Tube Expanders For Expanding the Internal Diameter of Tubes

To offer heat and cooling effect for changing one state to another, condensers, boilers, heat exchangers, and other special machines are employed. To give power to the machinery, they are utilized in different factories, industries, and manufacturing units also. With the utilization of tube sheets fitted with boilers, one state of matter is converted into the other state. To mold and to give shape to the diameters of the tube, they require special tube expansion systems that assist in adjusting the diameter of the tube sheets.

Various special kinds of tools and parts are fitted with boiler tube expanders which assists in less effort required in shaping and facing tube sheets inside boilers. The procedure of filling the tubes and enhancing the diameter for moreefficiency and betteroperations helps in simplifying the whole procedure.

The concerned companies are involved in the production of the expanders that are made available in several forms, characteristics, and dimensions. These expanders are available on the offline shops and on the online websites of the companies working in this field at much economical prices. The expanders are mainly utilized in the manufacturing units that are directly involved in utilizing the boiler to power up the machinery and manufacturing head exchangers and condensers.

There are basically three kinds of tube expansion systems that are as follows:

• Electric tube expansion system
• Pneumatic rolling motors
• Hydraulic tube expansion system

All the equipmentare well-fitted with the essential parts such as end faces, pilots of various thickness & diameters, aligned rollers, and mandrel. All the mentioned parts operate in a manner to offer the optimal outcomeconcerned with the required work i.e. expanding and facing tube sheets. These are composed of titanium and best in class protective layers are coated over it so that it can last for maximum time and are lasting in nature. These components are heat proof and give frictionless expanding capabilities without causing any kind of damage to the condenser tubes.

In addition, these can also be utilized without being afraid of any type of accident or damage triggered due to an explosion. These parts are used in radiators, condensers, and in several machines that utilize tube and steel technology. Additionally, the latest kinds of expanders are fitted with the required parts which assist in creating the molding process more precise. The head frame on the expanders assists in offering more support and durability to the machine. The utilization of titanium materials and stronger steel helps in making the condenser expanders the best tools for performing the eeded activities with more effectiveness and efficiency.

Powermaster is a company that provides such kind of gears and tools for tube expanding and it also ensures that all the equipments are of the highest quality and remain operational for a longer period of time. They provide various kinds of services like hot bolting, re-tubing, in-situ machining, controlled bolting, etc. The products of Powermaster are used in more than 120 countries which prove that provides the best kind of services to their clients.

Electric Tube System Which Are Really Desirable

Electric tube expansion systems are worked by the electric control panel. This tube development framework is utilized for the most part for tube extension of condenser tube expansion, warm exchangers. The control board unit controls naturally subsequent to achieving the required torque, tube expansion withdraws out from the tube in the wake of squeezing the turn around Button. This programmed framework guarantee tube are moved to greatest snugness without intemperate worry of work in tube metal thus avoiding harm at tube closes or twisting ligaments of tube sheet.

Tube Expansion: Basic Principles And Methods

Tube Expanding is the process by which the tube wall is reduced by compressing the outer diameter of the tube against a fixed container. It can be done easily by keeping tubes into tube sheets. There is specified data to determine the correct tube wall reduction. Tubes are seated tightly whose expansion is somehow impossible manually as it is expanded so as to manufacture heat exchangers for high-pressure steam generators, Food and Pharmaceutical processing systems, Boilers for conventional power generation and Condensers. So, it is very important to decide the best method and tube expansion system for tube expanding. There are several factors for the determination of dimensions, thickness and application of force must be taken as prior so as to expand the tube in a better way.

There is a requirement of tube expansion tools for proper expansion and durability of the tubes. There are various types of tube expansion systems. Some commonly used tube expansion systems are:

• Hydraulic Tube expansion system
• Electric Tube expansion system
• Sugar Mill Tube expansion system
• Torque Controlled Tube expansion system
• Radiator Tube expansion system and others.

There are various accessories like Rolling drives, Torque controllers, Voltage stabilizer, Suspension system etc. are used. By the expansion of the tube inside the tube sheet, swaging of the tube gives the clear data about the space between the two components is always forced closed.

Tube Expansion Methods

1. Hydraulic Expansion: It is the latest expansion method, also known as hydro-swaging. It is the more effective method than roller expansion for high-pressure steam generators. In this method, expansion pressures are applied uniformly, tube after tube, which ensures the consistent joints throughout the tube sheet.
2. Explosive Expansion: It is done when tubes sheets are sealed by welding. It is used for variation in the thickness of tubes. It is the more expensive way of tube expansion than hydraulic expansion.
3. Mechanical Rolling: It is the process in which one roller expands tubes into grooved holes which lead the tube metal extrudes into the grooves. However, this process may cause tube-end fatigue, depending upon the frequency and amplitude of the stresses applied by the rollers.

Major Causes of Tube Leaks

Common causes of tube rolling leakage are under-rolling, over-rolling, improper preparation of tube sheets and differential thermal expansion. Improper expansion can lead to serious difficulties for the manufacturers and repair servicemen. It is important to set the torque of rolling devices. All the dimension should be kept in mind during tube expansion.

The wall dimension can be reduced and increased anytime with proper care. There are specified factors of specific materials like brass, copper, stainless steel, titanium, etc. It is the fact that harder the material, the less wall reduction is required to obtain a tube joint. It is very important to check the quality of the equipment required for tube expansion. There are many manufacturers who produce machines for tube expansion with technological advancements and machinery introduction. Thus, you can select any of them according to your needs.

Electric Tube Expansion System For Expanding Large Diameter Thick Wall Tubes

Electric Tube Expansion System is mainly done with the expanding of the tubes based on the set torque along with its value in much more efficient manner. Torque is the rotary force acting or present on tubes when the machine is operated under the control. For a given drive, with constant RPM then torque could be proportional to drive power. Drive power could be efficiently controlled by the tube expansion and it could result in the excellent operation of the machine in the more efficient way. Tubes are expanded equally as a result that mainly suitable for bringing the enticing option on the machine to the high extent. Powermaster is the top and leading manufactures and supplies of the extensive Tube Expansion System. Powermaster brings you the ultimate Electric Tube Expansion Systems that is widely used for the varied range of the devices and much more helpful for easily enabling more benefits.  Powermaster has manufactured the products using the best quality raw materials which are much more suitable for gaining more accuracy to the excellence.

How Do Tube Expansion Systems Work?

Powermaster is known to manufacture the products according to the standard from reliable vendors in the market. With the widest range of the product, that is mainly used for wide application and suitable for expansion of the tubes. Splendid features mainly include the energy efficiency, high durability, superior quality along with the low maintenance cost. In fact, the complete range of products is thoroughly quality tested. With each end of the stages, each of the machines is tested according to the international standard and delivers the accurate results based on the needs of the customers. Voltage fluctuations are common so that it does not affect performances of wattage that is based on the controller and it would trip on setting the wattage irrespective of the supply voltage. Tube expansion torque controllers are mainly used for the drive current that also becomes more proportional on the torque. When the supply voltage in the device is constant then it is much more efficient on the accurate. Supply voltages mainly suitable for varying as 20% to 25% so that it mainly affects on expansion on results with the drive trips that are set with the constant current. Tubes with the 20% higher supply voltage are effectively expanded up to 20% and it has more torque that mainly requires higher efficiency. Therefore, the Tube Expansion Systems is expanded based on the current that is provided in the process. When supply voltages are less than normal, then tubes are under proportionately expanded.

Features Of Tube Expansion Systems:

With keeping the extensive requirements of every customer in mind, Tube Expansion Systems is implemented in offering the high-quality range with better accuracy. Tube Expansion Systems is offered in the High-temperature resistance, long functional life and easy to use. Normally, torque in the system is constancy with the accuracy of 3%. With bringing the unmatched quality, flawless finish, as well as corrosion resistance, Tube Expansion Systems is designed to withstand the wear and tear in a more efficient manner.

Get the best system from popular suppliers

The word tube expansion itself makes one understand what the device is all about. In the industries, thousands of devices are used for lots of processes. Some of these processes are directly involved with the production while some of them are used for a part of the process. In the machines, there are processes with the help of which the raw material is converted to the finished product, and after the production cycle, the same is moved for the packing. However, there are industries where the processes are a little complex. The areas such as chemicals and acids as well refineries the chemicals used are hazardous for the movers, and hence they are not moved by man.

The chemicals:

Such risky chemicals are moved to the concerned plant or area with the help of different types of tubes. These tubes are made from the material that can resist the corrosion of the same. Hence one can see the tubes of metals such as aluminum, iron, and steel, as well as copper, are used in different industries, and the same is determined before installing the tubes by experts. As some of the chemicals are not fit to be moved by some of the metals and hence for them, there is also the provision of tubes made of materials other than metal. At certain points the tubes also need joint, and here the tube expansion system comes to the help. The tube expansion systems suppliers can produce the tubes of various metals as per the requirement of the industries from best of the class materials.

The agencies of the government and fields have set various standards that one must follow during the production. Keeping the same in mind, the electric tube expansion systems manufacturer can offer quality devices. They also follow global norms and standards so that can export the devices to foreign countries also.  The industries that require this device can get them from a local store or online one.

Both of these stores have own benefits and limitations, and hence one needs to check the same as per the cost, requirement and other factors. The buyer needs to see if he needs the product to use right away. If yes, it is better that he rush to the nearest store in the local market and check the same personally. Here though he cannot have a huge variety to check, he can get a satisfactory device for sure.

The local seller may not offer negotiation of rates also, and hence one needs to be prepared to pay high rates also. Compared to this situation the online stores can offer the latest device at a reasonable rate and in some cases also offer some discounts. The only drawback of this system is the product is sent to the buyer with the help of courier service which takes time to reach the place of the buyer. Other than that the buyer who wants to order the products need to have a smartphone or computer with internet connection.

Right Pipe Installation Tools for Perfect Installation

Pipes are normally used in almost every industry. They are used in oil and gas industry, heat exchangers, boilers, condensers, textile industry, chemical industries and many others. The pipes can be of metal, plastic, PVC and many different materials. One thing that needs to address in industries is that the pipes need to be installed efficiently and correctly so that they could work fine and deliver the best efficiency. In order achieve perfect installation of the pipes, it is essential to employ the well-trained profession for the installation of the pipelines as they can only understand the importance of right inclination of the pipes as well as proper sizing and clamping.

Along with well-trained professionals, you also need to use the best available tools for pipe installation so that the task could be performed in an efficient and effective manner. In addition to that, the right tools save you a lot of time, energy and money. Here are discussed some of the most commonly sued pipe installation tools that can be sued for effective installation of the pipes.

Pipe cutting tools

When you are installing pipes or tubes in an establishment, you need to cut pipes many time. In this case, it is essential that the pipes are cut in right measurement and with a smooth face. A pipe cutter is essential to obtain that. With proper cutting tool, the pipes can be cut in very less time and with great efficiency avoiding any sort of accidents.

Clamping tools

Clamping is another important thing when performing pipe installation job. The clamping tools can make sure that you have clamped the pipes in the right manner for better safety and efficiency. Some of the majorly used clamping tools for pipes include chain clamps, OD clamping spilt frame, clamping end prep.

Bolting tools

Bolting tools are also an important requirement when performing any pipe or tube installation task.  You can use tools like torque multipliers, torque wrenches, hydraulic bolting heads, bolt tensioner, nut splitters, flange spreaders to ensure that the pipes and tubes are connected and installed firmly and there is no chance for any leakage or accidents. With the right type of bolting tool, you have proper speed and accuracy that save you a lot of time and also increase the efficiency of your work.

Tube expansion systems

The tube expansion systems are mainly used in pipe installation operation like boilers, heat exchangers or condensers. The tube expanders allow you to install tubes in a condenser or a boiler with great accuracy and precision. It gives you the right strength and speed to perform the task perfectly with the heap of an efficient torque control drive motors.

With the possession of right tools, it becomes very easy to ensure that the job of installation of pipes is done in the right way. In addition to that, it also ensures better safety and efficiency of the installed arrangement adding to the profits of the industry.

MASTER THE PERFECT WAY OF JOINING TUBES….!!

If you are carrying out servicing or installation processes at the firms like power plants, food industries, sugar refineries; you would definitely accept that joining a hole and tube is going to be one of the toughest jobs. The processes, which are employed for this purpose, are the tube expansion systems. Over the years, various techniques are being developed to ensure a tight and leak proof joint. You have to select the perfect expansion system for your application considering various factors like dimensions of the tubes and holes, materials and other working parameters.

POPULAR TUBE EXPANSION SYSTEMS:

• Hydraulic tube expansion system: As the name suggests, in this method, the driving force is supplied by the hydraulic pressure. They have gained a huge reputation for their quite operation and varied applications. If you are dealing with heavy machinery, then hydraulics would be your best choice of operation. You have to be a little cautious in determining the motor specifications, which can meet your requirements.

• Electric tube expansion system: Compared to other expansion systems, these devices have a compact design and can be used in any complex work area. You can adjust the torque inputs with ease in an electric tube expansion system. The common feature between hydraulic and electric types is their quiet operation.

• Explosive expansion system: This is regarded as one of the most expensive and dangerous expansion system ever. However, when all the other expansion systems can’t help you out, the explosive system can do the work for you. They are primarily used for titanium and austenitic stainless steels.

A FEW KEY POINTS IN TUBE EXPANSION:

• Make sure that the tube is rolled enough to result in a perfect fit of the tube and hole. Incomplete expansion is referred as under rolling.

• If the tube is rolled to larger dimensions, than what is actually required, that is known as over rolling. This results in damage of the tubes.

• Ensure that the tube holes are leak proof.

• The tube and hole interface is prone to corrosion as it develops stress as a result of joining process. As a preventive measure, coat such areas with non corrosive paintings.

ACCESSORIES:

The following are the commonly used accessories in a tube expansion system:

• Telescopic shafts: If you find handling drives difficult, then it’s a high time for you to start using telescopic shafts. You can also achieve a smooth operation as these devices absorb the torque produced during operation.

• Grooving tool: As the name suggests, it is used to make grooves in the tubes.

• Torque controller: It is used to give the required torque input to the system.

CLEANING AND MAINTENANCE:

• Regular cleaning is the key to enhance durability of the device.

• Ensure tight and safe connections of electrical cables and hydraulic hoses before initiating the operation.

• Since there are moving parts in the system, we must lubricate the moving parts periodically.

• Have a keen look at the rolls. If you find any damages or chips, replace them immediately.

Tube Expander For Stronger Bonds….!!!

While dealing with power plant equipment, sugar factories, oil refineries, a major problem encountered is sealing of the tubes. A tight mechanical seal between the tubes can be achieved by tube expansion methods. In this process, a tube is expanded into the other tube. Their point of contact is sealed by applying intense pressure on it. Check out the info about the tube expansion systems, which are detailed below.

Tube Expansion Methods:

In any of the processes employed, the ultimate aim is to force the space between the tube sheets. A few processes are detailed here under:

• Hydraulic expansion: Hydraulic pressure is applied at directly at the surface of the section to be sealed.
• In case of explosive type of expansion, we place explosives along the tubular column of the section to be sealed. The high pressure developed during the explosion results in tight joint between the tubes.
• In the process of mechanical rolling, rolls are used to exert high pressure along the contact surface of the tubes.

Components Of The Tube Expander:

The basic components of the tube expander are listed below. It is to be noted that the design of the tube changes with the type of expander and the application.

• Roller: The internal surface of the tube is deformed plastically under the action of this component. It is so designed that, even under the expansion process, the internal surface of the tube remains in perfect cylindrical shape.
• Mandrel: The rollers are rotated with the help of these mandrels. They are designed to be tapered in shape similar to that of the roller design. The materials employed in the manufacture of the mandrels and rollers must withstand the high pressure and friction developed.
• Frame: Multiple rollers can be held at equal distances with the help of the frame. In general, the frame is designed to carry 3-7 rollers.
• Bearing collar: The high thrust developed during the expansion process is minimized with these devices to safer levels. Tube ends and tube sheets can be protected from damages by employing bearing collars.

Accessories:

• Eledrive: As the name suggests, electricity is the driving force for this device. The load torque during the expansion process is detected and the tube expansion is confined to its predetermined size while expanding with the help of this device.
• Tube roller: the driving unit of the tube expansion system is the tube roller. Clockwise and counter clockwise rotations are possible with this unit.
• Servo drive: Installing servo drives reduces the work time to appreciable levels. It is a high speed machine which yields truly precise results.
• Grooving tool: Often, we may have to make grooves on the internal surface of the tubes. This can be done with ease by employing a grooving tool which is supported by a drilling machine.
• Expander oil: Any moving part undergoes friction which results in wear and tear of the machine. If unchecked, the tool life gets diminished. Expander oil is a lubricant which is used to minimize the friction of the expansion system.
• Spring balancer: The effort of the operator to handle the expansion tools can be reduced greatly by using spring balancers.

Various tools necessary for proper boiler care

For a company with a boiler installed in their premises, it is necessary to take good care of that equipment as it holds a great responsibility. For those companies, a boiler is the most basic machine without which the company processes and operation cannot be performed in an efficient manner. The boiler is used for producing high steam and pressure for various operations any break down in the boiler can stop the entire working of an industry where it is used. Additionally, without proper care, the boiler becomes very dangerous to work on as it can cause very serious accidents, which can lead to heavy losses to lives and property.

To take care of your boiler, you must know two things, one is that you must have a well-trained and experienced boiler operator and the other is that you must have a professional maintenance team for your boiler equipped with proper equipment to maintain the optimum state of your boiler.

Some of the boiler maintenance tools and equipment are discussed below-

Boiler tube cleaners

When a boiler is used for a long time, there is a lot of debris accumulated on the inner surface of the boiler tubes, which clog the tubes and lower their efficiency. If this debris is not removed from the tubes time to time, the boiler will not be able to deliver its full potential and lead to energy loss and more consumption of fuel. Additionally, this debris can cause the tube to crack, which will need you to get the tubes replaced for proper working of the boilers. There are many types of boiler tube cleaners that are used in industries such as electric, hydraulic, and pneumatic tube cleaners.

Tube expansion systems

Sometimes you need to put a tube in a tube sheet, which has a large area than the tube. In that case, the diameter of the tube needs to be expanded to attain the right size. For this purpose, tube expansion systems are used, which increase the cross sectional area of the tube without causing any damage to the tube surface. The tube expansion systems suppliers provide plenty of different choices regarding tube expander such as hydraulic tube expansion drives, pneumatic tube expansion drives and several others.

Joint testing kits

Sometimes, while installing a boiler, you need to make joints between two tubes to attain the desired length for the boiler. It is necessary to make sure that these joints are always leakage free and intact. Any leakage in the tube joints will not only lead to economic loss of energy but also to hazardous accidents.

Apart from these, you also need several other tools, such as tube pulling systems, tube facing machines and many more, which make sure that the maintenance of your boiler is done in a proper way for a long life.

Importance of boiler maintenance and necessary tools for it

If you are related to an industry where boilers are used, you must have an idea about how important these boilers are for proper working of those industries. There are many aspects that lead to a better health and long life of a boiler, and it is important to take care of those aspects to keep your boiler working in a safe and efficient manner.

The risk thing you need to take care of is the operation of the boiler. If the person working on your boiler is not competent or does not have proper qualification to work on a boiler, he might cause great damage to the equipment. When you are hiring a boiler operator, make sure that he is well experienced and qualified to work on the boiler so that he could run it efficiently.

Other than boiler operation, boiler maintenance is another aspect, which plays an important role in better functioning of the boiler. For efficient boiler maintenance, you need several tools and equipments that help you in keeping your boiler healthy and efficient for a long time. Below are given the tools that you must have to keep your boiler safe and healthy.

Tube cleaners

Tube cleaning is the most important and one of the primary tasks that are carried out during boiler maintenance. Tube cleaning helps in removing the dirt, sludge, corroded particles of the tube from the inner surface of the tubes and enhances its efficiency. Tube cleaners are available in three main types that are electric tube cleaners, pneumatic tube cleaners and hydraulic tube cleaners. These tube cleaners are used for big boiler although for smaller boilers, cleaning is also done manually using several cleaning agents and chemical solution.

Tube expansion systems

Tube expansion systems are used for increasing the diameter of a tube so that another tube could be inserted in to it. Tube expansion is done for tubes that have cracks or leakage and are not fit for further use. Tube expanders increase the cross section of the tube without causing any damage to it.

Tube pulling systems

There are times when you need to replace several or all of the boiler tubes in your boiler. In that case, you need to pull the tubes out of the boiler without causing any damage to the tubes or the boiler shell. For that purpose, tube pullers are used. They can pull all the tubes of the boiler in very less time and with much accuracy that there is no damage caused to the other parts of the boiler.

Joint testing kits

Joints are made in the boiler tubes to get the desired length of the tubes, but it is important to ensure that these joints do not have any leakage otherwise it can lead to fatal accidents and also loss of heat, which causes economic losses. The joint testing kits ensure that there is no leakage in the joints and they are working perfectly.