Tube expansion

Methods and Procedures By C.P.Parekh

Tube fitting with Tube sheet

By welding only By expansion only By welding and expansion

Introduction
Tube expansion is the art of reducing tube wall by compressing the OD of the tube against a fix container.

Tube

Welded side Tube sheet

Tube

Before

Tube sheet

After

Why Tube Expansion Is Required?

To avoid... Sludge accumulation Secondary side IGA/SCC crevices Corrosion in tube sheet Damage to the tube due to vibration

Tube

Tube sheet

Stage of tube expansion

Prior to start of rolling, the tube to tube sheet welds shall have successfully passed the helium leak test. ( as per spec.no PB-P188, para. 3.2) Before expansion Cleanliness of the tube inside surface . Primary side rolling and checking shall completed before commencing secondary side of rolling

Methods of tube expansion

1. Mechanical :
A mechanical tube expander consists of an odd number roller (usually 3 Nos.), a taper mandrel to push the roller outward, a cage to house the roller and a collar to set the location of the expansion.A typical Expander is shown in fig.

Methods of tube expansion

2. Hydraulic:
This is differs from other known anchoring methods in that the tube is physically deformed simply by means of pressurized liquid. The amount of pressurized liquid introduced is a function of the proportion of elastic and plastic expansion occurring in the tube and tube sheet.In this a mandrel with two O rings at appropriate location is inserted into the tube sheet.Hydraulic pressure applied between two O rings causes the tube in that region to expand.

Methods of tube expansion

3. Explosive Forming:
This is done by detonating a carefully sized charged inside each tube causing it to deform and make contact with the tube sheet.

4. Hydro / Mechanical:
This system makes use of mechanical expander but the self feed of mandrel is replaced by positive hydraulic feed using a separate hydraulic circuit apart from the electric drive used for rotation of mandrel.

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 . A tube expansion cross section shown in figure.

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. Cont....

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

% Thinning calculation
Percentage thinning = (Do - Di) - (d - Di w) 2S Where, Di w = Average tube inside diameter after rolling Di = Average tube inside diameter before rolling Do = Average tube OD before rolling d = Average hole diameter S = Do - Di 2 Percentage thinning shall be in the range of 3-6%

Testing and Insp. on expanded joints

Check on job
Check completeness of rolling by ensuring tube ID at rolled /Expanded portion with respect to unexpanded portion by using bore gauge or air gauge. 1% of rolled tubes surface shall be examined by boroscope on both rolling length. In the reference hole % thinning at both rolled places shall be computed at the middle of expanded region by using formula. Removal of lubricants to be checked as peer approved cleaning procedure. Length of rolling to be checked at random.

Check on RCBs
Visual examination of tube surfaces Length of rolling on each tube Pull out test for all the tubes. Pull is between 764 - 1530 kg. % thinning between 3 - 6 %

Qualifying the Procedure And joint

Prepare a procedure qualification block , which has to simulate the job condition. Carry out the expansion as per procedures. Take adequate trial to get the parameter by which % thinning, Pull out test, helium leak test,visual check meet the required values. If the above values are meeting the requirement the process is qualified to perform on job. During production control is exercised in rolling quality control block (RCBs)

Operator Qualification
The person who are engaged for qualifying machine is automatically qualified for performing on the job. For other 10 nos. tubes hole to be rolled and following is the test required on that. % thinning of that rolled tube within limit. Pull out test on all tube Out of 10 tubes 2 tube ID to be sectioning for scratch free expansion.

List of non conformance

In case of RCB Tube s fails to meet the acceptance criteria two successive tubes shall be rolled and shall meet the acceptance criteria before proceeding on the job If roller breaks during rolling all the previous holes rolled using the above tool shall be inspected for any damage. The holes, where rolling is incomplete or interrupted due to power failure, shall be identified and rolling shall be performed after all other holes rolling completed. On job rolling shall be performed only after RCBs satisfactory results on above holes. There are few mores other than this.

Record of expansion
Following record to be kept for expansion of tubes No. of tube rolled (with location R x C) for each shift, day, operator,equipment and settings. Correlation of RCBs with the tube locations, equipment and operator. Melt and heat no. of tube and block. Report of % thinning and surface inspection of 1% tubes in the tube sheet. Pull out test and % thinning results of RCBs Certificate of checking of length of expansion and termination from secondary side . Non conformance list

Tube cleaning Procedure

Cleaning operation
Pug all the tubes at 450 mm depth from tube end. Fill 2 storage tank with DM water In 1st tank add approved cleaning agent to make 5% w/v concentration and stir the solution and raise temp up to 50c. In 2nd tank also raise and maintain the temp. between 50c- 55c.. With help of CF pump put the cleaning agent in circulation and inject the solution in tube at 8-10 kg/cm with injection lance at a depth of 450mm. Cleaning operation shall be start from top row and finish at bottom row. Withdraw injection lance towards tube end. Repeat this for few times. Check on tube end with help of filter paper / tissues by rubbing them in ID of the tube for any oil spots. Stop pump and allow cleaning agent to drain from tube injector.

Cont...

Tube cleaning Procedure

Flushing operation:
Close discharge valve from cleaning tank. Start the pump and open DM water by transverseing the injection lance in to the tube and back. Start from top and bottom. Random check of pH on the flushing at the tube end with phenolophthalene indication shall not show any pink color.

Inspection :
Check all tube end for free from lubricants. Remove all plugs and with ball test check for free passage.