JUTASAMA SDN. BHD.

TUBE TO TUBESHEET JOINT (MOCK-UP TEST)

Document Title PROCEDURE & TUBE EXPANSION Document No.
PROCEDURE
Revision No. Revision Date Page Number 3 OF 2

TUBE EXPANSION PROCEDURE

1.0 Objective
1.1 To give guideline to production worker on how to perform tube expansion.
1.2 To give guideline to QC Inspector on how to inspect and measure tube expansion.

2.0 Scope
2.1 This procedure is applied to all heat exchangers fabricated by Jutasama’s, which
require tube expansion.

3.0 Definitions
3.1 QC - Quality Control

4.0 Reference
4.1 TEMA Eighth Edition.
4.2 Tube expander manufacturer’s guide.

5.0 Responsibilities
5.1 QC Inspector to ensure that tube expansion is carried out in accordance with this
procedure and as per drawing.
5.2 Project Engineer to make selection on suitable type and range of tube expander.
5.3 Production Section (Subcontractor) to perform tube expansion work.
5.4 QC Inspector to make tube expansion measurement and report.

6.0 Procedure
6.1 Tubes expansion shall be carried on tube-to-tubesheet joint when required by design
or client.
6.2 When tube welding is required as per drawing, tube expansion shall be carried out
after completion of tube to tubesheet welding.
6.3 Before production takes place, selected welders must to undergo mock-up test on
tube to tubesheet joint.
6.4 Mock-up test specimen is then will be tested for Macroscopic Examination & Weld
Strength Test. Mock-up test specimen will also be tested with tube expansion test if it is
requested by client.
6.5 Tube expansion ratio shall be as below:
i. Tube expansion : 3% to 6%.
6.6 Tube expansion ratio shall be measured at random tube’s location. Number of tubes
to be measured shall not be less than 10% of total number of tubes.
6.7 Before expansion
a. Project Engineer shall provide suitable tube expander to production foreman.
b. QC inspector shall measure and record values for parameter below:
JUTASAMA SDN. BHD.
TUBE TO TUBESHEET JOINT (MOCK-UP TEST)
Document Title PROCEDURE & TUBE EXPANSION Document No.
PROCEDURE
Revision No. Revision Date Page Number 4 OF 2

i. Tube’s Outside Diameter (OD), a

ii. Tube’s Inside Diameter (ID), b
iii. Tubesheet’s hole ID, d
All this parameter shall be recorded into Tube Expansion Report Form
(Attachment 1)
c. From this values, QC inspector will calculate the required ID, e after expansion
by using formula below:
er = [E(a-b) / 100%] + b + d - a
where; er – tubes ID required after expansion
E – tubes expansion ratio (assume as 5% - average)
a – tubes OD
b – tubes ID before expansion
d – tubesheet hole ID
d. From the er value above is to be used as a guideline for tube expansion.
6.6 During Expansion
a. Lubricate tube expander’s head with oil lubricant.
b. Insert the expander into tube to the required depth.
c. Start expansion using pneumatic expansion tools.
d. Up to certain stage, QC Inspector to measure tubes ID. Expand and measure
processes are repeated until tube’s ID reached the value of er, calculated
above.
e. When the required tube ID achieved, QC Inspector will make marking on the
expander using masking tape. The mark will be used as a guideline for
subsequent tubes expansion.
6.7 After Expansion
a. Upon completion of tube expansion, QC Inspector shall measure tubes ID, e
at random location. Minimum 10% of total number of tubes shall be
measured.
b. From the value e, tube expansion ratio can be calculated using formula
below:
Tube expansion ratio,
E = [[(e-b) – (d-a)] / (a-b)] x 100%
where; e – tubes ID after expansion
E – tubes expansion ratio (assume as 5% - average)
a – tubes OD
b – tubes ID before expansion
d – tubesheet hole ID
c. Tubes Expansion Report shall be completed and sign by QC Inspector &
Client.
6.8 After completion of tube expansion works and measurement, the joint shall be
cleaned by using soapy water or by acid pickling for stainless steel.
JUTASAMA SDN. BHD.
TUBE TO TUBESHEET JOINT (MOCK-UP TEST)
Document Title PROCEDURE & TUBE EXPANSION Document No.
PROCEDURE
Revision No. Revision Date Page Number 5 OF 2

6.9 Tube expansion report shall be prepared and submitted to client for review.

7.0 Attachment
7.1 Tubes Expansion Report (F-QC-025)