JUTASAMA SDN. BHD.

TUBE TO TUBESHEET JOINT (MOCK-UP TEST)

Document Title PROCEDURE & TUBE EXPANSION Document No.
PROCEDURE
Revision No. Revision Date Page Number 1 OF 2

TUBE TO TUBESHEET JOINT

(MOCK-UP TEST PROCEDURE)
1.0 SCOPE & RESPONSIBILITIES

1.1 This procedure is applied for conducting Mock-up test for tube to tubesheet joint.
1.2 Production Department is responsible for preparing the test specimen and testing
equipment.
1.3 Quality Control Inspector is responsibility to conduct the testing and record all the
data.

2.0 SPECIMENT & EQUIPMENT

2.1. Test block (simulating the tubesheet) - thickness of the test block may be less but not
necessary be more than 50mm.
2.2. Tubes - material and dimension are as to be used in production.
2.3. Tubes Expander - HB type Expander with adjustable ball bearing collar and
pneumatic drive tool.
2.4. Welding Process - GTAW process.
2.5. Mechanical Testing - External mechanical testing laboratory.

3.0 PROCEDURE

3.1 Preparation of Test Block

3.1.1 Test Block A for Macroscopic Examination.

25mm 25mm

25mm

a
25mm
D

A B C

Figure 1

a. Test block for Microscopic Examination shall be prepared as per Figure 1.

b. Tube spacing a, and weld detail to be used are as per actual joint for the heat
exchanger.
c. Tubes material, size and thickness are as per actual heat exchanger. Tube length shall
be the thickness of tube plate plus 25mm minimum.
d. Saw cut will be made by mechanical testing laboratory after completion of welding
and expansion of the test piece on reference line A, B, C and D. Saw cut D shall be
made at a stop/ start position.
JUTASAMA SDN. BHD.
TUBE TO TUBESHEET JOINT (MOCK-UP TEST)
Document Title PROCEDURE & TUBE EXPANSION Document No.
PROCEDURE
Revision No. Revision Date Page Number 2 OF 2

e. Each weld region on one surface of each saw cut shall be carefully prepared by
emerying to a minimum 180's grit emery finish, and then etched in suitable reagent to
reveal the weld structure.

3.1.1 Test Block B for Weld Strength Test

Figure 2

a. Test Block for Weld Strength Test shall be prepared as per Figure 2 and their tube to
tubesheet joint detail.
b. Tubes material, size and thickness are as per actual heat exchanger. Tubes length
shall be minimum 200mm.
c. Saw cut will be made by mechanical testing laboratory after completion of welding
and expansion on the reference line A and B.

3.2 Dimensions listed below shall be recorded for each tube and tube holes.
a. Tube holes ID
b. Tubes ID
c. Tubes OD

3.3 Insert the tubes into tube plate and tack weld on the reverse side of tube plate. Joint
configuration shall be as per actual heat exchanger. Quality Control Inspector to inspect the
fit-up of tubes-to-tubesheet to ensure that the joint configurations are correct.
3.4 Welding to be performed on same process and position to be used in production weld.
3.5 Visual inspection to be carried out after complete welding.
3.6 Tubes are then expanded using tube expender to the required thinning ratio. The Thinning
ratio shall be between 3% and 6% of the original tube thickness.
3.7 Tube ID after expansion are measured and recorded for calculating the thinning ratio.

4.0 EXAMINATION OF TEST PIECE & RECORD

4.1 The completed test pieces shall be examined as follow:

a. Visual examination
b. Dye Penetrant examination
c. Microscopic examination for the test piece A
d. Pull Test (Weld Strength Test) for test piece B

4.2 The weld shall meet the requirements of ASME Section IX 2015 Ed.
4.3 The mechanical testing laboratory shall prepare Microscopic and Pull Test Report.
4.4 Jutasama's Quality Control Engineer will prepare WPS, PQR and WQT for the testing.