Let us understand the forging head
In heat exchangers (especially shell and tube heat exchangers), Forged Heads are key pressure-bearing components used to close the shell or channel. They are usually made by forging process and have the characteristics of high strength, high temperature and high pressure resistance.
1.Definition and function of Forged Heads
(1)Definition:
- Forged Heads are metal heads made by forging process, used to seal the shell or tube box of the heat exchanger to form a closed fluid channel.
(2)Core functions:
- Pressure bearing: As a pressure boundary component, it bears the internal or external pressure of the shell or tube fluid.
- Sealing fluid: Preventing medium leakage and ensuring the safe operation of the heat exchanger.
- Connection structure: Welded/bolted with the shell, tube sheet or flange to fix the overall structure.
2.Common types and structures
(1) Forged Heads in Shell and Tube Heat Exchangers
- Front Head:Located at the front of the channel, connected to the tube sheet, distributing the tube fluid into the heat exchange tube bundle.
- Rear Head:Depending on the design type, it may be fixed (Fixed Head) or removable (such as the floating head of a floating head heat exchanger).
- Typical shapes:Hemispherical Head: Strong pressure bearing capacity, suitable for high pressure scenarios.
- Ellipsoidal Head: Balances strength and manufacturing cost, most common.
- Flat Head: Used for low pressure or small diameter heat exchangers.
(2) Other application scenarios
Forged heads are widely used in high pressure heat exchangers (such as hydrogenation reactor feed heat exchangers) or under extreme working conditions due to their high reliability.
3. Advantages of forging process
- High strength: Forging eliminates internal defects of metal (such as pores and slag inclusions), refines grains, and has better tensile and fatigue resistance than castings or welded parts.
- High temperature and high pressure resistance: Suitable for harsh working conditions (such as petrochemical and nuclear power fields).
- Corrosion resistance: Forged materials have high density, reducing the risk of medium penetration corrosion.
- Long life: More durable under alternating loads and reduced maintenance requirements.
4. Key points for design and selection
| Parameter | Explanation |
| Material | Carbon steel (SA-105), stainless steel (SA-182 F304/F316), nickel-based alloy (Inconel), etc. |
| Standard | Comply with ASME BPVC Section VIII (Pressure Vessel Code) or TEMA standards. |
| Connection | Welded (butt-weld) or bolted flange connection (detachable). |
| Pressure level | Select thickness and shape according to design pressure (such as Class 150, 300, 600, etc.). |
5. Application scenarios
- High-pressure heat exchangers: such as heat exchangers in hydrogenation units and synthetic ammonia reactors.
- High-temperature steam systems: power plant boiler feed water preheaters.
- Corrosive media: heat exchangers for acid and alkali fluids in chemical production.
- Nuclear power plants: primary coolant heat exchange equipment.
6. Comparison with other heads
| Type | Forged Head | Cast Head | Formed Head |
| Strength | Highest (dense grains) | Lower (prone to defects) | Medium |
| Cost | High | Low | Medium |
| Applicable pressure | High pressure (≥10 MPa) | Low pressure (≤5 MPa) | Medium pressure (5~10 MPa) |
| Typical industries | Petrochemical, nuclear power, military industry | General industrial equipment | Conventional chemical industry, HVAC |
- Forged Heads are key pressure-bearing components of heat exchangers, and they are made through forging processes to ensure high strength and reliability.
- Application scenarios: high pressure, high temperature, corrosive or safety-critical working conditions.
- Design core: materials, pressure ratings and connection methods must be matched, while complying with international standards (such as ASME, TEMA).
When maintaining or replacing forged heads, non-destructive testing (NDT) and pressure testing must be strictly performed to ensure their integrity.
Forged head design
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