IDBC-TX-MPZZZ-NG0084

BANYU URIP TUBE EXPANSION PROCEDURES 24-07-2012

PROJECT Rev. C
MPI: Not Classified Page 2 of 11

REVISION MODIFICATION LOG

Revision Section Description

A All Issued for Internal Review

B None Issued for Review

C None Reissuend for Review

IDBC-TX-MPZZZ-NG0084 Rev C TUBE EXPANSION PROCEDURES

 CLIENT COMMENT'S ON TUBE EXPANSION
SR.NO. THERMAX CLARIFICATION
PROCEDURE

To be added : Point 3. Inspection and Record

3. Inspection and Report
We are checking mock up sample for 8% to 14%
3.1 Acceptance Tolerance
thinnning and report of the same will be available,
Tobe provided standard acceptance tolerance
however we are carrying out inspection of tube ID after
3.2 Tube Diameter Check
1 expansion by Go & No-Go gauge and which should be
To be checked tube diameter before and after
within 8% to 12% thinning,if thinning goes beyond 12%
expansion
same will be reported however 22% of thinning is
acceptable.refer sample report attached.

3.3 Tube Projection We are checking tube projection before & after tube
2 To be checked tube projection max./min. from steam expansion which should be within tolerence as specified
drum inside shell in drawing.and same has been incorporated in procedure.
 THERMAX LIMITED
BOILER & HEATER GROUP
Chinchwad, Pune – 411019, INDIA

CONTROL NO. : SIP-PH0511-19

DOCUMENT TYPE : STANDARD INSPECTION PROCEDURE REVISION NO. : 00
DATE : 20.07.2012

PROCEDURE FOR TUBE EXPANSION

DOCUMENT REVISIONS SIGNATURE

00 20.07.2012 FIRST ISSUE S.V.LANDAGE R.S.SURVASE S VENKATARAMANA

REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

Record of Revisions

PAGE 1 OF 5 QUALITY ASSURANCE & CONTROL

File Name: SIP-PH0511-19A - Tube expansion procedure.doc Thermax Lilited, INDIA
 CONTROL NO. : SIP-PH0511-19A
PROCEDURE FOR TUBE EXPANSION REVISION NO. : 00
DATE : 20.07.2012

Sections Added/
Rev. Date Description Sections Revised
Deleted

00 20.07.2012 First Issue

File Name: SIP-PH0511-19A - Tube expansion procedure.doc PAGE 2 OF 5 QUALITY ASSURANCE & CONTROL
Thermax Limited, INDIA
 CONTROL NO. : SIP-PH0511-19A
PROCEDURE FOR TUBE EXPANSION REVISION NO. : 00
DATE : 20.07.2012

CONTENTS

1. GENERAL.......................................................................................................................................................4
1.1 Scope ...........................................................................................................................................................4

2. PROCESS.......................................................................................................................................................4
2.1 Expansion machine set-up for Mock up ...................................................................................................4
2.2 Inspection of tube expansion- at Mock up stage:....................................................................................4
2.3 Tube Expansion operation in the Drums-.................................................................................................5

File Name: SIP-PH0511-19A - Tube expansion procedure.doc PAGE 3 OF 5 QUALITY ASSURANCE & CONTROL
Thermax Limited, INDIA
 CONTROL NO. : SIP-PH0511-19A
PROCEDURE FOR TUBE EXPANSION REVISION NO. : 00
DATE : 20.07.2012

1. GENERAL

1.1 Scope
This procedure defines the method of the tube expansion and seal welding in the boiler drums.

2. PROCESS

2.1 Expansion machine set-up for Mock up

2.1.1 Set the torque for each tube diameter and tube wall thickness combination, which is to be
expanded.

2.1.2 Verify that the thickness of test block to be used shall be as per drawing requirement into which
tubes are to be expanded.

2.1.3 Ensure the surface of tube hole into which the tube will be expanded shall be finished as per
standard and drawing requirement.

2.1.4 Ensure after each hole has been finished as per standard and Drawing requirement, the hole
shall be examined to ensure there is no longitudinal marks, it is free from foreign material, oil
and grease etc if any.

2.1.5 Ensure Tubes shall be buffed in circumferential direction.

2.1.6 Clean the mock up plate holes and tube OD in the expansion area for removal of foreign
particles with cotton swap and buffing machine.

2.1.7 Insert the tubes in the holes keeping projection as per drawing.

2.1.8 Select the expander for particular tube size with parallel rollers.

2.1.9 Set the power pack pressure in such a way that the machine trips till the time expansion of 10
to 12% thinning is achieved.

2.1.10 Check Inner Diameter of the expanded tube using a dial bore gauge till 10 to 12% thinning is
achieved.

2.1.11 Re-set Power pack pressure and expansion trials will be continued till 10 to 12% thinning of
inner diameter of tube is achieved and record the Power pack pressure at this stage.

2.1.12 Consistency of thinning will be confirmed by expanding two tubes at the pressure recorded
above. Check and record the ID of those tubes and calculate % thinning also.

2.2 Inspection of tube expansion- at Mock up stage:

2.2.1 Check and record the mock up plate thickness, hole size and finish.

2.2.2 Check and record the average hole size, tube outside diameter and average tube thickness.

2.2.3 Calculate the expanded tube ID with 10 to 12% and 12 to 14% thinning.
File Name: SIP-PH0511-19A - Tube expansion procedure.doc PAGE 4 OF 5 QUALITY ASSURANCE & CONTROL
Thermax Limited, INDIA
 CONTROL NO. : SIP-PH0511-19A
PROCEDURE FOR TUBE EXPANSION REVISION NO. : 00
DATE : 20.07.2012

2.2.4 Record the pressure gauge reading for required thinning range.

2.2.5 Measure and record the expanded tube inner diameter at 10 to 12 % thinning by Dial Bore
Gauge and Go, No-Go Plug gauges.

2.2.6 Check the expanded tube ends visually for splits, crack, and tube inside surface, which should
be free from metal flakes, scabs etc.

2.3 Tube Expansion operation in the Drums-

2.3.1 Verify that torque setting used on the drum is identical with the setting established by above
requirement to expansion of any tubes in production

2.3.2 The operator who is carried the above procedure in the mock up is qualified to expand the
tubes. The additional operator will be qualified based on actual expansion of one tube in the
drum at above set pressure.

2.3.3 Clean the drum holes & tube outside diameter in the expansion area for removal of foreign
particles, oil & grease etc. if any.

2.3.4 Insert and lock the tubes in the drum. Maintain the required projection inside the drum as per
drawing and carry out the tack expansion of the tube.

2.3.5 Face / trim the extra projection of the tube before full expansion as per drawing.

2.3.6 Carry out the tube expansion in both the drums at the set pressure to achieve 10 to 12%
thinning with similar expander and mandrel used for mock up expansion.

2.3.7 Care to be taken to check the mandrel length to avoid it touching the inside of the tube during
expansion.

2.3.8 Insert and expand tubes in longitudinal direction. Repeat this process to finish the expansion in
circumferential outward direction.

2.3.9 Measure and record the expanded tube inner diameter at 10 to 12 % thinning by Dial Bore
Gauge and Go, No-Go Plug gauges.

2.3.10 Check the expanded tube ends visually for splits, crack, and tube inside surface, which should
be free from metal flakes, scabs etc.

2.3.11 Check the projection of expanded tube ends from drum inside & it should be as per tolerances
specified on drawing.

2.3.12 Check the dimension of tube end flaring if applicable & it should be as per tolerances specified
on drawing.

File Name: SIP-PH0511-19A - Tube expansion procedure.doc PAGE 5 OF 5 QUALITY ASSURANCE & CONTROL
Thermax Limited, INDIA
 PRE-PRODUCTION EXPANSION MOCK UP
PROJECT MAIN DRAWING NO. REV.NO.
NUMBER

ITEM MOCK UP DRAWING NO. REV.NO.

DESCRIPTION

SR Description SAMPLE 1 SAMPLE 2 SAMPLE 3

1 Average tube thickness, in mm :T
2 SEAT CLEARANCE
i) Average Drum Hole diameter (mm) : HD
ii) Average tube outer diameter (mm) : OD
Seat Clearance : C = HD - OD
3 TUBE INTERNAL DIAMETER
ID1 = OD - 2T
4 TUBE ID AT METAL TO METAL CONTACT
ID2 = ID1 + C
5 EXPANDED TUBE INTERNAL DIAMETER FOR 8% THINNING
ID08 = ID2 + (0.08T X 2)
6 EXPANDED TUBE INTERNAL DIAMETER FOR 9% THINNING
ID09 = ID2 + ( 0.09T X 2)
7 EXPANDED TUBE INTERNAL DIAMETER FOR 10% THINNING
ID10 = ID2 + (0.10T X 2)
8 EXPANDED TUBE INTERNAL DIAMETER FOR 11% THINNING
ID11 = ID2 + (0.11T X 2)
9 EXPANDED TUBE INTERNAL DIAMETER FOR 12% THINNING
ID12 = ID2 + (0.12T X 2)
10 EXPANDED TUBE INTERNAL DIAMETER FOR 13% THINNING
ID13 = ID2 + (0.13T X 2)
11 EXPANDED TUBE INTERNAL DIAMETER FOR 14% THINNING
ID14 = ID2 + (0.14T X 2)
12 MOCK UP PRESSURE

Signature : Engineer QC

Page 1 of 2 THERMAX LIMITED, Boiler & Heater Group

QUALITY ASSURANCE & CONTROL
 OD : Tube OD
C : SEAT CLEARANCE

T : Tube Thickness

Thickness
Drum
ID1

HD : HOLE DIAMETER

DRUM INSIDE

ID2

ID08 TO ID14

DRUM OUTSIDE

Page 2 of 2 THERMAX LIMITED, Boiler & Heater Group

QUALITY ASSURANCE & CONTROL
 I-VII-1-10

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