Tube Expander Tools: Basic Care and Operation

TC Wilson tube expander tools for boilers and heat exchangers are carefully crafted tools made to the highest standards of quality and precision. With proper care you will get consistent quality results from these valuable tools made in the U.S.A. Here we will walk you through the basics of maintenance and operation to ensure your tools will be trusted to perform for a long time to come.

Anatomy of a Condenser Tube Expander:

All Wilson 3- and 5-roll expanders come standard with a reversible flip-flop collar, letting you choose either a flush (no recess), or adjustable 1/16″ recess. When rolling tubes that do not protrude from the tube sheet, loosen the second set screw, slide the collar assembly off the mandrel, flip it, then reinstall with the flush face forward.

A boiler tube expander does not have a thrust collar:

TC Wilson tube expander tools for boilers and heat exchangers are carefully crafted tools made to the highest standards of quality and precision. With proper care you will get consistent quality results from these valuable tools made in the U.S.A. Here we will walk you through the basics of maintenance and operation to ensure your tools will be trusted to perform for a long time to come.

Keep ’em clean

Thoroughly remove all rust and dirt. In addition, cleaning any scale and foreign matter from the inside and outside of each tube will help avoid damage to your tools. Thrust bearing grease should also be checked before each use for consistent performance results.

Set collar recess

You can change the collar recess depth to accommodate tubes protruding from – or flush with – the tube sheet. Start by loosening the forward set screw with the hex key provided. Then, spin the collar clockwise or counterclockwise to accommodate a recess up to 1/16″. (Recesses up to 15/16-inch available on special order.) Re-tighten the set screw.

Lubrication

Friction and metal forming generate a lot of heat during tube expansion. Minimizing heat lessens the chance of damage and will extend the life of your tools. Wilson Expander Lube, or another pressure resistant lubricant, is the best way to minimize heat. For the Wilson Combination Beading Expander we recommend B-Kool. After rolling each tube, clean and cool the expander in solvent or light oil and then properly lubricate the expander again.

Start Rolling

Condenser tube expanders should be placed into the tube so the thrust collar is up against the tube sheet. The rolls should always be inside the rear tube sheet by 1/16″. Avoid rolling outside the tube sheet. Here’s how it should go:

For larger diameter boiler expanders, position the expander in the tube such that the flare rolls are about 1/2″ away from the open tube end before starting to roll.

Tool Rotation

It is a good practice to keep two identical expanders on hand when you have more than 15 tubes to roll. This allows one expander to cool while the other is used for the next 10 to 15 tubes.

Post Job Inspection

Inspect the rollers and mandrel after each use. Be sure to replace any chipped rolls or mandrels immediately. One small chip in a roll can cause the whole set, as well as the mandrel to be damaged in just one cycle. To prevent scarring and chips, you should always replace roller bearings and mandrels at the same time.

Proper Storage

When finished with the job, clean your expanders again with a commercial solvent and/or light oil #10 weight. Then store them in a warm, dry, temperature-controlled environment to avoid surface condensation and the possibility of rust forming.

The TC Wilson experts are available during business hours to answer questions about your specific wet or dry tube cleaning needs. Contact us or use the online chat for advice on tool selection for your application.