STANDARD OPERATING
PROCEDURE
( SWAGED TUBES )
Prepared By: Checked By Approved By:
Sandeep S. Bhandari M. K. Jadhav A. S. Kulkarni
SOP / BnHQAC / 05, Rev. 0 Page 1 of 5
SOP:- STANDARD OPERATING PROCEDURE
SWAGING OF TUBE ENDS
For Tolerance, refer control sheet no. TOL / BnHQAC / 04
Pre - production sample of Swaged Tube ends:-
Shop QC shall ensure pre-production sample for surface defects [Linear pitting, longitudinal or open
spiral, splits], Dimensionally [Ovality, thickness, length, concentricity], Hardness & carry out physical
testing [ one of flattening & one of flaring]
Shop QC shall ensure the preparation of pre-production sample on a change of die size, tube
dimensions, tube material or new job.
Shop QC shall ensure that dimensions are as per mentioned in approved drawing.
Inspection after Swaging of tube ends:-
Shop QC shall ensure the inspection of swaged tube ends dimensionally & visually.
During visual inspection, tube ends shall be free from:-
OD of swaged ends free from linear pitting,
OD of swaged ends free from linear scores (Longitudinal & open spirals),
OD & ID of swaged ends to be free from splits,
Light longitudinal or spiral grooves on the ID of swaged ends are permissible within the 250 RMS
standard.
During Dimensional inspection of tube ends:-
Ovality of swaged ends shall be within acceptable limit,
Thickness of swaged tubes shall be within acceptable limit,
Length of swaged ends & overall length shall be within acceptable limit.
Shop QC shall ensure the OD surface finish of swaged ends after polishing is held to 125 RMS.
Shop QC shall ensure that if minor grinding marks are appearing due to result of polishing on OD, then
they are acceptable only if they are radial and surface condition of the area is within 125RMS.
Shop QC shall ensure the no presence of any spiral grinding marks as they are not acceptable.
Shop QC shall ensure ID of swaged ends whether as swaged, machined or ground is held to 250 RMS.
If swaged tube end in production fails to meet the dimensional tolerances, Shop QC shall ensure that
production is stopped & all swaged tubes produced in that production run are subjected to complete
dimensional [Link] any defective tubes are found during inspection then Shop QC shall ensure
the non-conformity of the same unless dimensions are brought into tolerances by re-swaging.
If statistical sample of swaged tube end in production fails to meet the accept / reject criteria because
of splits, deep scores or other defects, then Shop QC shall inspect the entire production run. If any
defective tubes are found during inspection then Shop QC shall ensure the non-conformity of the same
unless they are reworked by grinding such that the tube end is not reduced below acceptable wall
thichness.
SOP / BnHQAC / 05, Rev. 0 Page 2 of 5
Shop QC shall ensure that the tubes required as per drawing are to be swaged single time or double
time.
Heat Treatment requirements of Swaged Tube ends:-
Shop QC shall ensure that swaged tube ends which are to be expanded or expanded & seal welded are
heat treated. The tubes ends which are not to be expanded shall not require Heat treatment.
Shop QC shall ensure the Heat Treatment for the following materials as below:-
P1 Material:
Heat to 6200 C +/- 150 C (11500 F +/- 250 F).
1
Hold for one hour per inch of thickness or 30 minutes, which ever is greater.
Cool in still air to room temperature.
P3, P4 & P5 Material:
Heat to 7200 C +/- 150 C (13250 F +/- 250 F).
2
Hold for one hour per inch of thickness or 20 minutes, which ever is greater.
Cool in still air to room temperature.
P8 Materials:
3 All mateiral require Heat treatment after cold swaging opeations, including partial swaging
& is divided into 2 groups.
TP 304, TP 304H, TP 347, TP 310
Heat to 10500 C +/- 150 C (19250 F +/- 250 F).
(a)
Hold for one hour per inch of thickness or 30 minutes, which ever is greater.
Cool in still air or furnace cool.
TP 316H, TP 321H, TP 347H
Heat to 11100 C +/- 150 C (20250 F +/- 250 F).
(b)
Hold for one hour per inch of thickness or 30 minutes, which ever is greater.
Cool in still air or furnace cool.
Heat Treatment Process for swaged tube ends:-
Shop QC shall ensure that if single time swaging is done then follow PWHT as discussed or if double
swaging is to be done then after single swaging intermediate stress relieving is to be carried out & then
again swaging second time & then normalising of the swaged tube ends.
Heat treatment shall be performed either by heating the complete tube length in furnace or by heating
the entire swaged end including the stepped section in an electric open gap furnace.
The tubes shall be loaded in such a way that no swaged end for treatment rest on a support or directly
on another tube such that furnace gases shall be able to circulate freely round the entire outside
surface of the tubes.
Furnace temperature during each heat treatment cycle or for an open gap furnace (for each production
run) shall be monitered by either a temperature recorder or indicator.
Temperature reocrder chart shall be identified by Date, Job number, Section, Suffix, Number of
pieces, Material.
Shop QC shall review the chart in accordance with the requirements & file it.
SOP / BnHQAC / 05, Rev. 0 Page 3 of 5
Shop QC shall periodically verify that heat treatment is within the parameters specified by the
procedure, when temperature indicating device is utilized.
Shop QC shall moniter the heat treatment at least once every four hours.
Shop QC shall ensure the inspection of swaged tube ends for hardness determination from statistical
sample such that hardness meets the requirement for the tube material & show a maximum harness
variation of 10RB within the swaged region. Statistical sample shall be taken at random from a group
of swaged ends not to exceed fifty pieces.
If one or more tubes in the statistical sample for P1, P3, P4 & P5 material show unacceptable hardness
or variation in hardness, the complete group shall be reheated as mentioned below & shall again
inspected.
Re - Heat Method for Swaged tube ends:-
If reheat temperature is necessary, the tubes shall be given a full anneal. The tubes shall be heated
from 315o C (600o F) at a rate not exceeding 260o C (500o F) per hour maximum to 870o C +/- 15o C
(1600o F +/- 25o F), & hold for one hour per inch of thickness, with a minimum of 30 minutes.
The tubes shall be cooled at a maximum of 93o C (200o F) per hour to 510o C (950o F) & that
temperature, the tubes shall be withdrawn from the furnace & cooled in still air.
Thermocouples clipped to two tubes shall be used to control temperature.
No scale paint shall be used to control scaling.
The above heat treatment process shall be used with the consent of the process control metallurgist or
an equivalent alternate.
Acceptable hardness values for Swaged tube ends after Heat treatment:-
P1 Material:
SA 210 - A1 RB 79 max.
SA 192 RB 77 max.
SA 178A RB 72 max.
SA 178C RB 85 max.
P3 Material:
SA 213 T2 RB 85 max.
SA 209 T1a RB 85 max.
SOP / BnHQAC / 05, Rev. 0 Page 4 of 5
P4 Material:
SA 213 T11 RB 85 max.
P5 Material:
SA 213 T22 RB 85 max.
SA 213 T5 RB 90 max.
SA 213 T9 RB 90 max.
SOP / BnHQAC / 05, Rev. 0 Page 5 of 5
