Heat Exchanger Tube to Tubesheet Welding Machine with AVC Control for Boiler Manufacturer Productivity

Case Study: High-Productivity Tube to Tubesheet Welding for Boiler and Heat Exchanger Manufacturing

A boiler and heat exchanger manufacturer in the Middle East faced a production bottleneck in tube to tubesheet welding. Manual TIG welding of thousands of tube joints was slow, inconsistent, and dependent on scarce skilled welders. Hyzont provided an automatic tube to tubesheet welding machine with AVC (Arc Voltage Control) to transform their production line.

Challenge

• Welding hundreds of tube to tubesheet joints per heat exchanger
• Consistent weld quality across carbon steel and stainless steel tubes
• Reducing dependency on highly skilled manual welders
• Meeting ASME pressure vessel code requirements

Solution

Hyzont's automatic tube to tubesheet welding machine combines precise orbital torch rotation with real-time AVC control, delivering uniform arc length and penetration for every joint.

Results

• Production output increased by 200% with two shifts replacing three
• First-pass weld acceptance rate rose from 85% to 99%
• Reduced rework costs by approximately 40%
• New operators reached full productivity in just one week of training

The manufacturer has ordered additional Hyzont tube to tubesheet welding systems for their new production facility, confirming the solution's reliability and return on investment.

Overcoming Skilled Welder Shortage

The global shortage of certified pipe welders is one of the biggest challenges facing boiler and heat exchanger manufacturers. By automating tube to tubesheet welding, Hyzont's machine allows manufacturers to maintain production levels with fewer, less specialized operators. The touch screen interface guides operators through the welding process, while pre-programmed weld schedules ensure consistent quality regardless of individual skill level.

Technical Features

• Orbital torch rotation with stepless speed adjustment
• AVC (Arc Voltage Control) maintains constant arc length automatically
• Supports protruding, flush and recessed tube end configurations
• Water-cooled torch for continuous high-duty-cycle operation
• Multi-language touch screen interface (English, Chinese, Russian, Spanish)
• Weld current range 5-315 A suitable for carbon steel and stainless steel

Quality and Compliance

Hyzont tube to tubesheet welding machines help manufacturers meet ASME Section VIII, EN 13445 and other international pressure vessel codes. The consistent weld quality reduces the need for radiography re-inspection and rework, saving both time and cost. Documentation generated by the machine supports quality management systems and client audit requirements.

About Hyzont

Hyzont (Shanghai) Industrial Technologies Co., Ltd. is a professional manufacturer of automated welding equipment, including orbital welding machines, tube to tubesheet welders, welding carriages, seam welders and pipeline construction equipment. Our products are exported to more than 50 countries and trusted by manufacturers in the energy, chemical, food and construction industries. We are committed to providing complete solutions backed by responsive service and reliable spare parts supply.

Start Your Project

Contact Hyzont today to discuss your heat exchanger or boiler welding requirements. Our team will help you select the right machine configuration, provide a competitive quotation, and support you from installation through full production.