Tube Expansion & Re-Rolling
Products
Tube Expansion & Re-Rolling
Tube expansion and re-rolling are critical processes in the assembly, repair, and maintenance of heat exchangers and condensers. These methods ensure a tight, leak-proof joint between the tube and the tube sheet, enhancing the mechanical strength and sealing integrity of the equipment.
Metalok Industries employs hydraulic, mechanical, and pneumatic expansion systems to achieve precise tube-to-tube sheet contact. The re-rolling process is carried out to restore or improve existing tube joints, ensuring consistent wall contact and eliminating potential leak paths caused by wear, corrosion, or vibration.
All expansion and re-rolling activities are performed by qualified technicians using calibrated tools and gauges in accordance with ASME and TEMA standards. This ensures uniform expansion, controlled torque, and reliable long-term performance under both low- and high-pressure operating conditions.
- Inspect and clean the tube ends and tube sheet holes before starting expansion.
- Verify tube dimensions and ensure proper alignment within the tube sheet.
- Select the correct expansion or re-rolling tool based on tube size and material.
- Apply suitable lubrication to reduce friction during expansion.
- Insert the expander into the tube to the required depth for uniform contact.
- Perform controlled mechanical or hydraulic expansion to achieve a tight metal-to-metal seal.
- Avoid over-expansion to prevent tube thinning or cracking.
- For re-rolling, remove the old tube or rework loose joints to restore sealing integrity.
- Inspect the expanded area visually and dimensionally to ensure proper fit and finish.
- Record all expansion parameters and inspection results for quality documentation.