Beading, Rolling, and Welding Boiler Tubes - The Boiling Point

Summary

In this video, Steve Taylor, director of the rental division, and Jimmy Kurtzinger demonstrate the intricate process of tube rolling, welding, and beating in boiler maintenance. They explain that rolling is essential for sealing tubes to the tube sheet, while beading helps dissipate heat and prevent cracks. The video showcases the technical steps, including using different types of rolls and the importance of not over-rolling to avoid thinning the tubes. The demonstration highlights the skill and strength required for beating, ensuring a smooth and secure seal.

Takeaways

• 🔨 Labor Day is a time to celebrate the hard work of those in trades, like tube welding and boiler maintenance.
• 🛠 Rolling a tube is essential for sealing it against the tube sheet, not the weld itself.
• 🌡 Beading is a technique used to prevent overheating and cracking of the tube ends, especially in high-temperature areas.
• 🔥 The hot pass, or the first pass of welding in a boiler, is crucial for heat management and preventing leaks.
• ⚒ Welding on the hot pass helps create a better seal and is often recommended by manufacturers.
• 🛡 Over-rolling a tube can thin it out, making it difficult to re-roll and repair if it leaks.
• 🔩 Proper tube rolling is vital as new boilers can sometimes leak until they are heated and fired for the first time.
• 🛠️ The rolling process involves using a tapered pin and rolls to press the tube against the tube sheet.
• 🛠️ After welding, a tube is re-rolled to ensure a tight seal, using a different type of roll known as a Collins roll.
• 🔧 Beading involves flaring the tube end and then beating it to create a smooth, sealed surface.
• 👨‍🏫 The process of beating requires skill and strength, and it's important for the final appearance and integrity of the tube end.

Q & A

What is the main purpose of rolling a tube in boiler work?

The main purpose of rolling a tube in boiler work is to seal the tube to the tube sheet by pressing the tube out against the tube sheet. This process ensures a tight seal and prevents leaks.

Why is it important to bead the end of a boiler tube?

Beating the end of a boiler tube is important to transfer heat away from the tube end and towards the tube sheet. This helps prevent overheating and cracking, which could lead to leaks.

What is the role of welding in the tube sealing process?

Welding plays a role in the tube sealing process by providing a better seal from the end of the tube to the tube sheet, especially in the hot pass where temperatures can reach 1800-1900 degrees.

What is the potential issue with rolling a tube too much?

Rolling a tube too much can thin out the tube material, making it difficult or impossible to re-roll if a leak occurs later. This could result in the need to cut out and replace the tube.

Why might a new boiler have leaking tubes when it first arrives on site?

A new boiler might have leaking tubes due to the tubes loosening up during transit. Once the boiler is heated and fired for the first time, the tubes expand, and any leaks can be tightened up.

What is the difference between a straight roll and a beading process in tube work?

A straight roll is used to seal the tube to the tube sheet without flaring, while the beading process uses a special roll to flare the end of the tube and then beat it to create a smooth, sealed surface.

How does the use of a collins roll differ from other types of rolls in tube work?

A collins roll is used for a straight roll without flaring the tube end. It's typically used after welding to tighten the tube against the tube sheet.

What is the significance of the tube's curvature when beating the end of a boiler tube?

The curvature of the tube when beating is significant because it determines the final shape and seal quality. A properly formed curvature ensures a smooth, tight seal against the tube sheet.

Why is it necessary to clean the inside of the tube before re-rolling after welding?

Cleaning the inside of the tube before re-rolling after welding is necessary to prevent any weld splatter from getting caught in the rolls, which could compromise the seal and cause leaks.

What is the importance of speed when beating the end of a boiler tube?

The speed when beating the end of a boiler tube is important for achieving a smooth surface. If done too slowly, it can result in an uneven and jagged appearance, which is not only unsightly but could also affect the seal quality.

Outlines

00:00

🔧 Labor Day Celebration of Boiler Tube Work

The video script begins with a Labor Day tribute to workers specializing in boiler tube work, emphasizing the importance of tube welding, rolling, and beating. Steve Taylor, the director of the rental division, shares his extensive knowledge on the topic, having spent 35 years in the industry. The script explains that the weld on the tube does not seal it but is part of a process to transfer heat. The actual sealing is achieved through the rolling process, which presses the tube against the tube sheet. Beading is highlighted as a method to prevent overheating and cracking by transferring heat to the tube sheet. The script also discusses the importance of proper welding techniques on the hot pass of the boiler to prevent leaks. The process is demonstrated by Jimmy Kurtzinger, who performs rolling, welding, and beating on a tube, with Steve providing commentary on the steps and their significance.

05:01

🛠️ Detailed Process of Boiler Tube Sealing and Beading

This part of the script delves into the technical aspects of sealing and beading boiler tubes. It explains that rolling is crucial for sealing the tube to the tube sheet, and if done excessively, it can thin the tube, making it impossible to re-roll and necessitating tube replacement. The video demonstrates the process of re-rolling after welding to ensure a tight seal. Beading is introduced as the next step, where the tube is flared before being beaten to form a smooth, sealed end. The use of specialized tools and the skill required for this process are emphasized, with Jimmy showcasing his expertise in beating the tube to achieve a perfect seal. The script concludes with a final touch-up using a straight roll to secure the bead and complete the tube sealing process. The segment ends with thanks to the participants and a teaser for the next episode of 'The Boiling Point.'

Keywords

💡Labor Day

Labor Day is a public holiday celebrated to honor the contributions of workers. In the context of the video, it is used to set the scene for a discussion about the hard work of those involved in tube work, particularly in the welding and maintenance of boiler tubes.

💡Boiler Tubes

Boiler tubes are cylindrical tubes through which hot gases or fluids pass to heat water in a boiler system. The video focuses on the maintenance and repair of these tubes, which is crucial for the efficient operation of boilers.

💡Welding

Welding is a process used to join two or more pieces of metal by heating them to a point where they become molten and then allowing them to cool and solidify. In the video, welding is discussed as a method to seal the ends of boiler tubes to prevent leaks.

💡Rolling

Rolling, in the context of boiler tubes, refers to the process of using a roller to press the tube against the tube sheet, creating a seal. The video explains that rolling is essential for the proper sealing of tubes to prevent leaks.

💡Beading

Beading is a technique used in tube work where the end of the tube is shaped into a flared or rounded bead. This is done to protect the end of the tube from overheating and cracking, as discussed in the video.

💡Tube Sheet

A tube sheet is a part of a boiler where the tubes are expanded against it to create a seal. The video emphasizes the importance of the tube sheet in the sealing process of boiler tubes.

💡Hot Pass

The hot pass is the initial welding pass in a welding operation, particularly in the context of boiler tubes. The video mentions that beading is important to protect the tube from overheating during the hot pass.

💡Sealant

Sealant is a substance used to make something airtight or watertight. In the video, the sealant's role in sealing the tube to the tube sheet is discussed, emphasizing that the weld itself does not create the seal.

💡Overheating

Overheating refers to the condition where a material is exposed to temperatures beyond its safe operating limit. The video explains how beading helps to prevent the end of the boiler tube from overheating and cracking.

💡Leak

A leak is an unintended escape of a fluid or gas. The video discusses how proper tube rolling and beading are essential to prevent leaks in boiler systems by ensuring a tight seal between the tube and the tube sheet.

💡Morrison Tube

A Morrison tube is a specific type of boiler tube. The video mentions it in the context of the welding process, indicating that welding is often done on the hot pass, starting from the Morrison tube and moving around the boiler.

Highlights

Labor Day celebration for tube workers.

Introduction to the process of beating, rolling, and welding boiler tubes.

Steve Taylor, with 35 years of experience, discusses tube maintenance.

Explanation of why tubes are rolled: to seal them against the tube sheet.

The weld does not seal the tube; rolling is essential for sealing.

Beating and rolling prevent overheating and cracking of tubes.

Beading transfers heat from the tube end to the tube sheet.

Welding is typically done on the hottest pass to ensure a better seal.

Demonstration of the straight rolling process by Jimmy Kurtzinger.

Importance of lubrication during the rolling process to prevent tube damage.

Potential issues with over-rolling and how it affects future maintenance.

Common occurrence of new boilers leaking until they are heated and fired.

Seal welding after rolling to ensure a tight seal.

Re-rolling with a Collins roll to tighten the tube after welding.

Introduction to beading, a process to flare the tube end.

The use of a specialized tool and technique for beating the tube end.

Final touch-up with a straight roll after beading to secure the seal.

Conclusion and appreciation for the demonstration of tube maintenance techniques.

Transcripts

well happy labor day

make sure before we get this video going

that you like or you share or you

actually hit that little bell for the

notification when our videos come up

that you will be notified

now labor day is here and we want to

celebrate all those guys out there that

do tube work and these boiler tubes get

welded they get beaded

and they get rolled and today we're

going to be looking at that on the

boiling point

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[Applause]

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welcome to the boiling point we're with

steve taylor director of the rental

division and we're going to be talking a

little bit today about beating rolling

welding the tube now steven's not um a

novice at this he's in the rental

division but he actually worked a lot of

time out here in the shop doing this a

long time

got a few years anyway steven's been

with us about 35 years so a lot of

knowledge here well let's talk a little

bit about the beating and rolling and

first let's just talk about um

rolling you know why are we actually

rolling a two well a lot of people think

that the weld that's on there actually

seals the tube it doesn't it has a

different process what it's there for

and we'll talk about that uh the sealant

of the tube in the tube sheet is done by

rolling in it so you're just more or

less you're pressing that tube out

against the tube sheet really really

hard with a roll and that's the entire

process that seals that tube to the tube

sheet the rest of this is superfluous it

doesn't do anything to seal the tube

okay so the uh the beading what is that

for the beading you know if you leave

that tube sticking out like this at

least on the hot pass which is the very

first pass where the the

you know the the hot gas of the fire

comes down through here by the time it

gets back here it's 2000 degrees hits

the rear

door or if it's a water back boiler the

water back and turns it goes back so

we're talking 18 1900 degrees here if

you leave it sticking out like this

that's going to overheat and start to

crack when it starts to crack it's going

to continue to go in until it cracks

inside then you're going to have a leak

in that tube you can't have that so all

this does we're trying to transfer that

heat we want to get the heat off the end

of that tube transferred to that tube

sheet and one of the ways to do that is

to bead that tube turn that over seal

that against the tube sheet and that

that transfers the heat straight to the

tube sheet protects the end of that tube

that's all it's for okay and sometimes

you see welding on one side

and then yeah

on the other right typically the the

welding is on the on the hottest pass

the very end of the boiler the the first

password starts back through from the

morrison tube back around and we like to

to weld the hot pass a lot of the

manufacturers do and we follow their

procedures it does a better job if

you're 18 1900 degrees here over time

you will have some of those tubes will

start to leak

they'll just overheat okay but if you

weld that and seal well that it just

gives you a better seal from the end of

that tube to the tube sheet and all

we're doing is trying to transfer that

heat that's what that's there for okay

we thought it would be kind of a good

idea to really go through each one of

these processes from rolling

to beating and the welding and really

how we do that steven's going to walk

through we're going to have our man

jimmy come in and he's actually going to

do that all right well we got my man

jimmy kurtzinger that's going to be

doing the hard labor for us here and

he's going to get started stephen why

don't you walk through the process as he

starts this uh the rolling process on

what he's actually doing okay what he's

going to do here is do a straight roll

on this tube these tubes we're going to

seal weld like this one is so you're

gonna do a straight roll

jimmy go ahead and show us what you're

gonna do

see he'll all at first get some oil in

there some lubrication so those rolls

don't lock up inside that tube

slide the tube in there this pin is

tapered all the way in so the further

that pin goes in the more it pushes

those rolls out against those that tube

you hear that road bogging down that

motor bogging down that's that roll

really tighten it up against that tube

and press it out

and that's pretty much it he's done the

roll what would happen now is he would

seal weld that and he would come back

and roll it again and that tube's done

that's how quick it happens now steven

can you actually roll that too much

yeah you can if you roll it too much uh

you'll thin that tube out and you'll

you'll keep somebody further down the

road if that tube was to leak uh they

they scaled the boiler up something

happened and they overheated it and

caused it to start leaking they shocked

the boiler pulled that tube a little bit

loose from that tube sheet they had to

re-roll it if you roll it too much then

they can't re-roll it they have to cut

the tube out put a new tube in there i

know and sometimes we sell a new boiler

um and they'll actually show up on the

job site and they're actually leaking um

you'll bring the roll out is that

typically what happens that's typically

what happens well a lot of times in

transit they'll get shook up and they'll

loosen up but it's real common for a

brand new boiler to have tubes leaking

in it until they heat it up and fire it

the first time everything swells up all

the tube stretches all the tubes stretch

get all that process going through then

you may have some tubes leak a little

bit you'll come in and tighten them up

just a little bit just to snug them

you're good to go okay

okay so the tube has been rolled and so

now we're just going to go ahead and

weld jimmy once you go ahead and start

that and get out of the way

so now he's going to take a quick a

pencil grinder clean the inside of the

tube so that when he re-rolls he doesn't

get any of that splatter in the rolls

themselves

so now he's going to re-roll that tube

to tighten it up after welding it this

time he'll use a collins roll just a

different style roll that doesn't flare

doesn't do anything to it just a

straight row go ahead jimmy

okay so now we're going to do a new

process it's called beading

and we're going to actually flare the

tube

first right yep and then he's going to

come back and he's actually going to do

the bead right yep he's using a

completely different type of roll it has

a

rollers on it that are at an angle and

that's going to put the flare to the end

of that tube so we'll do the same

process

you see that that roll is a combination

roll it rolls the tube into the tube

sheet and it flares the end of it at the

same time preparing it so we can beat it

like this one is

so now we're going to move on to

actually beating the end of that to that

tube this tool is a special tool they

use

and they'll form these themselves to get

the right curvature

exactly what they want to use use a

little air

hammer

to do it with and it's a technique that

requires a lot of skill it took me a

long time to learn how to do it

and it requires a lot of arm strength

that i don't have anymore so go ahead

jimmy show us how this is done

you saw there that that towards the end

jimmy was going around pretty fast with

it that's how you get that smooth

surface to it if you didn't do that if

you went real slow with it you'd have

jags in there and it would look like it

doesn't hurt it just looks awful

so jimmy's done a good job he's done

that a lot of times so you can tell by

the way he put that in there so it's

perfect perfect beaded tube

so he's beaded that tube the last thing

in this process is to touch that up when

you bead that tube there's a chance you

could loosen that tube up a little bit

so he'll go in with that collins roll

that straight roll touch it up just like

we did on the other end when we welded

it and that'll be the end of that tube

it'll be sealed up

all right well thanks jimmy thanks

steven for coming out here it's always

good to have one of these jigs these

guys actually practice this all the time

and i really just appreciate you taking

the time to show everybody this to

beating

rolling and welding and we'll see you

next time on the boiling point

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[Applause]

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