Heat Exchanger Tubes - Pneumatic
Tube Rolling - Pneumatic Specifications
Features of Pneumatic Rolling
Tube rolling tubes in heat exchangers are best achieved with lightweight, pneumatic, ergonomic rolling guns.
- Lightweight aluminum body.
- Ergonomically designed.
- Auto stops expansion at the defined setting.
- Precision control measures the torque output.
When rolling tubes from 1/4″OD up to 1.1/4″ OD the most productive way is by pneumatic rolling guns. These are easy to operate and have a consistent and dry air supply, tube joints are quickly achieved. The lightweight body of the gun is ergonomically designed with the operator in mind.
Once a finished ID is calculated and tested, the gun can be set to auto-stop at the defined setting to have consistent and accurate joints with the correct wall thinning.
Tube Expanders - 1/4" to 1.1/4" OD
Tube Expanders by Powermaster Industrial
Powermaster Industrial Supplies now produces tube expanders in Canada. Our components are manufactured then assembled here in Ontario. We inspect and test all tube expanders before being released to our customers.
Model 720-2500
Model 720-1800
Model 850-400
Example of a Rolling Calculation
Below, we have outlined a detailed process for determining the proper expansion dimensions for tubes. This method ensures that the tube joints are secure and the wall reduction is optimal for the application. Here are a few key points to keep in mind:
- Accurate Measurements: Ensure all measurements are precise, especially the tube sheet hole ID and tube OD.
- Use of Gauges: Utilize a tube hole gauge to determine the ID before and after rolling.
- Wall Reduction Calculation: Calculate the wall reduction accurately to avoid over-rolling, which can damage the tube.
- Torque Adjustment: Adjust the torque based on the calculated wall reduction to achieve the desired tube joint quality.
- This technique is indeed a reliable way to set torque rolling devices and ensure consistent tube expansion. If you have any specific questions or need further clarification on any step, feel free to call us at (613) 764-0572, or email sales@tubetools.ca
Tube Rolling Calculation Based on 3/4″ OD Tube 16 BWG (0.065″)
| Letter | Tube Test (Example) | No1 (Example) | No2 |
|---|---|---|---|
| A | Tube Sheet Hole Size (ID) | 0.757″ | |
| B | Tube Outside Diameter (OD) | 0.750″ | |
| C | Clearance (A-B) | 0.007″ | |
| D | Tube ID | 0.620″ | |
| E | Tube ID When Metal -to-Metal Contact is Reached (D+C) | 0.627″ | |
| F | Tube ID after Rolling | 0.636″ | |
| G | Wall Reduction (F-E) | 0.009″ |
Preventing Tube Leaks
Certainly! Preventing tube leaks in heat exchangers is crucial for maintaining efficiency and safety. Here are some strategies to consider:
- Regular Inspection and Maintenance: Schedule routine inspections to identify early signs of tube wear, corrosion, or damage. Address any issues promptly to prevent leaks.
- Tube Material Selection: Choose materials that resist corrosion, erosion, and thermal stress. Stainless steel, copper-nickel alloys, and titanium are commonly used for heat exchanger tubes.
- Proper Tube Expansion: During installation, ensure proper tube expansion. Over-rolling or under-rolling can lead to leaks. Follow manufacturer guidelines for tube expansion techniques.
- Tube Hole Preparation: Clean and deburr tube holes before inserting tubes. Properly sized and prepared holes prevent leaks caused by misalignment or stress concentration.
- Tube Supports and Bracing: Use tube supports and bracing to minimize tube vibration and prevent fatigue-related leaks. Vibrations can cause fretting wear and stress corrosion.
- Tube Cleaning: Regularly clean the tubes to remove fouling, scale, and deposits. Fouling can lead to localized overheating and tube failure.
- Water Treatment: Properly treat the cooling water to prevent scaling, corrosion, and fouling. Scale deposits can reduce heat transfer efficiency and increase the risk of leaks.
- Thermal Expansion Considerations: Account for differential thermal expansion between tubes and the shell. Use expansion joints or bellows to accommodate movement without stressing the tubes.
Remember that each heat exchanger system may have specific requirements, so consult with experts and follow manufacturer guidelines for optimal performance and longevity.
Powermaster Industrial Supplies provides quality tools worldwide when using tube expanders for retubing. A tube expander is a precision instrument used to widen the ends of tubes within a tube sheet. It comprises a Mandrel, Rolls, and a Cage. The mandrel, when rotated, is pulled into the cage due to the rollers’ angle. This action forces the rollers outward into the tube’s ID, causing the tube’s exterior to form a seal with the tube sheet. Consequently, the tube wall thickness is reduced to a predetermined percentage, which varies based on the tube’s size and material.
