Oil & Gas Project: Heat Exchanger Tube Sheets & Pressure Vessel Rings

Client & Background

A Middle East EPC contractor building gas processing modules needed forged tube sheets for shell-and-tube heat exchangers and seamless forged rings for separator vessels.

The Challenge

Tube sheets up to 1.8m diameter and 320mm thick required thousands of holes in a custom triangular pitch with strict perpendicularity; separator rings had to meet NACE MR0175 sour service requirements; every piece required EN 10204 3.2 certification.

Our Solution

DHDZ forged tube sheets in ASTM A266 Gr.2 killed steel and separator rings in a 20MnMoNi55-equivalent alloy. Deep-hole drilling was done on in-house CNC gantry drills with coordinate-measured hole reports; PWHT applied per client WPS; full 3.2 dossier shipped with every component.

Project Execution

Two complete exchanger packages were delivered on schedule. The client's third-party inspector passed all components at first presentation with no repair or re-test.

The Result

The EPC added DHDZ to its Approved Vendor List and placed repeat orders for blinds, gaskets and forged nozzles.

Why DHDZ

We treat documentation as part of the product. In the oil & gas supply chain, a first-time-right certificate package is as valuable as the forging itself.