Massive Heat Exchanger Fabrication for Power Generation
When a leading global power generation firm required a highly specialized, extreme-pressure heat exchanger shell to upgrade their existing steam facility, they partnered with Openex. The project required impeccable metallurgical handling, heavy plate rolling, and perfectly concentric CNC machining to guarantee zero leakage under immense thermal stress.
The Challenge
The blueprint presented a dual-challenge. First, the main structural shell required the rolling and welding of extremely thick carbon steel plate that standard fabrication shops could not accommodate. Second, the accompanying internal baffle plates and tube sheets demanded perfectly aligned CNC deep hole drilling across hundreds of penetration points to prevent vibration during peak plant operation.
Because of a planned plant shutdown (turnaround), the entire delivery window was compressed, demanding an uninterrupted manufacturing workflow.
The Openex Solution
By executing this massive build entirely within our 180-acre facility, Openex was able to tightly integrate material prep, welding, and machining to eliminate multi-vendor transport delays.
- Heavy Plate Rolling: Using our extreme-capacity plate bending rolls, the thick structural carbon plates were cold-rolled perfectly to cylinder parameters with zero out-of-roundness.
- Certified SAW Welding: Our ASME-certified welding technicians deployed Submerged Arc Welding (SAW) rotators. Operating continuous heavy weldments while rotating the massive shell guaranteed defect-free seam strength.
- Dimensional Machining: Following post-weld heat treatment, the massive assembly was transferred directly to our large gantry CNC mills, where precise face milling and bolt hole tapping ensured perfect gasket alignment.
The Result
The fully assembled component was submitted to strict 100% Ultrasonic Testing (UT) and Radiographic Testing (RT) by our in-house inspectors. The piece achieved a zero-defect pass rate on the very first inspection. By managing the workflow in-house, the heat exchanger component was safely lifted and loaded onto custom transport two days ahead of the contracted shutdown schedule.
