Tube Insert

Inserts are used in shell-and-tube heat exchangers to protect the tubes. Inserts are placed at the ends of heat exchanger tubes to:

• Make sure they are protected from erosion at the inlet end
• Inflammation
• An impediment
• A falling fluid-type exchanger induces fluid to fall on the ID of a tube
• The exchanger tubes transfer extremely high heat past the tube sheet.

Tube inserts improve any production process that requires the use of heat exchangers. By modifying the flow stream characteristics of heat exchangers, tube inserts improve the tube side performance of heat exchangers. In the case of heat exchangers, tube inserts will increase tube life and efficiency, resulting in substantial savings on production and costs.

Shell & tube exchangers are prone to the following problems:

• Corrosion/erosions at the tube end
• Cracks caused by stress corrosion
• Rust in crevices
• Pitting on a localized basis
• Grooving with ammonia
• Expansion of the tube is improper
• Joints between tubes on sheet metal have become weak

Tube inserts are the most efficient and cost-effective solution to prevent these problems from affecting pipeline flow and reducing production loss.

In addition to tube inserts, RatnaExports.com offers a wide range of products, including:

• Inserts for threaded tubes,
• Tube inserts with square ends
• Tube inserts with round ends
• Inserts for metal tubes that are threaded
• Inserts for square tubes that are threaded
• Tube inserts with rectangular shapes
• Inserts for round tubes threaded on the inside

• Two plastic inserts are available: nylon (polyamide), LDPE, and PP.
• These heads are designed for tubes that project slightly outside the tube sheet. The projection is protected so high-velocity impingement does not affect the tube mouths and ensures increased tube and mouth life.
• When the tube sheet is not exposed beyond the flared head, then flared heads are used.
• Surface condensers typically use plastic inserts. Nylon inserts can withstand temperatures up to 150°C. PTFE inserts can withstand temperatures up to 250°C.
• It is possible to manufacture metal inserts from stainless steel 304, 310, 316, 317, 321/347, 410, Hastelloy, Cu-Ni 90/10, Cu-Ni 70/30, titanium, zirconium, Inconel 600, zirconium 702, aluminum brass, admiralty brass, and aluminum bronze. High alumina and refractory alumina ceramic inserts are also available.
• A ferrous insert is typically used for applications requiring high temperatures
• This insert is used for high-temperature applications with temperatures of 900°C, where tube sheet warping is an issue. High-temperature ceramic paper is used to add to the level of protection.
• The tube plugs are designed to protect tube ends during storage and transportation and for coating. There are two types of tube plugs:
• High-temperature applications call for tapper plugs.
• There are solid and hollow pressure plugs available in LDPE, PP, brass cupro-nickel, etc., for different sizes of tubes.
• The condenser performance suffers when condensation deposits inside the tubes are scraped away with projectiles. These deposits are the result of water deposits that affect heat transfer.
• A variety of materials make up the projectiles, which have blades rounded at the tip and positioned so that deposits be removed at the inner length of the tube.
• Compared to other cleaning methods, these projectiles are incredibly efficient and economical.

SQUARE TUBE INSERTS

Our standard square tube inserts and end caps range from 10mm to 150mm. We manufacture flat, domed, and angled inserts.

ROUND TUBE INSERTS

We offer round inserts in a wide variety of diameters and lightweight or heavy-duty options. Some of our round inserts come in a variety of colors as standard.

RECTANGULAR TUBE INSERTS

Various rectangular inserts and endcaps, including domed, angled, and curved bases, are available. Whether you need rectangular, round, or square inserts, you can choose between ribbed or plain shanks. Ribbed shanks offer ease of installation and neatness. For furniture requiring castors, we provide threaded inserts in plastic or metal.

METAL INSERTS

Our metal tube inserts range from aluminum alloy inserts to steel tube inserts. Our chrome-capped ribbed products combine a metal finish with the optimal fit of a ribbed shank.

• Off-Shore Oil Drilling Companies
• Power Generation
• Petrochemicals
• Gas Processing
• Specialty Chemicals
• Pharmaceuticals
• Pharmaceutical Equipment
• Chemical Equipment
• Sea Water Equipment
• Heat Exchangers
• Condensers
• Pulp and Paper Industry

We at Ratna Exports provide Manufacturer TC (Test Certificate) following EN 10204/3.1B, Raw Materials Certificate, 100% Radiography Test Report, and Third Party Inspection Report. We also provide Standard certificates like EN 10204 3.1 and additional requirement. NACE MR 01075. FERRITE CONTENT as per norms if requested by clients.

• EN 10204/3.1B,
• Raw Materials Certificate
• 100% Radiography Test Report
• Third Party Inspection Report, etc.

Material Testing:

RatnaExports.com ensures that all our materials undergo strict quality tests before dispatching them to our clients.

• Mechanical Testing Such as Tensile of Area
• Hardness Test
• Chemical Analysis – Spectro Analysis
• Positive Material Identification – PMI Testing
• Flattening Test
• Micro and MacroTest
• Pitting Resistance Test
• Flaring Test
• Intergranular Corrosion (IGC) Test

• Commercial Invoice which includes HS Code
• Packing List including net weight and gross weight, number of boxes, Marks, and Numbers
• Certificate of Origin legalized/attested by the Chamber of Commerce or Embassy
• Fumigation Certificates
• Raw Material Test Reports
• Material Traceability Records
• Quality Assurance Plan (QAP)
• Heat Treatment Charts
• Test Certificates certifying NACE MR0103, NACE MR0175
• Material Test Certificates (MTC) as per EN 10204 3.1 and EN 10204 3.2
• Guarantee Letter
• NABL-approved Laboratory Test Reports
• Welding Procedure Specification/Procedure Qualification Record, WPS/PQR
• Form A for the Generalized System of Preferences (GSP)

Tube inserts are widely used in various industries including petrochemical, oil and gas, power generation, bulk liquid transportation, chemicals, pharmaceuticals, pulp and paper manufacturing, textiles, and others. All our Tube Inserts are manufactured following international standards. Tube Insert is packaged to ensure that there is no damage during transit. In the case of exports, standard export packaging is done in wooden cases. All Tube inserts are marked with Grade, Lot No, Size, Degree, and our trademark. We can also make custom markings on Tube Insert on special requests.