Plug-Type Header (Carbon Steel Or Stainless Steel), Used In Air-Cooled Heat Exchanger

Overview

Plug-Type Header is a specialized design of a fluid distribution header used on the tube side of air-cooled heat exchangers. It serves to distribute the process fluid evenly into the tube bundle or collect it from the tubes.

General Consideration And Requirements Of Plug-Type Header

• The Headers shall be Plug-type and shall be provided with plugs opposite the ends of each tube unless otherwise specified.
• The pressure seal shall be maintained by means of a gasket between the plug flange and the plug plate.
• The Plug holes shall be of sufficient size to allow roller expansion and cleaning of the tubes.
• The plugs shall be cylindrical with hexagonal head. it shall have sufficient length to fill the plug sheet threads.

Key Features:

1. Design:

   • The header is essentially a cylindrical or rectangular chamber connected to the tube bundle.

   • It has several removable plugs (usually threaded or bolted) on its body.

   • These plugs provide access ports for:

     • Cleaning

     • Inspection

     • Tube maintenance or plugging

2. Function:

   • Acts as the inlet or outlet for the fluid on the tube side.

   • Distributes fluid evenly into the tube rows for optimal heat exchange.

   • Provides easy access for maintenance without disassembling the entire heat exchanger.

3. Construction:

   • Made from carbon steel or stainless steel depending on operating conditions.

   • Designed to handle the pressure and temperature of the process fluid.

   • The plugs are sealed with gaskets or welding to prevent leakage.

4. Advantages:

   • Maintenance friendly: Plugs can be removed individually, which allows for easy inspection and cleaning.

   • Flexibility: Allows quick plugging of leaking or damaged tubes without shutting down the whole system.

   • Compact: Takes less space compared to other header designs with multiple flanges.

Where is it Used?

• Common in air-cooled heat exchangers where fluid is cooled by air flowing outside the tubes.

• Useful when the tube side fluid needs regular inspection or cleaning.

• Often used in petrochemical, refinery, and power plant applications where uptime and maintenance are critical.

Visual Description

• Imagine a pipe or chamber connected to multiple tubes.

• Along the header’s body, you’ll see several circular removable plugs (like caps or covers).

• These plugs allow easy access to individual tubes inside the header.

Summary

Carbon Steel Plug Type Header

Stainless Steel Plug Type Header

plug type header air cooler

Plug Type Header Carbon Steel Or Stainless Steel Used In Air Cooled Heat Exchanger Images