TUBE

EXPANDER
PROCESS
MANUAL

(HEAT EXCAHGER
&
BOILER)
 Basic Principles Of Tube Expanding

Tube Expanding is based on engineering principles, involving elasticity and plasticity, to

compress the OD of the tube against a fixed container, such as rolling tubes into tube sheets,
drums, ferrules or flanges. To assure a proper tube joint, the tube wall must be reduced by a
predetermined percentage. The following chart can be used for determining the correct tube
wall reduction.

This chart shows a typical 3/4” – 16 gauge tube. Before rolling this tube you would find the
proper rolling dimension as shown.

A. Determine the tube hole size.

B. Determine the tube outside diameter.

C. Subtract the tube outside diameter from the tube hole dimension.

D. With an Tube Gauge, determine the inside diameter of the tube before rolling.

E. Add the dimension found in “D” to the clearance between the tube OD and the tube hole
to get the tube’s inside diameter at metal to metal contact.

F. Roll the tube to what you feel is a good tube joint. This example was rolled and then the
ID of the tube was checked with an Tube Gauge.

G. Subtract “E” from the rolled diameter to determine the actual amount of expansion (tube
wall reduction) on the inside diameter of your tube. This can be converted to a % of wall
reduction by dividing the actual wall thickness (“B minus D”) 0.130″ into the amount of roll
0.009.
 You can use this chart to your advantage by predetermining both the % of wall reduction
required and the actual inside diameter which should be rolled. After the completion of “E”
you realize any additional increase of the inside diameter of the tube will result in actual wall
reduction. Since the amount of wall reduction greatly determines the quality of the tube joint,
you should arrive at the % required for your application prior to tube rolling.

By subtracting the tube inside diameter “D” from “B”, you determine actual wall thickness.
This example would, therefore, be .130”. If you then take the 7% wall reduction times the wall
thickness, you arrive at .0091”. Adding .0091” (“G”) to .627” (“E”) we get “F” the inside
diameter of the tube after rolling (.636”).

Tube Test Number 1 2 3 4 5 6

A Tube Sheet Hole Size 0.757

B Tube Outside Diameter 0.750

C Clearance (A – B) 0.007

D Tube Inside Diameter 0.620

Tube Inside Diameter

E 0.627
When Metal-To-Metal Contact Is Reached (D + C)

F Tube Inside Diameter After Rolling 0.636

G Actual Amount of Roll on Diameter (F – E) 0.009

Test Chart For Determining Proper Amount Of Tube Expansion

Note:
Take all measurements in thousands
Take “A” in middle of area to be rolled
Take “B”, “D”, and “F” in same position as 2
Take both horizontal and vertical diameters as tubes may be out of round
show mean diameter.
Tube Expanders
This technique is an excellent way to set torque rolling devices. Once you
have arrived at the rolled dimension for four or five tubes, you can roll them
and very simply determine if more or less wall reduction is required.
Knowing how to determine wall reduction is important; however it is equally
important to know the characteristics of the popular tubing materials. We
should know the proper wall reduction which would apply to each metal. A
simple rule of thumb is the harder the material, the less wall reduction is
required to obtain a tube joint. For example, you can assign these as
approximate percentages of wall reduction when rolling pressure vessels:

Tubing Material:
Copper & Cupro Nickel: 8-10%
Steel, Carbon Steel, and Admiralty Brass: 7-8%
Stainless Steel & Titanium: 4-5%

These materials and percentages can be your guideline to rolling tubes of like
materials.
Here is a summary of important factors in rolling certain alloys: When rolling 3003 or
4004 Aluminum you should not reduce the walls over 5%. When rolling 6061-T
Aluminum, which is one of the most popular materials used in aircraft fittings, you
can reduce the wall 10 to 12% for a mechanical joint.
There is a tube process called Alonizing. It is stated that Alonized steel combines the
heat and corrosion resistant properties of the iron aluminum alloy with the strength
and rigidity of steel. When rolling this tubing it is extremely important to lubricate each
tube end and make certain that the tube expanders are kept clean. Remove all
particles of the tubing materials from the expanders to decrease tool fatigue.

When rolling Alonized tubing, abrasive particles are removed from the inside
diameter of the tubing and gathered in the expander. It is recommended that two
expanders be used. One should be cleaned and lubricated while the other is being
used.

Admiralty Brass is widely used in condensers. This material should be well lubricated.
The tube wall is reduced approximately 7% to 8% for optimum tube joints. In general,
only a 4% to 10% reduction in wall thickness is necessary to produce a tight tube in a
serrated hole. On the other hand, reduction in excess of 15% may cause leaking, splits
or flaked tubes.

Carbon Steel is used in almost every type of pressure vessel built today. Tube wall
reduction should be approximately 7% to 8%. Heavy lubrication is a must. If the tube
is cracking or tooling shows excessive wear, tube hardness should be checked.
Carbon Steel tubes should be 90 to 120 Brinnel hardness for rolling. It is possible to roll
tubes up to 150 Brinnel; however, flaking and cracking are more likely to occur as the
tube hardness increases.

When rolling Copper and Cupro Nickel, consider approximately 8 – 10% wall
reduction to be a proper tube joint. Copper, since it is one of the softer tubes used in
pressure vessels, can be easily rolled. Use plenty of lubrication because copper has an
abrasive action on tube expanders.

When rolling Stainless Steel and Titanium, approximately 4 to 5% wall reduction is

sufficient to produce a tight tube in a serrated hole. When rolling these alloys the
entire wall reduction should be done quickly. These materials have a greater tendency
to work harden; therefore, minimal or no rerolling should done. Motor speeds should
be 400 to 750 RPM.

When rolling Titanium, it is recommended to use an expander with four rolls or more.
This will decrease diaphragm of a thin wall and help eliminate tube end cracking.
There are, however, exceptions to the above rule.
This discussion of alloys has been related to those used in pressure vessels such as
boilers, heat exchangers, and condensers. These factors would be approximately the
same in a mechanical joint for industrial use. However, a greater percent of wall
reduction is usually considered when making a mechanical joint. Higher quality tubes
are used in industrial applications.

Major Causes of Tube Leaks

Tube rolling leakage is usually caused by one of the following: under-rolling,
over-rolling, improper preparation of tube sheets and differential thermal expansion.
Improper expansion can lead to serious difficulties for both the manufacturer and the
repair servicemen.

Under-Rolling
Under-Rolling as the word would imply is when the tube is not expanded to fill the
tube sheet hole and the proper amount of wall reduction is not obtained. It is better to
under-roll than to over-roll.

Over-Rolling
Over-rolling is when the expansion of the inside diameter of the tube surpasses the
expansion required for the proper percentage of wall reduction for the ultimate tube
joint. Over-rolling can do considerable damage to a vessel. Over-rolling will decrease
the dimensions of the ligament between tubes and weaken this bridge. Once a
ligament is weakened, it will cause a reaction in all ligaments surrounding that weak
ligament. If we decrease the strength of the ligament the tube next to the tube being
rolled will leak.

Over-rolling also causes distortion in tube sheets or drums, such as egg-shaped holes.
It will also cause diametrical expansion which is the overall increase of a tube sheet or
drum. Over-rolling has been known to cause a tube sheet to bow or warp to the point
where the standard length tube could not be used in the vessel until the bowing or
warpage is returned to normal. This is usually corrected by placing stay rods in the
vessel and pulling the tube sheets back to their original position.

Improper Preparation of Tube Holes

Improper preparation of tube holes is another major cause in tube leakage. If the tube
sheet or drum is gouged, it is extremely hard to expand the tube to fill these gouges or
tears without over-rolling. The smoother the tube seat or tube hole the easier it is to
roll an optimum tube joint. The ligaments and light tube walls make it more important
that the finish of the tube hole be in the low micro range. We find many
manufacturers today are drilling, reaming and sizing or burnishing to get the
microfinish desired for tube holes.
Differential Thermal Expansion
Differential thermal expansion can result with thicker tube sheets. When the
expansion due to heat varies noticeably between the thinner tube and tube sheet, a
shift of the tube results. One of the most important steps for ensuring a safe and
permanent tube joint is to thoroughly clean the surfaces of the tube end and the tube
hole wall. These two surfaces must be clean and free of all dust, mill scale and pits or
scratches. It is extremely important to eliminate any longitudinal scoring in the tube
hole wall. These longitudinal lines will cause leaky tubes.

Preparation of Tube Holes

Preparation of tube holes in heat exchangers and condensers is as follows:
1. Drill and ream tube sheet holes to .007” to .010” over the outside diameter of the
tube to be used.
2. Be certain the ligaments are sufficient to guarantee a safe and permanent tube joint.
3. When conditions permit, utilize a sizing or burnishing tool to further assure a good
finish in the tube hole. This will also increase the tensile strength of the ligament.
4. The serrations or grooves to be used will determine the holding power of the tube.
5. It is extremely important when retubing that the grooves be cleared of all metals or
any foreign material.

Preparation of Tube Sheets

Preparation of tube seats in drums, tube sheets, and headers are as follows:
1. Tube holes are normally drilled and reamed to approximately 1/32” larger than the
nominal outside diameter of the tubes.
2. It is extremely important during this operation that there are no longitudinal
scorings left in the tube seat.
3. In cases where out-of-roundness is extreme, prerolling of the tube holes is advised.
4. Be certain that the tube hole walls and the grooves in the tube walls are cleaned
down to bare metal before tubes are inserted. Be certain all foreign material such as
oil, grease, rust, or just plain dirt are removed. Special attention during this cleaning
will prevent serious trouble later.
After tube holes have been prepared they are usually coated with a rust preventative
compound. Before inserting any tube it is important to remove all traces of this coating.
It is extremely important that great care be taken in handling the tubes for insertion in
all of the vessels discussed above. Be certain that the tube ends are clear of any foreign
material. Be especially certain that there are no chips on the tubing which may gouge
the tube sheet or tube seat when the tube is placed in the vessel.
In some cases it will be necessary to force a tube into a tube hole. This should be done
with extreme care. It is better to spring the tube than to try to force it with a hammer.
If a tube end is kinked or damaged before rolling, the expanded end will be damaged
and a leaky roll joint will result. Attention at this time to the tube ends and the tube
alignment will prevent future troubles.

Calculating The Rolled Inside Diameter

• Rule of thumb: the harder the material, less wall reduction
required.
• Percent wall reduction guidelines:
• Copper & cupro-nickel – 8% to 10%
• Steel, carbon steel, admiralty brass – 7% to 8%
• Stainless steel, titanium – 4% to 5%
• 3003 or 4004 aluminum – 5% maximum
• 6061T aluminum – 10% to 12%

Determining 3, 4, or 5 Roll Expander Design

• Generally a 3 roll expander is well suited but inquire about:
• Tube material:
• Stainless steel, titanium:
• Work – hardening materials.
• Minimum 4-roll design, if possible.
• Wall thickness:
• 20 gage (.035”) & thinner:
• Stainless steel, titanium – 5 roll preferred.
• Carbon steel, brass, copper, aluminum – 4 roll preferred.
• Tube pitch:
• Tube sheets with thin ligaments in a triangular tube pitch pattern may be
disrupted using a standard 3 roll expander.

When To Use 4 or 5 Roll Expanders

• Tube Materials
• Stainless Steel
• Titanium
• Other exotic alloys
• Materials that work harden rapidly
• Tube sheets with thin ligaments in a triangular pitch.
 How A Mechanical Bond Is Formed
• Tube Joint formed by compressing the tube into a fixed
container (i.e. tube sheet).
• Ideally rolled joint created when the tube state turns to
plastic (stays where it stops) and is contained by the tube
sheet’s elastic properties (fully recovers). This has to occur
right before the
tube sheet turns to a plastic state.
• Under-rolling occurs when the tube is not compressed
enough and remains at an elastic stage. A bond is not
created as yield of material is not compressed enough to
turn tube sheet to elastic.
• Over-rolling occurs when tube surpasses the elastic
property of the tube sheet and therefore the ligaments
between the tube sheet holes are shifted, causing adjacent
tubes to leak.
 Common Causes Of Tube Joint Failure

• Not enough tube expansion (under rolling).

• Too much tube expansion (over rolling).
• Dirty, scratched tubes or tube sheets.
• Dents or other imperfections of the tube.
 Proper Operation For Effective Joints & Tool Life

• The tube surfaces must be clean of debris, scratches,

dents, cracks and any other imperfections of the tube.
• Inspect the tube sheet where tube is being expanded into,
for any radial or longitudinal imperfections.

Proper Operation For Effective Joints & Tool Life

• The expander must also be clean and free from debris.
• Any visible signs of wear on the expander’s rolls and
mandrel - replace these items immediately.
• The expander must have the rollers and mandrel well
lubricated to prolong tool life.
• The kind of lubricant will make a difference.
• The expander’s thrust bearings must have liberal
amounts grease to reduce friction. (Extremely important if
rolling the joint to a torque).

Tips To Improve Tool Life

• Use 2 Expanders alternatively for one operator. Place one
expander in lubricant while the other one is under rolling
operation.
• Exchange expander about every 50 joints to allow for
proper cool-off and lubrication. Use Quick Change Chuck to
minimize downtime.
• Every 5-7 complete exchanges, check for debris trapped
between mandrel and rolls. Disassemble and clean if
required. Ensure thrust bearings have liberal amounts of
grease.
• Roll to suggested tube wall reduction using a Torque
Control Box. This ensures repeatability of Joint Tightness
and reduces overheating of tube expander and
components.
• Hold Rolling Motor in a vertical / straight position and
avoid motor to weigh on the mandrel to avoid possible
axial load on the mandrel creating fatigue and premature
tool breakage.
• Use double-radius rolls when rolling inside the tube sheet
(or inner-sheet). This will avoid sharp edges inside the tube
that will cause strain on the mandrel when withdrawn.
The torque which is being used in the process : Normally
more the torque more is the expansion and more is the
percentage reduction in the thickness if the tube. In some
cases the tubes normally crack due to over expansion.

Expansion limit for expansion of tubes

Tube expansion can be compared to the cold rolling of steel
sheets. The tube to be expanded can also be equated with
an endless steel sheet which, during the rolling process, has
been lengthened or enlarged to a point when the external
diameter of
the tube equals the diameter of the tube sheet hole.
This first stage is called 'metal to metal contact'. Note that
the expansion at this stage is not yet leakproof.
Metal to metal contact: about 3 - 5% of tube wall thickness
Further rolling is necessary to increase the expansion and
reach the point when the material is deformed. This creates
tension because of the compression between the tube and
the tube sheet. A leakproof expansion is assured if the
pressure tension is
greater than the service pressure, which arises from the
heating, the lengthening and finally the tension of the
medium. The difference of expansion between the 'contact'
and the final expansion is called 'expansion limit'
This 'expansion limit' must never cause a rupture in the
cohension of the molecules of the tube material by an
exaggerated deformation of the material. If this were the
case the tube material could become dammaged – it could
crack or break – and this would create the danger of
explosions etc. when the tube comes under high pressure.
It could then happen that, though the tests had turned out
positive, the tube will prove useless after a few days in
service.

Listed below are the tips for proper tube expansion

The tube plates must be shot blasted – parkerised – CNC

drilled – vapour degreased before fabrication.
· A groove must be provided for preventing the loctite
entering the machine and the groove must also contribute to
the strength of joint between the tube and the tube sheet.
· The tube hole should not have a prefect round shaped hole
without any longitudinal or helical scratches as they
contribute to he leak path.
Expander tool maintenance
·The grub screw should be made tight before the start
of the shift.
·The roller should be changed after the expansion
of ever 70 ends.
·The mandrel should be changed after the expansion of ever
1400 ends.
·The tube expander should be cleaned with the
soap solution after completing the four tube ends.
·All burr and loctite stick should be removed after ever
hundred tube ends are completed or even before.
· Under rolling may be preferred as it can be easily reworked
but in case of over rolling it is not accepted.
· In case of direct fired vapour absorption machine all gaps
should be sealed in order to prevent crevice corrosion.
· In case of titanium tubes which are used in conjunction
with saline water a four roller expander is normally
recommended with low rpm. This is done in order to prevent
cracking of tubes.
· The expansion length should normally be about 2 mm less
then the thickness of the tube sheet.
· In case of stainless steel tubes steam is used to prevent
elongation of the tubes during expansion process.
· In case of special tubes always swage the ends always
remove the tube from the same side.
· In case wherein the clearance between the tube and the
tube sheet is very large then the max tube expansion limit is
in sufficient than trust collar butting tube is used.
· The high temperature stainless steel tubes which are
internal seam welded should be ground to length of 60 mm
and the projection should not exceed 0.3mm.
· The best method of cleaning tubes and tube sheet is the
use of vacuum pump and not the use of compressed air.
· The holes of the tube sheet should be cleaned by the use of
vapour degreasing method. After this is done then the
cleaning is done by the use of clean rag and not with cotton
waste.
· Gloves should be used while handling tubes.

After the tubes are placed in the tube sheet expanded they
are checked for leaks between the tube sheet and the tubes.
The normally procedure for the leak detection is nitrogen
testing which is well known as soap test or bubble test,
which is
explained in the following steps below :

1) The unit is cleaned with a vacuum pump and the adapter

is welded to the unit.
2) After the welding operation is completed nitrogen is filled
in the unit to a pressure of about 1.3 Kg/m2. Then soap
solution is sprayed on the entire surface and
checked for bubbles.
3) The places with leaks are indicated by the formation of
bubbles. Once the tubes with expansion leaks are detected
they are marked.
4) After the detection of leaks in the tubes joints one end of
the tubes is crushed (collapsed) with the help of a tube
crusher, care should be taken that during the collapsing
operation no damage is made to the surface of the tube
sheet hole.
5) After the above operation, a Tube Puller with tapes is
inserted on the other side and the tube is puller out by the
hammering operation. And a new tube is inserted and
expanded by the same standard procedure.
CONCLUSION:
Tube expansion is a faster and most reliable method of
obtaining a perfect joint between the tube sheet and the
tube for the heat exchanger and high temperature
generator.
The cost of tube expansion equipment work to economical
at compared to any other tube to tube sheet joint. To avoid
this loss in some cases stresses are induced in bends so it
may causes a leakage in the joints so to avoid this, tube
expansion process is carried out.
Tube expansion is used to provide proper mechanical seal
between tube and tube sheet and to minimized friction.
Tube expansion process is having minimum distortion
between tube and tube sheet so to have proper leakproof
joint.
 TUBING of LOCOMOTIVE BOILERS
1. Introduction
a) This Guidance Note is one of a series dealing with Locomotive Boilers that were produced bythe
“Steam Locomotive Boiler Codes of Practice” practitioners meetings.
b) Railway locomotive boilers are designed to create, store and distribute steam at high pressure. The
working life of such a boiler can be considerably shortened if due care is not taken at all stages of
inspection, repair, running maintenance and day-to-day running.
c) In the past there have been a series of accidents and explosions due to work being undertaken
without having due regard to the inherent risks involved. It is with that in mind that HMRI and HRA
set up the series of meetings of boiler practitioners to discuss the issues distil good practice and
codify it into this series of Guidance Notes.
d) This guidance is written for the assistance of people competent to perform these tasks. In places the
terminology used may be specific to such practitioners.
e) This guidance should also be useful to those in a supervisory or more general role. However no work
should be undertaken unless the persons concerned are deemed competent to do so.

2. Recommendations
a) This guidance note is issued as recommendations to duty holders.
b) Where duty holders decide to take actions that are not in agreement with these recommendations
following appropriate risk assessments or for other reasons, it is recommended that those decisions
are reviewed by the senior management body of the organisation concerned and a formal minute is
recorded of both the decision reached and the reasons for reaching it.

3. Dimensional Notation
a) The dimensions in this document are variously described in a mixture of imperial and metric units.
Where practical equivalent dimensions have been shown but in some cases the dimensions do not
easily equate and so the units in force at the time the original designs were documented have been
used.

4. Personal Protective Equipment

a) Before undertaking any work a risk assessment must have been conducted.
b) Protective equipment is to be supplied and used at work wherever there are risks to health and
safety that cannot be adequately controlled in other ways.
c) The equipment must be:
i) Compliant with the latest Personal Protective Equipment Regulations.
ii) Properly assessed before use to ensure it is suitable.
iii) Maintained and stored properly.
iv) Provided with instructions on how to use it safely.
v) Used correctly by those undertaking the work.
5. Inspection
a) In the event of finding the tubes are suspect seek guidance from the boiler Competent Person before
proceeding with any replacement.

6. Material Specifications.
a) No boiler tubes should be replaced without prior approval of the Competent Person. All tubes
obtained as replacements should be to British Standard Specification, BS EN 10216-1: 2002
(Seamless steel tubes for pressure purposes), BS EN 10217-1:2002 (welded steel tubes for
pressure purposes), the grade of steel within either EN specification must be specified as P195TR1
(No 1.0107) or P195TR2 (No 1.0108). Alternatively an equivalent standard; see table below -
Tensile Strength BR Specification Equivalent
Detail Material
Tons / sq “ Number Grade
Boiler Tubes BS 3602-320
and Steel 20-28 123 or 122 BS 3059 PT1 320
Flue Tubes HFS/CFS or ERW
Boiler Tubes Copper 14.5 min 317a BS 2871 PT3 C107-PA3

b) All tubes must be perfectly sound, well finished, free from surface defects and rust, and the ends
must be faced clean and square.
c) The tubes must be normalised before fitting.
d) The responsible person should retain the relevant material and test certificates for such tubes for as
long as the tubes are in use.

7. Removal of Tubes
a) There are two distinct methods of tube removal, with variations depending on the tools andskills
available:
i) One method involves loosening the tubes from both tube plates and removing eachtube through
its own hole in the front tube plate.
ii) In the other procedure, tubes are cut at each end and allowed to fall into the boiler barrel,with
the tubes and cut ends removed later.
b) The first method can substantially be carried out with hand tools if shop facilities and power tools are
not available, although the use of power tools will speed up the process and require less physical
exertion. Removing the tubes through their own holes is also particularly advantageous if only a
small number of tubes are to be removed – such as when replacing a group of thin or leaking tubes
as a maintenance procedure or when removing two or more sample tubes from near the boiler
bottom for examination to help determine general tube condition.
c) Work begins in the firebox where the bead (formed by riveting the end of the tube over so it bears
against the plate) is removed from the tube end by using either a hand chisel, oxy-acetylene cutting
torch or special chisel in a small pneumatic hammer. A tube drift is then inserted into the tube and the
tube driven forward, loosening its grip where it has been rolled into both tube plates. Once loosened,
the tube is easily removed unless heavily coated with scale, in which case it may be slid back and
forth to knock off the scale. It is easier to drive the tube out if the smokebox end of the tube is first slit
along its length for several inches using a square-ended “ripping” chisel, allowing the tube to collapse
slightly. An alternative is to slit both ends of the tubes in two or more places and fully collapse the
ends with chisels, then insert a long bar into the tube at the smokebox end and use it to draw the tube
out far enough to be grasped by hand.
d) The second method involves cutting each tube at both tube plates using either a oxy-acetylene
cutting torch or an internal tube cutter driven by a powerful pneumatic motor. If the cutting torch is
used, tubes should be cut far enough back to avoid accidental damage to the plate.Cut tubes are
removed through a specially enlarged tube hole in the front tube plate (the “king hole”, located
near the bottom of the centre column of tubes), or through suitable boiler openings such as a large
superheater flue holes. The remaining tube ends in both tube plates are then removed by
collapsing them with chisels and knocking them out of their holes. Collapsing can be aided by
slitting the tube ends with a oxy-acetylene torch (using a small cutting tip), or cutting partially
through with an electric saw or hacksaw. Another method is to heat the end of the tube that is still
in the plate; then bend it away from the tube hole by striking with a chisel. The tube end may then
be drawn clear through with little risk of damaging the hole.
e) A few cautions and helpful hints for tube removal should be mentioned.
i) Extreme care must be exercised when using a cutting torch in case the flame nicks or gouges
the seating surface of the tube hole. Because tube material is thin, only a smalloxy-acetylene
torch equipped with a tip designed for this type of work should be used in order to reduce the
chance of accidental damage. The operator must be skilled – this is not a job for the
inexperienced. Careful work at this time will reduce the amount of time and effort needed to
repair damaged tube plate holes later.
ii) If using an electric saw or hacksaw, be careful that the saw does not cut into the tube plate – the
same precautions given for using the oxy-acetylene cutting torch apply here.
iii) If tubes removed through the king hole, three or four small U-shaped shims or clips made from
thin steel or brass should be placed around the inside of the hole to serve as wear plates. The
abrasion wear produced by removing 200-300 tubes through the hole can wear the hole so out
of round that it will have to be repaired by welding.
iv) It’s a little more difficult to remove tubes when the firebox end beads have been seal welded to
the tube plate, because either the bead or the weld (or both) must be cut through to permit tube
removal.
v) Three methods of weld and bead removal may be used:
(1) Grinding through the tube bead using a small disk or die grinder
(2) Chipping off the weld and bead with a special angled chisel used in a pneumatic hammer
(3) Cutting off the weld and bead with a oxy-acetylene cutting torch.
vi) The last two processes require considerable skill to remove enough of the weld and bead so the
tube can be removed while at the same time avoiding damage to the rear tube plate by either
undercutting with the chisel or nicking with the torch. Once the weld and bead have been
removed the procedure is the same as for non-welded tubes.
vii) Superheater flue removal presents additional problems of its own. Flues are made of thicker,
less workable material than are tubes (making collapsing difficult), and their greater weight
creates handling problems. Often these flues are removed through their own holes in the front
tube plate, but this may be difficult if heavy scale has built up on them. It may be necessary to
hammer off such scale prior to removal or to sacrifice the flues and cut them into pieces small
enough to be passed through the steam dome. On some locomotives, particularly ex GWR
types, flues maybe screwed into the firebox and beaded-over. The only method of removal is to
cut the tube free from the firebox and remove the threaded portion later.
viii) Avoid cutting too many tubes off at one end without cutting them free at the opposite end, as the
hanging weight may strain the tube plates and cause cracks. This is especially true when cutting
off the heavy superheater flues.
 8. Cleaning of Tube Holes
a) The front and rear tube plate condition should be checked, possibly revealing cracks, cuts and
gouges around tube holes not readily apparent beforehand. Also check for damage caused by tube
removal, such as chisel or torch nicks not only on the faces of the plates but also on the surfaces of
the holes themselves. Carefully grind the fire side of the tube plate (especially if tubes have been
welded to the rear tube plate), removing as little material as possible in order to provide a fresh,
smooth surface against which the tubes can be beaded. Grinding will reveal a narrow band or ridge
around each tube hole, an indication that the tube plate is thicker where the metal has been forced
outwards by the previous expanding process and where it has been protected from fire by the bead.
It’s not necessary to remove these bands by grinding them down to the same thickness as the rest
of the plate.The tube holes will require cleaning and polishing, best done with a high speed fine wire,
flap or sanding wheel. It can also be done with half-round files or by carefully manipulating a
pneumatic or electric die-grinder with a 25 to 38mm (1″to 1½″) round grinding tool, but be careful
not to introduce out-of-roundness or enlarge the hole excessively. The edges of each hole should
be rounded slightly 1.6mm (1/16”) radius is suggested) on both faces to prevent the tube from being
cut whenit is expanded and beaded. This job is best done using a large diameter 45° grinding stone
in a high speed grinder.
b) Nicks, gouges or cracks on the tube plates or in the tube holes will require attention unless they are
very minor. (See section on Reaming of Tube Plate holes).

9. Reaming of Tube Plate Holes

a) Any holes for small tubes which are elongated or otherwise out of round by (0.8mm) 1/32″ or more
must be dealt with in the following manner:

For Copper tube plate.

b) Ream out to take a new tube. Alternatively after reaming an annealed copper liner can be fittedto
bring the tube hole back to the original size. (Refer to section on Tube Plate Liners)
c) Expanding of holes for this purpose is prohibited.

For Steel tube plates.

d) Ream out to take a new tube. Holes may be built up by welding then either filed, reamed or bored to
the correct size; subject to the agreement of the Competent Person and suitable NDT. Only welders
properly qualified and certificated for this type of welding can undertake the task.

10. Screwed Tube Plate Bushes and Plugs

a) Whilst a repair by copper welding is preferred, fractured tube plate bridges maybe repaired byfitting
screwed copper bushes which must be screwed in tightly and; where feasible; riveted over on both
sides of the tube plate.
b) The bush may be made by drilling and opening out one of the standard copper plugs as shown in
diagram below.
c) If circumstances warrant it then the fitting of a maximum of four plugs in any one tube plate is
permissible provided no two of these four plugs are adjacent to each other; however plugged and
bushed holes may alternate.
D) The plugs to be used, copper for the firebox tube plate and steel for the smoke box tube plateare shown in
the diagram below.

Threads to be Whitworth form normal to the angle of taper.

Dimension ‘X’ to vary from 1 7/16” to 2 9/16” in 1/16” increments

E) An alternative method of bushing of small tube holes is as follows:

i) A parallel tap of 11threads per inch to be used for tapping tube holes, into which is to be tightly
screwed a hollow parallel bush, chamfered inside at each end to a depth of 7/16".
ii) The bush to project an equal amount on each side of the plate, to be expanded from both sides by
drifting or expanding, and beaded over on each side. The beads to overlap across the cracked
bridge so that the crack is completely covered and the bushes interlocked.
iii) The thickness of the finished bush in question to be not less than 3/16".
iv) Bushes to be made from copper tube
v) Bushing is to be limited to six on each side of the vertical centre line.
vi) Bushes fitted with surrounding tubes in position to be beaded over on the firebox side and
expanded with taper rollers, the large end of the taper being on the water side.
F) The bushing of large tube holes is prohibited.
11. Ferrules

a) A ferrule was a short length of tube driven into the firebox end of the smoketubes to protect the tube
from burning.
b) The use of ferrules to protect tubes is not permitted other than where originally specified from new or
a design change has been approved by the insurer.
c) Ferrules must not be used as a repair for tubes that are worn thin or leaking to an extent that they
cannot be kept tight after expansion.
12. Tube Plate Liners
a) In order to use standard tubes in tube plate holes which have been reamed out, annealedcopper
liners may be used in accordance with the following table:

Nominal inside Nominal outside Nominal thickness

diameter of liner. diameter of liner. S.W.G. mm
For Tubes 1.1/2” -38.1mm 1.9/16” - 39.68mm 21 0.8
1.1/2”(38.1mm) 1.1/2” -38.1mm 1.19/32” -40.48mm 18 1.2
Diameter At End 1.1/2” -38.1mm 1.21/32” -42.06mm 14 2.0
For Tubes 1.5/8” -41.2mm 1.11/16” -42.86mm 21 0.8
1.5/8”(41.2mm) 1.5/8” -41.2mm 1.23/32” -43.65mm 18 1.2
diameter 1.5/8” -41.2mm 1.3/4” -44.45mm 16 1.6
At end 1.5/8” -41.2mm 1.25/32” -45.24mm 14 2.0
For tubes 1.3/4” -44.4mm 1.13/16” -46.03mm 21 0.8
1.3/4”(44.4mm) 1.3/4” -44.4mm 1.27/32” -46.83mm 18 1.2
Diameter At End 1.3/4” -44.4mm 1.7/8” -47.62mm 16 1.6
1.3/4” -44.4mm 1.29/32” -48.42mm 14 2.0
1.3/4” -44.4mm 1.15/16” -49.21mm 13 2.3
1.3/4” -44.4mm 2” -50.80mm 10 3.2
For tubes 2”(50.8mm) 2” -50.8mm 2.1/8” -53.97mm 16 1.6
Diameter at end

b) Where it is considered a possibility to fit liners, it should be established that there is sufficient
material to support the tubes. This work should not be undertaken without the prior consent of the
competent person. In no circumstances should the thickness of a liner exceed 3.2mm (10SWG).
c) The liners must be lightly driven in flush with the fireside of the tube plate and then expanded in
position. Standard five roller expanders must be used for this purpose.

13. Tube Plates

a) Bowed tube plates in a poor condition must be replaced; but if serviceable, must be levelled.

14. Preparing for Tube Installation

a) Be certain that all boiler repairs which cannot be performed after the tubes are in have been
completed.
b) Examine the insides of both tube plates for any undiscovered cracks or nicked tube holes, and make
sure the tube holes are clean.

The ends of old tubes or tubes that have been swaged down will require normalising (heating their ends
to bright cherry red (840 - 870 C ) and cooling them slowly) to soften the material - not only to ease
rolling and beading, but also to prevent cracking during the installation process. A regulated gas oven is
the best normalising tool, but a forge or heating torch will also work if care is taken to prevent burning
 the tubes, which results in heavy slag build-up, pitting and possible brittleness. The tube ends are
usually cooled by plunging them into a bed of dry sand, which not only insulates, but also helps to
minimize oxidation (scale). It’s not necessary to normalise the ends of new tubes, if they are delivered in
a normalised state. If you have difficulty rolling new tubes, or if cracking occurs during rolling or beading,
reject the tubes and contact the tube supplier for an explanation.
c) The tube ends must be free of any burrs left over from cutting, and should be lightly polished both
inside and out for a length of 2”(50mm) to 3”(75mm) on both ends to remove mill scale or scale
resulting from normalising.
d) After being cut to length, cleaned and swaged (if necessary), the tubes are ready to be placed into
the boiler. Wipe the tubes just before inserting to remove dirt, loose scale, and any remaining oil or
rust preventative; then inspect the tubes a final time, rejecting those which are dented, deeply
scratched or gouged, or have damaged ends.

15. Flue Tubes

Procedure for new screwed superheater flue tubes and tube plates

a) Pilot holes to be drilled in tube plate for tube holes. Tube holes to be opened out and a radius
machined on the fireside of each hole, and finally tapped to suit the screwed end of the superheater
flue tube.
b) Tube ends are to be screwed .007″(0.19mm) to .015″(0.38mm) below the nominal diameter, and at
the same setting the bore must be cleaned out exactly concentric for a depth of 3¼″(82mm) from the
end of the flue tube. From that point inwards the cut must be run into the original rough bore of the
tube without any abrupt change in section. It is permissible to fabricate flue tubes by welding a
separate swaged end onto a plain tube.
c) Only welders properly qualified and certificated for this type of welding can undertake the task.

d) The tube ends must be strictlyconcentric and in accordance with the appropriate drawing in all
respects.
e) The threads in the copper tube plate must be cleaned out with a short tap revolved from the steel
tube plate end by a long adaptor, the adaptor being guided by a bush put in the corresponding
smoke box tube plate hole.
f) The tube plate on the water side must be lightly faced when necessary and coned 45 degrees to a
depth of approximately 1/8” (3.18mm), the cutter being mounted on a mandrel screwed tightly into
the copper plate.
g) At the firebox end on a screwed flue tube the wall thickness below the threaded portion of the tubeat
the point of expansion must be 3/16”(4.76mm) minimum, ¼″ (6.35mm) maximum.
h) Tubes may be screwed in using the standard tool, see sketch below, or if they have been ordered
over length they may be screwed into place using the waste end and then cut to length in situ. Care
must be taken to ensure that the end is clean and square before expansion.
 Tool for inserting flue tubes

16. Tube Expanding

a) The type of expander used will be determined by the origin of the boiler.
b) Typically the Eastern and Southern regions used fireside expansion and the Western region and
London Midland Region used waterside expansion. Modern industrial practice is to use parallel
internal expansion.

An over-scale sketch of the effects of the two forms of expander is given above:
c) To re-expand tubes with an expander having a different direction of expansion to that previously
employed will cause severe distortion and is therefore prohibited.
d) Tube expansion begins in the firebox. 3 roller expanders should not be used in coppertubeplates
due to the potential for deformation. Current practice favours the 5 roller expander as in drawing
below

5 roller expander for Copper Tube 1 ¼” to 3 ¼”

6 roller expander for Steel Tubes
Expanders for small tubes

e) Each tube must project from the tube plate a required, pre-determined amount, usually between
3/16” (4.76mm) to 5/16” (7.93mm). (As the tubes are driven into position, keep a small plate metal
gauge handy). The projection of the tube at both the firebox and smokebox ends must be checked
to verify correct tube length. A little excess length is allowed in the smokebox, but short tubes should
be rejected. The roller expander tends to pull the tube into the firebox as well as rotate it, so the tube
must be anchored to the front tube plate. A good method is to grasp the projecting portion of the
tube at the smokebox end with two pair of locking pliers, so that the lips of the pliers rest against the
tube plate when the tube is in its proper position (as gauged in the firebox); the pliers also prevent
the tube from spinning.
f) The expander should be lubricated, but be careful not to get oil between the tube and hole, which
can cause a hydraulic lock preventing the tube from sealing properly. Use water-soluble oil so that
the expander can be washed periodically. Compressed air maybe used to blow dirt from the interior
of the tube and from between the tube and its hole.
g) To avoid distortion of the tube plates, it is advisable to follow some systematic method in the fitting of
the flues.
h) The sequence in which tubes are to be expanded will be laid down and should be adhered to;
however, if the original order drawings are no longer available one the following methods may be
adopted:

Method 1.

i) Finish a vertical central row, followed by a horizontal central row. Then finish each quadrant,
successively working from the outside towards the centre.

Method 2.

j) Start expanding at the outside rows and work inward in a spiral manner to finish in the centre of the
tube plate.

Method 3.

k) The outer and bottom tubes are expanded first gradually working inwards and upward working
towards the centre of the tube plate; the object being to distribute the compressing action of the
expander as evenly as possible over the entire plate without distorting the tube plate.
l) The expander should be
fully inserted into the tube.
Expanders with thrust
collars have a “bridge”
which extends past the
outside of the tube, and
which must rest securely
against the tube plate. An
example is shown in
drawing to the right:
Adaptor for small tube expanders

m) Be sure to select the tapered mandrel that will fully engage the rollers at the start. The mandrel may
be turned by hand when necessary, but is generally driven by either pneumatic or electric “roll
motors”. Using these motors in the confines of either the firebox or smokebox is hazardous
because the high torque developed can easily cause the operation to lose control of the machine.
Whenever possible brace the motor against the side or crown plate, or upon a bar inserted into a
convenient tube, and hold onto the motor’s trigger in such a way as to avoid pinning the controlling
hand in the event of a problem.
n) Once the mandrel has been placed in the expander and the motor connected and switched on, watch
the action of the rollers against the tube wall as stretching begins. Most rollers are designed
to self-feed the tapered mandrel, making it unnecessary to push it into the expander. As the mandrel
is fed the tube will slowly grow in diameter and fill the hole. The rippling action of the tube will slowly
diminish and then stop, accompanied by a slight straining of the motor, both indications that the tube
has tightened in its hole.

o) Experience is necessary to determine if rolling should be continued beyond this degree of tightness.
Sometimes a standard such as “one-half turn more” or “one turn more” is applied; alternatively the
degree of expansion can be calculated as follows:

Step A - Measure Tube Plate Hole

Step B - Measure Tube OD
Step C - Calculate Clearance (A–B)
Step D – Measure Tube ID
Step E – Calculate Total Wall Thickness (B–D)
Step F – Calculate 7% Wall Reduction (.07 × E)
Step G – Calculate Finished Rolled Tube ID (C+D+F)
p) For steel tubes the tube wall should be reduced by approximately 7% to 8% for optimum tube joints.
When rolling copper, consider approximately 8% to10% wall reduction to produce a proper tubejoint.
q) Considering the variations which occur in such items as tube wall thickness and diameter of tube
hole, the work involved in measuring and re measuring each joint would make cost excessive.
r) Once the tube is tight, reverse the direction of the motor and pull the mandrel back while turning,
releasing it from the rollers. If the motor will not reverse, remove the mandrel by turning it with a
spanner.
s) When the firebox end is finished, proceed to the other end. Begin again at the centre to brace the
plate. Be careful of the pulling action on the first tubes, because the tube plates may be pulled
closer together at the centre, becoming dish-shaped. An expander without a thrust collar will help
reduce this pulling tendency.
t) Superheater flues require larger rollers, and may demand heavier motors. It’s safer to locate heavier
motors in the more spacious smokebox or on temporary platforms in front of the boiler. Many large
expanders have drive bosses or connections at both ends of the tapered mandrel; when rolling at the
rear tube plate; these connect the roller to the motor via a drive shaft slid through the flue.

u) Further consideration will show that regardless of the variation in clearance between the outside
diameter of the tube and the tube hole, the work done in expanding the tube up to the inside diameter
of the hole is relatively small compared with the work in actually reducing the wall thickness. Hence
the degree of expansion can be controlled by actually measuring the amount of work necessary to
give the required amount of wall thinning (which is, in fact, directly related to the torque exerted by the
mandrel itself for any specific size of tube joint). Once the initial joint is actually measured and related
to the torque on the mandrel, then the expansion of the other joints to the same torque reading give
consistent results in line with that of the first expansion.
v) Keep in mind that the desired result is to seal the tubes while producing the least amount of stress in
the tube plate. A tube which has been expanded slightly less than fully has a much better bond than
a tube which has been stressed by overexpansion. It is better to under-roll than over-roll.

17. Beading

a) Once all tubes and flues are properly expanded, the ends are generally “beaded”, or riveted over
against the tube plates. Beading begins in the firebox and should follow the same pattern used
when expanding the tubes. The projecting end of each tube must first be “belled” or flared to about
45° (Min 35°).
b) If the expander used had extra “flaring” rollers, belling was done as the tubes were expanded. If not,
use a commercial or home-made belling tool, driven by hand or pneumatic hammers. As shown in
diagram below:

First operation, pneumatic tool for flaring tubes

c) The second operation is to bead over the edge of the flared tube, with a beading tool as shown
below:
Beading tool for small tubes.

Example of a beading tool for large flue tubes.

d) A beading or “thumb” tool can be used by hand or in a small to medium pneumatic hammer.
Beading further seals or caulks the expanded joint; to produce the correct bead, hammer not only
the end of the tube, but also the tube interior, bending the tube out against the hole in the plate. As
shown.

Incorrect use of beading tool (left) Correct use of beading tool (right)
e) Start the air flow to the hammer slowly, and work the beading tool around the tube several times,
gradually hammering the belled tip over and producing the finished bead. The bead must be formed
without allowing the tip of the thumb to cut into the plate. As the tool wears, this tip will need to be
ground back. Select tools with the proper radius for the tube thickness and allowed projection, and
change tool size as necessary if the projecting length of tubes varies.
f) In the smokebox it isn’t always necessary to bead all the tubes. Generally a few rows of small tubes
at the bottom are beaded for ease of cleaning; the tubes around the washout plugs are beaded to
prevent damage from spanners and the small tubes in the area around the flues. Tubes which
require beading but project too far from the plate should be trimmed off with a grinder or chisel
before beading.

18. Seal Welding of Tubes

g) The method to be used should be agreed with the competent person prior to commencement. The
tubes must be expanded before welding and lightly re-expanded after welding to help relieve
stresses and prevent leakage caused by the welding heat.
h) In order to overcome problems caused by movement of the tubes and plates on steel fireboxes the
firebox ends of the tubes can be welded. Before welding the tube plate must be clean, dry and free
from oil.
i) The following diagrams on the next page illustrate welding alternatives. The second method
eliminates beading. When deciding which method to use the following should be considered:
j) When using method one the seal weld may crack around the beading, although this can then be
chipped out and the tube end re-welded to the tube plate.
k) The second method eliminates beading therefore the cracks around the beading; however, over a
period cracks can develop from the weld into the tube lengthways causing tube failure.
l) Only welders properly qualified and certificated for this type of welding can undertake the task.
 Method 1 Beaded tubes (1/4 to 5/16” weld) Method 2 Unbeaded tubes ( 3/16” weld)

19. Welding procedure

a) A welding procedure must be agreed with the Competent Person before commencement. Only
welders properly qualified and certificated for this type of welding can undertake the task. The
completed weld to be subjected to suitable NDT, unless agreed otherwise by the CompetentPerson.
b) A guide to the order of welding is given below.

ORDER OF WELDING
Start weld at “A” and work in the direction of “X” to
“B”.
Then return to “A” and weld in the direction of “Y” to
“B”, lapping over the end of the first weld.

20. Leaks
a) In order to avoid tube leaks, it is essential to realise that the tube moves longitudinally in the tube
plate as the temperature varies, and therefore correct manipulation of the fire-hole door and the
deflector plate must be understood to prevent cold air from striking the tube plate. As there is
movement between the tube and plate, the bearing surfaces of the tube and plate must be fairly
smooth. A rough hole and tube surface would certainly be steam tight for a short time but relative
movement soon wears the high spots and leakage occurs.
b) Continued expansion distorts the tube plate and thins the tube metal; in bad cases it is possibleto
imprison scale between the tube and the plate resulting in further leakages. It is sometimes
beneficial in bad cases to expand the tubes surrounding the defective one first, thereby closing the
metal onto the tube and reducing the amount of expansion for the one tube.
c) Rust should not be allowed to remain on the body of the tube or pitting is almost certain to result.
d) If leakages occurs around the tube ends remove the water from the boiler and re-bead the leaking
tubes, this is normally sufficient and avoids the need for re-expanding.
e) A significant leak that does not readily seal may indicate a cracked tube or a crack developing in the
tube plate bridge next to the tube.
f) If leakage occurs from the inside of the tube it is most likely due to corrosion or cracking. In this
situation a thorough examination of ALL the tubes must be carried out and, with the approval of the
responsible person, the defective tube(s) must be replaced.
g) The use of any type of tube plug or blank is not permitted unless specifically agreed with the
Competent Person.

21. Testing

a) If the Boiler has been re-tubed; or the tubes have been re-expanded; either partially or fully and no
other repair work has been undertaken. On completion of the tube replacement, expansion, beading
and seal weld operations the boiler shall be subjected to a static cold water head pressure test with
the boiler in a Water Wedged Condition (filled with no air space) for a duration no shorter than 12
hours.
b) The static head pressure test has a stipulated duration of 12 hours to ensure sufficient soak time for
the test. Care should be taken to ensure that the water temperature within the boiler is maintained
above 7 degrees Celsius at all times to avoid the possibility of Cold Brittle Fracture. (BS2790 Section
6 Issue 3)
c) Under certain circumstances hydraulic testing may supplement the static cold water head pressure
test if directed by the Competent Person
 INSTRUCTION FOR TUBE EXPANSION
1.0 SCOPE:

These instructions are issued for guiding tube expansion process at site for Condensers.

2.0 INTRODUCTION :

Condenser being a huge equipment it is dispatched to site in a number of

assemblies/sub-assemblies and various loose parts. It is built at site before the stage of tubing
comes. Proper expansion of tubes in condenser is very important as improper expansion may
result in tube to tube plate joint failure leading to water leakage into steam space. Apart from
interruption in power generation, these leaks contaminate the condensate which may lead to
damage to other equipments requiring expensive repair.

3.0 EXPANDED JOINT:

Tube expansion into the tube plate is a process in which the tube is expanded mechanically to
provide metal to metal contact with the hole surface. In this process, outer surface of the tube
first touches with the inner surface of tube hole and on further expansion, ductile material of
tube flows into the cavities of the tube hole surface undergoing plastic deformation thereby
providing leak tight joint. Normally roller expanders are used for above purpose. In this type of
expansion, taper mandrel is inserted between three high finish rollers. With the rotation of
mandrel by torque controlled motor, all rollers rotate. While feeding the mandrel inwards,
diameter over rollers increases which expands the tube, making the leak proof joint.
Expanded tube to tube plate joint obtained with above process is a pressure tight joint with
strength and stability. This type of tube to tube plate joint is most popular in Heat Exchangers.

4.0 CLEANING OF TUBE HOLE SURFACES IN MAIN TUBE PLATES AND TUBE
ENDS:
All contact surfaces in the expanding operation should be clean. No foreign mate- rial is
allowed to be entrapped between the tube and tube hole mating surfaces, as it will result into a
poor joint, which may ultimately lead to leakage. Foreign mate- rial will fill in the cavities of
holes in which tube material would have flown. Remove all rust, dust, scale, oil, dirt,
protective coating and other foreign matter from tube plate holes and inside and outside
surfaces of tube ends. Foreign matter on the inside of tube will tend to become embedded into
tube wall and may cause flaking and galling of rollers and mandrel. Cleaning of tube hole may
be done by the application of suitable light oil or solvent like carbon tetrachloride etc. If
required round steel brushes may also be used. Tube ends can be cleaned by using rough cloth
and if necessary very fine emery paper may also be used, avoiding scratches over the tube
surface.

5.0 TUBE HOLE SURFACE FINISH AND SIZE OF HOLES :

Very glossy finish of the tube hole surface is not desirable, as it produces poor inter- locking of
material during tube expansion, thus resulting into a weak joint. On the other hand very rough
surface finish and excessively oversized hole is equally harmful, as excess material flow
during expansion will set severe stresses in the tube ends due to excessive cold working.
Normally recommended oversize of hole over tube diameter is 0.2 to 0.6 mm and surface
finish of holes between 6.3 to 12.5 microns. Before insertion of tubes, hole should be
inspected for its finish after cleaning. Holes should not have longitudinal or spiral-through tool
marks. Such marks should be made smooth before tube insertion.

6.0 TUBE INSERTION :

The tubes duly fitted with tapered guide are inserted through various intermediate support
plates while positioning the same between the two main tube plates. Depending upon the
number of supports and tube length, requisite no. of persons should be employed between
different compartments to guide the tubes in right holes with proper care to avoid scratches on
the tubes. Burrs, if any, should be cleaned from support plate holes before tube insertion.

7.0 TORQUE/CURRENT SETTING :

Before starting actual expansion, torque should be set to achieve required tube wall
thinning. Normally tube thinning is kept between 6% to 11% for non-ferrous and 5% to
10% for ferrous tubes. Calculation procedure of tube thinning is shown in the enclosed
Annexure-l.

7.1 Select 10 holes at random in each of the zones in the tube nest representing various
roughness and hole sizes. Use 3-pin point micrometer for measurement of hole size and
note the same in logsheet (Annexure-Il). Measure corresponding tube O.D. and record average
value for reference.
Site Erection Expert’s own experience may also be kept in view while zone selection is
done.

7.2 | Measure thickness of corresponding tube directly by using spherical tipped or pointed
tipped micrometer and note the same in logsheet. Calculate theoretical internal- dia of tube
after expansion as per Annexure-I.

7.3 Set the torque based on experience.

7.4 insert the tubes in 2 holes, with their dimensions duly recorded. Expand the inlet end,
keeping 1.5 mm protrusion.

7.5 Measure internal diameter of the tube after expansion using 3-pin point micrometer.

7.6 Compare above expanded diameter with theoretical diameter calculated at 7.2 above.

7.7 (a) If expanded internal diameter is more than the theoretical, this would mean that the tube
is over expanded. Lower the setting of torque/current and repeat above exercise with two fresh
holes and tubes.

7.7 (b) If expanded internal diameter is less than the theoretical, this would mean that the tube
is under-expanded. Increase the setting of torque/current and repeat above
exercise with two fresh holes and tubes.
7.8 Finally set the controller to the torque/current where actual expanded internal diam- eter is
achieved within the theoretical range of expansion.
7.9 Re-expand the tubes where under expansion has taken place.

8.0 SEQUENCE OF EXPANSION :

8.1 Expand about 6 rows, vertical and horizontal at center to avoid distortion of tube plate.
Subsequently proceed as recommended by BHEL Erection Experts.

8.2 Complete the entire tube expansion with right torque/current setting and if necessary with
selective torque/current setting for selective holes.
9.0 GENERAL PRECAUTIONS BEFORE EXPANSION:

9.1 At few places, measure distance between outer faces of tube plates and keep the record of
the same in logsheets.

9.2 Measure the tube length and see that margin is about 10mm. No tubes should be used
having margin less then 3mm over the dimension measured at 9.1 above.

9.3 Slacken the set screw on the thrust collar of the expander and adjust it, by moving the
collar body along the screwed body, to suit the length of expansion as per the drawing. Lock
the collar in the set position by tightening the set screw at required position.

9.4 Inlet tube end should be expanded first and then outlet end should be expanded. While
expanding inlet end, collar washer should be used to prevent axial move-ment of tube beyond
tube plate on water box side (See fig.1 of Annexure-III} How- ever, while expanding outlet
end, collar washer should not be used so as to allow axial movement of tube beyond tube plate
towards water box end (See fig.2 of Annexure-III) If necessary. two different tube expanders
may be used to meet this requirement.

9.5 After expansion, inlet end should be bell mouthed by light blow of hammer, using belling
tool. Bell mouthing is not recommended for Stainiless steel & Titanium tubes

9.6 Protrusion of tube at outlet end between 1mm to 10mm is acceptable. Excess length
should be cut after expansion.

9.7 Suitable oil or glycerine may be used for lubrication of rollers.

10.0 DO'S:

10.1 Cool and clean the expander in a mixture of soap solution and glycerine at regular interval.
It is better to use two expanders so that one can be cooled and cleaned
when the other expander is in service.

10.2 Inspect the rollers, mandrel and expander cage at regular interval for wear! scratches/
burrs.
10.3 Check torque/current setting whenever rollers and mandrel are changed.

10.4 Measure rolling langth of tube at regular interval to ensure that expansion length is as per
drawing.

11.0 DON'TS :

11.1 Do not use expander with over flowing coolant/lubricant. This will overflow into the f
gap between tube and tube hole in lower rows and create film there causing weak e joint in
these lower rows. Coolant/ lubricant should be just sufficient to prevent
overheating of expander.

11.2 Never expand the tube beyond tube plate face.

11.3 Never use worn-out rollers/mandrel/cage. This will dig on tube material.

11.4 Never change only rollers or mandrel. Complete set of rollers and mandrel should be
changed.

11.5 Do not expand the tube at any end if tube is suspected to fall short on either tube plate
face.
Enclosures: Annexure-l, |I & III
 WORK INSTRUCTION FOR TUBE EXPANSION
PROCEDURE FOR TUBE EXPANSION

1.0 Scope

This standard covers the tube expansion process carried out in Boiler, Condenser
and other heat exchangers and coolers.
The tubes of condenser or beat exchanger or boiler are fixed in tube plate holes by
means of roller expansion,

2.0 Guidelines

•Guidelines for boiler tube expansion is enclosed in Annexure 1.

•Guidelines for condenser tube expansion is enclosed in Annexure 2,
•In case any specific instructions are given by the manufacturing unit the same shall be
followed.

3.0 The Equipment

The area in charge shall inspect and ensure the adequacy of the equipment, tools and lubricants
available / to be selected, for the tube expansion work.
3.1 Tube hole numbering system as given by manufacturing units to be followed. If not given,
it may be decided and recorded.
4.0 Mock up test for selling of parameter
4.1 Purpose
Before starting the lube expansion (on actual job) a mock expansion shall be carried out to
ensure that the design requirements can be adequately met.
4.2 Procedure
Obtain the mock lip trial pieces (of the same material with the same hole size as that of the
main plate) from manufacturing unit or in case it is not available choose a few holes from the
original tube plate on the equipment itself.
The test tubes shall be representative of the tubes to be expanded.

4.2.2 Drive Equipment to be used shall be the same for the mock up test and for the main job.

AMENDMENT NO. 1 (i of ii)

4.2.3 Check for the tube holes of mock up plate. They are to be cleaned and free of burrs,
scratches etc. running lengthwise.

The surface shall be metal clean, when examined without magnification under normal
lighting. Surface shall be cleaned free of films and contaminants such oil, oil, water, paint
and preservatives as determined by visual inspection or after cleaning with a solvent
dampened white cloth or an equivalent alternate method. When there is a groove or
separation in the tube sheet, particular attention to be pa id to ensure that the groove is
clean.

4.2.4 Check the tube end and tube holes. Measure OD & ID of Tube and ID of the plate hole.
(As in Format I)

4.2.5 Based on the recommendation of the manufacturing unit, calculate the expansion and
wall thinning to be obtained. And determine the range of tube II) after expansion.

4.2.6 Insert the tubes as required in the drawing furnished by supplier in the measured
holes and expand. In case of electrical drive, the torque requirement is to be determined
by means of trial expansion. The electrical drive unit controller Ammeter shall be
checked for consistency. In case of Hydraulic and pneumatic drives, the pressure gauges,
pressure switch set up, are to be checked for consistency.

Starting with lower values continue expansion till the required ID of the expanded tube, as
recommended by the manufacturing unit is achieved.

4.2.7 Record the dimensions measured in the test as per Format 1.

4.2.8 If there is a specific requirement from the designer to carry out the pullout test, same
shall be carried out. In such cases the testing shall be done in the mock up test plate, by
obtaining the required test procedure for pullout test from the designer concerned.

4.2.9 Airleak test will be conducted on the mockup test piece to pressure of 1.5
kg/cm2 to ensure that these joints are leak proof and also to ensure the
qualification of parameters. However, if the pull out test is done as per clause
4.2.8, the air leak test is not required.

FORMAT: 1
TUBE EXPANSION MOCK TEST REPORT
Site : Type of Expander: Reference Document
Unit: S. No.:
Area: Thinning %

Specified -------------------- --------------------------

Before Expansion After Expansion

Tube Tube Set
Plate Plate Tube Thinning Value/
Hole No. Hole ID Tube OD Tube ID Thick ID % Remarks

Range of ID of Tube after expansion to meet specified

Current Range/Pressure setting
Certified that the process is adequate to meet the percentage thinning
specified.
FORMAT: 2
RECORD OF TUBE HOLES & TUBE DIMENSIONS FOR 5% OF TOTAL
HOLES PRIOR TO EXPANSION
(May be taken in parts daily or at any convenient intervals)
Site: Document Reference
Unit:
Area: ------------------------

S. No. Tube Plate Tube Plate Tube OD Tube ID Remarks

Hole No. Hole ID

Specification
Tube Plate hole ID
Tube OD
Tube ID
FORMAT: 3
RECORD OF PERCENTAGE THINNING AFTER EXPANSION (RANGE Of ID OF
TUBE AITER EXPANSION AS OBTAINED FROM
FORMAT:1)
Site: Range of ID as per format 1
Unit: =
Area: Date:

S. No. Tube Hole Tube ID Acceptable Not Remarks

Number Measured Acceptable

4.2.10 After the mock up trial readings are obtained satisfying the
recommended/specified results, the main job shall be taken up.
4.2.11 In case the drive unit is to be changed either during mock trial or during the
actual expansion, the mock up test shall be repeated.
5.0.0 Procedure for tube expansion on actual job
5.1.0 Clean the tubes and tube plate holes as per the cleaning, procedure indicated in
clause 4.2.3
5.1.1 Take random measurements for 5% of tube holes and 5% of tubes to ensure that
the dimensions are as specified. Record the same as per Format 2. This may be done in
parts also on daily basis or at convenient intervals. Average value may be taken for tube
expansion calculation.
5.2.0 The length of cleaning to be done for the tube shall be based on site
requirement and application.
5.3.0 Ensure that the final cleaning of tubes and tube plate holes are done not
earlier than one day prior to their expansion,
5.4.0 Determine the sequence of tube expansion as per the recommendation of the
manufacturing unit.
5.5.0 Determine the sequence of tube insertion, tack rolling, cutting off ends, flaring,
expansion etc as required.
5.6.0 Insert all tubes, Ensure tube projection as per drawing.
5.7.0 After insertion of the tube, the rolling will be done at the earliest to avoid the
formation of rust and ingress materials in the annular space between the tube and tube
plate.
5.7.1 Every day at the start of the work, first 10 expansion done shall be checked (or
correct expansion, before proceeding with further expansion.
5.8.0 After the final expansion, for the day, measure 10% of the tubes expanded, to
ensure results are obtained as per the required range and record the same as per format.
In case the result is under expansion, in 10% of the tubes, continue examination for
another 10% or the tubes expanded. In this case if the expansion is below the range
specified, expand the earlier 10% tubes with under expansion, to the specific range.
While examining the additional 10% of tubes also, if under expansion is noted, all
100% tubes expanded that day should be checked. Wherever under expansion is noted,
the same shall be expanded further to get the results desired.
In case or over expansion in the first 10% tubes examined, the cause is to be analysed
and process corrected if required even by going in for another mock up test and the
matter shall be referred to the manufacturing units for opinion.

1.0 Instruction for Condenser Tube Expansion

These instructions are issued for guiding tube expansion process at site in KWU design
of Condensers. These are also to be used as reference document for heat exchangers
manufactured at shop.
1.1 Introduction
Condenser being huge equipment it is dispatched in different
assemblies/sub-assemblies and various loose parts. It is built at site before the stage of
tubing comes. Tubing in Condenser is done after welding/fitting all internals in lower
half. Trouble-free and safe operation of Condenser depends mainly on subject operation.
Improper expansion of tubes may result into tube joint failure which may lead to water
entry in steam space resulting in contaminated condensate, hence interruption in power
generation and expensive repair due to likely damage to other equipments.
1.2 Expanded Joint
Tube expansion into the tube plate is a process in which the tube is expanded
mechanically to provide metal to metal contact with the hole surface. In this
process, outer surface of the tube first touches with the inner surface of tube hole
and on further expansion, ductile material of tube flows into the cavities of the
tube hole surface undergoing plastic deformation thereby providing leak-tight
joint. Normally roller expanders are used for above purpose. In this type of
expansion, taper mandrel is inserted between three high finish rollers. With the
rotation of mandrel by torque controlled motor, all rollers rotate. While feeding
the mandrel inwards, diameter over rollers increases which expands the tube
making the leak-proof joint.
Expanded tube to tube plate joint obtained with above process is pressure-tight
joint with strength and stability. This type of tube plate joint is most popular in
Heat Exchangers.
1.3 Cleaning of tube hole surfaces in main tube plates find tube ends
All contact surfaces in the expanding operation should be clean. No foreign
material is allowed to be entrapped between the tube and tube hole mating
surfaces, as it will result in a poor joint, which may ultimately lead to leakage.
Foreign material will fill in the cavities of holes in which tube material must have
down.
Remove all rust, dust scale, oil, dirt, protective coating and other foreign matter
from tube plate holes and inside and outside surfaces of tube ends.
Foreign matter on the inside of tube will tend to become embedded into the tube
wall and may cause flaking and falling of rollers and mandrel. Cleaning of tube
hole may be done by the application of suitable light oil or solvent 1il<e carbon
tetrachloride etc. Tube ends can be cleaned by using rough cloth and if necessary
very fine emery paper may also be used avoiding scratches over the tube surface.
 AMENDMENT NO. (ii of ii)

1.4 Tube Hole Surface Inspection

Before insertion of lubes, holes should be inspected visually: after cleaning. Hole should not
have longitudinal or spiral - through tool marks. Such marks should be smoothened before tube
insertion.
1.5 Tube Insertion
The tubes are to be threaded through various intermediate support plates while positioning the
same between two main tube plates at either ends. Depending upon the number of supports and
tube length, requisite number of persons should be employed between different compartment
to guide the tubes in right holes with proper care to avoid scratches on the tubes. Burrs, if any,
should be cleaned from support plate holes before tube insertion.
1.6 Torque / Current Setting
Before starting actual expansion torque should be set to achieve required thinning. Normally
for condenser, thinning is kept between 7% and 10%. Calculation procedure of tube
thinning is shown in Annexure-I
1. Select 10 holes in different zones in the tube nest representing; various roughness and
various hole sizes and note the same in log sheet.
2. Measure tube, outside and inside diameter of corresponding tubes and note the same in log
sheet.
3. Set the torque based on experience.
4. Insert the tubes in 2 holes with their dimensions; duly recorded. Expand the inlet
end, keeping 1.5 mm protrusion for bell mouthing, if required.
5. Measure internal diameter of the tube after expansion.
6. Compare above expanded diameter with theoretical diameter as per Annexure I.
7. a) If expanded internal diameter is more than the theoretical, this would mean
that the tube is over- expanded. Lower setting of torque current and repeat above with
two fresh holes and tubes.
b) If expanded internal diameter is less than the theoretical, this would mean that the
tube under- expanded. Increase setting of torque/current and repeat above with two
fresh holes and tubes.
8. Finally set the controller to the torque/current where actual expanded internal
diameter is achieved within the theoretical range of expansion.
9. Re-expand the tubes where under expansion has taken place.
1.7 Sequence of expansion
1. Expand about 6 rows vertical and horizontal at centre to avoid distortion of tube plate.
2. Complete the entire tube expansion with right torque/current setting and if necessary
with selective torque/current setting for selective holes.
1.8 General Precautions Before Expansion
1. At a few places, measure distance between outer faces of tube plates and keep the record of
the same.
2. Measure the tube length and see that margin is about 10 mm. No tube should be used
hawing margin less than 3 mm over the dimension measured at 1 above.
3. Slacken the set screw on the thrust collar of the expander and adjust it, by moving the collar
body along the screwed body, to suit the length of expansion as per the drawing. Lock the
collar in the set position by tightening the set screw at required position.
4. Inlet end should be expanded first find then outlet end should be expanded. Proper
collar washer should be used while expanding individual ends of the tube. While
expanding inlet end, collar washer should be used not to allow axial movement of lube
beyond tube plate on water box side (See rig.1 of Annexure-II). While expanding outlet
end, collar washer should not be used so as to allow axial movement of tube beyond lube
plate towards water box end (see fig. 2 of Annexure-II) necessary two different tube
expanders may be used to meet this requirement.
5. After expansion, inlet end should be bell mouthed by light blow of hammer, using
belling tool if recommended in the drawing.
6. Protrusion of tube at outlet end should be between 1 mm and 10 mm. or as per
drawing. Excess length should be cut after expansion.
7. Suitable oil or glycerin may be used for lubrication of rollers.
1.9 Do's
1. Cool and clean the expander in a mixture of soap solution and glycerin at regular
intervals. It is better to use two expanders so that one Gill be cooled and deemed when
the other expander is in service.
2.Inspect the rollers, mandrel and expander cage at regular intervals for wear /
scratches.
3. Check torque/current setting whenever rollers and mandrel are changed.
4. Measure rolling length of tube at regular interval and see that expansion does not
exceed beyond tube plate.
5. Expanders should be rotated at a speed proportionate to the tube size, gauge
(thickness), depth of expansion, tube material, tube plate material and hole ligament.
Ideal speed will keep minimum mandrel slippage and will prevent overheating of
mandrel, rollers find cage assembly.
1.10 Dont's
1. Do not use expander with overflowing coolant/lubricant. This will overflow into the
gap of tube and lube hole in lower rows and will create film between tube and tube plate
causing weak joint of these lower rows. Coolant/lubricant should be just sufficient to
prevent overheating of rollers and mandrel.
2. Never expand the tube beyond tube plate face.
3. Never use worn out rollers / mandrel / cage. This will dig on tube material.
4. Never change only rollers or mandrel. Complete set of rollers and mandrel should be
changed.
5. Do not expand the lube at any end if lube is suspected to fall short of either tube plate
face.
Enclosures: Annexure I & II
ANNEXURE-I
ANNEXURE-II
 BOILERS
1.0 Purpose
1.1 To provide general instruction and establish recommended procedures for rolling boiler
tubes and seal welding boiler tubes in the field.
1.2 To furnish background information on the theory of tube expanding, and to highlight the
factors which can influence the quality of a rolled joint.
1.3 These guidelines reflect what have been found over many years, to be a successful method
of tube rolling. It should be stressed that by far the greatest percentage of problems
experienced during tube rolling in the field are attributable to lack of attention to the most
basic demands (or cleanliness, careful handling of components and proper equipment
selection.
1.4 For specific data on given contracts, the Area in change should consult the engineering
drawings, bills of material and other documents for that contract. These instructions are
intended for use in erecting industrial boilers, but certain sections are adaptable for other types
of work.
2.0 Tube Expanding:
2.1 The Theory of Tube Expanding:
2.1.1 The Process of Tube Expanding:
Tube expanding or rolling can be defined as the process of cold working the tube ends by
means of a tool, usually a rotating expander, until that tube end has increased in size enough to
fill a given space. Applied to boiler erection, tube rolling is performed with the intention of
creating a strong mechanical bond and a pressure tight hydraulic seal between the tube end and
the drum or header to which it is joined.
The operation of expanding a tube into a tube sheet or boiler drum consists of two stages.
First, cold expanding the end of the tube until the outside surface of the tube is in contact
with inside surface of the tube hole. This step merely serves to remove the commercial
tolerance between the tube and tube hole, and adds very little to the final strength or
hydraulic seal of that joint.
As the rolling action continues during the second stage of expanding, a further increase
in the diameter is opposed by the metal of the tube sheet or drum with the result that a
slight elastic deformation is imparted to the tube hole and a permanent or plastic
deformation imparted to the metal of the tube. These changers provide the rolled joint
with the following characteristics.
1. As the pressure of the expander is removed from the inside of the tube, the elastic
properly of the tube hole metal tries to force the tube hole back to its original size.
This action is resisted by the permanent deformation of the tube diameter, and thus a
pressure is established between the two surfaces.
The finish of the two surfaces determines the coefficient of friction, and this coupled with
the pressure between the tube end and the tube hole determines the holding strength of
the joint. A joint rolled to the maximum friction pressure possible, coupled with a
maximum coefficient of friction is best able to withstand the stresses imposed upon it by
the constantly changing operating conditions of a steam boiler in service.
2. With further increases of the tube end diameter resisted by the metal of the tube
sheet, and the metal of the tube walls being displaced by the expander rolls, the voids and
irregularities ever present in the contacting surfaces become filled and ideally form a
water tight joint capable of withstanding test and operating pressures. The increasing
rolling diameter of the expander rolls causes a further reduction in wall thickness of the
tube and only a small portion of the metal thus displaced can be accommodated radially
in the tube wall and by the yielding of the tube hole metal. The excess portion causes the
meted in the tube wall to now axially and manifests itself as an increase in length of the
tube end metal in contact with the lube shed and cold worked by the action of the
expander, thus pushing the tube proper along with it. For a practical example, suppose
two headers me to be connected by straight tubes. Picking anyone of the tubes in position
with both ends projecting say 3/8" through the header walls and making provisions at
one end of the tube to measure any end movement, it will be found that expanding the
other end will cause the loose end of the tube to move further into the header, the
increase in tube length depending on the degree of rolling imparted to the rolled end. If
the expanding should cease when this axial movement has reached say 1/16", the loose
tube end will project 3/8" + 1/16" a total of 7/16". Measuring the tube projection at the
rolled end will disclose, providing a parallel expander is used (non-flaring in this (else to
make measuring possible) that this end projects 7/16" through the header wall also. This
is an increase of 1/16", the same increase a noted at the loose end, indicating that the
axial movement of the tube metal of a rolled joint is due to the expanding operation and
that the movement is in both directions and about equal the flow of metal in the middle of
the lube sheet thickness being zero. This plastic axial flow of the tube metal has been
termed "elongation".
2.1.2 Requirements of a Properly Rolled Joint
The major requirement of any joint is that during the life of the boiler it does not leak
and it resists the stresses imposed by and incident to boiler operation.
An equally important, but often neglected requirement, is that all joints between two
tube sheets be expanded uniformly.
It has been demonstrated that the same degree of expansion in a series of tube ends will
produce joints of uniform strength provided that all other factors affecting joint strength
remain equal. Also, once tube sheet spacing has been fixed, the elongation that must
occur as a tube end is rolled tight causes stress to develop in that tube as well as others
that the permanently fixed at both ends to the tube sheet.
The magnitude of the stress varies with the amount of elongation and if adjacent tubes
are rolled to significantly different elongations, initial stresses may be set up which will
exceed the holding strength of the joints affected.
The sequence in which tubes are rolled can also cause stresses to accumulate in other
tubes, particularly short straight tubes or tack tubes resulting in premature failure. A
boiler bank erection procedure should recognize that these stresses will develop and
provide an installation sequence that will neutralize the accumulative effect of these
stresses.
To develop the maximum holding strength from a joint, it must be first determined what
amount of rolling is required to develop that strength. Destructive testing of rolled joints
has shown that continued expanding of a tube after it has made contact with tube sheet
causes the holding strength of the joint to rise quickly to its maximum, and then decline
steadily with additional rolling, A joint rolled to its maximum strength will also be
water-tight. Over- rolling a joint will significantly reduce its holding strength whereas
hydraulic tightness mayor may not be affected. Hawing a minimum number of leaks at
hydro is generally taken to indicate a good rolling in spite of the fad that the tubes may
be rolled ill such a manner that many may give way at any time. Likewise, if the test
discloses many leaks, it is considered poor rolling even though the leaks may be
attributable to another problem.
Assuming that a boiler has been rolled uniformly to the proper degree of expansion, leaks
discovered during hydro should
disappear with only a light re-rolling. Continued rolling will lead to a reduction in
holding strength and should not be permitted, If a leak persists, seal welding might be
advisable.
2.1.3 Measuring and Controlling Tube Expansion
As energy is expended during the rolling of a tube end, a number of, changes take place
to that tube which can be seen, and sometimes measured accurately. These changes
include elongation of the tube, swelling of the lube just outside the area of roller- contact,
flaking of mill scale around the tube hole and reduction in tube wall thickness.
For comparative tests of maximum holding strength to be of practical value, they must
include a means to indicate the relationship existing between the degree of expanding
imparted to a joint and the holding strength. To be acceptable for test purposes, any of
these measuring methods must give reasonably accurate results, and to be of practical
value, must also permit the easy duplication of such results in commercial tube rolling.
Measuring means in common use, follow two directions, namely, measuring power
applied to obtain a particular degree of expansion or measuring work done.
The power required to expand a tube is affected by varying commercial tolerances in the
tube wall thicknesses, variations in tube hole dimensions, and variances in the hardness
of the tube and tube sheet.
The power may be measured by some means at the source or at the expander mandrel
direct. Torque measurements are the most common method of measuring the motor
power.
This will be discussed in more detail below.
Means to measure the work done consist of measuring the reduction in wall thickness,
measuring the bulge at the edge of the roller contact area and measuring the elongation.
In many cases, we do not expand the tube for full thickness of the tube sheet, thus
measuring the bulge at the edge of the roller contact area cannot be used.
The other two methods, either measuring the reduction in tube wall thickness or tube
elongation are both recognized as valid measurements and will be discussed in detail
below.
1.3.1 Percent Wall Thickness Reduction
During the process of tube rolling, the mandrel, while being driven deeper into the expander
body, causes the rolls to compress the tube material tighter into the tube sheet. This results in
thinning of the tube wall, which is better known as "wall reduction".
The percentage of wall thickness reduction can be determined very accurately by taking a
series of measurements on both the tube end and the tube hole before and after rolling.
Although less than practical for field use, this method is probably the closest to being a
definitive rolling standard since it can be stated at what degree of expansion a lube has
achieved maximum holding strength, and at what point a tube has been over-rolled. This
method is recommended by a number of tool manufacturers and is generally used in scientific
studies.
The percent of wall reduction can be calculated by using the following formulae:
ID + (TOD – OD) + %WR (2t)/100 = FID (1)
Where
ID = Initial inside diameter of tube
TOD = Tube hole diameter, measured before insertion of tube OD = Outside
diameter of lube, initial
%WR = Percent wall reduction t = Tube thickness, initial
FID = Final inside diameter of tube
Further development of formula: OD - ID = 2t
Therefore, formula (1) becomes;
%WR (2t) / 100 + TOD - 2t = FID (2)
Solve formula (2) for wall reduction:
%WR = FID + 2t – TOD/2t x 100 (3)
Tests have shown a wide range of wall thickness reductions to be acceptable, and that an
inverse ratio exists between the wall thickness and needed percent reduction in wall thickness
to obtain a properly rolled joint, i.e., as the tube wall becomes thicker, the necessary percent
reduction in wall thickness becomes smaller.
For carbon steel boiler tubes in the thicknesses we are accustomed to dealing with, a wall
thickness reduction of 7 or 8% is recommended to obtain optimum joint strength and
hydraulic tightness.
A reduction of 20%, or greater will result in a joint of reduced holding strength with the
possibility of leaking - an over-rolled joint. For production rolling, a wall thickness
reduction of 10% + 5% is considered acceptable.
This method has been described primarily to illustrate the relationship between joint
strength and excessive rolling, and to present the accepted limits for an optimum and
over-rolled joint. It is not recommended for frequent field use due to the time consuming
and therefore expensive measurements that are required.
If, however, torque controlled equipment is to be used for rolling, the wall thickness reduction
measurement is an excellent means to determine the job torque setting.
2.1.3.2 The Elongation method for Measuring
Measuring the elongation, or the amount the tube grows axially as the walls are thinned during
expansion, also has a wide range of acceptable values. The factors affecting elongation are the
tube wall thickness, the presence or lack of a serration or groove in the tube sheet, and the
depth of roll. Elongation is a manifestation of the actual work done to produce the friction
pressure between tube and tube hole contacting surfaces, and since actual work only is
measured and the above variables are known prior to the start of expanding, all variable factors
inherent in other means for controlling tube expanding are eliminated.
There is no need to take measurements prior to starting the work, and the elongation can be
measured while the work is being performed. This we feel elongation is the most economical
means available for field use of satisfactorily determining when a joint is properly expanded.
Curves indicating the correct elongation have been established through experimentation and
empirical work. Use of the elongation curves in actual practice has confirmed the validity of
these curves. Thus, we feel elongation is for field use the most practical measure of the tube
expanding and the use of elongation eliminates guess work rind individual preference.
As with the percent wall thickness reduction method, if torque controlled rolling equipment is
to be used on the job, elongation measurements provide an excellent means to determine the
proper torque setting.
2.1.3.3 Torque Control Tube Rolling
The principle behind torque control rolling is simple. When a given torque input is supplied to
an expanding tool for a series of uniformly sized tube ends, the same amount of work is
performed at each tube end, and the same degree of expansion is obtained. To obtain more
expansion on any of the tube ends, torque input must be increased.
In practice, torque control techniques provide rolled joints of a very consistent quality and
protection against over-rolling.
High quality electric torque control motors capable of rolling 4" OD tubes have been available
since 1950, but for reasons that will be discussed later, electric equipment is not recommended
for field use inside a boiler drum.
For condenser or heat exchanger tube rolling, however electric torque control equipment will
produce excellent results and are recommended. There are also several mechanical clutch type
or magnetic drive torque control rolling motors available from the expander manufacturers that
will work very well.
If torque control rolling is to be used on a job, it is recommended that the specific job torque
setting be established at least once a day for each device in use. A group of tubes should be
expanded to the degree desired, and the torque selling on the machine producing that
expansion would then be the job torque selling. Either the elongation or wall thickness
reduction methods are used to determine that the proper amount of expansion has been
reached.
2.2 Equipment Selection
2.2.1 Expander Selection
Various types of expanders are commercially available; however, those in common use in
field assembled boilers are the parallel, self feeding type surfaces of the rolls in contact
with the tube inside diameter are parallel and the individual rolls are mounted on the
expander cage at a feed angle which allows the mandrel, at it is routed, to spiral deeper
into the expander. As the tapered mandrel moves deeper, the rolls are forced further
apart, thus increasing the effective diameter of the expander.
The expander, rolls, and mandrel for lube rolling are selected by considering the ID of
the tube, the depth of roll or expanding length and whether the tube will be flared or not.
in general, only those tubes which will be seal welded are not flared. Expanders with odd
number of rolls are preferred. They can adjust to minute differences in the tube
thickness and any out of roundness of the tube inside diameters. When flare rolls are
used, there should be at least two rolls.
 METHOD FOR DETERMINING EXPANDEG LENGTH*

Straight roll Flared Roll

Drum Thickness Expander Expander

Upper Drum Less than 2 1/2" Not Required Drum Thickness

2 1/2" or Greater Drum Thickness 2 1/2" **

Lower Drum Less than 3" Not Required Drum Thickness

3" or Greater Drum Thickness 2 1/2" ***

• It is recommended that a minimum of 1/4" be added to the

expander length to compensate for tube protrusion into the
drum.
• When the lower drum is between 2 1/2" and 3" thick, the same
flared roll expander may be used in both the upper drum and
the lower drum. The intent here is to reduce the number of
different length expanders on a job when this condition is
present.
• When the lower drum is more than 3" thick, a two step
expanding procedure is used in the Lower Drum; the first
steep requires a deep roll expander, without flare rolls, to close
the annular space between the tube ; and tube hole. When the
tube stops vibrating, the annular space is closed up. The second
step is the final roll alone with a conventional .expander with a
2 1/2" depth of roll and the usual flared rolls.
Note: Care should be taken not to flare tube end all the away to drum or tube sheet surface.
Observe detail and dimensions on contract drawing.
Once the expander length and tube ID are known, the proper expander body, rolls, and
mandrel can be selected from the expander vendors catalogue. Expanders with an odd
number of rolls are preferred since they can adjust to minute differences in the tube
thickness and any out-of-roundness of the tube inside diameters. Tubes over 2 1/2" OD
should use expanders with more than three rolls.
2.2.2 Expander Accessories
When expanding tubes in headers or other confined areas, various accessories may be
necessary to drive the expander
2.2.3.Drive Motor
Expander Driving Motors come in three basic categories air (pneumatic), electric, and
hydraulic. When selecting your motor, consider the thickness of the tube wall and the OD
of the tube. Also keep in mind the fact that expander drive sizes may vary (usually 3/4"
or 1” and the motor chuck size selected should be compatible.
Air motors are generally preferred for field application. They are available for
expanding tube to 5 inch diameter. These motors are heavy and require two people to
operate. They do not overload as electric motors do; therefore, maintenance is reduced.
The air supply to the motor must be adequate, dry, lubricated, and clean. Motor rotation
will stop rapidly in an emergency and may be started much more smoothly them electric.
The exhaust of the motor should be arranged so it does not blow water and oil into the
surface of the drum.
By selecting the properly sized rolling motor (or a specific application, it is possible to
greatly reduce the chances of an over- rolled condition. Use the following chart to select a
motar having torque output range that is compatible with the job. If, due to a large
variance in tube size, it becomes necessary to order motors of different power outputs,
restrict motor use to the size tube it is intended for.
The following is a general guide to the reversible air motors usually used.

Motor Torque Maximu Motor Motor

Ft. Lb. Tube Wall thickness m Tube RPM Weight in lb
OD
200** Under .200 to 2 1/2' 120 25

310 Under .200 to 3 150 36 1/2"

400 .200 to .220 to 4 150 38

445 .200 to .220 10 4 1/2' 150 57

1225 Over 0.25 over 4 60 69

*With 90 lb. Air Pressure

** Corner-type molars for use in areas of limited access.
Electric Motors me available that will expand tubes upto 4 inch OD. However, we feel
these motors are unsatisfactory for extended use in erecting boilers for the following
reasons:
Electrical shock hazard exists.
Motor rotation will not slop immediately on release of the run button.
Motors become overloaded on 3 inch high pressure tubes causing overheating of the
motor and excessive downtime due to maintenance.
Hydraulic motors will roll up to 5 inches in diameter and are available in two basic
designs; one in which the motor is taken into the boiler drum and another in which the
molar is mounted outside the drum and power is t transmitted by a shaft into the drum.
2.2.4 Maintenance of Equipment
2.2.4.1 Before using an expander, wash all parts thoroughly, in any commercial solvent,
making sure all dirt, grease, and girt is removed. It is desirable to keep all petroleum
based lubricants off the inside surface of pressure parts since they are very difficult to
remove during chemical cleaning.
2.2.4.2 Lubricate expander properly before using. Use a commercial lube rolling
lubricant.
2.2.4.3 Wash expander thoroughly after each rolling operation with any commercial
solvent or light non-petroleum oil.
2.2.4.4 Allow expander to cool in a solvent or light non-petroleum oil bath when it
becomes hot. Whenever possible, use at least two expanders during a rolling operation.
This makes it possible to have one cleaned of all foreign matter and to be cooling in a
solvent or light non-petroleum oil bath for immediate use. This procedure will speed up
the rolling job and at the same time, insure long service life for the expanders.
2.2.4.5 Replace scarred or chipped rolls or mandrels immediately. One small chip in a
roll can cause a complete set of rolls and the mandrel to be damaged in a single rolling
operation.
2.2.4.6 When the rolling job is completed, wash the expanders thoroughly and lubricate
generously to prevent rusting while in storage. Prior to re-using, this lubricant must be
removed.
2.2.4.7 The air motor should be inspected and put in proper operating condition prior to
shipment to the job. Equipment, such as these air motors, designed to produce a torque
of 200 fl - lb. or over, must be well maintained to sustain this type of performance.
2.2.4.8 Before using an air motor, ensure that you have an ample supply of clean dry air,
with 90 psi pressure at the tool. Manufacture's literature about the motor you are using
will list the proper air flow and hose size needed.
2.2.4.9 Moisture in compressed air lines can be damaging to air tool performance. It pays
to take steps to remove it. Water in the air supply tends to wash away lubricants in air
motors. It also can cause corrosion of internal parts. In cold weather, moisture in the
air can form ice in the tool's air passages which slows down or completely stops an air
tool. Use of excessively wet air results in water shooting out of the air tool's exhaust. This
is unpleasant to the operator and can be damaging to the work.
Individual moisture separators should be installed at the end of each pipe line connected
to an air tool hose.
Most of the moisture can be removed at the compressor before it enters the piping system.
This is done by installing an after cooler and a moisture separator in the air compressor
discharge line between the compressor and the air receiver tank. The after cooler should
cool the compressed air to a temperature just below the lowest temperature anywhere in
the distribution piping system. This cooling will condense the moisture out of the air. The
condensed moisture and compressed air then pass though the moisture separator which
removes most of the water and delivers relatively dry air to the air receiver and
distribution lines. After coolers and moisture separators are not standard equipment on
most air compressors but can be obtained from all air compressor manufacturers.
2.2.4.10 Individual lubrication requirements of air tools vary widely, and specific
instructions for each type tool should be followed. In general, most rotary vane type
motors require the use of a light oil similar to SAE #5 or #10W or good grade of spindal
or turbine oil. Heavier oils, unless specifically recommended, will cause sticking and
sluggish performance. Many air tools have built in oil reservoirs to provide continuous
lubrication; however, it is often difficult to provide adequate supervision to assure that
these reservoirs are kept filled.
A widely used and highly recommended method of measuring proper air tool lubrication
is to install air line lubricators at the end of each pipe line leading to an air tool hose. This
line lubricators mixes a small amount of oil with the compressed air.
This adequately lubricates all parts of most air tools except portions of a tool requiring a
grease type lubricant.
Its permanent location makes it easy to find, and it is more likely to be kept filled by the
person assigned to oiling. Care must be taken not to over-lubricate, such that the
lubricant is exhausted on to the pressure parts inner surface.
2.3 Expanding Instructions
2.3.1 Practice
2.3.1.1 The actual mechanics of tube expanding is more nearly an art then a science. The only
way to assure a properly rolled tube is by having qualified supervision directing experienced
mechanics who have developed a feel for a properly rolled joint. As an aid to developing and
maintaining this feel, we recommend that a dial indicator be used to measure the elongation on
about 10% of the tubes (Step 2.3.2.). The mechanic should be monitored (or consistency by
measuring elongation on a group of tubes, in the morning.

After the tubes have been installed and proper stock set, expanding may proceed. When
a deep roll is required to close the annular space, a deep roll expander with a stop flange
is set in the tube with the stop flange about 1" to 1 1/2" away from the tube end. When
the tube has been expanded sufficiently to close the annular space, the tube will stop
vibrating and the rolling motor will start to slow down and the expander should have fed
in enough to cause contact between the stop flange and the tube end. Reverse the rolling
motor and back out the expander.
Caution: Do not continue to roll after the tube has stopped vibrating. This is an
indication that the annular space has been closed and the first stage of rolling is complete.
This is a touch roll only, excessive rolling at this time may interfere with elongation
measurements and the next stage of rolling.
When the tube is tight in the tube hole, i.e., it has stopped vibrating, the dial indicator,
should be set to measure the elongation. It is recommended that about 10% of the tubes
be checked by elongation.
2.1.1.3 The hard roll is performed by inserting the expander so the bottom of the flare
rolls are about 3/4" from the tube end. The tube is then expanded to the correct degree.
The flare rolls should have engaged the end of tube and created a flare on the tube so the
outside diameter of the flare is at least 1/8” greater than the diameter of the tube hole. If
the tube was fully expanded before the flare rolls engaged, reset the expander so the flare
rolls are at the end, and roll the flare onto the tube end.
2.3.1.4 During the assembly of the boiler and particularly during the rolling
operation most important to keep the internal surface as clean as possible. Special care
should be taken not to introduce dirt, petroleum-based products or other foreign
substances to accumulate inside tubes, headers or drums. Keep openings closed at all
limes when not required for working areas.
2.1.2 Measuring Elongation
Since elongation takes place axially in both directions, it may be measured relative to the tube
sheet and at either side of same. However, the rotating expander usually precludes any
measuring at the front and elongation measurements are therefore preferably taken at the back
of the joint which is the gas side of the drum on water tube boilers.
Various measuring means may be employed, but perhaps the simplest is an ordinary dial
indicator clamped to the tube with the point of the spindle in contact with the boiler drum.
It must be remembered that the elongation pushes the tube proper along with it, thus the axial
movement of the tube relative to the tube sheet registered by the dial indicator will coincide
with and will therefore represent the elongation. Holding the tube in its correct position,
expanding is then started. During the first stage of the expanding process, the tube is loose in
the tube hole, consequently the operation of the expander causes the tube to vibrate, the
vibration being transmitted through the spindle to the needle on the dial indicator. The instant
that the outside surface of the tube contacts firmly with the inside of the tube hole, the needle
of the indicator becomes quiet and remains so until the irregularities of the tube and the tube
hole surface are wholly or partially filled. Any movement of the indicator needle after the
beginning of this period of quiet represents the elongation or axial flow of the tube metal. This
axial tube movement or elongation varies with and is a measure of the degree of expanding.
Some selected elongation figures are given below.

Tube OD Depth of Roll Tube Wall Thickness Recommended

Elongation
2.00” 2 1/2" .110 .019
.125 .022
.135 .023
.150 .026
.165 .029
.180 .032
.200 .035
.220 .039
.240 .044
.260 .047
2.50” 2 1/2" .120 .021
 .035 .024
.150 .027
.165 .029
.180 .032
.20() .036
.220 .039
.240 .046
.260 .048

Selected Elongation Figures

2.2.3.1 A properly expanded joint Gill fail in operation due to many external forces.
Since the drum's tube sheet and the tubes have substantially different thicknesses, the tube
heats up and cools down much quicker than the drum. A rapid change of temperature, such as
that caused by a lower water casualty or spraying a hot drum with a fin hose to hasten cooling,
can cause the tube to cool more quickly than the drum, thermally contract faster than the drum,
break the seal between the surfaces and leak. Vibrations, puffs and externally applied leads can
also break the tube to tube sheet seal.
3.0 Seal Welding of Boiler Tubes to Tubesheet
3.1 When to Use
Seal Welding is not normally performed during the erection of new units, and should never be
attempted without prior approval from Engineering. In some cases, however, as noted below,
seal welding may become necessary or even desirable.
3.1.1 Customer Request
Based on a customer's past experience with his own unique operating conditions, or solely on
performance, that customer may specify that all boiler tubes be seal welded. In this case, the
tube rolling diagram will also contain the necessary welding information.
3.1.2 Defective or Poorly Rolled Joint
It is not unusual during the hydrostatic pressure test to find a few rolled joints that
"weep" or leak a small amount of water, but this situation is normally corrected by
re-rolling the leakers.
If the water loss can not be stopped by re-rolling, or if there is a danger of over-rolling, it
may become necessary to seal weld those joints only.
When a pre-assembled boiler is shipped to a job site, it is likely that stresses or vibration
suffered during loading or transportation will have caused some of the rolled joints to
loosen. If these cannot be repaired by re-rolling, then seal welding will be required.
3.1.3 Tube Repair on Maintenance
When, for some reason, it becomes necessary to remove a rolled joint from either a new
or operating boiler, there is an increased likelihood of the replacement joint leaking and
thus requiring seal welding. This is a result of striations left on the surface of the hole
while pulling the end of the tube through, or possible deformation of the tube hole during
the initial rolling.
3.2 Instructions for Seal Welding
3.2.1 Seal welding can be performed on either the inside or outside surface of the drum.
3.2.2 Tubes that mare to be seal welded on the inside drum surface should be hard rolled
first, and then seal welded. Do not flare those tube ends.
Tubes to be seal welded on the outside drum surface should be hard rolled, flared, and
seal welded. In both cases, the joint should be lightly re-rolled after seal welding.
Investigation of the expansion requirement of tube to tubesheet rolling fitting
SINCE THE WIDTH OF THE GROOVE IS NOT LARGE IN COMPARISON
WITH THE TUBE WALL THICKNESS, THE USE OF A SHELL THEORY
THAT NEGLECTS THE EFFECT OF TRANSVERSE SHEAR STRESS IN
THE MECHANICAL BEHEAVIOUR MAY APPEAR SUSPECT. TO CHECK
THAT THIS IS NOT THE CASE, WE CALCULATED THE AVARAGE
TRANSVERSE SHEAR STRESS i.e. TRANSVERSE SHEAR FORCE DIVIDED
BY WALL THICKNESS, FOR THE SAME PROBLEM. ITS VALUE TURNED
OUT TO BE AN ORDER MAGNITUDE BELOW THE OTHER
CALCULATED STRESSES; THUS, THE USE OF SHELL THEORY WAS
JUDGED ACCEPTABLE.
 Mathematical calculation for bonding expansion
Mathematical calculation for bonding expansions, gave the
following results.
1. Average tube sheet hole diameter (a1) = 19.30 mm.
2. Average tube outside diameter (a2) = 19.05 mm.
3. Average tube inside diameter (a3) = 16.56 mm.
4. Average tube thickness (a4) = 1.245 mm.
5. Average inside diameter before rolling in (a5) = 16.81
mm.
6. Thinning at 5% (a6) = 0.1245mm.
7. Final inside diameter of tube after expansion (a7) =
16.6345 mm.
8. Bonding expansion = 0.3745 mm.
3.2 Mathematical calculation of pullout load
Mathematical calculations of pullout loads gave the
following results.
Length of tube to tube sheet expansion = 0.041 m.
Coefficient of friction at interface -for admiralty
brass and
common steel = 0.12.
(With surface finish 1.6µm on tube and 3.2µm in
hole)
Tube hole diameter = 0.0193 m.
Residual pressure at interface = 0.32E+08 pa.

Or (3263092Kg/M2).
Pull out load = 0.12*Π*0.0193*3263095*0.041.
= 973 Kg.
The above calculated value of pull out load is compared with the values obtained in laboratory
and it is found that the mathematically calculated values are in excellent agreement with that
of the values obtained in the laboratory.The pull out load obtained through manual
calculations resulted in the value of 973kg, where as those of experimental results are found to
be 978.6 kg and not much difference is found between them.
Requirement for Nuclear Steam
Generator
In order to control the cold work imparted to the tube during expansion,
percentage thinning restricted between 3 and 6 %. Apart from this , the
strength of joint should qualify for a
minimum pull out strength 764 - 1530 kg and the leak tightness has to be
ensured by leak test. Leak rate shall not be more than 1 x 10^-7 cc/sec .

Expansion process by Pilgrim

technique
Expansion is carrying out mainly in two stages process.
1. Closing of gap between hole id and tube OD.
2. Thinning against wall.
As clearance between tube OD and hole dia varies,
tube ID cannot decided until sufficient trials will be
taken to determine the limiting torque value.
When the expansion length for the product is more
then the roller length of the tube expander, more than
one stage of expansion has to performed. That type of
expansion is called as Pilgrim technique of expansion.
Pilgrim expansion technique
In this technique
• Overlapping of stage is automatically performed by
– arrangement available in tube expander.
– Special control employed in control unit.
• After fixed rolling,
– The restraining collar is pushed back to the second groove position and
the control switched to pilgrim mode
– controller gives desired(Can be set by timer switch) no of anti
clockwise rotation to expander.
– Clock wise rotation starts for actual expansion
– Once the torque limits per setting is reached , the rotation is reversed
again to anti clockwise direction.
– This continues till the collar of the expander is touches the tube sheet
and switched off.

Pilgrim expansion technique

• Advantage of this technique
– Faster then other processes
– Ensures better control on cold work imparted to the tube.
– Very smooth transition due to design of profile of roller end resulting
in
• lesser stress level
• hence better resistant to stress corrosion cracking.
– Leakage can be minimized between tube and tube sheet
Pilgrim Tube Expander
The Pilgrim Tube Expanders is manufacture using best quality raw material, which we
procures from most reliable vendors. It is a Traveler Expander. It is generally used in nuclear
power projects STEAM GENERATOR thick tube & deep tube expansion. Longer length tube
expansion & performs uniform, parallel and smooth expansion zone. PILRIRM tube expander
roller, mandrel and cage have expanded the tube length required in a same set PILGRIM tube
expander is not taken out ones it put to use in tube for expansion operation by nonstop gradual
forward reverse travel hence no missed out of stag in between long expansion length is
possible. Every forward rotation gives longer overlap hence it irons out the earlier expanded
area that give good finish & accuracy. Clutch assembly on last groove on pilgrim Tube
expander secure correct and consistent depth of expansion. Because it has larger overlap gives
repeat expansion the earlier back tail expanded area helps the seat that seals perfectly and
gives better push out strength in minimum percentage thinning thus life of the equipment is
longer than other conventional method of tube expansion system.
Minimum Breakage: Pilgrim tube expansion every forward stroke covers only 20% of
effective roller length as new increased expansion zone keeping remaining 80% as overlap
requires very light torque. Hence the operating load on the pilgrim tube expander is light and
wear out of tooling is cut. Construction of pilgrim tube expander is such that at any place
roller or mandrel do not fall out of the cage & no misplacing of loose rollers in deep hole tube
is possible.
It is a traveler Expander generally used in nuclear power projects steam generator of thick
tube & deep expansion. Longer length tube expansion & performs uniform, parallel and
smooth expansion zone.
The tube is expand required length by same set of Pilgrim Tube Expander roller, mandrel and
cage in one go. Pilgrim Tube expander is not taken out once it put to use in tube for expansion
operation by Non-stop gradual forward reverse travel gradual hence no missed out of stage in
between long expansion length is possible every forward rotation gives longer overlap and
hence it irons out the earlier expanded area that give good finish & accuracy.
Clutch assembly on last groove on Pilgrim Tube expander secure correct and consistent depth
of expansion. Because it has larger overlap gives repeat expansion the previous black tail
expanded area helps the seal that seal perfectly and gives better push out strength in minimum
percentage thinning thus life of the equipment is longer than other conventional method of
tube expansion system.
Minimum Breakage: Pilgrim Tubes expansion every forward stroke covers only 20% of
effective roller length as new increased expansion zone keeping remaining 80% as overlap
requires very light torque. Hence the operating load on the Pilgrim tube expander is light and
were out of tooling is lower.
Construction of Pilgrim tube expander is such that at any place roller or mandrel do not fall
out of the caps & no misplacing of loose rollers in deep hole tube is possible.
HYDRAULIC EXPANSION SERVICES
HYDRAULIC EXPANSION
Hydraulic expansion is a method for the expansion of heat exchanger tubes using direct
hydraulic pressure to expand the tube forming the tube to tubesheet joint. It is the preferred
method of expansion after strength weld per ASME code.

THE PROCESS & ITS APPLICATIONS

Water pressure from an air driven pumping system is intensified to the desired high pressure and is
transmitted through a small bore, flexible high pressure tube to a lightweight hand-held mandrel
holder. A mandrel directs the pressure to the inside diameter of the tube and is held within an
accurately prescribed pressure zone and is applied over the full length of the joint in one step.
The pressure zone is accurately adjusted which reduces the damaging crevices at the edges
of the tube sheet. Stress, crevice corrosion, and metallurgical changes are thus minimized.
Direct hydraulic expansion with pure water produces clean joints. Lubricant is not forced
into the tube surface, and there is no surface flaking or galling inside the tube.

A smooth transition from expanded to unexpanded areas, along with no change in tube
material properties, greatly reduces strain hardening, tube fatigue and stress induced
corrosion cracking. Tube wall thickness and tube length change is minimal. Before contact is
made with the tube sheet, a small reduction in tube wall thickness and length occurs because
a constant volume of tube material is expanded to a larger diameter. However, no change
occurs during the high pressure swaging, eliminating the shear strain and loss of seal
between tube and sheet that is a characteristic of roller expanding technologies, regardless of
the control mechanisms of the drive motor of the roller expander.

The Hydraulic expansion cycle is automatic and initiated by the operator. The tube is filled with
water at a low pressure, intensified to the higher setting and held for the time required to
accomplish a stable plastic condition of the tube. This dwell time is essential to stabilize exotic
Tube materials. After the pressure is released, water is drained back into the reservoir.
All of this occurs in a time period of a few seconds. Actual pressure at the tube is read on an
analog or digital pressure indicator.

HYBRID EXPANSION SERVICES

Hybrid expansion is a method of expansion or re-expansion of tubes comprised of difficult
materials or combination of materials. Typically situations in which the tube is harder than
the tube sheet for example, a Duplex 2205 tube into a Carbon Steel alloy clad sheet.
This combination proves to be particularly difficult to expand due to the metallurgical differences
between the two materials and the work hardening that occurs during conventional mechanical
expansion methods.
THE PROCESS
Hybrid expansion is a two step process in which two forms of expansion technology are
employed to expand the tube. First a hydraulic expansion is performed. This step expands the
tube and eliminates the clearance gap between the tube and tube-sheet. The second step of the
process is to mechanically roll the tube using an electronic torque controlled rolling unit providing
structural strength. Alternatively, the second expansion can be done using a higher pressure
hydraulic expansion.
TUBE EXPANDER
FABRICATION
Tube to tube sheet joint (Heat Exchanger)

-> Welding prior to or after expanding?

Please describe what is feasible if joint for tube to tube sheet is expanded and strength

welded. (Consider fixed tubesheet heat exchanger)

1-Welding after expanding

2-Welding before expanding

There are certain merits and demerits of both the sequences you mentioned.

Codes including ASME Sec. VIII Div. 1 and TEMA do not say anything regarding the

recommended sequence to be followed.

But the preferred and recommended sequence is 2, that is welding before expanding based

upon following reasons:

1. Welding shall be performed in an atmosphere where welding gases can escape; welding

after expansion will surely result in bad tube-to-tubesheet joints having porosity or weld

inclusions by lubricants (if cleaning not done properly)

2. Welding after expansion would cause adverse effects on expansion (can get loosened) due

to welding heat. Such tubes would be requiring re-rolling.

On the other hand, the de-merits of above mentioned recommended solution include:

a. No foolproof check would be in place for leak tightness of expansion done

b. Chance of welding getting damaged during expansion process. The later can be overcome

by increasing the starting distance of expansion towards shell side (recommended is > 15 mm

from the toe of the weld joint, used by manufacturers)

The leak tightness of expansion generally done only through Mock-up test.After mock-up test

the test piece is cross sectioned and leak path is measured under microscope.

The % of expansion is strictly done as per TEMA Rules and it is measure by GO and NOGO

gauge and Bore dial gauges.

To carryout full expansion after welding also induce more stresses into the tube to tubesheet

weld joint.

Generally initial rolling i.e 25% to 50% expansion done initially to make sure that the tube is

in position and does not move inward or outward during welding and complete the final

expansion after welding and this will reduce stress on the tube to tubesheet weld joint.
ASMS BPVC-I
BS-2790 STANDARD
BS-1113 STANDARD
TEMA STANDARD
HEI STANDARD CLOSED FEED WATER HEATER
HEI STANDARD FOR STEAM SURFACE CONDENSER
HEI STANDARD FOR POER PLANT HEAT EXCHANGER
API STANDARD - 661
API STANDARD-660
INDIAN BOILER REGULATION
STANDARD SPECIFICATION
FOR
 STANDARD SPECIFICATION No.

ENGINEERS INDIA LIMITED EXPANDED TUBE TO 6-15-0004 Rev. 4

STANDARD SPECIFICATION FOR

EXPANDED
TUBE TO TUBESHEET JOINTS

1.0 SCOPE

This specification covers the minimum requirements of expanded tube-to-tubesheet joints for

shell & tube heat exchangers and air coolers. It is the fabricator's responsibility to furnish

sound, leak free joints. For the purpose of this specification, the term "joints" shall be

construed to mean "tube-to-tube sheet joints".

2.0 APPLICABLE CODES

The latest edition of the following Codes and Standards shall be complied with:-

a) ASME Sec. VIII Div. 1 (Code)

b) TEMA for tubular exchangers

c) API 661 for aircoolers.

3.0 JOINT CONFIGURATION

Joint with two grooves as per 7-15-0006 shall be used unless specified otherwise.

4.0 PROCEDURE TESTING

4.1 Procedure testing is required to be carried out in any of the following cases:-

a) Authorised Inspector of Purchaser or Ell, requires it to be carried out.

b) There are no previously established procedures for Fr values (Factor of Reliability) in the

last five years with the same combination of tube and tubesheet material, outside diameter
(OD) and thickness of tubes, tube hole groove detail and length of expansion (excluding

contact expansion).

c) Code or specification or the equipment drawing requires it to be carried out.

d) The length of expansion in the job is less than existing qualification length of expansion of

same materials, tube size, tube hole groove detail. However, if qualification exists for

length of expansion of 51 mm or more for the same combination of materials, size of

tubes, tube hole grooving details, and the length of expansion for the job is 51 mm or

more, the procedure testing need not be repeated. The length of expansion to be

considered excludes any contact expansion.

e) If previously established procedure of the fabricator is to be used, Authorised Inspector

has the option of asking for a demonstration of the procedure to satisfy himself of its

accuracy or to confirm the suitability of the expanding equipment or control unit. With

time, the equipment used for expansion may change its characteristics and Authorised

Inspector may like to check this by actual procedure tests.

4.2 Procedure test shall demonstrate % thinning vs machine setting and shear load test as per
the requirements given below.

4.2.1 A sample tubesheet of same material and thickness as required for the job shall be
drilled and/or reamed to achieve the required surface finish as per clause 6.0 and grooved as
per 7-15-0006. Tube hole dimensions shall be as specified in clause 6.0 and as far as possible
tube holes shall be prepared to cover the complete range of tolerance allowed. Tubesheet
thickness used for procedural testing shall be as per item drawing or specification except that
it need not exceed 55 mm. Diameter of tube holes drilled in the sample tubesheet shall be
measured accurately. Hardness of tubesheet shall be measured and reported.

4.2.2 At least eight tubes from the same heat shall be selected with extreme tolerances as far
as obtainable from the given lot of tubes to the satisfaction of the Authorised Inspector. The
OD, inside diameter (ID) & hardness of these selected tubes shall be measured and reported.

4.2.3 One of these tubes shall be selected and positioned in the tube hole and assembly held in
the same position as shall be adopted for production. Tube expander to be used for production
shall be set at an estimated low value and tube shall be expanded inside the tube hole.
Expander setting shall be increased until the thinning is in the range of 8-10% for all
materials, except for non-ferrous and stainless steel, in which case it shall be 6-8%. In no
case shall the % thinning exceed the values given in clause 8.1. The thinning figures are
to finally such that these can result in achieving the required Fr value. It shall be the
fabricator's responsibility to ensure the same.

Percentage thinning is defined as follows:

% thinning = [ 1-(Dh -IDf )/(0D-ID, )] * 100

Where

Dh = Tube hole diameter in tubesheet

IDf = ID of tube after complete expansion

OD = OD of tube before expansion

ID, = ID of tube before expansion.

4.2.4 Expander setting thus found shall be tested on the remaining tubes and thinning shall be
checked to be within the range specified above. Results of these tests (reporting combination
number and % thinning achieved and various diameters used for calculation of thinning) shall
be reported to the Authorised Inspector.

4.2.5 Samples prepared above, shall be cut in two halves along the axis of the tubes to show
the flow of metal into the grooves. These cut-sections shall be presented to the Authorised
Inspector who shall check the samples for flow of metal into the grooves and also check the
expansion length. Authorised Inspector's approval shall be obtained on the same.

4.2.6 Fabricator is advised to satisfy himself that settings reported and to be used in the
production shall be the best for the job, will enable him to achieve the required Fr value and
give workmanship guarantee for the equipment. Authorised Inspector's approval shall in no
way relieve the fabricator of his responsibility and guarantee to supply the equipment as per
the conditions of the purchase order.

4.2.7 Shear load tests shall be carried out as per Appendix-A of Code. Fr value of the joint
shall be established and shall be demonstrated to be greater than or equal to Fr (test) required
as per Appendix-A Table A-2 of Code. For nonferrous and stainless steel combination of
tubes & tubesheet a minimum Fr value of 0.7 shall be achieved. Actual value shall be reported
in the test reports.
5.0 CARE OF TUBES

5.1 Ends of the tubes (tubesheet thickness + 100 mm) shall be subjected to careful visual
inspection. These shall be cleaned to remove scales, rust, grease and dirt and should
subsequently be cleaned by using a suitable sulfide free and chloride free solvent to get rid of
oil and grease. The solvent should be non-residue forming and should not lead to any possible
fire hazard. The area should be defect free and should have no scoring marks, rough surface
etc. No repair is permitted on defective tubes unless approved by Authorised Inspector. In
case a repair is done using an approved procedure, the tube dimensions after repair shall be
within limits laid down by the tube material specification, otherwise the tube shall be
discarded.

5.2 At least 10% tubes (subject to a minimum of 20 tubes per shell) shall be tested for
hardness at the tube manufacturer's shop (This shall be taken care during sub-ordering). The
hardness — All rights reserved measured should not be greater than the maximum hardness
reported in the mockup. Tubes with greater hardness shall be rejected. Further hardness
testing shall be done, if required by Authorised Inspector.

6.0 TUBE HOLES IN TUBESHEETS

Tube holes in tubesheets shall be drilled as per TEMA special close fit for shell and tube
exchangers and as per API 661 special close fit for air coolers. For example, metric tube of
size 20 mm OD, the nominal size of tube holes shall be 20.20 mm with tolerances as + 0.05
mm, for 25 mm OD tubes, nominal size of holes shall be 25.25 mm with tolerances as + 0.05
mm and so on.

Tube holes in tubesheets shall be drilled or drilled and reamed to final size and surface finish.
Grooves shall be machined in the tube holes as per 7-15-0006. Tube holes shall have no burrs
or scoring marks and shall be circular with parallel sides and normal to the tubesheet surface.
Longitudinal and spiral scratches are not permitted, Edges of the tube holes shall be deburred
and chamfered as per the figure in 7-15-0006. Tube holes shall have surface finish to 63
AARH or better & shall be cleaned prior to assembly.

7.0 ASSEMBLY AND EXPANSION

7.1 Care shall be taken during assembly to avoid scoring of tube holes in tubesheet or outer
surface of the tubes. The tubes shall be positioned so that their projection from the tubesheet is
as per 7-15-0006. For vertical shell & tube exchangers, the tubes are required to be flush with
top tubesheet unless specified otherwise.

7.2 Tube expanders used by the fabricator shall be electronically or pneumatically or

hydraulically controlled type and shall be in good condition and shall have the Authorised
Inspector's approval. The tube expanders shall have 'stops' to prevent the rollers approaching
nearer than 3 mm to the back of the tube sheet.
7.3 Expansion of tube into tubesheet shall be done as per the established procedure.

7.4 Tubes shall be expanded for the full thickness of the tubesheet leaving 3 mm (minimum)
at the backside face of the tubesheet. However, for tubesheet thickness more than 55 mm, the
expansion may be limited to 51 mm from the tube side face and remaining portion to be
contact expanded leaving 3 mm (minimum) to 6 mm (maximum) at the back of tubesheet.
Contact expansion shall have thinning of 3 - 5% which shall be ensured by measuring the ID
of tubes.

7.5 Care shall be taken to avoid any distortion of the tubesheet or gross deformation of the
ligaments. It is suggested that tubes be expanded systematically in small, diametrically
opposite groups. The tube expansion shall be uniform on the whole expanded length. There
shall be no abrupt transition at junction with unexpanded zone.

7.6 A check shall be made of the percentage thinning on tubes selected by Authorised
Inspector and the results recorded and compared against percentage thinning figures of the
procedure test.

8.0 TESTING

8.1 After expansion of all joints is completed on the job tubesheet, tubesheet face and the
internal surfaces of the tubes to a length of about 15 mm shall be thoroughly cleaned. Any
grease or oil shall be suitably removed using proper solvent or steam jets. These joints shall
then be subjected to pneumatic air-soap solution test of 1.25 kg/cm2 (g). Leaking tubes shall
be further expanded, in the presence of Authorised Inspector after the reasons for the leakage
are ascertained and accepted by the Authorised Inspector. If the % thinning is greater than
15% for carbon steel and low alloy steel combinations and 12% for non ferrous and
stainless steel combinations, then the defective tube shall be replaced and re-expanded.

8.2 Joints shall also be subjected to hydrostatic leakage test at a test pressure indicated in the
drawings or requisition for at least one hour. Leaking tube, if any, may be further expanded
keeping the guide lines given above in view.

9.0 INSPECTION

Inspection of the equipment shall be carried out as per the purchase order by the Authorised
Inspector. For expanded tube to tubesheet joints, following stages of inspection shall be
observed and reported:

a) Agreement regarding expansion procedure. If procedure testing is to be carried out, then all
preparations, cut samples, test results etc. shall be inspected by the Authorised Inspector.

b) Inspection of tube ends. Special attention shall be paid to tube dimensions & hardness.
These shall be within the specified tolerances.

c) Approve any repair procedure to rectify defective tube end.

d) After tube holes in the tubesheet have been drilled, and / or reamed and grooved, all tube
holes shall be given a careful check for:

i) Tube layout pattern and locations.

ii) Tube holes meeting requirements of clause 6.0 above. Also it is to be checked that grooves
in tube holes are located properly and of required dimensions.

iii) Minimum ligament width as per TEMA or API as applicable.

e) Check the tube projection before expansion is to be started.

f) Agree to the sequence of expanding tubes into the tubesheet holes.

g) Check for distortion of tubesheet and thinning of tubes after expansion is complete.

h) Witness pneumatic & hydrostatic testing.

Crevice corrosion
Crevice corrosion is an electrochemical oxidation-reduction (redox) process, which occurs within localized
volumes of stagnant solution trapped in pockets, corners or beneath a shield (seal, deposit of sand, gasket,
fastener, etc.).
Crevice corrosion is considered much more dangerous than uniform corrosion since its rate is 10-100 times
higher.

Crevice corrosion is highly accelerated if chloride, sulphate or bromide ions are present in the electrolyte
solution.
Stainless steels, Aluminum alloys and other metals forming a passive oxide layers on their surfaces in
electrolytes and atmosphere are sensitive to crevice corrosion.

Mechanism of crevice corrosion is similar to that of Pitting corrosion: dissolution of the passivating film and
gradual acidification of the electrolyte caused by its insufficient aeration (Oxygen penetration).

In presence of chloride ions corrosion proceeds by

autocatalytic mechanism. Crevice corrosion of steel is illustrated in the figure.

Anodic reactions inside the crevice:

Fe = Fe2+ + 2e- (dissolution of iron)

The electrons given up by the anode flow to the cathode (passivated surface) where they are discharged in the
cathodic reaction:

1/2O2 + H2O + 2e- = 2(OH-)

As a result of these reactions the electrolyte enclosed in the crevice gains positive electrical charge in contrast
to the electrolyte surrounding the crevice, which becomes negatively charged.

The positively charged electrolyte in the crevice attracts negative ions of chlorine Cl- increasing acidity of the
electrolyte according to the reaction:

FeCl2 + 2H2O = Fe(OH)2 + 2HCl

PH of the electrolyte inside the crevice decreases (acidity increases) from 6 to 2-3, which causes further
acceleration of corrosion process.
Large ratio between the anode and cathode areas favors increase of the corrosion rate.
Corrosion products (Fe(OH)3) form at the crevice resulting in further separation of the electrolyte.
Crevice Corrosion
Introduction
Crevice corrosion is a type of localized corrosion that can be found within crevices or at
shielded surfaces

where a stagnant solution is present.

Crevices make a chemical environment which is different from that of freely exposed surfaces
and therefore

accelerate corrosion. This environment keeps moisture, traps pollutants, concentrates

corrosion products and

meanwhile excludes oxygen.

The crevices in which crevice corrosion happens may be formed by:

1.The geometry of the structure, e.g. riveted plates, welded fabrications, threaded joints.

2.Contact of the metal with non-metallic solids, e.g. plastics, rubber, glass.

3.Deposits of sand, dirt or permeable corrosion products on the metal surface (a type of
crevice corrosion

that is referred to as deposit attack)

Mechanism
Crevice corrosion is initiated by a difference in concentration of some chemical constituents,
usually

oxygen, which set up an electrochemical concentration cell (differential aeration cell in the
case of oxygen).

Outside of the crevice (the cathode), the oxygen content and the pH are higher – but chlorides
are lower.

Cholrides concentrate inside the crevice (the anode), worsening the situation. Ferrous ions
form ferric

Chloride and attack the stainless steel rapidly. The pH and the oxygen content are lower in the
crevice than

in the bulk water solution, just as they are inside a pit. The pH inside the crevice may be as
low as 2 in a
neutral solution. Once a crevice has formed, the propagation mechanism for crevice corrosion
is the same as for pittong corrosion.

The major factors influencing crevice corrosion are:

Crevice type: metal-to-metal, metal-to-non-metal

Crevice geometry: gap size, depth, surface roughness

Material: alloy composition(e.g Cr, Mo), structure

Environmnent: pH, temperature, halide ions, oxygen.

Stage 1: Corrosion occurs as normal both inside and outside the crevice: Anodic reaction:
M•¨Mn+ +ne,

cathodic reaction: O2+2H2O+4e=4OH-. The positively charged metallic ions are electro
statically counter

balanced by OH-.

Stage 2: at this stage, the cathodic reaction inside the crevice consumed most of the oxygen
available.

Stage 3: Cl- and OH- diffuse into the crevice to maintain a minimum potential energy. Metal
chloride is

formed. Hydrolysis of metal chloride lowers pH and MCln + nH2O = M(OH)n + nHCl.

Stage 4: More Mn+ ions attack more Cl- leads to lower pH inside crevice, metal dissolution
accelerates and

more Mn+ ions will be produced that will lower pH.

Prevention
Crevice corrosion can be designed out of the system

Use welded butt joints instead of riveted or bolted joints in new equipment

Eliminate crevices in existing lap joints by continuous welding or soldering

Avoid creating stagnant conditions and ensure complete drainage in vessels

Use solid non-absorbent gaskets such as Teflon.

 In this photo, a type 316 stainless steel tube and tube sheet from a heat exchanger in a
seawater reverse osmosis (SWRO) desalination plant suffered crevice corrosion due to the
presence of crevice (gap) between the tube and tube sheet.
 This form of attack is generally associated with the presence of small volumes of stagnant
solution in occluded interstices, beneath deposits and seals, or in crevices, e.g. at nuts and
rivet heads. Deposits of sand, dust, scale and corrosion products can all create zones where the
liquid can only be renewed with great difficulty. This is also the case for flexible, porous or
fibrous seals (wood, plastic, rubber, cements, asbestos, cloth, etc.).

Crevice corrosion is encountered particularly in metals and alloys which owe their resistance
to the stability of a passive film, since these films are unstable in the presence of high
concentrations of Cl- and H+ ions.

The basic mechanism underlying crevice corrosion in passivatable alloys exposed to aerated
chloride-rich media is gradual acidification of the solution inside the crevice, leading to the
appearance of highly aggressive local conditions that destroy the passivity.
in an interstice, convection in the liquid is strongly impeded and the dissolved oxygen is
locally rapidly exhausted. A few seconds are sufficient to create a "differential aeration cell"
between the small deaerated interstice and the aerated remainder of the surface. However,
"galvanic" corrosion between these two zones remains inactive.

As dissolution of the metal M continues, an excess of Mn+ ions is created in the crevice,
which can only be compensated by electromigrationof the Cl- ions (more numerous in a
chloride-rich medium and more mobile than OH- ions). Most metallic chlorides hydrolyse,
and this is particularly true for the elements in stainless steels and aluminium alloys. The
acidity in the crevice increases (pH 1-3) as well as the Cl- ion concentration (up to several
times the mean value in the solution). The dissolution reaction in the crevice is then promoted
and the oxygen reduction reaction becomes localized on the external surfaces close to the
crevice. This "autocatalytic" process accelerates rapidly, even if several days or weeks were
necessary to get it under way.

Means of preventing or limiting crevice corrosion : Use welds rather than bolted or riveted
joints, design installations to enable complete draining (no corners or stagnant zones),
hydrofuge any interstices that cannot be eliminated, and in particular, grease all seals and seal
planes, use only solid, non-porous seals, etc.
This form of attack is generally associated with the presence of small volumes of stagnant
solution in occluded interstices, beneath deposits and seals, or in crevices, e.g. at nuts and
rivet heads. Deposits of sand, dust, scale and corrosion products can all create zones where the
liquid can only be renewed with great difficulty. This is also the case for flexible, porous or
fibrous seals (wood, plastic, rubber, cements, asbestos, cloth, etc.).

Crevice corrosion is encountered particularly in metals and alloys which owe their resistance
to the stability of a passive film, since these films are unstable in the presence of high
concentrations of Cl- and H+ ions.
The basic mechanism underlying crevice corrosion in passivatable alloys exposed to aerated
chloride-rich media is gradual acidification of the solution inside the crevice, leading to the
appearance of highly aggressive local conditions that destroy the passivity.
in an interstice, convection in the liquid is strongly impeded and the dissolved oxygen is
locally rapidly exhausted. A few seconds are sufficient to create a "differential aeration cell"
between the small deaerated interstice and the aerated remainder of the surface. However,
"galvanic" corrosion between these two zones remains inactive.

As dissolution of the metal M continues, an excess of Mn+ ions is created in the crevice,
which can only be compensated by electromigrationof the Cl- ions (more numerous in a
chloride-rich medium and more mobile than OH- ions). Most metallic chlorides hydrolyse,
and this is particularly true for the elements in stainless steels and aluminium alloys. The
acidity in the crevice increases (pH 1-3) as well as the Cl- ion concentration (up to several
times the mean value in the solution). The dissolution reaction in the crevice is then promoted
and the oxygen reduction reaction becomes localized on the external surfaces close to the
crevice. This "autocatalytic" process accelerates rapidly, even if several days or weeks were
necessary to get it under way.

Means of preventing or limiting crevice corrosion : Use welds rather than bolted or riveted
joints, design installations to enable complete draining (no corners or stagnant zones),
hydrofuge any interstices that cannot be eliminated, and in particular, grease all seals and seal
planes, use only solid, non-porous seals, etc.