Boiler Tube Expanders and Boiler Tooling
Powermaster Industrial
(613) 764-0572
1262 Baker Road, CASSELMAN Ontario Canada K0A 1M0
Boiler Tube Expanders
Powermaster Industrial Supplies, founded in 2001. Above all, the company emerged with a vision of diversification. At first, we focused on supplying boiler tube expanders. Secondly, related equipment to the industry. The company’s tenacity and dedication led to its evolution as a leader within the industry. Today, Powermaster Industrial is a global force, distributing tooling solutions across the world. Collaborating with trusted manufacturers in Germany, the USA, and beyond. We offer a comprehensive array of boiler tube replacement and repair tools, along with essential service equipment.
Understanding Boiler Tube Expanders
Boiler tube expanders play a crucial role in achieving a secure and leak-tight connection between tubes and tube sheets. Let’s break down the process:
Sealing the Joint:
- When using a boiler tube expander, it compresses the tube against the tube sheet, creating a tight seal.
- This seal prevents leaks and ensures efficient heat transfer.
Tube Wall Thinning:
- As the tube expands, it exerts pressure on the tube sheet.
- This pressure can cause slight thinning of the tube wall, but it’s necessary to achieve the gas-tight seal.
Tube Rolling Motors:
- These motors provide the necessary torque for tube expansion.
- They can be powered by pneumatics, hydraulics, or electrical drive units.
Filling the Gap:
- Expanding the tube effectively fills the gap between the tube and the sheet.
- This eliminates any potential gaps or voids that could compromise the seal.
Mandrel and Rollers:
- The rotation of the expander draws in the mandrel (a central rod) and forces out the rollers.
- The rollers expand the tube against the tube sheet, ensuring a secure fit.
In summary, boiler tube expanders have become essential tools for maintaining the integrity of heat exchangers and boilers, allowing for efficient heat transfer while minimizing leaks.
Three Main Types of Boiler Tube Expanders
Beading Expander
Beaded tubes allow the heat at the end of the tube to pass into the tube sheet. Thus avoiding burn back on the end of the tube. So the Combination Beading Expander is the most economical choice. Protecting your technicians and the safest way for a perfect bead.
Straight Expander
Used when a straight rolling especially when the tube is then welded. Once welded, the joint should be re-rolled. This will negate any distortion from welding. Albeit the most robust of all expanders.
Flaring Expander
Flare rolling is a process used in mud and steam drums and air heaters. Available in 30 and 40-degree flare designs. Three different models provide all flaring requirements within the heat transfer industry.
Combination Beading Expanders
Rolling and beading the tube in one operation with no re-roll saves time and manpower. Compared to the old manual procedure. Whereas the stress on your workforce, and extra labour time required all add to costs. Not including the re-rolling of the tube a second time is not required. Simple bearing and bead roller changes configuration to each wall thickness. Consult the pdf for the full specs for these time-saving tools.
114 Series - Flaring Expanders
The 114 series flaring tube expander covers tubes from 2.0″ OD to 4-1/2″ OD. These are specifically used in fire tube boilers and air heaters. The self-contained rollers within the cage enable the expander to reach into confined spaces. For instance, by placing the cage into the tube before inserting the mandrel. This is a general-purpose boiler tube expander used for expanding and flaring tubes. More information is available through the link below.
A Series - Straight Expanders
The A Series is a straight rolling expander enabling tube expansion from 7/8″ OD up to 4.1/2″ OD. These expanders, furthermore are one of the most cost-effective expanders available.
The design allows the rolls to be self-contained, and protected within the cage. This is the best mode of tube expansion when flaring is not necessary. Also with this in mind, available with various mandrel designs. Mandrels available: Short Series, Drum Type and Header Type. To clarify, consult the associated PDF link for more information.
AF3 Series - Flaring Expanders
When flaring of tubes, the AF3 series is the ideal tube expander for flaring at 30 degrees. In addition, available from 7/8″ OD up to 4.1/2″ OD. The rolls are self-contained within a constructed cage. A cost-effective expander when flaring at 30 degrees. The AF3 series is also used with the short series mandrels. To clarify, more information, follow below to the associated PDF.
AB Series - Boiler tube Expanders
The AB Series is a straight rolling boiler tube expander. This expander is a high-production tool. Above all, fitted with a thrust bearing. Without a doubt, reduces frictional heat build-up allowing for longer periods of use. In this design, tubes from 7/8″ to 4.1/2″ OD and tube sheets thicknesses up to 2.5/8″. These boiler tube expanders work with the short series mandrels. For clarity, more information is in the link below to the associated PDF.
AFB3 Series - Boiler Tube Expanders
The ABF3 Series is a high-production flaring boiler tube expander. As a result, its fitted bearing reduces frictional heat build-up. The design covers tubes from 7/8″ to 4.1/2″ OD and tube sheet thicknesses up to 2.5/8″. This boiler tube expander can also use the short series mandrels. See the link for the PDF below for more clarity.
P-1000 Series
The P-1000 series is an expander used in limited access spaces in mud and steam drums up to 2.3/4″ thick. Three flaring rollers prevent ridging of the tube. These boiler tube expanders are also used with the P-3000 series for extra thick tube sheets up to 5.3/8″ thick. See pdf for details and other mandrels.
P-3000 Series
The P-3000 series, aligned in the boiler tube in relation to the drum thickness. for consistent expansions. Used in boilers with tube sheets or drums thicker than 2.3/4″ (70mm). Used in conjunction with the P-1000 series when achieving a flared finish. Once again, is ideal for use in a limited–access space. Used in mud and steam drums up to 5.3/8″ thick. Adjustable for step rolling. See pdf for details and other mandrels.
