Heat exchanger Ferrules & Tube Inserts

Heat Exchanger Ferrules and Tube Inserts

Tube inserts and Tube ferrules are a metal ,plastic or polymer inserted into the end of a heat exchanger tube to provide protection to the Tube mouth ends of a shell & tube type heat exchanger. The requirement for this Ferrule arises as all tube failures occur within the first few inches of the heat exchanger tube inlet-end. The solution to this situation is the use of a thin wall covering in form of metal tube insert expanded full length into the inlet-end of condensers and heat exchangers. This ensures lots of time and cost saving for the system as maintaining is always cheaper then replacing . FAV make Heat Exchanger Ferrules is designed to ensure a smooth and gentle transition of the fluid down the tube insert to the condenser or heat exchanger tube. We have Metal tube insert and Plastic/Delrin Tube Inserts.

 Common problems at Shell & Tube Type Heat Exchangers the lead to need of Inserts

1.       Tube-end erosion/corrosion
2.       Stress Corrosion Cracking
3.       Crevice corrosion
4.       Localized pitting
5.       Ammonia grooving
6.       Improper tube expansion
7.       Weakened tube-to-tube sheet joints

For the above problems, FAV tube ferrule inserts offers its most cost-efficient tube protection ,repair, Shield/Seal, also known as a tube insert or ferrule. Although inserts are typically only 3" - 15" long, some applications have required lengths up to 3 metres.

The purpose of the Tube Ferrule &  Inserts

1)      Protect inlet-end erosion &  corrosion
2)      Act as a protective layer
3)      Reduce the medium impact
4)      Transfer extremely high heat past the tube sheet to the exchanger tubes.

Material of Construction for FAV Heat Exchanger Ferrules .

Metal tube inserts in Stainless Steel Grades like 304 /310/316/ 317 /321/347/ 410 / duplex, Hastalloy, Cu-Ni 90/10,Cu-Ni 70/30, Titanium,  Inconel 600,Aluminium Brass,  Aluminium Bronze ,  Carbon Steel(B) Hastelloy C 276 , Incoloy, Monel 400, Monel 500, Duplex, Super Duplex , Incoloy 800, Incoloy 825

Plastics : Nylon ( Polyamide ), PTFE, PP.

These are the basic form of Tube Ferrules . Very economical and serves the basic purpose of Tube Mouth Protection . Ideal when there is not enough space at Tube Mouth for Ferrule Flares.

These are machined from Solid Round Bar . Expensive as lot of material is wasted in manufacturing. Useful for small sizes and where precision is of utmost important. Commonly used when the material is PP ,Plastic, Nylon ,PTFE Teflon or Bakelite . Is used in metal when Pipes are not available for Construction.

With Single Flare on the outer side this the most commonly used and widely accepted Ferrule Inserts. Flaring serves the purpose of holding the Ferrule Inserts with Tubes . Also does not necessarily require use of Ceramic Fiber Paper.

A variation in above design having degree at the tail. Helps in easier installation where there may be hindrance/aberration in the tubes.

With Extra Length after Flaring this Tube Insert is useful when used with Ceramic Fiber Paper. Sometimes these are hammered inside the Tube for proper fit.

With Double Flaring this Tube Insert is useful when used with Ceramic Fiber Paper.

This has Flaring at both Start and End . Degree may defer at both ends to ensure correct installation .