MOCK-UP PROCEDURE FOR TUBE TO TUBE-SHEET JOINT MOCK-UP NO. : 06NO38/MOCK-UP / Lloyd's JH501 /38.10D Tube PAGENO.: 10F 3 REVISON NO. ‘Skomatic Reprosenattion of Tube Sheet so.08:0.18 Hole Sizo 38.56 3400. TUBE ‘Two grooves of 39.36X3mm wide spacing mm and 3mm from top ALL DIMENSIONS. ARE MM sR. No. PARAMETERS DETAILS REMARKS O41] -WPS. NO. 02] P.QR. NO. 03| TUBE-SHEET MATERIAL SA 240 Type 304 T.C. REVIEWED 04] TUBE MATERIAL $A 249 TP 304 7.0. REVIEWED os] Tupe size 38.100 x1.6 Th 06] TUBE HOLE SIZE AND 38.58mm NO.OF HOLES 49 Nos o7| TUBEHOLE PITCH 47.83mm Triangular 08| EXPANSION GROOVE 2No. Groove As shown in above figure o9| EXPANSION 10812% 10| WELDING PROCESS. NIL. i PREPARED BY Praj industries LtdMOCK-UP PROCEDURE FOR TUBE TO TUBE-SHEET JOINT MOCK-UP NO. : 06NO38/MOCK-UP / Lloyd's /H501 /38.10D Tube PAGENO.: 20F 4 MOCK-UP EXAMINATION ETCHING OF TUBE TO TUBE-SHEET JOINT CROSS SECTION ‘The Tube to tube sheet fitment observed uniform after expansion for tubes with 10 % expansion than 12 % expansion. ESTABLISHING RELIABILITY FACTOR AS PER ASME SECTION Vill, DIV.1, APPENDIX A (1995 EDITION) ‘Type of Joint as per Table A2 i Reliability Factor (As per A2) fr (No Test) Lax 4 (As pe ) Max * Sey Reliability Factor (As per Ad) fr (Test) Lest) x 4 st AUFe Fy L (Test) Lowest actual load at which failure of the test specimens occurs. st ‘Specified minimum UTS of Tube material 515 MPa = 52.518 Kg/mm? At Nominal cross section area of tube wall 3.14 (38.1 -3.2)1.6 = 183.46 mm? Fy ‘Tube-sheet material yield stress = 205 = 1 ‘Tube material yield stress 208 Fe 1 = For Expanded Tube joint with 2 no Groove in Tube holes Sa Allowable stresses of Tube material at Room temperature 11.95 Kg/mm? - From stress table. FrxSaxAtxFexFy — Asper A-2 O.7 x 137.89 x 183.46 x 1x1 1T.TOKN (No test load )MOCK-UP PROCEDURE FOR TUBE TO TUBE-SHEET JOINT MOCK-UP NO. : 06N038/MOCK-UP / Lloyd's /H501 /38.10D Tube PAGENO.: 30F 4 Formula for Calcuation of fr L1 (Test) ='SOKN '= 50000N As per A4 fr = LTest x 1 Load Test Calcuation Chart ( Ref.:Formula and sample calculation) fr_ 10% Expansion Calculation _|fr- 12% Expansion Calculation Load in KN [_frvalue [Load in KN 50 62 82 56 88 n TESTING REPORT NO. : V3299A / 07.05.2007 Perfect Laboratory Pune CONCLUSION Required reliability factor ‘fr’ for joint category ‘g' is 0.9 as per Appendix ‘A’ of ASME Sec. VIll Div.1. Since the major value above of ‘fr is >0,7 and <0.9 and Visual visual observation ,the test is satisfactory S\ Mr. Nagrajan y Mali AUTHORISED BY PREPARED BY | \Project:- 06N038 Equipment no.- H- 501 A, H-501 B Tube size:- Dia. 38 mm , Thk. 1.6 mm. No. of tubes:- 19 ‘Tube sheet thickness:- 36 mm EXPANSION OF TUBES Sr.no. | ED after expansion(mm) | Torque applied(Nm) | — % Expansion i 35.76 335 12 2 35.78 555 12 3 35.75 535 12 4 35.77 555 12 5 35.74 555 12 6 35.75 555 12 7 35.78 555 12 8 35.78 HHH 12 9 35.75 555 12 10 35.70 340 10 11 35.68 540 19 12 35.68 540 10 2B 35.67 540 10 14 35.69 540 10 15 35.68 540) 10 16 35.70 340 10 17 35.68 340 10 18 35.70 540 10 19 35.68 540 10 a Checktd\by QAC(EOU)_ PERFECT LABORATORY SERVICES PHYSICAL, CHEMICAL & METALLOGRAPHIC TESTING OF METALS 58,59 / 13,14 / UNIT NO. 2, D-II BLOCK, M.LD.C., CHINCHWAD, PUNE - 411 019. sonane'Ttust TELEFAX - 091 - 020 - 27488180, 27454716 TEST CERTIFICATE © Doe No. Lab /QR/ 18/5 T.C.No.& Date + VY 32992 A/ 07.05.2007 Our Client 1 M/S.PRAJ INDUSTRIES LIMITED, Address + S.No. 105, Alandi = Markal Road, Village Dhanore, Tal. Khed, Pune 412 105, Client's Ref./Dt. + Identification Stamped By + Witnessed By : Material Spec. Environ. Cond? 543/ 04.05.2007 Sample Recd.On + 04.05.2007 As Below Marked As » As Below Praj Testing Code : ASME Sect.VIII: 1 DIV.1.Ed.2004 Add .2008 As Below Cond of Sample: Satisfactory Ambient Temp. Page No. t fof t Description Tube To Tube Sheet Mock up Assembly + Tube + 38,10 OD X1.8 Thk. Specification 1 84 249 TP 304sEd.2004 Add.2005 Tube Sheet + 30 mm Thr. Specification 1 BA 240 Type 304:Ed.2004 Add. 2008 Marked As Q6NOSB/Mock Up/Lloyd’s/HS01/38.1 OD Tube PUSH OUT TEST i For 12% Expansion Sr. No. Tube No. Push Gut Load CNY, OL. 4 80 02, 6 62 os. 5 82 04, 7 86 os. a 58 06. 9 74a XX WITNESSED BY: Mr. 8. NAGARAJAN OF M/S. LLOYDS REGISTER ASIA. Mr. NuV. VIDHATE OF M/S. PRAJ GAC END OF TEST CERTIFICATE~ SOX For PERFECT ae IRVICES LAB INCHDRGEPERFECT LABORATORY SERVICES PHYSICAL, CHEMICAL & METALLOGRAPHIC TESTING OF METALS 58,59 / 13,14 / UNIT NO, 2, D-I BLOCK, M.LD.C., CHINCHWAD, PUNE - 411 019. ‘ne ama to ust TELEFAX - 091 - 020 - 27458150, 27454716 Perfect TEST CERTIFICATE Doc. No. : Lab /QR 18/5 T.C.No.& Date ' v 32992 A/ 07.05.2007 Our Client + Address : M/S.PRAd_ INDUSTRIES LIMITED, 8.No Tal. Khed, Pune 412 105. 108, Alandi - Markal Road, Village Dhanore, 843/ 04.05.2007 Sample Recd.0n Client's Ref./Dt. + 3 04.05.2007 Identification 2 As Below Marked As : As Below Stamped By 1 Praj Testing Code : ASME Sect.VIII: Witnessed By 2 ke DIV. 1.Ed.2004' Add. 2008 Material Spec. As Below Cond of Sampler Satisfactory Environ. Cond" Ambient Temp. Page No. ro lofd Description Tube To Tube Sheet Mock up Assembly Tube + 38.10 OD X 1.6 Thk. Specification SA 249 TP 304:Ed.2004 Add .2005 Tube Sheet, 30 mm Thk. Specification SA 240 Type 304:Ed.2004 Add.2008 Marked As O6NOSB/Mock Up/Lloyd's/H501/38.1 OD Tube PUSH OUT TEST : For 12% Expansion Sr. No. Tube No. Push Gut Lead Cen) OL. 4 80 02, é 62 os. 5 82 04, 7 56 os. a 3a 08. ° 78 4X WITNESSED BY Mr. 8, NAGARAJAN OF M/S, LLOYDS REGISTER asta. Mr. NV. VIDHATE OF M/S. PRAJ GAC “END OF TEST CERTIFICATE Yor PERFECT LABORATORY LAB IN (RVICES. RGEPERFECT LABORATORY SERVICES PHYSICAL, CHEMICAL & METALLOGRAPHIC TESTING OF METALS 58,59 / 13,14 / UNIT NO. 2, D-II BLOCK, M.LD.C., CHINCHWAD, PUNE - 411 019. ‘ro ome TeTust TELEFAX - 091 - 020 - 27458150, 27454716 Perfect TEST CERTIFICATE 2 Doe. No, : Lab / QR /.1R/S T.C.No-& Date V 32992 BI/ 07.05.2007 Qur Client Address ¥1/S.PRAJ INDUSTRIES LIMITED, 8.No. 105, Alandi - Markal Road, Village Dhanore, Tal. Khed, Pune 912 105. Client's Ref./Dt. Identification Stamped By Witnessed By Material Spec. Environ. Cond". B43/ 04.08.2007 Sample Recd.On : 04.05.2007 As Below Marked As : As Below Prai Testing Code : ASME Sect.VIII: ~ DIV.1.£d.2004 Add. 2005 As Below Cond" .of Sample: Satistactory Ambient Temp. Page No. Lott Description Tube Specification Tube Sheet Specification Marked As Tube. To Tube Sheet Mock up Assembly 38.10 OD X 1.6 Thk. SA 249 TP 304:6d.2004 Add. 2005 30 mm Thk. SA 240 Type 304:£d.2004 Add.2005 QONO3B/Mock Up/tloyd’s/H501/38.1 OD Tube For 10% Expansion MACROETCH TEST Observation 4 Nos. The samples reveals satisfactory expansion, For PERFECT LABORATORY SERVICES yer LAB INCHARGEia PERFECT LABORATORY SERVICES PHYSICAL, CHEMICAL & METALLOGRAPHIC TESTING OF METALS 58,59 / 13,14 / UNIT NO. 2, DAI BLOCK, M.LD.C., CHINCHWAD, PUNE - 411 019. ‘pata’ TELEFAX - 091 - 020 - 27458160, 27454716 Perfect T.C.No.& Date TEST CERTIFICATE 2 Dee. No: Lab/QR/18/5 V 32992 AL/ 07.05.2007 Our Client Address /S.PRAJ_ INDUSTRIES LIMITED, S.No, 105, @landi - Markal Road, Village Dhanore, Tal. Khed, Pune 412 10! Client’s Ref./Dt. Identification Stamped By Witnessed Hy Material Spec. Environ. Cond”. 543/ 04.05.2007 Sample Recd.On : 04.05.2007 As Below Marked As. : As Below Praj Testing Code + ASME Sect-VITI: DIV.1.Ed.2004 Add «2005 As Below Cond".of Sample: Satisfactory Ambient Temp. Page No. » Lofd Description Tube Specification Tube Sheet Specification Marked As Tube To’ Tube Sheet Mock up Assembly 38.10 OD X 1.6 Thk. 5A 249 TP 304:Ed.2004 Add. 2008 3O mm Thk. BA 240 Type 304:Ed.2004 Add.2005 O6NO3B/Mock Up/Lloyd’s/H501/38.1 OD Tube For 12% Expansion MACROETCH TEST Observation 4 Nos. The samples reveals satisfactory. expansion. END OF TEST CERTIFICATE: For PERFECT LABORATORY SERVICES ior LAB INCHARGEPERFECT LABORATORY SERVICES PHYSICAL, CHEMICAL & METALLOGRAPHIC TESTING OF METALS 58,59 / 13,14 / UNIT NO. 2, D-II BLOCK, M.LD.C.; CHINCHWAD, PUNE - 411 019, the tome ast TELBEAX - 091 - 020 - 7458150. TEST CERTIFICATE Doc. No: Lab /QR 18/5 T.C.No.& Date v 32992 B/ 07.05.2007 Our Client Address M/S.PRAJ INDUSTRIES LIMITED, S.No. 105, Alandi - Markal Road, Village Dhanore, Tal. Khed, Pune 412 105, Client's Ref./Dt. + 543/ 04.05.2007 Sample Recd.On : 04.05.2007 Identification + As Below Marked As + As Below Stamped By 2 Prag Testing Code 1 ASME Sect.VIII: Witnessed By +e DIV.1.Ed,2004 Add.2005 Material Spec. + AS Below Cond of Sample: ‘Satisfactory Environ. Cond" + Ambient Temps Page No. 1 Lota Description Tube To Tube Sheet Hock up Assembly Tube 36.10°00 K tee Thke | Specification 249 (Ed<2004) Add.2005 Tube Sheet 50 mm Thee Specification 58 240 Type S04:Ed.2004 add. 2008 Farked As SéNOSB/MRER pl toyd''s/H801/8861 OD Tube PUSH OUT TEST + For 10% Expangion Sr.No. Tube Nos Push Out Load coy on. 10 64 oz. 1 59 03. 12 89 on. 16 52 i os. 15 36 06. 14 39 or. 1s w | #4 WITNESSED BY: Mr. 8, NAGARAJAN OF 1/8. LLOYDS REGISTER AgIA. | Mr. N.V. VIDHATE OF M/S. PRAJ: GAC : SUBJECT TO CONDITIONS OVERLEAF Kuri For PERFECT LABORATORY SERVICES 7 (eer, 4 LAB INCHARGEPERFECT LABORATORY SERVICES PHYSICAL, CHEMICAL & METALLOGRAPHIC TESTING OF METALS 58,59 / 13,14 / UNIT NO. 2, D-II BLOCK, M.LD.C., CHINCHWAD, PUNE - 411 019. tometerust TELEFAX - 091 - 020 - 7458180 TEST CERTIFICATE Dor. No. :Lab/QR/18 /5 T.C.No.& Date Y 32992 B/ 07.08.2007 Sur Client N/S.PRAd INDUSTRIES LIMITED. Address S.No. 108, Alendi ~ Narkal Road, Village Dhanore. Jal. Khed, Pune 412 108. Client's Ref./Dt. + 543/ 04.08.2007 Sample Recd.On + 04.05.2007 Identification 1 As Below Marked As : As Below Stamped By p Prag Testing Code + ASME Sect.VIIE: Witnessed By 14a DIV.T.Ed, 2004 Add.2005 Material Spec. : AS Below Cond of Sample: Salisfactary Environ. Cond Ambient Temps Page No. : Loft Description Tube To TubeSheet Mock up Assembly Tube 1 38.10 OD X 1.6. Thies Specification + SA 249° TP SOAsEd, 2004; Add.2005 Tube Sheet 130 mm Thee | : Specification + SA 240 Type SO4:Ed. 2004 Add .2005 irked As + GeNOse/Maek Up/Lieyds/H804/38.1 OD Tube PUSH OUT TEST 1 For 10% Expansion sr. No. Tube No. Push Out Load (KN) | on. 10 64 ' uu 3° | 03. 12 87 | 05, 16 52 O85. 15, 56 | 06. 4 39 o7. 15 62 Ye WITNESSED BY fir. S. NABARAMAH OF M/S. LLOYDS REGISTER ASIA. RAJ GAC Me. NV. YIDHATE OF M7 SUBJECT TO CONDITIONS OVERLEAF For PERFECT LABORATORY SERVICES (Wor, LAB INCHARGE, fae of