When the tubes inside a shell-and-tube heat exchanger become corroded, damaged or begin leaking, replacing the complete heat exchanger may not be necessary. Emergent Coils provides tube bundle replacement solutions for commercial and industrial heat exchanger applications.

We offer custom and replacement U-bend and straight tube bundles designed to meet the specifications and operating requirements of existing equipment.

Commercial and Industrial Replacement Tube Bundles

A tube bundle is the internal heat transfer component of a shell-and-tube heat exchanger. One fluid travels through the tubes while another passes around them inside the shell, allowing heat to transfer through the tube walls.

Because these tubes are continuously exposed to fluids, pressure and temperature changes, the tube bundle can eventually become one of the components most susceptible to corrosion and failure.

Replacing the tube bundle can restore the heat exchanger while allowing the existing shell and associated equipment to remain in service.

Custom Tube Bundle Replacements

Emergent Coils can provide replacement tube bundles in a variety of configurations, including:

• U-tube bundles
• Straight tube bundles
• Fixed tubesheet configurations
• Floating tubesheet configurations
• Enhanced and low-fin tube bundles
• Tank heater tube bundles
• Fuel oil heater tube bundles
• Double-wall vented tube bundles
• Custom tube bundle designs

Standard and specialty materials can be selected according to the fluids, pressures, temperatures and operating environment of the application.

Replacing an Existing Tube Bundle

In many cases, an existing tube bundle replacement can be identified using the heat exchanger manufacturer and model number.

When additional information is required, photographs and field measurements can be used to document the existing bundle. Important information may include nominal diameter and length, number of passes, connection configuration, materials, fluid type, steam or water pressure and operating conditions.

Emergent Coils also provides blank drawings that make it easier to record tube bundle dimensions in the field.

OEM Replacement Tube Bundles

Emergent Coils supplies replacement tube bundles for numerous heat exchanger brands and equipment configurations.

Replacement solutions are available for common commercial and industrial applications, including steam-to-water and water-to-water systems.

If the original manufacturer's tube bundle is obsolete, damaged or difficult to source, a replacement can often be produced based on the existing equipment specifications.

Tube Bundle Materials and Construction

Selecting the correct materials is important when replacing a tube bundle.

Fluid composition, pressure, temperature and the operating environment can influence which tube and tubesheet materials are appropriate. Specialized materials may also be needed for corrosive or demanding industrial applications.

Our team can review your existing equipment information to help determine the requirements for the replacement.

Need a Tube Bundle Replacement?

If your heat exchanger has a leaking, corroded or failed tube bundle, Emergent Coils can help.

Send us the manufacturer, model number, photographs, dimensions and operating information for your existing equipment. We'll help determine the replacement tube bundle required for your application.

Request a Free Tube Bundle Quote

Frequently Asked Questions

Can you replace only the tube bundle in a heat exchanger?

Yes, in many shell-and-tube heat exchangers the tube bundle can be removed and replaced while the existing shell remains in service.

How do I identify the correct replacement tube bundle?

Start with the manufacturer and model number of the existing heat exchanger. If additional information is required, dimensions, photographs, number of passes, materials and operating conditions can help identify the correct replacement.

What causes a tube bundle to fail?

Tube bundles can fail because of corrosion, erosion, fouling, vibration, pressure or temperature conditions and normal deterioration over time.

What is the difference between a U-tube and straight tube bundle?

U-tube bundles use tubes bent into a U-shaped configuration, while straight tube bundles use straight tubes extending between tubesheets. The appropriate design depends on the heat exchanger and application.

Can obsolete tube bundles be replaced?

In many cases, yes. A replacement tube bundle can often be manufactured using the existing heat exchanger specifications, model information or field measurements even when the original component is no longer readily available.