It is a Traveler Expander. It is generally used in nuclear power projects STEAM GENERATOR thick tube & deep tube expansion. Longer length tube expansion & performs uniform, parallel and smooth expansion zone. The tube is expanded as required length by same set of PILGRIM tube Expander roller, mandrel and cage in one go. PILGRIM tube expander is not taken out ones it is put to use in tube for expansion operation by nonstop gradual forward reverse travel hence no missed out of stage in between long expansion length is possible. Every forward rotation gives longer overlap hence it irons out the earlier expanded area that furnish good finish & accuracy. Clutch assembly on last groove on pilgrim Tube expander secure correct and consistent depth of expansion. Because it has larger overlap gives repeat expansion or iron out the previous backtail expanded area helps the seat that seals perfectly and gives better push out strength in minimum percentage thinning thus life of the equipment is longer than other conventional method of tube expansion system. Minimum Breakage: Pilgrim tube expansion every forward stroke covers only 20% of effective roller length as new increased expansion zone keeping remaining 80% as overlap requires very light torque. Hence the operating load on the pilgrim tube expander is light and wear out of tooling is minimized. Construction of pilgrim tube expander is such that at any position roller or mandrel do not fall out of the cage & no misplacing of loose rollers in deep hole tube is possible.

It is a traveler Expander generally used in nuclear power projects steam generator of thick tube & deep expansion. Longer length tube expansion & performs uniform, parallel and smooth expansion zone.

The tube is expanded as required length by same set of Pilgrim Tube Expander roller, mandrel and cage in one go. Pilgrim Tube expander is not taken out once it is put to use in tube for expansion operation by Non-stop gradual forward reverse travel gradual- hence no missed out of stage in between long expansion length is possible every forward rotation gives longer overlap and hence it irons out the earlier expanded area that furnish good finish & accuracy.
Clutch assembly on last groove on Pilgrim Tube expander secure correct and consistent depth of expansion. Because it has larger overlap gives repeat expansion or iron out the previous blacktail expanded area helps the seal that seal perfectly and gives better push out strength in minimum percentage thinning thus life of the equipment is longer than other conventional method of tube expansion system.

Minimum Breakage: Pilgrim Tubes expansion every forward stroke covers only 20% of effective roller length as new increased expansion zone keeping remaining 80% as overlap requires very light torque. Hence the operating load on the Pilgrim tube expander is light and were out of tooling is minimized.

Construction of Pilgrim tube expander is such that at any position roller or mandrel do not fall out of the caps & no misplacing of loose rollers in deep hole tube is possible.

Sarel undertake such tube expansion & consultation work.
 

After successful removal of tubes from reclaimed tubesheet, it is necessary to inspect tubesheet holes dimensionally to assess the deviation or variation of dimension with respect to its original tubesheet holes dimensions stated in drawing. It is observed that while retubing strength expanded tubesheets vary most in dimension than light expanded tube sheet holes. Due to higher limit of % of thinned tube expansion or marginally over-rolled tube, tube sheet holes are found oversize, oval ligaments disturbed or even digmarks in tubesheet holes. In such condition customer should not expect the same parameters established as earlier in original construction condition. It is a challenging work to carry out tube expansion according to the merit of individual hole dimensions. Tube expansion, whether fresh or retubed it is most important that the quality of tube expansion depends upon:

1. Quality Tube Expander Sets :
2. Appropriate parameters calculations of required working conditions
3. Alert attention of expansion operator

If the expander components are precisely manufactured in very close limit of tolerance with perfect heat treatment cycle observed to a special alloy steel recommended for the tube components then end results of expansion carried according to parameters fixed in mock-up holds good. But one of the factor is not matching as above mentioned even 10% thinning may not sufficient and may lead to distort ligament and in future retubing of same tubesheet may not qualify for reclaiming condition. Experience operators should be appointed to carry out such tube expansion and at the same time, should be alert to understand replacement of tooling according to the working experience, properties of tube qualities etc. To establish the parameters of tube expansion wall thinning of expanded tube determines the power of strength of holding joint and it is established by the specified operating conditions that the equipment must withstand and for the reason push-out of expanded tube is tested by pull-out method. Supposing pull-out load is required to be minimum 1000kg and consistent ten numbers of tubes are expanded at 3.5 to 4.5% thinning and their pull-out load is observed to be 1100 plus then thinning parameters should not be exceeded beyond 5%. Over-rolling must be avoiding at any case.

Basically used to expand the small diameter tubes in oil coolers and radiators, we offer wide variety of condenser tube expander that finds its application in diverse industries. Our range includes short length and long length tube expanders.

Short length tube expander with adjustable thrust cooler assembly is used for thin tube sheet tube expansion while long length tube expander with same assembly is used for thick tube sheet tube expansion. To protect front tube sheet tube hole surface, long threading should be avoided.

This is the most challenging tube expansion work for inner tube sheet tube expansion. Following points must be observed before starting tube expansion of double tube sheet tube expansion.

1. All the dimensions of inner tube sheet hole must be checked 100% and recorded in the direction of 90 degree and 0 degree by bore dial gauge.

2. All the tube sheet hole and tube OD must be cleaned by acetone before tube insertion.

3. Deviated tube sheet hole to be attended separately according to the simulated mock-up hole qualification.

4. Do not alter the expansion parameters once established on mock-up during tube expansion on the job.

Parameters: A) Type of Expander B) Drivegun C) Torque Control setting

10% of total number of holes on the trial block should be kept aside to qualify the tube expander tooling to be used on the job which will be qualified and kept ready to use on the job.

Check the tube expansion after every five expansion operations and understand the behavior of operating expander. Use alternate expander using cooled tube expander from the solvent approved by the customer.

For Titanium, monal and SS Tube expansion, use sulphur and chlorine free lubricants as approved. Uniform tightness is only possible by using torque control tube expansion unit which is qualified for above work.

Sarel undertake expansion and consultation of such jobs.

Our range of boiler thick drum tube expanders is designed to accomplish the inner or the first operation. These expanders are non flaring adjustable collar type which controls the length of expansion by threads, provided on the body for the final operation. Depending upon the thickness of tube sheet, flaring type tube expanders are expanded in several progressive operations when boiler drums are thicker than standard roll size.

The combination of these two expanders should fulfill the exact requirement of thicker tube sheet tube expansion by 1/4" or 5-6 mm overlap of rolls between progressive operation. Boiler expanders we offer are self-feeding, parallel rolling and for serving the purpose of expanding and flaring in one operation, expanders are used.

When automatic or manual fuse weld of tube to tube sheet is required to be done, Tube end OD must be in one centre line and uniformly mallet push contact expanded with its tube sheet hole. Contacting surface area should be in the range of 2-4 mm length. Cone rolling serves the above purpose for making good weld preparation operation. Tag welding can be avoided by cone rolling for retaining tube in one position in tube sheet hole.

Our range of Plate oil cooler tube expanders have sturdy construction and durable designing. These expanders are available in expansion & sealing of copper sleeve, with size in width ranging from 4mm onwards (S.S). This comprises a coupling plate which not only helps in fastening the production but it avoids brazing also.

Condenser Tube expander for thin wall tubes e.g. Titanium Tubes

It generate better expansion results. Covers 40% more area in one rotation of expanding operation and expands tube more spherical than three  roller expander in free expansion at less than 0% expansion thinning.

Five roller expander expansion gives better push out results, accuracy and mirror finish. 5 roller expander with minimum helix angle of rolls performs as burnishing tool.

Burnishing:

Roller burnishing work is one of the method for precision finished in which precision finished rollers are caused to rotate in contact with the work to effect plastic deformation metal surface to a very slight degree.

The surface of the section through lathe or boring machine is a succession of projections and indentation when microscopically examined roller burnishing compreses these projections into indentations to form a smooth surface.

3 roller & 5 roller on request. Complete set of Tube expander is made from stainless steel material suitably heat treated. Short bend tube expander with short mandrel tube expander as per requirement Pressure tight fitting of pipe to flange, coupling etc. Tube Rolling:Sulphur & Chlorine free lubricant. The conventional mineral lubricants available in the market contains some amount of sulphur & chlorine as they have derived from crude petroleum, which contains these impurities. For sulphur & chlorine free oil we recommend our synthetic oil S440/460 worm gear lubricant having viscosity of 440 CST. This oil being synthetic base can also withstand high temperatures during rolling stage without affecting performance of the product

Weld preparation tool assembly is mainly used in nuclear heat exchanger tube to tube sheet fuse/tig welding. This tool trims the tube to under flush the tube sheet face and chamfers the tube sheet hole 45 deg in one operation. Facing and chamfering is done by specially designed cutter attached to the tool assembly.

We design tube facer or trimming tools with premium quality of raw materials to maintain tube projection accurately with adjustable thrust collar assembly (within 0.05 mm) for unbalanced/disproportionate projection from tube sheet or drum. These facer or tools can also be used as weld preparation tool by radiusing the correct length cutting edge, as required.

We design torque control tube to switch off the current to an electric drill by driving a tube expander automatically, when a preset torque value is reached. This motor drill is a reversible type and by manipulating coarse and fine rotary controls, this setting is obtained. Our control unit measures the current drawn accurately and switches off the power supply at the preset value. This results in limiting the torque at the mandrel of the tube expander from the tube.

We offer tube end insert that is used for protecting a tube end or restoring a tube back to service. This tube is specially designed for inserting at the end of pre-heater or heat exchanger tube in an attempt to economize the unit without the necessity of tube replacement. Available in short length, these can be customized as per the specification of the client. We also offer solid taper plug and blind hole expansion plug with customization.

SAREL worm Drive designed for heavy duty, maximum service life and extremely suitable for operating in very conjusted and confined areas of header in boiler. The case housing is suitably designed to the shaped to provide for expander feed movement when working through a handhole approach for expanding tube at right angle but OFFSET from handhole. Fitting of knurled hollow shaft to accommodate long hardened worm shaft such a way can fit and assembled as "P" as well "q" Ratchet drive. The case assembly is designed to accommodate the gear assembly in minimum possible thickness. Chilled  bronze worm wheel gears up the drive with hardened worm shaft. High heat resisting grease is recommended inside the case assembly at the time of maintenance of drive assembly. Replaceable part like worm wheel, worm shaft and trust washers can be provided on demand.

This is the most challenging tube expansion work for inner tube sheet tube expansion. Following points must be observed before starting tube expansion of double tube sheet tube expansion.

1. All the dimensions of inner tube sheet hole must be checked 100% and recorded in the direction of 90 degree and 0 degree by bore dial gauge.

2. All the tube sheet hole and tube OD must be cleaned by acetone before tube insertion.

3. Deviated tube sheet hole to be attended separately according to the simulated mock-up hole qualification.

4. Do not alter the expansion parameters once established on mock-up during tube expansion on the job.

Parameters: A) Type of Expander B) Drivegun C) Torque Control setting

10% of total number of holes on the trial block should be kept aside to qualify the tube expander tooling to be used on the job which will be qualified and kept ready to use on the job.

Check the tube expansion after every five expansion operations and understand the behavior of operating expander. Use alternate expander using cooled tube expander from the solvent approved by the customer.

For Titanium, monal and SS Tube expansion, use sulphur and chlorine free lubricants as approved. Uniform tightness is only possible by using torque control tube expansion unit which is qualified for above work.

Sarel undertake expansion and consultation of such jobs.