Retubing Plan on Heat Exchanger

unit 020-ET01.01 & 030-E02

Bayu Frilyan Wahdiat
Inspection Section
Introduction
 History of tube defect due tue wall lose (based on Eddy Current Test) :
EQUIPMENT 1997 - 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
020-ET01.01 0 1 1 22 24 25 27 34 35 56
030-E02 1 9 10 15 15 17

60

50
Blocked
40

30 ID Defect
OD & ID Defect
20

10 020‐ET01.01
030‐E02
0
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Total tube 020.ET01.01 = 1762 (3% pluged); 030-E02 = 754 (2% Pluged)
Introduction
 Inspection plan 2016 :
- Eddy current test
- Plugging
- Retubing (prepare spre tube as a number of plug) on TA 2017
 17 Jan 2017 – Recomendation of retubing program heat exchanger of unit 020-ET01.01 and 030-E02 are
released for TA 2017
 There are different dimension, this condition will lead to retubing plan and mechanical strength
issues, Seamleass tube bellow are mentioned :
EQUIPMENT ORIGINAL MATERIAL INCOMING MATERIAL
020-ET01.01 Material : ASTM B111 UNS C70600 Material : ASTM B111 UNS C70600
(Condenser) Dimensi : 25,4 OD x 1,25 Thk x 5452 L (mm) Dimensi : 24,5 OD x 1,3 Thk x 6510 L mm
030-E02 Material : ASTM B111 UNS C70600 Material : ASTM B111 UNS C70600
(Prerun Column Condenser) Dimensi : 25,0 OD x 2 Thk x 5000 L (mm) Dimensi : 24,5 OD x 1,3 Thk x 6010 L mm
Objective
 Analyze all mechanical strength issues that could be happened on the tubes
 Decide on the utilization of tube, installation strategy and inspection plan
Risk Mitigation
 Retubing Plan :
Retubing will be done by utilize incoming tubes for a year (or more). The following item should
be done :
1. Engineering review for all mechanical issues that are occured on the tubes.
- Tube Expanding Plan
- Pull Out Force vs Force due to internal pressure to tubesheet
- Material Strength vs Internal and External Pressure
- Tube Stess vs Tube allowable stress at Transition Zone
- Fluid Limit Velocity
2. Special visual inspection, eddy current test and fill test will be conducted every year to
ensure the condition of the tubes.
Mechanical Issues on The Tube to Tubesheet Joint
Requirement should be fulfilled :
1. Wall reduction 8 – 10%
Ftubesheet 2. Fpo > Ftubesheet
3. treq > tafter expand
4. τactual > τallowable

Allowable

Fpo Pint

Source : Updike. D.P., Kalnins. A., and Caldwell. S.M.,”Residual

Stresses in Transition Zones of Heat Exchanger Tubes” Journal
of Pressure Vessel Technology, Vol 114, May 1992, Page ‐ 155
1. Tube Expanding Plan
Wall Reduction Ratio 030-E02
d1 (mm) Wt (%) H (mm) D (mm) do (mm) D0 (mm)
22,8040 4 25,3000 24,5000 21,9000 25,404
22,8560 6 25,3000 24,5000 21,9000 25,456
22,9080 8 25,3000 24,5000 21,9000 25,508
22,9600 10 25,3000 24,5000 21,9000 25,560

Wall Reduction Ratio 020-ET01.01

d1 (mm) Wt (%) H (mm) D (mm) do (mm) D0 (mm)
23,2040 4 25,7000 24,5000 21,9000 25,804
23,2560 6 25,7000 24,5000 21,9000 25,856
23,3080 8 25,7000 24,5000 21,9000 25,908
23,3600 10 25,7000 24,5000 21,9000 25,960

Limit value for expanding

Wall reduction ratio limit value are 22,96 for 030-E02 and 23,36 for
020-ET01.01 with max Wt 10% (standard Wt for Copper = 8 - 10%)
Sourch : Sugino Machine Manual CAT.NO.L3213E
2. Pull of Force Calculation

Fpo must be greater than FTubesheet

FTubesheet

Source :
Merah. N., Al‐Zaher. A., Shuaib. A., and Arif. A., ” Finite element
Fpo evaluation of clearance effect on tube‐to‐tubesheet joint
strength” International Journal of Pressure Vessels and Piping
80 2003 879–885, Page 882 – 883.
Pull Out Force Calculation 030-E02
F = Pull out Force
f = Friction Coefisien 0,7
Pcon = Residual Interfacial Pressure
ro = Outer Radius of the tube
ri = Inside Radius after expand 8%
Le = The Expanded Tube Length
Pe = Expanding Pressure
Ty = Yield Strength
,
Pe 240 N/m2 1,945‐1,384 . ) 156,22 N/m2
,
, ,
Pcon 156,22 N/m2 1‐ 2 – .240 N/m2. ln
, ,
Pcon 1,02 N/m2
F 2 x 3,14 x 0,7 x 1,02 N/m2 x 0,01225 m x 0,050 2756 N
FCP 2756 N x 754 tubes 2.078.253 N
Ltubesheet 3,14 x 0,563 m 2 0,9953 m2
Ltubes 3,14 x 0,0125 m 2 x 754 tubes 0,3699 m2
Ltotal 0,9953 – 0,3699 0,6254 m2
Poperasi 2,1 barg 210.000 N/m2
FTubesheet 210.000 N/m2 x 0,6254 m 2 131.324 N
Hence, FCP Ftubesheet : 2.078.253 N 131.324 N
Safe for Operation
Pull Out Force Calculation 020-ET01.01
F = Pull out Force
f = Friction Coefisien 0,7
Pcon = Residual Interfacial Pressure
ro = Outer Radius of the tube
ri = Inside Radius after expand 8%
Le = The Expanded Tube Length
Pe = Expanding Pressure
Ty = Yield Strength
,
Pe 240 N/m2 1,945‐1,384 . ) 150,80 N/m2
,
, ,
Pcon 150,80 N/m2 1‐ 2 – .240 N/m2. ln
, ,
Pcon 0,49 N/m2
F 2 x 3,14 x 0,7 x 0,49 N/m2 x 0,01225 m x 0,08 2131,15 N
FCP 2131,15 N x 1762tubes 3.755.082 N
Ltubesheet 3,14 x 0,9750 m 2 2,9850 m2
Ltubes 3,14 x 0,0127 m 2 x 1762 tubes 0,8924 m2
Ltotal 2,9850 – 0,8924 2,0926 m2
Poperasi 1 barg 100.000 N/m2
FTubesheet 100.000 N/m2 x 2,0926 m 2 209.260 N
Hence, FCP Ftubesheet : 3.755.082 N 209.260 N
Safe for Operation
Internal & External Pressure at Transition Zone 030-E02
Pext

Pint
, ,
tinternal = 0,24 mm
, ,

texternal 0,20 mm
Tinitial, after expand 1,3 x 92% 1,19 mm
Sourch : Updike. D.P., Kalnins. A., and Caldwell.
S.M.,”Residual Stresses in Transition Zones of Heat Hence, tinitial, after expand tinternal or external : 1,19 0,24 mm
Exchanger Tubes” Journal of Pressure Vessel Technology,
Vol 114, May 1992, Page ‐ 155 Safe for Operation
Internal & External Pressure at Transition Zone 020-ET01.01
Pext

Pint
, ,
tinternal = 0,11 mm
, ,

texternal 0,10 mm
Tinitial, after expand 1,3 x 92% 1,19 mm
Sourch : Updike. D.P., Kalnins. A., and Caldwell.
S.M.,”Residual Stresses in Transition Zones of Heat
Exchanger Tubes” Journal of Pressure Vessel Technology, Hence, tinitial, after expand tinternal or external : 1,19 0,11 mm
Vol 114, May 1992, Page ‐ 155
Safe for Operation
Stress at Transition Zone 030-E02
FTubesheet 210.000 N/m2 x 0,6254 m 2 131.324 N
FTubesheet 131.324 N / 754 tube 174,17 N / tube

Tactual
Do 24,5 mm ; LDo 3,14 x 24,5/2 2 471,2 mm2
Di 24,5 – 1,3 x 2 21,9 mm ; LDi 3,14 x 21,9/2 2 376,5 mm2

,
Tactual 1,84 N/mm2
, ,

Allowable stress applied

Tyield, Transistion zone 15% x 240 N/mm2 36 N/mm2
Tactual Tyield, Transistion zone
1,84 N/mm 2
36 N/mm 2
Safe for Operation
Stress at Transition Zone 020-ET01.01
FTubesheet 100.000 N/m2 x 0,6254 m 2 209.260 N
FTubesheet 209.260 N / 1762 tube 118,76 N / tube

Tactual

Do 24,5 mm ; LDo 3,14 x 24,5/2 2 471,2 mm2

Di 24,5 – 1,3 x 2 21,9 mm ; LDi 3,14 x 21,9/2 2 376,5 mm2

,
Tactual 1,25 N/mm2
, ,

Allowable stress applied

Tyield, Transistion zone 15% x 240 N/mm2 36 N/mm2

Tactual Tyield, Transistion zone

Safe for Operation
1,25 N/mm 36 N/mm
2 2
Velocity through the tube

Equipment Velocity (m/s) Limit (m/s) Status

020‐ET01.01 1,07 2,5 Safe
030‐E02 1,69 2,5 Safe

Velocity through the tube at those unit 020-ET01.01 and 030-E02 still in
range for safety operation
Original Material
 Wall reduction 8%  Wall reduction 10%
Equipment Di (mm) Fcp (N) Equipment Di (mm) Fcp (N)
030-E02 22,9080 3.790.217 030-E02 22,9600 3.583.703
020-ET01.01 23,3080 13.899.072 020-ET01.01 23,3600 13.138.809

 Wall reduction ratio is inversely proportional to the Pull of Force

 Increasing wall reduction ratio will lead to smaller pull out force about 5,4 %
Incoming Material
 Wall reduction 8%
Equipment Di (mm) Fcp (N) Fts (mm) Treq (mm) τactual (N/mm2) τallowable (N/mm2)
030-E02 22,9080 2.078.253 131.324 0,24 1,84 36
020-ET01.01 23,3080 3.755.082 209.260 0,11 1,25 36

 Wall reduction 10%

Equipment Di (mm) Fcp (N) Fts (mm) Treq (mm) τactual (N/mm2) τallowable (N/mm2)
030-E02 22,9600 1.919.383 131.324 0,24 1,84 36
020-ET01.01 23,3600 3.328.730 209.260 0,11 1,25 36
 Increasing wall reduction ratio will lead to smaller Pull out force about 7,6 %
Pull of force Curve
16000
020‐ET01.01 030‐E02
RESIDUAL CONTACT PRESSURE (N)THOUSANDS

14000

12000 Wt 8%
10000
Wt 10%
8000 Original Tube Incoming Tube
6000
Wt 8% Wt 10%
4000

2000

0
0 1 2 3 4 5
EXPAND STRATEGY WITH DIFFERENT TUBE DIMENSION

 Reduced residual contact pressure from the original is about :

a. Remaining pull out force 27% for 020-ET01.01
b. Remaining pull out force 55% for 030-E02
Conclusion
 Based on calculation :
1. Wall reduction ratio limit value are 22,96 for 030-E02 and 23,36 for 020-ET01.01 (Wt = 10%)
2. Pull out force is higher than force due to internal pressure to tubesheet. Hence, this condition is safe for operation
3. Remaining thickness is still higher after expand. So material thickness can withstand safely to internal and external pressure
4. Even at transition zone has reduced yield stress until 85%. The material yield stress is still higher stress value than shell
side force where works on tubesheet.
5. Velocity through the tube inside 020-ET01.01 and 030-E02 are under limit allowable velocity for material CuNi 90/10.

 Special visual inspection, eddy current test and fill test will be conducted every year to ensure the condition of the tubes.
Thank You