06/06/2012

GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

GENERAL GUIDELINES FOR SELECTION OF INSTRUMENTS, IMPULSE PIPES AND FITTINGS AND WELDING ELECTRODE.
IMPULSE PIPE FITTING Normally socket welded fittings are recommended for impulse pipe, Socket welding does not require edge preparation. However, pipe shall be cleaned and burr should be removed. In view of the above, fast work progress can be achieved. Since cleaning of impulse pipes does not necessitate opening of the pipes from the joints and cleaning is accomplished by a process of blow-back arrangement all fittings have been chosen with welded type. Wherever there is absolute necessity, unions have been recommended, thereby restricting the use of the fittings to the barest minimum. The use of fittings may be limited to the minimum unless specifically required for a particular application, for easy maintenance. IMPULSE PIPE CUTTING AND BENDING Cutting Pipe cutter or wheel grinder shall be used for pipe cutting. Gas cutting shall be avoided. Burr inside the cut end shall be removed. The cutting surface shall be as perpendicular to the axis as possible. Bending It is recommended for cold bend for the impulse pipes with the help of a hydraulic bender machine to achieve a particular shape. Use of 45 elbow and 90 bends (ready-made) is restricted to bare minimum to minimise the number of joints in a system. Hot bending is not be used as this leads to flattening of pipes at the bends and also results in thinning of walls, apart from introducing changes in metallurgical properties of the pipe material. Hot bending may be permitted for carbon steel pipe for low pressure service as instructed by supervisor only when it cannot be avoided. In the case of 90 bending the radius shall be more than 3 times the outside diameter of pipe and in the case of U bending, radius of bending shall be 5 times the outside diameter of pipe. When the radius of bending becomes small, elbow fitting shall be used. Large bending shall be so made as to form smooth curve.

IMPULSE PIPE WELDING

Generally, welding of impulse pipe and fitting shall be carried out by arc welding and socket welding is adopted, as shown in the figure. Welding shall be performed by a qualified welders. Only D.C. arc welding is recommended for impulse pipe. In order to prevent the cracking of the weld it is recommended to provide a small gap between the bottom of the socket and pipe end as shown in the figure. Depending on the material type and resource availability different welding methods are followed SHIELDED METAL ARC WELDING PROCESS (SMAW) The arc is initiated by momentarily touching the electrode to the base metal. The heat of the arc melts the surface of the base metal to form a molten pool at the end of the electrode. The melted electrode metal is transferred across the arc into the molten pool and becomes deposited weld metal. It has maximum flexibility and can weld many metals in all positions.
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06/06/2012

GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

This process can be used to weld socket type weld. Min thickness of base metal is that can be welded is 1.6 mm for a skilled welder GAS TUNGSTEN ARC WELDING PROCESS (GTAW) (TIG) The gas tungsten arc welding process utilises the heat of an arc between a non-consumable tungsten electrodes and the base metal. The arc develops intense heat which melts arc surface of the base metal to form a molten pool. The filler material is externally fed. The filler material is not transferred across the arc but melted by it. The arc area is protected from atmosphere by inert shielding gas (normally argon) which flows from the nozzle of the torch. The shielding gas displaces the air so that the oxygen and the nitrogen of the arc does not come in contact with molten metal or the hot tungsten electrode. As the molten metal cools coalescence occurs and parts are joined. ADVANTAGES High quality welds in all metals and alloy. There is no filler material carried across the arc and so no spatter. Welding can be prepared in all portion. No slag produced.

GTAW is widely used for joining thin wall tubing and for making root passes in pipe points. Minimum thickness of base metal that can be welded 0.13 mm.

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06/06/2012

GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

GAS METAL ARC WELDING (GMAW) The gas metal arc welding process utilises the heat of an arc between a continually fed consumable electrode. The heat of the arc melts the surface of this base metal and the end of the electrode. The metal melted off the electrode is transferred through the arc to the work where it becomes the deposited weld metal. The shielding is obtained from an envelope of gas which may be an inert gas. The arc is maintained automatically and travel can be manually or by M/c welding process minor variation in process leads to spray arc welding pulsed arc welding short circuit metal transfer welding etc. ADVANTAGES 1. 2. 3. 4. 5. High deposition, rates when related to shielded metal arc welding. High operator factor with respect to shielded metal arc welding High utilisation of filler material Elimination of slag and flux removal Reduction of smoke and fumes.

Min thickness of metal to be welded should be greater than 0.13 mm. Recommended Fitting Fitting Electrode Material Rating As per AWS Specification Classification As Per ANSI B-16 3000 LBS As Per ANSI B-16 6000 LBS Forged Carbon Steel E6013 ASTM- A-105 Gr.II Forged Carbon Steel E6013 ASTM- A-105 Gr.II Forged Carbon Steel E 8018 B2 ASTM- A-182 Gr.II -DoE309

Sl.No. Max. Pr.

Max. Nominal Temp. Bore

Thickness Material Schedule Specification

Up to Up to 42 400 Kg/Sq.Cm Deg.C

Carbon Steel 1/2",1",1.1/2",2" all SCH 40 ASTM, A-106 Gr.B Seamless 1/2"SCH40 SCH 80

Up to Up to 250 350 Kg/Sq.Cm Deg.C Up to Up to 155 540 Kg/Sq.Cm Deg.C Up to Up to 190 550 Kg/Sq.Cm Deg.C Up to Up to 250 560 Kg/Sq.Cm Deg.C

1/2", 1",1.1/2",2"

Carbon Steel ASTM, A-106 Gr.B Seamless

1/2"

SCH 160

Alloy Steel ASTM, A-312 -DoGr.P11Seamless Stainless steel ASTM, A-312 Gr.TP316 Alloy Steel ASTM, A-335 Gr-II Seamless -Do-

1/2"

SCH 160

1/2"

SCH XXS

-Do-

-Do-

E9018 B3

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