Tube-to-Tubesheet Joints - Baher

Tube-to-Tubesheet Joints in
Shell and Tube Heat Exchangers
Baher Elsheikh
THE INDIAN INSTITUE OF WELDING
Free Webinar – 10 September 2022

Classification: General Business Use
Tube-to-Tubesheet Joints in
Shell and Tube Heat Exchangers
Webinar Outlines
Introduction to shell and tube heat exchangers
Types and features of tube-to-tubesheet joints
Application requirements of expanded and welded tube-

to-tubesheet joints
Common defects of tube-to-tubesheet joints
Inspection and Repair of tube-to-tubesheet joints
Case Histories
The Indian Institute of Welding Mumbai Branch – Free Webinar Baher Elsheikh – Sept. 2022
Introduction to Shell and Tube Heat Exchangers
Shell and Tube Heat Exchanger is a type of exchangers used to transfer thermal energy between two
fluids. The two fluids are not indirect contact; one pass in the tubes and the other in the shell.
Shell and Tube Heat exchangers are one of the most common equipment used in all oil and gas plants,
petrochemical and power plants.
Animation from: gfycat.com
Components of Shell and Tube Heat Exchangers
U Tube Heat Exchangers

Photo source: www.Maxwor.com
Tube-To-Tubesheet Joints (TTS)
Expanded
Process of expanding a tube to a fully plastic state into contact with tube hole that
creates residual interface pressure between the tube and tubesheet
Strength Welded
Weld design strength is equal to or greater than the axial tube strength
Can be Full strength Weld or Partial Strength Weld
Full Strength Weld: in which the design strength is equal to or greater than the axial
tube strength
Partial Strength Weld: in which the design strength is based on the mechanical and
thermal axial tube loads that are determined from the actual design conditions
Seal Welded
Weld is used to supplement an expanded tube to tubesheet joint to ensure leak
tightness
Heat Exchanger Data Sheet
Type of Tube-to-Tubesheet Joint is specified in the data sheet

during thermal design of the exchanger
Care shall be taken by mechanical engineer in the review of

the specified joint type
Balance your choice Each Configuration of Tube-to-
Tubesheet Joints has its features,
strengths and weakness
Strengths Weaknesses
Correct selection of the proper joint
type and quality applications and
testing are key features to obtain
leak free long lasting joint
Features of Different TTS Types
Expanded Only Expanded and Seal Welded
Strengths Weaknesses Strengths Weaknesses
✓ Economical and easy to ➢ Joint can loosen overtime and leak ✓ Higher leak resistance ➢ Smaller weld size can still leak in
apply compared to welding ➢ Potential to SCC of some materials compared to non welded severe service
✓ Easiest to re-tube ➢ Misunderstanding of proper expanded joints ➢ Re-tubing will require weld removal
✓ Future plugging can be by parameters to maintain during ✓ Less expensive than ➢ PWHT might be required and it is
simple tapper plug application is frequently reported strength welds challenging activity specially during
✓ No tube sheet beveling ➢ Highly sensible to axial scratches / future repair, plugging or re-tubing
required imperfections in tube holes crating ➢ Limitations in inspection techniques to
leading passes ensure weld quality
Strength Welded, Not Expanded Strength Welded and Expanded

Strengths Weaknesses Strengths Weaknesses
✓ Weld size calculated to be ➢ Potential crevice corrosion from ✓ The most leak resistant ➢ Most expensive technique
as strong as tube material shell-side over time make it proper selection for ➢ Limitations in inspection techniques to
✓ No expansion grooves ➢ Limitations in inspection techniques critical severe application ensure weld quality
need to be machined in the to ensure weld quality ✓ Only light expansion can ➢ Re-tubing will require weld removal
tubesheet holes ➢ Re-tubing will require weld removal be applied (expansion ➢ PWHT if required is a challenging
➢ PWHT if required is a challenging grooves are not application
application necessary) ➢ Future plugging either by wedded
➢ Future plugging either by wedded plugs or advanced mechanical plugs
plugs or advanced mechanical plugs
➢ Cyclic loading or vibration might
cause weld cracking
In high temperature or pressure services or with aggressive fluids, welding should be considered
Expanded Tube-To-Tubesheet Joints (TTS)
• Tubes to be expanded with sufficient length. Tubes shall be expanded into the tubesheet for a length no less than 2" (50 mm)
or the tubesheet thickness minus 1/8" (3.2 mm), whichever is smaller.
• In no case shall the expanded portion extend beyond the shell side face of the tubesheet.
• Expanding shall be uniform throughout without a sharp transition to the unexpanded portion.
• For welded-and-expanded tube-to-tubesheet joints requiring PWHT, the tubes shall be expanded after PWHT.
Suggested Amounts of Wall Reduction by Tubing Material

Tubing Material Target Percent Wall Reduction Max Percent Wall Reduction
(TEMA) (API 660)
Carbon steel and low alloy steel 5 to 8 % 8%
The harder the
Austenitic Stainless Steel 5 to 8 % 6% tube material,
Duplex stainless steel 4 to 6 % Per API 983C * the less wall
reduction is
Titanium and work hardening 4 to 6 % 5%
recommended
non-ferrous
Admiralty and non work 6 to 9 % 8%
hardening non-ferrous
Copper and copper alloys 7 to 10 % 8%
* For DSS: Light expansion with wall reduction of 2% + strength weld. Higher expansion might be applied and mock-up shall include hardness test
Tube Holes in Tubesheet
TEMA RCB-7.2
To minimize work hardening, a closer fit
between tube OD and tube ID as
shown in column (b) may be provided
when specified by the purchaser.
As a general rule the smaller the

clearance the better, from the
expanding point of view, no matter
what expanding method is used.
For Austenitic SS, Duplex SS, Titanium,

Cupronickel, or Nickel alloy tubes are
specified, the tube holes shall be machined
in accordance Special Close Fit.
Clearances are required to facilitate tube

insertion and stuffing in the bundle Skelton
Tubesheet Hole Preparation
• Holes shall be free from radial or longitudinal scratches or imperfections
• Hole surface to be in as machined conditions (no need for polishing)
• Tube holes and tube external surfaces shall be cleaned
• Longitudinal scratches are of higher risk as it would create leak pass across the joint
• Tube outer surface at the interface with hole shall be also free from scratches or imperfections
• In hydraulic expansion the applied pressure caused the tube to take exactly the shape of the hole including the grooves and
the imperfections or scratches (if exist)
• Mechanical roller shall be clean as well and free from scratches or imperfections. Its lubrications, temperature and
performance shall be monitored during application
Leak Passes
Tubesheet Hole Drilling Radial Imperfection Longitudinal Imperfection
Expanded Tube-To-Tubesheet Joints (TTS)
• Different methods techniques used to expand the tubes to tubesheet holes (Roller expander, Hydraulic, Explosive)
• Expanded joints should be machined with annular ring grooves (one or two grooves based on tubesheet thickness) for
additional longitudinal load resistance
Examples for Required Groove Width for Hydraulic and Mechanical
For roller expanded tube joints, when tubesheet Rolling Expansion
thickness exceeds 1" (25.4 mm) at least two
Tube
grooves shall be used, each approximately 1/8" (3.2 R t w for Mechanical w for hydraulic
OD Tube (BWG)
Roller mm) wide by 1/64" (0.4 mm) deep. mm mm Roller (mm) expansion (mm)
(mm)
Expander
Tubesheet with thickness less than or equal to 1" 15.88 7.94 12 2.769 3.2 7.31
(25.4 mm) may be provided with one groove. 15.88 7.94 14 2.108 3.2 6.38
15.88 7.94 16 1.65 3.2 5.65
15.88 7.94 18 1.245 3.2 4.90
19.05 9.525 12 2.769 3.2 8.01
For hydraulic or explosive expanded tube joints, at 19.05 9.525 14 2.108 3.2 6.99
least one groove shall be used. Minimum 19.05 9.525 16 1.65 3.2 6.18
groove width shall be calculated as w = 𝟏.𝟓𝟔√(𝑹 𝒕) 19.05 9.525 18 1.245 3.2 5.37
Hydraulic
25.4 12.70 12 2.769 3.2 9.25
Expander R = mean tube radius & t = tube wall thickness,
25.4 12.70 14 2.108 3.2 8.07
25.4 12.70 16 1.65 3.2 7.14
Max. groove width required 1/2" (12.7 mm).
Groove depth shall be at least 1/64" (0.4 mm). 25.4 12.70 18 1.245 3.2 6.20
Tubesheet t Tube
R
For Cladded Tubesheets, grooves should be in the base metal
TEMA RCB-7.2.4
Mechanical Rolling Expander
• Mechanical roller compress the tube wall against the tubesheet hole
• Tube material should be plastically formed (will not return to its original dimensions after removing the roller)
• Tubesheet at the ligament area should remain in the elastic zone. Applied force shall not be high to the level
which could a misplace tube holes
• Generally triangular tube pitch is more sensitive due to the less relative ligaments thickness
• Under rolling result in less wall reduction and less joint strength residual
• Over rolling result in higher plastic deformations of the tubes, potential tube cracking and /or shifting of tube
holes in the tube sheet
• Five rolls are recommended for thin wall tubes (~OD/T > 25). Typical examples are thin Ti tubes.
Tube
Rotated Square
Rotated Square 90°
Triangular 30° 40°
Triangular 60°
Tube Patterns Tube Expander Three Roller Expander
(Courtesy of Elliott Tool Technologies Ltd)
Hydraulic Expander
• The tube is physically deformed simply by means of pressurized liquid.
• The amount of pressurized liquid introduced is a function of the proportion of elastic and plastic expansion
occurring in the tube and tube sheet.
• In this a mandrel with two ‘O’ rings at appropriate location is inserted into the tube sheet. Hydraulic pressure
applied between two ‘O’ rings causes the tube in that region to expand
• The applied pressure caused the tube to take exactly the shape of the hole including the grooves and the
imperfections or scratches (if exist)
Cross secretion in expanded tube
(Courtesy of Sugino Machine)
Welded Tube-To-Tubesheet Joints (TTS)
• Welding can be manual or automatic (Orbital welding)
• Strength-welded tube-to-tubesheet welds shall have a minimum of two weld passes and usually produced by
gas tungsten arc welding (GTAW).
• TTS is a relative small size (deposited weld metal) in a high tubesheet thickness causing high heat sink and
possible non uniform HAZ structure
Manual Welding Orbital Welding Welded Joints
Welded Tube-To-Tubesheet Joints (TTS) Configurations
J groove is adopted in
many specifications to
enhance the penetration
at the root pass
Other welding configurations

can be used other than the
listed in ASME
Special set back weld

configuration used to prevent Welding to cladded / Weld overlay
crevice corrosion at the shell surface of tubesheet Some Acceptable Types
side ASME Sec. VIII div.1 – UW-20.1
Special TTS Welding Configurations
Special Set Back Internal Bore Weld Welded and Unexpanded joints
▪ The tubes are connected to the ▪ Joint welded is in single pass without ▪ Welding of corrosion resistance tubes to a
tubesheet by a full penetration weld addition of filler wire and hence the cladded (Weld overlay face) of a carbon stell
thickness of tube is limited to 4.5mm. tubehseet where the tubeside fluid is highly
▪ Root pass of tube to tubesheet weld
corrosive
is obtained by fusing edge of tube to ▪ Welding is carried out by Internal Bore
edge of tubesheet with filler wire with Welding technique from ID of the tube. ▪ Typical example of Urea stripper( ammonium
shield gas to avoid any crevice on Carbamate in tubeside and steam in shell
▪ The task becomes further critical due its
water side. Then multi-weld layers non-accessibility since the welding has to side)
are applied be done at a depth of 300 - 500 mm from
▪ In case of small leak, carbon steel can will be
▪ No crevice corrosion can occur as the Tube sheet face.
greatly corroded in short time
there is no gap between tube and ▪ Digital RT can be applied for inspection of
tubesheet. ▪ In such applications, tubes should NOT be
this joint
▪ Typical example is reformed gas expanded in the carbon steel portion, so that
▪ No crevice corrosion anticipated
WHB in reformed section of leak will pass to steam side causing
Hydrogen, methanol and ammonia conductivity increase and early detection of
plants the leak before tubesheet damage
Weld joint Calculations - ASME BPVC Sec VIII Div. 1
Combined Groove + Fillet Weld Combined Groove + Fillet Weld

Fillet Weld Groove Weld
af = ag af ≠ ag
Choose ag and calculate ar
Full strength af >= ar or 1.4 t ag >= ar or t ac >= ar or 1.2 t ac >= ar or (1.4 t-0.4 ag)
Weld
Partial ac >= ar ac >= (ar+ag)

af >= ar ag >= ar
strength Weld af = ag = ac/2
Welded and Expanded TTS – Sequence of Application
• Expansion is required for welded joints to close the cervices and to protect the weld form the effect of cyclic services and /
vibrations of the tubes which can lead to fatigue cracks in the welded joints
• Expansion can be done before or after welding, each has its characteristics, pros and cons
Expansion then welding Welding then expansion

o Expansion would close the gap at the backside o Welding might be affected /cracked during the
of the root and might result in weld porosity expansion. Clearance of unexpanded portion
o Welding heat can loose / relax the expansion. usually recommended from the weld
Re-expansion would be required after welding o There will be no chance to check the tightness
or heat treatment (if applicable) of the expansion
o Expansion can be tested before welding to
confirm its tightness / sealing
In expanded +seal weld: expansion will be the main sealing and seal weld is supplement. In this case proper expansion quality is
favoured over welding quality
In Strength weld + light expansion: strength weld is the main sealing and its quality control is favoured over quality control of expansion
Tube-To-Tubesheet Joints (TTS)- Cladding Thk. of Tubesheet
Cladding the tubesheet at tube side is beneficial in many situations:
- Corrosion resistance of the tube side fluid in lower cost instead of having solid thick corrosion resistance tubesheet
- Avoid dissimilar weld between tubes and tubesheet
- Avoid the need of PWHT in future plugging of tubes when required
Cladding / weld overlay thickness of the tubesheet depends on the type of tube to tubesheet joint Cladding
Tubesheet
When the tubes are expanded only to the tubesheet the required clad thickness is HIGHER compared to
the case when the tubes are welded to the tubesheet. This is to provide proper distance to expand the
tube to the cladding materiel and prevent the ingress of the corrosive media to the base metal of the Tube side
tubesheet.
Shell side
[API 660]: Tube

At the tube side face of a tubesheet shall not be less than 10 mm when tubes are expanded only, and 5
mm when tubes are welded to the tubesheet.
Tube
In shell side face of a tubesheet shall not be less than 10 mm
[TEMA]: RB-7.6
The nominal cladding thickness at the tube side face of a tubesheet shall not be less than 7.8 mm when
tubes are expanded only, and 3.2 mm when tubes are welded to the tubesheet.
The nominal cladding thickness on the shell side face shall not be less than 9.5 mm
Cladding and Weld Overlay
Clad material is the typical choice for aggressive environments as an economical alternative to solid alloy steel.
The corrosion resistant alloy is selected specifically for its performance in the process.
Cladding / WO
Base Metal
There are three typical choices
Explosion Welding Hot Roll Bond Weld Overlay
Explosive bonding uses the very-short- Produced when a steel mill heats the steel Weld overlay is a fusion deposition of
duration, high-energy impulse of an explosion and corrosion resistant alloy together and rolls corrosion resistant alloy onto a steel or alloy
to drive two surfaces of metal together, them as one package. steel substrate.
simultaneously cleaning away surface oxide
films and creating a metallic bond. The rolling, under high temperature and Usually, weld overlay is done in place, after
pressure, causes the two metals to clad the pressure vessel has been through many
Resist the most aggressive hydrogen together. of the fabrication steps, but not always.
charging scenarios
It is generally accepted that a roll bond clad In many cases, dilution concerns necessitate
plate has the lowest bond shear strength of the use of ‘butter passes’ and over alloying in
the three techniques described here. an attempt to overcome the issues of dilution
Cladding and Weld overlay
Characteristics Explosion Welding Hot Roll Bond Weld Overlay
Full Chemistry of Corrosion

Resistance Alloy YES YES NO
Unaltered Corrosion Resistance

YES NO NO
Easy to Inspect
YES NO NO
Resists Hydrogen Induced Dis-

bonding YES NO YES
Mock-UP of the tube-to-tubesheet welding
• ASME BPVC Sec. IX QW-193 to be followed with additional requirements based on case by case
• Mock-up required for EACH Welding / procedure qualification
• The mockup assembly shall essentially duplicate the tube-to-tubesheet weld joint design to be
used in production
• For tube-to-tubesheet welds to clad tubesheet, the cladding or overlay may be represented by a
base material with a chemical composition that is essentially equivalent to the cladding
composition
• The mock-up shall consist of minimum 10 tubes for procedure qualifications and minimum 5
tubes for EACH welder qualifications.
• Hardness testing to be considered for work hardening materials (ex. DSS and Ti) or for service
requirements (e.g sour service)
• It is advised that dummy tubehsheet to be from the same material of the production tubesheet, to
ensure that HAZ in the mockup (dummy) tubesheet will give representative results
Mock-up is required for procedure qualifications and for welder qualifications as well each time WPS should be applied
Mock-Up Procedure
Detailed mock-up procedure shall be prepared including the sequence of application,
sketch and dimensions of the used material, acceptance criteria, template for the
output results report
All Mock-UP shall be subjected to:

1. Check the conditions of the tubesheet holes and tube surface
2. Measure and record the actual holes diameters, Tubes’ inner diameter, tube
DPT
thickness for all tubes
3. Follow the same sequence of expansion and welding as agreed for the
production Sectioned
4. Visual Examination: complete fusion, free of visual cracks, porosity indications, Tube
no evidence for tube burn through
5. Liquid penetrant for root pass and final pass
6. Measure and record the actual tube ID after expansion and calculate wall
reduction ratio for all tubes
7. Macro examination: section the mockup through center and the 4 exposed
surfaces to smoothed, etched. Use magnifications 10X to 20 X (preferred 20 X
for better visibility)
Penetration
✓ Minimum Leak Path (MLP)
✓ No cracking
✓ Complete fusion
Target wall Reduction Measurements and Calculations
𝒅𝒊 − 𝒅𝒐 − (𝑯 − 𝑫)
𝑹= ∗ 𝟏𝟎𝟎 %
𝑫 − 𝒅𝒐
R = Expansion Ratio (%)
di = Inside diameter of tube after expansion
internal measuring gauge
do = Inside diameter of tube before expansion ‘ Internal three point expanding dial
H = Diameter of tubesheet hole calliper for measurement of tube ID
before and after expansion and
D = Outside diameter of the tube before expansion
Sample Calculations of Tube Wall Reduction %

Tubesheet
Tube ID before Tube Final Tube ID Expansion
# Tubesheet Hole Dia. Tube OD
expand. Thickness after expansion Ration %
1 25.26 25.17 23.592 0.789 23.784 6.46% Dt Do D Tube

i
2 25.26 25.11 23.529 0.7905 23.767 5.57%

3 25.263 25.11 23.571 0.7695 23.795 4.61%
4 25.265 25.09 23.512 0.789 23.777 5.70%
5 25.265 25.13 23.532 0.799 23.804 8.57%
Minimum Leak Path (MLP)
▪ Minimum Leak Path (MLP): is the minimum path where the media can leak and can
be defined as the minimum distance in any direction from the root of the TTS weld to
the nearest surface
▪ MLP will depend on the type of the joint (fillet / groove / Fillet + groove / … etc.) and
MLP
the actual shape of the applications (concave / convex / actual geometry / …etc. )
▪ In API 660 it is required to be >= 2/3 nominal tube thickness DPT
▪ In ASME sec. IX it is required to meet the design, but there is no specific MLP = the radius of the largest circle
requirements for how to be identified totally inscribed in the weld whose
centre is situated at the root of weld
MLP for different ASME joints
Minimum Leak Path (MLP)
Demonstrative Examples:
CS tube SA 179 to CS Tubesheet SA 266 Gr.2: Do= 19.05 mm, BWG 14 (2.108 mm thickness) – Td= 200 oC
MLP
Fillet Weld – Full Strength Weld Groove Weld – Full Strength Weld
DPT
ag >= ar or t
af >= ar or 1.4 t
Sa = 92.4 Mpa ….. Tube all. stress ASEM sec. II part D Sa = 92.4 Mpa ….. Tube all. stress ASEM sec. II part D
St= 138 Mpa….. Tubesheet all. stress ASEM sec. II part D St= 138 Mpa….. Tubesheet all. stress ASEM sec. II part D
Fw= Sa/Sw = 1 (Sw is smaller of Sa and St) Fw= Sa/Sw = 1 (Sw is smaller of Sa and St)
Fd = 1 for full strength weld Fd = 1 for full strength weld
ar= [ 0.75𝑋19.05 2 + 2.73𝑋2.018𝑋 19.05 − 2.018 𝑋1𝑋1] − 0.75𝑋19.05 ar= [ 0.75𝑋19.05 2 + 2.73𝑋2.018𝑋 19.05 − 2.018 𝑋1𝑋1] − 0.75𝑋19.05
ar = 2.93 mm ……. 1,4t = 1.4X2.018 = 2.825 mm ar = 2.93 mm …….

af >= greater of ar or 1.4t …….. af = 2.93 mm ag >= greater of ar or t …….. ag = 2.93 mm
MLP Throught distance = af / 2 = 2.93 / 2 = 2.07 mm MLP = depth of groove = ag = 2.93
Calculated MLP = 2.07 mm Calculated MLP = 2.93 mm

MLP as 2/3 t= 1.405 mm …… per API 660 MLP as 2/3 t= 1.405 mm …… per API 660
Common
Defects
Baher Elsheikh
The Indian Institute of Welding Mumbai Branch – Free Webinar Tube-to-Tubesheet Joints
Common Defects in Heat Exchanger Tubes
Shell Inlet Fretting
Inlet Nozzle Vibration Baffle Baffle
Baffle
Erosion Baffle Damage
Erosion MIC Fatigue cracks
Tubesheet
Tubeside Flow
SCC /Pitting Tube
Tube
Galvanic Corrosion
Fatigue cracks Crevice corrosion
Erosion-Corrosion Pitting Galvanic Corrosion MIC
Crevice Corrosion Fatigue Cracking Fretting Corrosion SCC
This is not inclusive list, only most common defects
Factors Influencing Corrosion
Environment Factors
- Degree of aeration
- Flow Velocity
- Impurities
Environment - pH
- Temperature
- concentration of corrodents
Stress Corrosion
- Design Factors ( crevice; U bends, Fatigue Corrosion
stagnant areas, geometry of TTS) SCC Material Factors
- Fabrication - Composition
- Metallurgical factors
Stress - Microstructure
Fatigue Material - Surface conditions
- Cold / hot hardening
Crevice Corrosion
Crevice Corrosion is an intense localized corrosion frequently occurs
within crevices and other shielded areas on metal surfaces exposed to
corrosives. This type of attack is usually associated with small volumes of
stagnant solution caused by holes, gasket surfaces, lap joints, surface
deposits, and crevices under bolt and rivet heads
Control
• Redesign of Tube-To-Tubesheet joint to eliminate crevices.
✓ Proper expansion of tube to tubesheet
✓ Use setback weld or internal bore weld
• Select more corrosion resistant or inert alloys Reference: NALCO Guide to Cooling Water System Failure Analysis
• Fluid of tendency to cause concentration cell to be allocated in tubeside Crevice Corrosion

• Vent / blead trapped or stagnant media
• Ensure full penetration of welded TTS
Trapped Vapors
Vapor Bleed
Tube Expansion Set back weld Internal Bore Weld
Crevice corrosion due to concentration of vapor phase and remedial measure.
Pitting and Erosion
Pitting is a form of extremely localized attack that results in holes Erosion-corrosion is a description for the damage that occurs
in the metal. These holes may be small or large in diameter, but in when particle erosion and/or high flow velocity contributes to
most cases they are relatively small. Pits are sometimes isolated or corrosion by removing protective films or scales or otherwise
so close together that they look like a rough surface. accelerating the corrosion rate.
For stainless steels, pitting resistance equivalent number (PREN) : Control

PREN = Cr + 3.3 (Mo + 0.5 W) + 16N
• Changes in shape, geometry, and materials can help mitigate
Control erosion and erosion-corrosion.
• Choose the material most appropriate for the service conditions • Heat exchangers utilize impingement protection (plates, rods,..)
• Avoid stagnant zones and deposits for shell inlet erosion and occasionally tube ferrules for tube inlet
portion
• Reduce the aggressivity of the medium (using inhibitors)
• Maintain the protective film of the material • Improved resistance to mechanical erosion is usually achieved by
increasing component hardness
• Avoid condensate corrosion (ex. CO2 cooled below dew point)
• Ensure proper operation to avoid water droplets in the steam
system.
Tube Ferrules Inlet tube erosion
Avoid projection of tubes in top tubesheet of vertical heat exchangers
Stress Corrosion Cracking
SCC is Cracking caused by the simultaneous presence of tensile stress and a
Material
specific corrosive medium. Usually lead to unexpected sudden failure. Environment
Composition Composition
SCC is believed to be nucleated at pitting damage sites and develops under local Heat treatment Velocity
Surface condition Electrode potential
tensile stresses as a highly branched network of fine cracks. Microstructure Temperature
Can be expected at TTS, baffle area, U bends
Examples: (Chloride SCC, Carbonate SCC, Caustic SCC, Ethanol SCC, HF SCC and Stress
Polythionic acid SCC)
Service stress
Control Stress
concentration
SCC Branched Cracks
• Use resistant material Residual stress
• Residual stress release application when applicable (for TTS and U bends as Stress level
applicable)
• Design to avoid stagnant conditions of species causing SCC (eliminate crevice).
• Proper tub expansion to tube sheet
• Full weld penetration
• PWHT application based on materials and service
• Reduce bundle vibration
Other Locations in the tube can suffer SCC
Stress Corrosion Cracking
Alloy Environment
Austenitic stainless steel Chlorides
Hot concentrated caustic
Sulphurous and polythionic acids
Hydrogen sulfide
Carbon steel Concentrated caustic
Concentrated nitrate solutions
Anhydrous ammonia
Carbonate and bicarbonate
Copper-based alloys Ammonia (vapors and solutions)

Amines
Sulfur dioxide
Nitrates, nitrites
Titanium Ethanol
Methanol
Hydrochloric acid
Reference: NALCO Guide to Cooling Water System Failure Analysis
Galvanic Corrosion
Galvanic Corrosion is an electrochemical action of two dissimilar metals in the
presence of an electrolyte and an electron conductive path.
It occurs when dissimilar metals are in contact.
It can be expected at the tube-to-tubesheet joint or interface between tubes and

baffles in case of using dissimilar material
Control
• Use of galvanically compatible materials
• Avoid unfavorable area effects of a small anode and large cathode
• Apply cladding / weld overlay of tubesheet to match the tube material at the TTS
• Apply coating to tubesheet after assembly to isolate from the electrolyte
Cladding
Tubesheet
Tube side
Shell side
Tube
Tube
Epoxy Coated Tubehseet Tubehseet Cladding Galvanic Cell

Galvanic Attack – Stainless Tubes with Carbon Steel Tubesheet
Common Defects in TTS Welds
Defect Possible Cause(s) Remedial Actions
Porosity • In sufficient shielding & purging gas, unclean • Sufficient flow of shielding and purging gas, proper
base material, unclean filler, etc. cleaning of base metal and filler wire, etc
• Improper welding parameters like low current,

Lack of fusion • Use of proper welding parameters, clean surface
high speed, unclean surface, etc.
• Low amperage, tight root opening, high travel • Use of proper welding technique and welding
Incomplete penetration speed, short arc length, etc. parameters
• Improper groove size, large size of filler wire • Use J or U groove for better penetration
• Reduce heat input by reducing current, increasing

• Excessive heat input
Burn through speed, use of heat sink, etc
• Very thin tubes
• Consider the weldability while selecting tube thickness
• Improper welding parameters like high • Use of proper welding technique and welding
Undercut
current, long arc length, high travel speed, etc parameters
• Follow recommended preheat, ensure proper cleaning,

• Improper preheat temperature, high restraint, etc.
Crack
unclean surface, base material impurity, etc. • Apply global heating instead of local preheat for thick
tubesheet
Inspection of Tube-To-Tubesheet Joints (TTS)
Visual Examination
Surface examination by PT
Volumetric examination by UT
In situ replica examination
Helium leak test
Hydrostatic test
Tube end Callipers for internal tube ID and expansion percentage
Radiographic Examination, RT (recent techniques, not common application)
TUBE-TO-TUBESHEET JOINTS
LEAK REPAIR
Baher Elsheikh
The Indian Institute of Welding Mumbai Branch – Free Webinar

Repair Options
TTS weld repair
Re-expansion
Retubing
Plugging (taper plug, mechanical plug, welded plug)
Internal sleeve / Ferrule
Suggested Weld Repair Procedure
▪ Grind out the defected weld carefully to avoid propagation of defect (especially in cracked welds).
Pencil grinder is preferred for small repairs and crack excavations (but time consuming)
▪ Step wise DPT application until confirming the full removal of the defect
▪ Welding first pass
▪ DPT for the first pass
▪ Pre-leak test (pneumatic / hydrostatic) to be applied for the root pass (optional step based on the
practicality of application)
▪ Second / filling passes
▪ DPT for the last pass
▪ PWHT if applicable
▪ Re-expansion of the tube to tubesheet to compensate the relaxation form the PWHT heat (if no
PWHT, this step can be omitted)
▪ Hardness check for the weld and HAZ
▪ Ferrite content measurement for DSS welds
▪ Hydrostatic test
▪ Helium leak test for critical applications
▪ Mock up can be prepared to simulate the repair situations
Tube Plugging – Tapper Plug
All tubes that are plugged should be pierced to provide venting and draining to prevent possible plug blowout.
Always puncture the tube before plugging
Tube
Tubesheet
Tubesheet
Plug Map
Friction Taper Plug to be used only when (per ASME PCC2)
• Shell side operating pressure <=1.5 Mpa

Excessive tube plugging may result in reduced
• Shell side operating temperature <=205 oC
thermal performance, higher pressure drop, and/or
mechanical damage
• Tube to tubesheet are expanded not welded
Tube Plugging – Mechanical Plug
• Mechanical plugs should be considered in situations where friction fit
tapered plugs are not appropriate for the pressure and/or temperature of
service or other technical / environmental conditions.
• Mechanical plugs are typically installed by a pneumatic or hydraulic

system. Other styles of plugs may be considered for higher pressures.
Tube Plugging – Welded Plug
• Plugs with different shapes can be installed by welding to the tubesheet or to the inner surface of the tube
• Sometimes the plug is welded to ensure it doesn’t leak or blow out and turn into a projectile.
• When it is welded, the plug should have a material test report.
• The welding must be done in accordance with approved WPS, with care of requirements of Dehydrogenration
(if applicable) PWHT … etc.
• Mock-up to be prepared to ensure proper application and qualifications of the welders
• Plug map shall be prepared to record number of location of plugged tubes
TUBE-TO-TUBESHEET JOINTS
CASE HISTORIES
Baher Elsheikh
CASE-1: Repair of Internal Bore Weld Joints
• Equipment: Synthesis Loop Waste Heat Boilers in Ammonia Plant
• Service: synthesis gas in tube side and BFW in shell side (H2 service)
• Tubesheet material: SA333 F22 Cl3
• Tube material: SA213 Gr.T22
• Tube-to-tubesheet joint: Internal Bore Weld IBW (Butt weld) – no filler used
• Ferrules material: Inconel 601
• Lifetime of the equipment up to the leak: 9 months
Original Configuration of TTS at inlet and outlet side
Leaking tube-to-tubesheet joint at the inlet (hot) side
CASE-1: On site Repair of IBW Joints – Cont’
Repair Methodology
• Inconel ferrule inserted inside the tubesheet extended beyond the IBW
• Ferrule welded to the inner tube surface and the tubesheet face
• Mock-up done with all details including simulation of the actual tubesheet
and tube hardness
• Thorough clean applied for the inner surface of the tube
• Visual inspection, hardness, Borescope examination, DPT, and
hydrostatic testing Joint Restoring Scheme
Investigation results for the cause of immature failure

• Sample taken showed High hardness coarse grain
Highly advised to use in the mock-up
• Comparing the mock-up results during equipment fabrication, it was
material from the same heat number
concluded that impurities in the used material is the cause of the
of the production in order to have
failure.
representative results
• Although same material use for the mock up but from different heat
number which did not have the same impurities issue
Source: FBM Hudson Italiana SPA – Ammonia technical manual, 2003
CASE-2: SCC and Crevice Corrosion Attack
Equipment: Waste heat boiler in ammonia plant.
• Many cracks were found in U-tubes and in resurfacing welding layer of tube sheets.
• The design pressure and temperature of shell side is 2.8MPa and 340°C.
• The design pressure and temperature of tube side is 31.4MPa and 380°C.
• The hot flow in tube side is mixed gases. They are H2, N2, CH4, Ar, and NH3.
• Tube size is Φ35×6.5mm
Multiple Cracks in TTS as detected by DPT
• Tube material: SS 304
Investigation :
• Cracks are SCC from the BFW side
due to improper expansion of the tube
to tubesheet
Leak caused by crevice corrosion at the
gap between tube and tubesheet
• Proper expansion is crucial to the integrity of the exchangers

in potential crevice corrosion attack service
• Austenitic stainless steels are highly sensitive to chloride Cracks optical micrograph
SCC even with very low Cl content especially at high
temperature applications
Source:The Stress Corrosion Cracking of Austenitic Stainless Steel Heat Exchange Tubes:, Shugen Xu and W. Wang, ASME PVP 2010
CASE-3: Carbamate Condenser TTS Leak
Equipment: HP carbamate condenser (HPCC)
• Shell side: water / steam, P 0.8 Mpa and T 165 C – Tube side Carbamate, P 16.1 Mpa, T 220 C
• Tubes are SS 316 L urea grade , tubesheet Carbon steel cladded with SS 316 L Urea grade
Investigation :
• Leak occurred from a small pin hole in the tubesheet, passed the
aggressive carbamate to the carbon steel base material of the tubesheet
• A huge cavity in the tubesheet at the backside of the SS cladding
• Leal usually detected by monitoring the chemistry of the water / steam
chemistry (conductivity, Ammonia content)
• If tubes are expanded to the tubehsheet causing a restriction to pass the
carbamate to the water side, more corrosion will occur to the carbon steel
tubesheet Corroded are after grinding
the tubesheet face
• Tubes shall not be expanded to the tubesheet for the HPCC equipment
• There is no one joint type suits all applications, usually expansion of the tubes are recommended, but
for this case it is prohibited to allow for early leak detection before sever impact on the tubesheet.
• There is no one size fits all ! Balance your Choice
Source:High Pressure Carbamate Condenser Leak Detection and Control,- Ammonia Manual-2013
CASE-4: SCC and Crevice Corrosion Attack
Equipment: HE process gas in tubeside (250oC/0.25 Mpa and water in shell side 130oC/0.8 Mpa)
• Tubesheet and tubes are carbon steel
• TTS is strength weld + expansion ( no grooves)
• Exchanger failed by multiple cracks / leaks at inlet side TTS after 30 days in service
Investigation :
• Cracks at the weld without any corrosion signs
• Failure mechanism is fatigue exited by tube vibrations / cyclic
service and cracked at a lack of fusion at the TTS
• Expansion was extended to nearby the weld joint causing high
stress concentration at this area
• Weld quality is crucial, considering the inspection limitation, Mock up is of high value
• Enough clearance / gap shall be maintained between end of expansion distance and the weld (min 6 mm as per API 660)
• Service conditions (e.g. vibration, corrosion,..) might have no tolerance for lack of quality of the TTS
Source:Failure analysis of tube-to-tubesheet welded joints in shell and Tube heat exchanger, Long Liu, Ning Ding,- Elsevier
Recommended Readings
TEMA, Tubular Exchanger Manufacturer Association
API Std 660, Shell and Tube Heat Exchangers
ASME BPVC: Sections VIII div.1 , Sec. V and Sec. IX
NALCO Guide to Cooling Water System Failure Analysis
ASME PCC2, Repair of pressure equipment and piping
API TR 938 C, Use of Duplex Stainless Steels in the Oil Refining Industry
Tube to Tubesheet Joints

In Shell and Tube Heat Exchangers
Thank you for Attending
Baher Elsheikh
Contact me @
Baher Elsheikh

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What are the main components of a shell and tube heat exchanger?

What are the main components of a shell and tube heat exchanger?

What are the different types of tube-to-tubesheet joints?

What are the different types of tube-to-tubesheet joints?

Tube-to-Tubesheet Joints in

Shell and Tube Heat Exchangers

THE INDIAN INSTITUE OF WELDING

Free Webinar – 10 September 2022

Types and features of tube-to-tubesheet joints

Application requirements of expanded and welded tube-

Inspection and Repair of tube-to-tubesheet joints

Animation from: gfycat.com

U Tube Heat Exchangers

Type of Tube-to-Tubesheet Joint is specified in the data sheet

Care shall be taken by mechanical engineer in the review of

Strength Welded, Not Expanded Strength Welded and Expanded

Suggested Amounts of Wall Reduction by Tubing Material

As a general rule the smaller the

For Austenitic SS, Duplex SS, Titanium,

Clearances are required to facilitate tube

Tubesheet Hole Drilling Radial Imperfection Longitudinal Imperfection

Tube Patterns Tube Expander Three Roller Expander

(Courtesy of Elliott Tool Technologies Ltd)

Cross secretion in expanded tube

(Courtesy of Sugino Machine)

Manual Welding Orbital Welding Welded Joints

Other welding configurations

Special set back weld

Combined Groove + Fillet Weld Combined Groove + Fillet Weld

Choose ag and calculate ar

Partial ac >= ar ac >= (ar+ag)

Expansion then welding Welding then expansion

[API 660]: Tube

Explosion Welding Hot Roll Bond Weld Overlay

Characteristics Explosion Welding Hot Roll Bond Weld Overlay

Full Chemistry of Corrosion

Unaltered Corrosion Resistance

Resists Hydrogen Induced Dis-

All Mock-UP shall be subjected to:

Sample Calculations of Tube Wall Reduction %

1 25.26 25.17 23.592 0.789 23.784 6.46% Dt Do D Tube

2 25.26 25.11 23.529 0.7905 23.767 5.57%

MLP for different ASME joints

ar = 2.93 mm ……. 1,4t = 1.4X2.018 = 2.825 mm ar = 2.93 mm …….

Calculated MLP = 2.07 mm Calculated MLP = 2.93 mm

Erosion-Corrosion Pitting Galvanic Corrosion MIC

Crevice Corrosion Fatigue Cracking Fretting Corrosion SCC

This is not inclusive list, only most common defects

• Fluid of tendency to cause concentration cell to be allocated in tubeside Crevice Corrosion

Tube Expansion Set back weld Internal Bore Weld

Crevice corrosion due to concentration of vapor phase and remedial measure.

For stainless steels, pitting resistance equivalent number (PREN) : Control

Tube Ferrules Inlet tube erosion

Avoid projection of tubes in top tubesheet of vertical heat exchangers

Can be expected at TTS, baffle area, U bends

Copper-based alloys Ammonia (vapors and solutions)

Reference: NALCO Guide to Cooling Water System Failure Analysis

It occurs when dissimilar metals are in contact.

It can be expected at the tube-to-tubesheet joint or interface between tubes and