Why a “Wattage” Based Torque Controller is Right and a “Current” Based Torque Controller is Wrong.
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Tube expansion can best be done by expanding tubes at a set torque value. Torque is nothing but a rotary force acting on the tubes. For a given drive, the 'RPM' being constant, torque becomes proportional to the drive power.
Hence, if the drive power is controlled for tube expansion, the results will be excellent. All tubes will be expanded equally. Supply voltage fluctuations which are very common, do not affect the performance of a wattage based controller as the controller will trip at a set wattage irrespective of the supply voltage.
In case of a current based tube expansion torque controller, the drive current can become proportional to the torque if & only if the supply voltage is absolutely constant. This is never the case. Practically, the supply voltages vary as much as 20% to 25%. This directly affects the expansion results as the drive trips at a set current. That means for a 20% higher supply voltage, the tubes will be effectively expanded by 20% more torque than the required one. Hence tubes will be over-expanded. For supply voltages less than normal, tubes will be under expanded proportionately.
Since, the supply voltages fluctuate quite often, the expansion results of current based controllers will be unpredictable. They will have no consistency.
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It is our experience that a seasoned operator will more consistently expand tubes with just a drive than if he is to use a current based Torque Controller. Of course if he were to use a Wattage based torque controller, he would achieve near perfect tube expansions all the time.
POWERMASTER is the only company in the world to offer you a choice of 2 Wattage based Torque Controllers.
The most critical piece of equipment in a heat exchanger or any shell and tube type process equipment is the tube itself. Due to its continuous operation the tube undergoes strenuous use. The tube heat transfer is the main task that it must be prepared for.
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The Tube must be installed correctly in order to ensure long use of the process equipment. There are several methods for the installation of tubes on to the tube sheets
The steps of tube installation are as follows:
1) The Tube sheet hole is reamed as per the fit required against the tube.
2) The tube hole is grooved using grooving tools to create recesses for the tube to expand into.
3) The tube is inserted and the walls of the tube are expanded by using an electric tube expansion machine or a hydraulic tube expansion system
4) The tube end that is protruding is reduced in length and then the remaining portion is rolled on the tube sheet using a flaring tube roller.
This process is used for boiler tubes as well as for heat exchanger tubes. Where pneumatic standard in plant air supply is available, pneumatic tube expansion systems are used.
But to control the degree of tube expansion accurately a wattage based electric tube expansion system. The electric tube expansion system has control panels or a control unit to set the wattage, torque control and receive feedback of the process of expansion for tubes in heat exchangers.
Heat Exchanger and Condenser tubes with varied characteristics are covered in the vast portfolio of Tritorc's vast Tube Expander Series.
- Tube Sheet Thicknesses
- Tube Materials
- Tube Wall Thicknesses
- Inner Diameter
The tubes face several modes of failure such as the following:
- Thermal stresses
- Leakages
- Cross contamination with feed water
- Scale deposit build up
- pH level of water
Damage tubes are an obstacle to the efficient functioning of the Heat Exchanger. This can be a hazard to the safety of the personnel and equipment.
The leakages between tubes and tube sheet joints must be checked with a tube leak detection system and the tube itself must be checked for leakages with a tube leak detector. Both leak detection systems work on the basis of vacuum loss detection and a drop in pressure indicates leakages.
The same expansion tools or techniques used for heat exchanger tube expansion cannot be used for boiler tube expansion. Thus selecting the correct tool is a must, you can select the one suited for your needs from our product brochure. Expect the best Tube Expansion machine price.
When you ask for a quotation for the tube installation tools, be rest assured of receiving the latest price for the systems for tube expansion in heat exchangers.
Why a “Wattage” Based Torque Controller is Right and a “Current” Based Torque Controller is Wrong.
Tube expansion can best be done by expanding tubes at a set torque value. Torque is nothing but a rotary force acting on the tubes. For a given drive, the 'RPM' being constant, torque becomes proportional to the drive power.
Hence, if the drive power is controlled for tube expansion, the results will be excellent. All tubes will be expanded equally. Supply voltage fluctuations which are very common, do not affect the performance of a wattage based controller as the controller will trip at a set wattage irrespective of the supply voltage.
In case of a current based tube expansion torque controller, the drive current can become proportional to the torque if & only if the supply voltage is absolutely constant. This is never the case. Practically, the supply voltages vary as much as 20% to 25%. This directly affects the expansion results as the drive trips at a set current. That means for a 20% higher supply voltage, the tubes will be effectively expanded by 20% more torque than the required one. Hence tubes will be over-expanded. For supply voltages less than normal, tubes will be under expanded proportionately.
Since, the supply voltages fluctuate quite often, the expansion results of current based controllers will be unpredictable. They will have no consistency.
It is our experience that a seasoned operator will more consistently expand tubes with just a drive than if he is to use a current based Torque Controller. Of course if he were to use a Wattage based torque controller, he would achieve near perfect tube expansions all the time.
POWERMASTER is the only company in the world to offer you a choice of 2 Wattage based Torque Controllers.
The most critical piece of equipment in a heat exchanger or any shell and tube type process equipment is the tube itself. Due to its continuous operation the tube undergoes strenuous use. The tube heat transfer is the main task that it must be prepared for.
...
The Tube must be installed correctly in order to ensure long use of the process equipment. There are several methods for the installation of tubes on to the tube sheets
The steps of tube installation are as follows:
1) The Tube sheet hole is reamed as per the fit required against the tube.
2) The tube hole is grooved using grooving tools to create recesses for the tube to expand into.
3) The tube is inserted and the walls of the tube are expanded by using an electric tube expansion machinetube expansion machine or a hydraulic tube expansion system
4) The tube end that is protruding is reduced in length and then the remaining portion is rolled on the tube sheet using a flaring tube roller.
This process is used for boiler tubes as well as for heat exchanger tubes. Where pneumatic standard in plant air supply is available, pneumatic tube expansion systems are used.
But to control the degree of tube expansion accurately a wattage based electric tube expansion system. The electric tube expansion system has control panels or a control unit to set the wattage, torque control and receive feedback of the process of expansion for tubes in heat exchangers.
Heat Exchanger and Condenser tubes with varied characteristics are covered in the vast portfolio of Tritorc's vast Tube Expander Series.
- Tube Sheet Thicknesses
- Tube Materials
- Tube Wall Thicknesses
- Inner Diameter
The tubes face several modes of failure such as the following:
- Thermal stresses
- Leakages
- Cross contamination with feed water
- Scale deposit build up
- pH level of water
Damage tubes are an obstacle to the efficient functioning of the Heat Exchanger. This can be a hazard to the safety of the personnel and equipment.
The leakages between tubes and tube sheet joints must be checked with a tube leak detection system and the tube itself must be checked for leakages with a tube leak detector. Both leak detection systems work on the basis of vacuum loss detection and a drop in pressure indicates leakages.
The same expansion tools or techniques used for heat exchanger tube expansion cannot be used for boiler tube expansion. Thus selecting the correct tool is a must, you can select the one suited for your needs from our product brochure. Expect the best Tube Expansion machine price.
When you ask for a quotation for the tube installation tools, be rest assured of receiving the latest price for the systems for tube expansion in heat exchangers.