METHODS OF TUBE

EXPANSION IN
TUBE TO
TUBESHEET JOINT
(TTJ) FOR HEAT
EXCHANGERS
Introduction
Tube expansion is the art of reducing tube wall by compressing the OD of the tube against
a fix container.

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
How tubes fit with Tube sheet?
1. By welding only
2. By expansion only
3. By welding and expansion
Types of Tube Expansion

1. Parallel tube expansion 2. Flaring tube expansion

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.
Hydro Expansion FEATURES
Expands in one action tubes with a large wall thickness.
Expands tubes over a long length.
Eliminates the need for step tube expanding.
No work hardening of the tube as this is not a rolling type
expansion.
Eliminates distortion of the tube sheet, as there is no
extension of the tube during expansion.
Does not therefore stress welded tube ends.
Increased holding strength between tube and tube sheet.
Tighter tubes in ring grooved tube sheets.
Smooth contour change between expanded and non
expanded part of the tube.
Eliminates the need to clean down after expanding.
No rotary reaction of the tube to hold.
Reduced operator fatigue.
Hydro Expansion Unit
PRINCIPLES OF OPERATION
 Methods of tube expansion

3. Explosive expansion process

The controlled detonation of specific and precisely positioned explosive charges generates high
pressures in the
bores of the tubes resulting in the almost instantaneous expansion of the appropriate sections. The
outside of
the expanded lengths of tube are coined or pressed into the tubesheet holes resulting in a high
integrity bond
regardless of tubesheet hole ovality or surface finish.
EXPLOSIVE EXPANSION EXPLOSIVE WELDING
PROCESS

a. linked strand cortex

b. kwik lok fastener
c. polythene insert
d. plastic insert
e. tubesheet
f. tube
EXPLOSIVE WELDING OPERATIONAL STEPS
 ADVANTAGES OF EXPLOSIVE
No practical limitations exist on the length of expansion that can be produced by one detonation
multiple / stepped roller expansion can often be avoided with consequential, much reduced joint
production times and costs.
A number of explosive expansion charges can be detonated in one shot significantly reducing
production times / costs.
Restricted access is often much less of a limitation than with other mechanical tube / tubesheet
fixing methods.
Tube wall thinning, work hardening and lengthening of the explosively expanded sections of tubes
are normally negligible.
Satisfactory joints can often be produced in tubesheet holes where ovality and surface finish would
preclude the use of alternative mechanical jointing systems.
Tube Expanding Machine & Accessories
% 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%
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/bubble 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
PREPARED BY

MAULIK R . PRAJAPATI
WELDING ENGINEER
WORK EXPERIENCE - TEMA INDIA LTD. , L&T HEIC , WELSPUN CORP LTD.
,ME & BE METALLURGY AND MATERIALS ENGINEERING (ME IN
WELDING TECHNOLOGY )