EXPANSION PROCEDURE FOR RE-TUBING OF FRESH

COOLING WATER EXCHANGERS TAG NO.

25-E0609A/B/C/D, C3 CONDENSER & 25-E0610, C3 SUB
COOLER

Client Approval :________________________

JOB TITLE : RE-TUBING OF FRSH

COOLING WATER EXCHNAGERS
METHOD STATEMENT

Al-Muftah Contracting Co. WLL

Job No.: J510 APPROVED BY: Doc. Ref.: Oil & Gas Division
Kavindra Jani PO Box 875. Doha-Qatar
AMCOG-DOC-18-02

CHECKED BY:
Contract No.: Rev.:01
SHIJU Pages Tel. No.: Fax No.: Email:
LTC/C/MNT/3164-
A/17 ORIGINATOR 13 Date: 44223333 44223385 mechanical@almuftah.com
RAJASEKAR 11/06/2018

AMCOG-DOC-18-02, Rev.01 Page 1 of 13

 TABLE OF CONTENTS

1.0 RECORD OF REVISIONS

2.0 OBJECTIVE

3.0 SCOPE

4.0 REFERENCE

5.0 DEFINITIONS

6.0 RESPOSIBILITIES

7.0 HEALTH, SAFETY & ENVIRONMENT

8.0 EQUIPMENT’s

9.0 DETAILS OF EXCHANGER’S

10.0 METHODOLOGY

11.0 INSPECTION & TESTING

AMCOG-DOC-18-02, Rev.01 Page 2 of 13

1.0 RECORD OF REVISIONS

ISSUED FOR
02 REVIEW & 01 11/06/2018 RAJASEKAR SHIJU K P JANI
COMMENTS
ISSUED FOR
01 REVIEW & 00 17/05/2018 SKD SKD KPJ
COMMENTS
S. CHECKED APPROVED
DESCRIPTIONS REVISION DATE ORIGINATOR
No. BY: BY:

AMCOG-DOC-18-02, Rev.01 Page 3 of 13

 2.0 OBJECTIVE:

The objective of this document is to perform the tube to tube sheet expansion for
providing a mechanical strength and sealed joint for the successful re-tubing of Shell
and Tube exchanger’s 25-E0609A/B/C/D & 25-E610. The procedure comply with,
01 safety procedures applicable & precaution/mitigation that need to be taken in
accordance with QG safety rules and regulations.

3.0 SCOPE:

The scope of this procedure is to describe in details of how to make the tube to tube
sheet expansion joint for the Re-Tubing of Condenser 25-E609A/B/CD & 25-E610 as
01 described in the SOW at AMC Workshop or Any AMC recommended designated area
(Sub-Contractor Premises).

4.0 REFERENCE:

 QGX-20-00-ME-TS-NA-201_E1 - Shell and Tube Heat Exchanger - Design and

01 Construction
 QGX/24/06/ME/DS/NA/209 - Shell and Tube Heat Exchanger Specification Sheet
 Equipment Dwg. DK2005-120-01 to 04, Rev.X1 and DK2005-055-01 to 03, Rev.X1
 ASME SEC. VIII, Div. 1 - Rules for construction of Pressure Vessel

5.0 DEFINITIONS:

● PROJECT : RE-TUBING OF FRESH COOLING WATER

EXCHANGER’S

● COMPANY : Qatar Gas

● CONTRACTOR : Al-Muftah Contracting Co. WLL

● PROJECT MANAGER : Contractor’s Project Manager

● QA/QC INSPECTOR : Contractor’s QA/QC Inspector

● WORK SITE SUPERVISOR : Contractor’s authorized Work Person

AMCOG-DOC-18-02, Rev.01 Page 4 of 13

6.0 RESPONSIBILITIES:

 PROJECT MANAGER

- Shall be responsible for overall work and coordinate with COMPANY & AMC
team and resolve the re-tubing issues while execution.

 WORK SUPERVISOR

- Shall be responsible for overall work which allocated to him and he shall report
all job related constraints and update to designated Project Manager and
manage the work progress as per schedule.

 QA/QC Inspector

- Shall be responsible to develop and determine all standards to perform

inspection and tests on all procedures and oversee all testing methods and
01 maintain high standards of quality for all process.
- Carryout inspection and checking for all quality related procedures in the site
and ensures activity at the site as per approved method statement and ITP.
- Responsible of all QA/QC documents specific to the job.

7.0 HEALTH,SAFETY & ENVIRONMENT

 Daily Tool Box Talk to be performed with all crew at Workshop with heat
mitigation, pinch point issues and scope to be performed each day. Daily
information and communication attached with a signed attendance sheet of all
attending employees there working that day. Listing specific points of interest and
available in several languages.
 All jobs above height 1.2mtr must be carried out by using proper scaffolding
platform and proper tagging to be done.
 All personnel who works height for the removal of nozzle blind, must wear safety
harness.
 All the planned activity and duration must be communicated with all team member
to avoid confusions and loose talk.
 If any change in planned activity must have to reported or intimated to COMPANY
person.
 Work shop escape routes must be clearly highlighted and properly communicated
to everyone.
 HSE-coordinator will monitor site safety requirements & compliance during
execution.
 Appropriate PPE’s will be worn by personnel working at site.
 Housekeeping will be maintained on regular basis.

AMCOG-DOC-18-02, Rev.01 Page 5 of 13

  Adequate rest shelter/tents, first aid box, drinking water, salt tablets will be made
available at site during working hours.
 Adequate & appropriate barricades, sign boards & cones will be made available at
work site to control movement of site vehicles and other traffics.

8.0 EQUIPMENT’S

8.1 SPECIAL TOOLS

- Digital Torque Controller Panel (Make - Tritorc/Equivalent, Model- TCW)

- Electric drive for tube expansion (Make - Tritorc/Equivalent, Model- PED2)
- Tube Expander for First Stage Expansion (Make - Tritorc/Equivalent, Model-
T824)
- Spare Mandrel for above Expander(Make - Tritorc/Equivalent, Model- TM8)
- Spare Roll Set for above Expander (Make - Tritorc/Equivalent, Model- TR9A)
01 - Tube Expander for 2nd & 3rd Stage expansion (Make - Tritorc/Equivalent,
Model- T1224)
- Spare Mandrel for above Expander (Make - Tritorc/Equivalent, Model- TM58)
- Tube End facer (Make - Tritorc/Equivalent, Model- TTF750)
- Spare Tool bit for above Facer (Make - Tritorc/Equivalent, Model- TTFB750)

8.2 MEASURING TOOL

- Bore Gauge with Micrometer (or)

- 2 Pin Dial Gauge

01 9.0 Details of Exchangers for Re-Tubing

Sr. Exchanger Qty. Cate Tube Detail Tube Tube Tube Sheet Tube T-TS Joint
No Details & Tag gory Qty. Material Material Pitch
. No. (Nos) In Total
(Nos)
01 25- 04 O.D 19.05mm 6467 x 4 SA179 SA765-2+N 25.4 Heavy
E0609A/B/C/D A x 2.11 thk. = 25,868 Expanded
-9000L 50mm, Light
Expanded-
47mm
02 25-E0610 01 O.D 19.05mm 5912 x 1 SA179 SA765-2N 23.8 Heavy
A x 2.11 thk. = 5912 Expanded
-12000L 50mm, Light
Expanded-
82mm

AMCOG-DOC-18-02, Rev.01 Page 6 of 13

 10.0 WORK METHODOLOGY : To carry out the Tube to Tube Sheet Expansion Work for the
Re-Tubing of Fresh Cooling Water Exchanger’s under Category A

10.1 Tube Pulling/Removal Procedure

01  Inspection of received exchangers for its internal condition.

 Record all findings and communicate with COMPANY QA/QC.
 Check internal tube cutter, whether it going inside to the old tube or not (due to
internal rib). If it going without any issue, then cut the tube internally from one
side and pull from other side by using pulling power pack. Remove the tube stub by
using stub puller.
 If internal tube cutter not going inside smoothly due to tube internal corrosion or
less ID in the fin/internal rib area, then check whether wall thickness reduction by
using reaming tool is applicable. But due to extensive of corrosion on the tube
internal area, wall thickness reduction may not be feasible. So that, finally go for
drawing the whole tube from one side by suing the following steps.
 Thread mandrel into the old tube with impact wrench. (No damage will cause due
to impact wrench.)
 Mount pulling gun onto mandrel.
 Switch to forward cycle till expansion joint breaks once joint breaks switch to auto
cycle by pressing ‘AUTO’ button till tube is completely removed from tube sheet
area.
 When tube is free, a tool can be inserted into jaws to enable the tube to be pulled
by hand.
 Unscrew the mandrel from pulled tube and proceed to next tube.
 The tube removal will be step by step by pulling 25% (approx. 1600) of alternate
tubes from each row.
 Clean the tube sheet hole and after satisfactory inspection by COMPANY QC,
proceed for new tube insertion.
 After 25% tube insertion, for remaining tubes removal the same sequence (25-
50%) will follow until 100% achieve in order to facilitate proper tube insertion
through baffles.
 After all tube removal, the face area of tube sheet will be thoroughly cleaned and
offer for inspection. The dust or any residues which may fall into the shell inside or
tube fin area will be removed by using industrial vacuum machine.

AMCOG-DOC-18-02, Rev.01 Page 7 of 13

 10.2 Adjustment of expansion Torque

 Reduction range of tube wall thickness for heavy expansion shall not exceed 6% to
8% of tube thickness & % expansion shall be max 8% (heavy expansion), as
specified in the approved drawings. Light expansion % shall be max. 3%.
 The reduction in thickness is controlled with the adjustment of the expansion
torque.
 The expansion length is specified (Para.9, Details of Exchanger for Re-Tubing) for
each type heat exchanger.(for expansion sequence, see 10.3)
 The differential expansion will be achieved by controlling the torque given by
01
wattage reading on the torque control.
 Light expansion is just closing the clearance but heavy expansion is to have the
tube to forced and embedded into the tube sheet. Light expansion is normally 0-
3% (Min. 2-3% to be considered) where as heavy expansion is 6-8%.
 Start at a lower testing of the torque and check inside diameter of tube for %
expansion.
 Repeat the operation till the correct dimension as per approved drawing is
achieved.
 The unit is now ready for complete use. This torque setting gives uniform tube
expanding.
 After expanding of each tube the expander rotates in opposite direction which
facilitates easy removal of the expander.

10.3 Expansion Procedure for the re-Tubing of C3 Condenser 25-E-0609A/B/C/D

& C3 Sub Cooler 25-E-0610 (At workshop-Salwa)

 Receive the exchangers and new tubes at AMC/Designated workshop.

 Arrange all exchanger’s so that all the activities can be performed simultaneously.
 The exchanger will be inspected by AMC QC Inspector after receipt and inspection
report shall be prepared.
 Preparatory activities such as scaffolding, removal of end blinds and rest shelter
preparation etc.
01
 QA/QC inspection to be carried out after removal of end cover.
 Offer to QG QC for the internal inspection after tube removal.
 Offer QG QC for tube projection and alignment checking before performing
expansion. As per drawing 3mm projection is required at both inlet and outlet side.
 After clearance from QG QC about tube alignment and projection, start expansion
from both inlet and outlet side. Arrange the tube expander at both sides of the
exchanger. (Using one set expander at any one side of exchanger for expansion is
not allowed in order to achieve the sequence and integrity from both inlet and

AMCOG-DOC-18-02, Rev.01 Page 8 of 13

 outlet side. During expansion, exchanger both side should possess with correct
tube expander)
 Tube expanders must be greased (Special tubes expander grease entirely soluble in
water).
 Roll expands about 6%-8% of the tubes in the heavy expansion area of the tube
sheet on the inlet side (The tubes flash with the tube sheet surface). And Roll
expands about 0-3% (Min. 2-3% to be considered) of the tubes in the light
expansion area of the tube sheet.
 Roll expands the same tubes in the outlet side tube sheet for both light and heavy
expansion.
 During Expansion, it will be done in two different ways at both the end of the
exchanger tube sheet, at one end (inlet side) first heavy expansion (@6%) to be
carried out and then light expansion (@3%) to be done this will enable the flow
of thinning material to the free end and at then at the opposite end (outlet side)
first light expansion(@3%) will be done which will lock the tube and then heavy
expansion(@6%) will be carried out.
 Complete the expansion by expanding tubes one after another.
 The projection length of outlet side tubes, which are out of the tolerance indicated
on the drawing, shall be trimmed of.
 Tube expansion measurement to be taken at the beginning of each shift to ensure
01
that the procedure is followed to capture appropriately.

11.0 INSPECTION & TESTING

Inspection: 01

 The equipment must be offered to QG QC for inspection of expanded joint after

every 25% of tube expansion. The frequency must be repeated at all stages of
expansion.
 Record all dimensions and readings (in Attachment-1) for % of expansion
calculation.
 Record the dimensions of tube before and after expansion by using bore dial gauge
randomly. (Min. 5% of tubes considered for taking reading after every 25% tube
expansion cycle).
 Take reading for both inlet and outlet side for each heavy and light expansion
length and record both readings separately to calculate the % of wall thickness
reduction for both heavy and light expansion.
 Calculate and compare the values with mockup test values (of pull-out tested
tubes values) and compare if any values are below required limit. If minimum
required % not achieved, reroll the joint again to achieve required value.

AMCOG-DOC-18-02, Rev.01 Page 9 of 13

Testing:

The integrity of the expansion joint will be tested through shell side hydro test. (Refer hydro
test procedure (AMCOG-QAQC-HYDRO-18-002) for more details.)

11.1 Calculation of Expansion %:

 To assure a proper tube joint, the tube wall is reduced to a predetermined

percentage. This is done by the following steps:
 Measure the tube hole ID in the Tube Sheet = A.
 Measure the tube OD = B.
 Calculate clearance, T = A – B.
 Use tube gauge to measure ID of the tube before rolling = C.
 Roll the tube and measure actual ID of tube after rolling with tube gauge as “Da”
 Calculate the actual percentage of wall reduction as

%R = ((Da - (T+C)) / (B-C)) x 100

 Since the amount of wall reduction greatly determines the quality of the tube joint,
it is important to arrive the % required prior to tube rolling. This technique is used
to set torque of the rolling devices. The following % reductions are recommended
to achieve a proper tube joint (Mechanical Joint).

Tube Material - Carbon Steel, SA 179

01
Heavy Expansion - 6 to 8 % & Light Expansion - 3%

 Check that the expansion is within the recommended range. Torque setting may be
gradually changed to achieve the proper expansion ratio. Later use the same
torque value for rolling the rest of the tubes.
 Use suitable lubricant for rolling.
 In case tube is under rolled i.e. tube is not expanded to fill the tube sheet hole and
proper amount of wall reduction is not obtained then reroll using the next higher
size roller. Take care not to over roll as that can do damage to T/S.

AMCOG-DOC-18-02, Rev.01 Page 10 of 13

Following are the figures of tools which are involved in the job

Torque Controller

MAKE: Make - Tritorc/Equivalent, Model- TCW

01

AMCOG-DOC-18-02, Rev.01 Page 11 of 13

 Tube Expander

Make - Tritorc/Equivalent, Model- TM8

Tube Expander/Roller

Make - Tritorc/Equivalent, Model- T824

AMCOG-DOC-18-02, Rev.01 Page 12 of 13

 Attachment-1 01

EXPANSION REPORT
PROJECT : RE-TUBING OF FRESH COOLING WATER EXCHANGER
REF.CODE/SPECIFICATION : ASME Sec VIII Div.1/ASME
EXCHANGER TAG. 25-E0609A/B/C/D & 25-0610 Sec IX /TEMA R, API 660

JOB NUMBER : LTC/C/MNT/3164-A/17 REPORT NO :

EXPANSION DETAILS :- After every 25% tube expansion (Approx. 1600 tubes) *

EXCHANGER SIDE :- INLET/OUTLET

EXPANSION TYPE : HEAVY/LIGHT

EXCHNAGER TAG NO. Date :-

Tube sheet hole Clearance

Tube No. Tube OD(B) Tube ID (C) After rolling (Da) (T+C) (B-C) Reduction R% =
ID(A) (T)=(AB)
((Da(T+C))/(B-C)x100

PREPARED BY AL MUFTAH QA/QC QATAR GAS

Name :

Designation :

Signature :

Date :

*25% cycle will repeat until complete tube get expanded.

AMCOG-DOC-18-02, Rev.01 Page 13 of 13