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Factory Transparency & Real-Time Milestone Tracking

Live Heat Exchanger Order & Manufacturing Tracking

PAL ENGINEERS provides our industrial clients with complete, transparent milestone-by-milestone visibility into their heat exchanger fabrication — from HTRI thermal design and raw material NDT clearance to CNC bundle expansion, hydrostatic pressure testing, and dispatch.

Client Order Lookup

Enter your Work Order Number, PO Reference, or Quotation Code.

Interactive 3D Engineering Digital Twin • TEMA Type BEU Exchanger

Explore mathematically verified ASME Section VIII Div 1 & TEMA Class R U-Tube heat exchanger pressure vessel and bundle mechanics.

EQUIPMENT: TEMA Type BEU U-Tube Exchanger
CODES: ASME Sec VIII Div 1 • TEMA Class R • API 660

Real-Time Manufacturing Lifecycle • 8 Quality Milestones

Every heat exchanger manufactured by PAL ENGINEERS adheres strictly to our traceable quality management framework.

STAGE 01 ✓ Completed

Thermal & Mechanical Design

Thermal simulation via HTRI Xchanger Suite and mechanical calculation per ASME Section VIII Div 1 & TEMA Class R.

  • HTRI Thermal Rating Approval
  • ASME Thickness Calculations
  • GA & Fabrication Drawings Signed
STAGE 02 ✓ Completed

Raw Material Procurement & NDT

Receipt of certified boiler quality plates (SA 516 Gr 70) and seamless heat exchanger tubes (SA 213 TP316L / SA 179) with EN 10204 3.1 MTRs.

  • Ultrasonic Testing (UT) on Plates
  • Positive Material Identification (PMI)
  • 100% Dimensional Verification
STAGE 03 ✓ Completed

CNC Tubesheet Drilling & Grooving

High-precision multi-spindle CNC drilling of tube holes with serrated grooves per TEMA Class R standards for maximum tube joint integrity.

  • Tube Hole Tolerance (+0.05 mm)
  • Double Serration Groove Profile Check
  • Tubesheet Ligament Clearance Audit
STAGE 04 ✓ Completed

Tube Bundle Skeleton & Baffle Assembly

Assembly of segment-cut transverse baffles, tie rods, and spacer tubes ensuring precise baffle pitch and fluid cross-flow distribution.

  • Baffle Chamfering & Deburring
  • Tie Rod Torque & Locking Checks
  • Tube-to-Baffle Diametral Clearance
STAGE 05 ✓ Completed

Tube Insertion & Torque-Controlled Expansion

Precision insertion of U-tubes followed by computer-controlled electronic torque expansion and seal welding per ASME Section IX WPS/PQR.

  • Wall Thinning Verification (< 5%)
  • GTAW Orbit Seal Welding (Tube-to-Tubesheet)
  • Liquid Penetrant (DPT) on Tube Welds
STAGE 06 ✓ Completed

Pressure Vessel Shell Fabrication & RT

Heavy plate rolling, SAW long seam and circ seam welding, nozzle fit-up, and 100% Radiographic Testing (RT) per ASME Section VIII Div 1 UW-51.

  • 100% Radiography on Long & Circ Seams
  • Nozzle Flange Alignment & Orientation
  • 2:1 ASME Ellipsoidal Dished Head Fit-up
STAGE 07 • Active Inspection

Hydrostatic Pressure Testing (1.5x Design)

Shell side and tube side independent hydrostatic pressure test holding at 1.5x design pressure for 1 hour with calibrated pressure gauges.

  • Shell Side Hydro Test (Zero Pressure Drop)
  • Tube Side Hydro Test (Zero Tube Joint Leakage)
  • Client / Third-Party Inspector Witnessing
STAGE 08 ○ Next Milestone

Sandblasting, Painting, Preservation & Dispatch

Surface preparation to SA 2.5, high-build epoxy primer and polyurethane coating, nitrogen purging, wooden crating, and logistics release.

  • Surface Profile SA 2.5 & DFT Audit
  • Final Manufacturing Data Record (MDR) Dossier
  • Dispatch Clearance & Transit Tracking

Why Our Clients Rely on PAL ENGINEERS Live Tracking

Industrial projects operate on rigid turnaround schedules. Our tracking system guarantees total accountability.

Zero Hidden Delays

Live production status eliminates blind spots so your project procurement team can plan plant shutdowns with confidence.

Direct Engineer Contact

Direct direct line to our chief thermal and mechanical engineers overseeing your specific heat exchanger assembly.

Digital Inspection Dossiers

Instant access to hydro test charts, radiographic films, material test reports, and third-party inspection sign-offs.

Transit & Delivery Logistics

GPS-enabled freight tracking from our Anand Industrial Estate plant directly to your refinery, factory, or power plant site.

Visit Our Anand Industrial Estate Manufacturing Facility

Industrial clients and third-party inspection agencies (TUV, Lloyd's, BV, Engineers India Ltd) are always welcome to conduct in-person stage-wise inspection at our works in Mohan Nagar, Ghaziabad.

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