, but the old exchanger bundle is fouled, corroded, leaking, or no longer efficient.
4. What types of tube bundle structures can Gelan support?
Gelan can support common industrial tube bundles, including straight tube bundle, U-tube bundle, floating bundle, fixed tubesheet bundle, removable bundle, and finned tube bundle.
The final structure depends on your equipment type, cleaning needs, thermal expansion, medium, and maintenance plan.
5. Can Gelan fabricate stainless steel tube bundles?
Yes. Gelan can fabricate stainless steel tube bundles and other material options based on your working condition.
Common options include carbon steel, stainless steel, alloy steel, duplex stainless steel, clad material, and high-temperature alloy. Material selection depends on corrosion risk, temperature, pressure, and process medium.
6. What is the difference between a removable tube bundle and a fixed tube bundle?
A removable tube bundle heat exchanger is easier to pull out, clean, inspect, or replace. It is often used when fouling or maintenance access is a concern.
A fixed tubesheet bundle has a compact structure, but maintenance access is more limited. Gelan can help review which structure fits your replacement or new fabrication project.
7. Does Gelan provide inspection documents for tube bundle fabrication?
Yes. For tube bundle fabrication, Gelan can provide material certificates, dimensional inspection records, welding records, leakage test reports, pressure test reports, and handover documents when required.
This helps EPC teams, plant owners, and inspection teams complete review, delivery, and site acceptance more smoothly.
Need a Custom Tube Bundle for Your Equipment?
Send your drawing, datasheet, or old bundle details. Gelan can review the structure, material, inspection needs, and replacement feasibility.