P.T.

SULFINDO ADIUSAHA
Technical Department – Engineering Procedure Tube Expansion

(SAU-TE-BE-HTV-004-00)

PROCEDURE OF TUBE EXPANSION

ITEM: HEAT EXCHANGER

3 2
2 1
1 0 19-12-06 CK
No. Rev. Prepared By Reviewed By Approved By

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P.T. SULFINDO ADIUSAHA
Technical Department – Engineering Procedure Tube Expansion

CONTENTS
1. Title 1
……………………………………………………………………… 2
2. Contents 3
…………………………………………………………………. 3
3. General …………… 3
……………………………………………………. 5
4. Applicable Specification, Code and Standard
…………………………….
5. Application
………………………………………………………………
6. Acceptance Criteria
………………………………………………………

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P.T. SULFINDO ADIUSAHA
Technical Department – Engineering Procedure Tube Expansion

3. GENERAL.
This Engineering Specification describes the general requirement governing the
expand tube to tubesheet of Exchanger for PT. SAU.

4. APPLICABLE SPECIFICATION, CODE and STANDARD.

a. TEMA, Eight Edition 1999.
b. ASME code section VIII Division 1 2004 edition.
c. API 660, 2003 Edition.

5. APPLICATION.
5.1. Preparation
a. All tube ends and tubesheet holes shall be greased, cleaned and shall be dried and
free from contaminations.
b. Make sure the tubesheet, which have been machined as required tolerances in
accordance with relevant drawings. The inside edges of tubesheet holes shall be
free
of burrs and sharp corners to prevent cutting of tubes.
c. Cleaning shall be accomplished through the use of compressed air, power brush,
etc.
d. The tubesheet holes and tubes shall be checked for over-sizing and tolerance
prior
to installation in to position.
e. Align of tubesheet horizontally on the bundle to prevent relative movement in
any
direction.

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Technical Department – Engineering Procedure Tube Expansion

f. Stay tubesheet and specified arrangement in position by light rolling a few tubes.
Insert all tubes carefully with correct protrusion at the ends as requirement as
shown
on drawings.
5.2. Strength / Seal Weld.
Strength / seal weld of tube to tubesheet, with a minimum of two passes. The final
welds shall be 100% examined by dye penetrant method.
5.3. Leak Test.
a. Strength weld inspection by performing of leak test from shell side with pressure
1
bar G.
b. Leakage is indicated with formation of bubble.
c. Repair strength weld as per approved welding procedure and re-inspection.
5.4. Tube Wall Expansion.
a. Light expansion / Heavy expansion shall be carried out using an electric or
pneumatic expanding equipment after strength weld. The percentage wall
reduction
shall be set by adjusting the torque setting and when hold measurement verifies
that
the requirement wall reduction has been achieved the torque setting is noted and
setting fixed.
b. Roller expansion at inlet side to be done first. Expansion to bottom row, left to
right.
c. Outlet/return side to be secured in position. Recheck and ensure tube protrusion
of
all tubes are as per approved drawing construction. Roller expand all tubes from
bottom side row, left to right.
d. The lubricant used for rolling shall be safe material without any effect to tubes.
Lube of tube rolling compound and its use shall be restricted to tube internal-to-
expander portion only.
e. The length of expansion shall be referred to drawing.
f. This percentage is calculated using the following equation:
E = (D – A) + C + 2B% ASM, Shell and Fin tubes Exchanger
Where:

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Technical Department – Engineering Procedure Tube Expansion

A = tubes outside diameter (mm)

B = tubes wall thickness (mm)
C = tubes inside diameter before expand (mm)
D = tubes hole diameter on tubesheet (mm)
E = tubes inside diameter after expand (mm)
% = Desired percent of wall reduction.

Table-1. Allowable tubes thickness reduction for roller-expanded

tubes to tubesheet joints API 660

Material Tubes wall thickness reduction ( % )

Carbon steel and low alloy steel 4 to 6 a
Stainless and high alloy steel 6 to 8 a
Non-ferrous 4 to 5 a
a The upper limit may be increased by a further 2%, if approved by
purchaser

g. The tube shall not be over rolled. Micrometer shall be used to check the inside
diameter of tubes after rolled.
h. Check the horizontal dimensions while rolling to maintain proper measurement
and
alignment. If it required being necessary to re-roll joint, it should be done lightly
by
rolling several times.
i. Dimensions of tubes must be recorded in a form in a form for inspection and
record.

6. ACCEPTANCE CRITERIA.
a. Tube hole diameter and tolerance shall follow RCB-741 of TEMA.
b. All tubes shall be fully inspected.

Table RCB-7.41 of TEMA

TUBE HOLE DIAMETER AND TOLERANCES
(All Dimensions in Inches)

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Technical Department – Engineering Procedure Tube Expansion

Nominal Tube Hole Diameter and Under Tolerance Over Tolerance: 96% of tube

Standard Fit Special Close Fit holes must meet value in

Nominal column ( c ). Remainder may
(a) (b)
not exceed value in column
Nominal Under Nominal Under
Tube OD
Diameter Tolerance Diameter Toleranc
e (c) (d)
¼ 0.259 0.004 0.257 0.002 0.002 0.007
3/8 0.384 0.004 0.382 0.002 0.002 0.007
½ 0.510 0.004 0.508 0.002 0.002 0.008
5/8 0.635 0.004 0.633 0.002 0.002 0.010
¾ 0.760 0.004 0.758 0.002 0.002 0.010
7/8 0.885 0.004 0.883 0.002 0.002 0.010
1 1.012 0.004 1.010 0.002 0.002 0.010
1¼ 1.264 0.006 1.261 0.003 0.003 0.010
1½ 1.518 0.007 1.514 0.003 0.003 0.010
2 2.022 0.007 2.018 0.003 0.003 0.010
Note:
Tube holes in tubesheets shall be finish to the diameters and tolerance shown in
Table RCB-7.41, column (a). To minimize work hardening, a closer fit between
tube OD and tube ID as shown in column (b) may be provided when specified by
the purchaser.

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