Heat Exchanger Manufacturing

Challenge
Bharat Heavy Electrical Ltd. (BHEL) is an integrated power plant equipment manufacturer. 75% of the total power generated in India is produced by equipment from BHEL. The Trichy plant makes thousands of welds yearly on superheater, reheat and economizer tubular coil assemblies, (typical size range 25 – 75 mm OD, W.T. 4-12 mm). The tubing is bent into serpentine coils, and welds to join coils must be made with tight radial clearances between tubes. All welds must be made to ASME B31.1 code and 100% radiographic inspection is required. The combination of restricted welder access and high quality caused BHEL to investigate mechanized welding.

Solution
BHEL purchased Magnatech D-Heads to weld in the restricted spacing.
Today BHEL has twelve systems in continuous operation.