1.

0 Scope

This procedure establishes method to tube reduction to:

SA 192/SA 192M Specification for seamless carbon steel boiler tubes for high-pressure
service.

SA 210/SA 210M Grade A -1 Specification for seamless medium-carbon Steel boiler

and superheater tubes

2.0 Reference code and paragraphs

Tube forming processes: A comprehensive guide Gregory Miller

ASME section II Part A
ASME section I
ASME section IX
ASME section V
ASM International: Heat treaters guide: Practice and procedures for irons and steels
ASM International Volume 14: Forming and forging
Boilers: A practical reference.
AWS D1.1

3.0 Personnel.

All personnel shall be trained and qualified in compliance with this procedure prior to
performing any work.

Record of training and qualifications shall be maintained in a personnel qualification file

by the QCM.

4.0 Performance demonstration

Prior to performing any work shall be demonstrate that the tube reduction by swaging,
this in according under tolerance of hardness, and dimension required, by a coupon
test.

5.0 Swaging

The swaged portion of the tube should be drawn to the desired dimensions. Shall be
use an internal mandrel during the swaging process to help assure dimensional
uniformity for the completed swages. All burrs, sharp edges, gouges, surface
laminations and other potential stress risers shall be removed. The swaged portion shall
be free of all oils or other compounds used in the swaging process. Residual oil
remaining in the tubes after swaging (especially bent tubes) should be drained and/or
cleaned chemically to remove the oil prior to drum insertion. Smoothness of inside of
tubes in swaged areas will affect rolling expanding of tubes into drums.

6.0 Procedures

The basic reduction forming punch (see Figure 1) consists of four sections of
travel for the tube.
The tube enters what is called the tube size section, which is nothing more than
the outside diameter of the beginning tube.
Capturing this section helps support the tube and minimizes backup or bulging
of the material.
The tube is then forced into the transitioning section that begins reducing the
tube to the desired dimension.
 The tube is then moved to the sizing area that controls the outside diameter of
the tube end.
The final area of the punch provides relief for the tube and is commonly
oversized by 0.005 in. (0.13 mm).
This area minimizes friction on the tube as the punch traverses through the
cycle. It also helps prevent springback on the end of the tube. Springback
imparts a flared look to the tube end.

Wall thickness, column strength, and material composition play a major role in the
degree of reduction. Considering all of these above items, the average reduction for
each operation is 2 times the wall thickness. Each type of metal reacts differently. A
general rule for the common carbon and stainless steels is the softer the material
(annealed), the better the tube reacts to a reduction punch or die. The tube may be
reduced by up to 20% in diameter. Conversely, the harder the material, the more likely
the tube under reduction stresses as it tries to move back away from the initiating force.

When the dimensions of the tube end have been altered, the wall will thicken, and the
length of the tube will increase. The following equation may be used for a practical, but
not a precise, value for growth in length:

2 2
D1 - d 1
L= l
2 2
D - d
Where:

L= length of tube, in. (mm)

D= outside diameter of tube, in. (mm)
d= inside diameter of tube, in. (mm)
D 1= outside diameter of reduction section, in. (mm)
d 1= inside diameter of reduction section, in. (mm)
l= length of reduction section, in. (mm)

7.0 Tolerances

Swaged area length variance in, max.

Swaged area OD finish 250 microns min.
Swaged ovality variance 0.010 in, max.
Swaged eccentricity variance 0.010 in, max.
Swaged area heat treatment maximum hardness specification (Table 2).

8.0 Nondestructive testing

Swaged area length shall be applied liquid penetrant testing or magnetic particle
testing, to detect possible cracks.

9.0 Annealing

There is normally some work hardening of the tube ends during the swaging process.
After swaging, the tube ends shall be annealed (Subcritical annealing) by heating to
100F and 1200F [600C and 650C] to a maximum hardness specification.

a) The temperature of the furnace shall not exceed 315C at the time the tube
ends is placed in it.

b) Above 600F, the rate of heating shall not be more than 400 F per hour divided
by the maximum metal thickness of the thicker part, in inches, but in no case
more than 400F per hour. Above 315C, the rate of heating in C/hr shall not
exceed 5600 divided by the maximum metal thickness, in millimeters, but not
more than 220C/hr. During the heating period, variations in temperature
throughout the portion of the part being heated shall be no greater than 250F
[140C] within any 15 ft [5 m] interval of length. The rates of heating and cooling
need not be less than 100F [55C] per hour.

c) After a temperature range between 1100F and 1200F [600C and 650C], the
temperature of the tube ends shall be held within the specified limits for a time
not less than specified in Table 1, based on thickness. During the holding period
there shall be no difference greater than 150F [85C] between the highest and
lowest temperature throughout the portion being heated.

d) Above 600F [315C], cooling shall be done in a closed furnace or cooling

chamber at a rate no greater than 500F [260C] per hour divided by the
maximum metal thickness of the thicker part in inches, but in no case more than
500F [260C] per hour. From 600F [315C], the assembly may be cooled in still
air.

Table 1 Chart Temperature/Time to thickness of in or less

10.0 Hardness Requirements

All of the tube ends (100%) should be hardness tested following the annealing process
to insure that the material is suitable for expanding, with additional testing performed if
initial samples indicate hardnesses outside the acceptable range (see table 2)

Table 2
Tube Brinell Hardness Rockwell Hardness
SA 192 137 HB* 77 HRB**
SA 210 A-1 143 HB 79 HRB

Notes:
* Tubes 0.200 in. [5.1mm] and over in wall thickness (only SA 192)
** Tubes less than 0.200 in. [5.1mm] in wall thickness (only SA 192)

11.0 Records

a) Procedure shall be documented on form FFAIO-03 by QCM.

b) Liquids penetrant Inspection report
c) Magnetic particle Inspection report
d) Hardness report