Tube expansion details (Mechanical versus

Hydraulic expansion
During the last step, the tubes can be expanded. Two types of
expansion can be distinguished:
Mechanical expansion is executed by the dual axis CNC
machine mentioned under figure 2.3. This CNC machine will
continuously control the tool wear and tube diameters before
and after rolling. Expansion percentages from 3 to 5 % are
typical. The normal expansion length as prescribed by TEMA
is 50 mm. Longer expansion lengths will be executed in
different steps.
Fluid expansion or hydraulic expansion is used in case of
tubes with high strength and/or high ticknesses. In case of
fluid expansion, the expansion is normally executed over the
total length of the tubesheet excluding 6 mm on the tubesheet
surface. (Is depending on the fact that clad material is used, or
solid material) For a schematic overview see Fig. 2.7

Fig. 2.7

Fluid expansion has the advantage that no contamination of the tubes can occur due to the sliding of the
rollers on the inside of the tubes. An expansion pressure of 4.500 bar for tubes with a thickness of 2.4 mm
is typical for normal contact expansion. (Expansion to optimize contact between tube and tubesheet.)

Fluid Expansion procedure

In Fig. 2.8 an overview is given of the different steps executed
during the fluid expansion procedure:
a) Inserting the probe into the tube
b) Loading the expanding zone with water at low
pressure
c) Reaching high pressure (4000 - 5000 bar)
d) Recuperating the water
e) Probe pulling out
f) Expanded tube
Before and after the expansion, the inside diameter of each tube
will be measured
and will result in a
printed mapping overview of all tubes based
on their dimensional
characteristics.

Fig. 2.9.

Fig. 2.8.

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For fluid expansion, a dedicated probe is made for each

particular expansion project. (See fig 2.9 and fig 2.10 )
This probe is produced taking into account the inner
diameter of the tube holes and the expansion length in the
tube sheet.
Due to the construction of the probe, the relative expansion
zone within the tubesheet is always correct.
It is standard procedure to measure the inner diameter of the
tube before and after the expansion with an electronic
micrometer connected to a computer, indicating the results
per tubeposition.
After expansion, an eddy-current test can be executed, to
determine diminution of wall thickness, and to check on
cracks in the tube. (See also fig. 2.6)

Fig. 2.10

Conclusions
The tube to tubesheet connection as described above has proven its high quality result over the years, and is
highly recommended. It has become part of the standard Coek Engineering working procedure, and
guarantees a low defect percentage on tube to tube sheet connections.

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