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welding
PUBLICATION 143
Edition 2
Publication 143
Edition 2
EEMUA Copyright © 2017 The Engineering Equipment and Materials Users Association
Recommendations for tube end welding Publication 143
Contents
Preface������������������������������������������������������������������������������������������������������������������������������������������������������������������ VII
1. Scope�������������������������������������������������������������������������������������������������������������������������������������������������������������������1
3.1 Introduction...................................................................................................................................................................................................... 7
3.2 Test samples..................................................................................................................................................................................................... 7
3.3 Non-destructive testing............................................................................................................................................................................. 7
3.3.1 Visual examination............................................................................................................................................................................ 7
3.3.2 Radiographic examination............................................................................................................................................................ 7
3.4 Destructive testing........................................................................................................................................................................................ 7
3.4.1 Weld strength tests........................................................................................................................................................................... 7
3.4.2 Macroexamination and hardness tests.................................................................................................................................. 8
3.4.3 Ferrite test.............................................................................................................................................................................................. 9
3.4.4 Corrosion test....................................................................................................................................................................................... 9
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5.1 Cleaning............................................................................................................................................................................................................13
5.2 Tube holes.......................................................................................................................................................................................................13
5.3 Assembly..........................................................................................................................................................................................................13
6. Tube location��������������������������������������������������������������������������������������������������������������������������������������������������� 15
7.1 General...............................................................................................................................................................................................................17
7.2 Practical limits................................................................................................................................................................................................18
7.3 Weld interruption........................................................................................................................................................................................18
7.4 Preferred means of preheating............................................................................................................................................................18
8. Welding������������������������������������������������������������������������������������������������������������������������������������������������������������ 19
8.1 General...............................................................................................................................................................................................................19
8.2 Welding individually..................................................................................................................................................................................19
8.3 Distortion minimisation...........................................................................................................................................................................19
8.4 Autogenous welding.................................................................................................................................................................................19
8.5 Additional controls.....................................................................................................................................................................................19
9.1 General...............................................................................................................................................................................................................21
9.2 Heating rates..................................................................................................................................................................................................21
9.3 Additional welding.....................................................................................................................................................................................21
10.1 General............................................................................................................................................................................................................23
10.2 Samples..........................................................................................................................................................................................................23
10.3 Examination of materials......................................................................................................................................................................23
10.3.1 Tubes....................................................................................................................................................................................................23
10.3.2 Tube-plates.......................................................................................................................................................................................23
10.4 Health and Safety......................................................................................................................................................................................23
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Recommendations for tube end welding Publication 143
11.1 General............................................................................................................................................................................................................25
11.2 Dye penetrant testing............................................................................................................................................................................25
11.3 Other................................................................................................................................................................................................................25
12.1 General............................................................................................................................................................................................................27
12.2 Air testing......................................................................................................................................................................................................27
12.3 Gas leak testing..........................................................................................................................................................................................27
12.4 Other leak testing......................................................................................................................................................................................27
12.5 Leak investigation.....................................................................................................................................................................................27
13. Repairs����������������������������������������������������������������������������������������������������������������������������������������������������������� 29
13.1 Leaks.................................................................................................................................................................................................................29
13.2 Qualified procedure.................................................................................................................................................................................29
13.3 Cause of defect...........................................................................................................................................................................................29
14.1 General............................................................................................................................................................................................................31
14.2 Location..........................................................................................................................................................................................................31
14.3 Equipment....................................................................................................................................................................................................31
14.4 Tube wall thinning...................................................................................................................................................................................31
14.5 Bores.................................................................................................................................................................................................................31
15.1 Cleaning.........................................................................................................................................................................................................33
15.2 Final acceptance pressure test..........................................................................................................................................................33
15.3 Leaks.................................................................................................................................................................................................................33
15.4 Repair...............................................................................................................................................................................................................33
16.1 General............................................................................................................................................................................................................35
16.2 Heating...........................................................................................................................................................................................................35
17.1 General............................................................................................................................................................................................................37
17.2 Inspection and Test Plan (ITP)............................................................................................................................................................37
VI EEMUA Copyright © 2017 The Engineering Equipment and Materials Users Association
Publication 143 Recommendations for tube end welding
18. Records���������������������������������������������������������������������������������������������������������������������������������������������������������� 39
References������������������������������������������������������������������������������������������������������������������������������������������������������������ 41
Figures
Tables
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Preface
Publication 143 was first published under the In the interim, codes such as ASME BPVC VIII,
EEMUA banner in 1985 following the merger of the ASME IX and particularly EN ISO 15614-8:2002
Engineering Equipment Users Association (EEUA) have covered much of the same ground. This
and the Oil Companies Materials Association new Second Edition of EEMUA 143 takes
(OCMA). The Publication was originally OCMA ISO 15614-8:2016 Specification and qualification
Specification No. TEW-1: Recommendations for of welding procedures for metallic materials -
tube end welding: tubular heat transfer equipment, Welding procedure test – Part 8: Welding of tubes
Part 1 – Ferrous materials. It was written by OCMA’s to tube-plate joints as the primary source material
Welding Panel with assistance from the Heat with some additions where it was felt that the
Transfer Society. standard required further clarification, or does not
address the topic sufficiently.
A joint meeting was convened in October
1966 of members of OCMA welding panel and
representatives of the Heat Transfer Society to
exchange information on experience gained in
making welded joints between heat exchanger
tubes and tube-plates. It was the opinion of
that meeting that an urgent need existed for
standardised procedures to be established for the
design, fabrication, inspection and testing of these
and similar components. At that time, there was
no national or international standard in existence
that adequately covered this important subject.
Members pooled their knowledge and experience,
and co-operated in preparing a recommended
practice for tube end welding and testing. Such a
recommendation could then be used as a basis for
specifying requirements for the oil, chemical and
other industries.
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1. Scope
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processes
All welding processes are permissible, provided
that acceptable results and appropriate
metallurgical properties can be achieved
during procedure qualification and reproduced
consistently in production. This Publication does
not prohibit the use of any suitable welding
process.
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For certain applications, and where specified in The tube passes completely through and extends
the Purchase Order, expansion into ring groove(s), beyond the tube-plate, allowing a fillet weld
coupled with seal-welding may be utilised. to be performed on the outside diameter of
This method introduces risks if the tube is fully the tube. The fillet leg size can exceed the tube
expanded prior to welding as gases evolved/ wall thickness and is normally specified as 1.4t
released during welding will not be able to escape minimum to provide a weld throat thickness at
from the root side of the joint. Therefore, partial least equal to the tube wall thickness.
expansion to secure the tube, followed by welding This method is recommended for manual and
and final expansion is recommended. semi-automatic welding processes.
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2.4.4 External butt and fillet weld 2.4.5 Internal fillet weld
This configuration is similar to the external fillet Internal fillet welds are commonly applied using
weld, but a bevel is cut into the tube-plate allowing manual, semi-automatic, or automatic welding
the resulting butt weld throat to be supplemented processes. There is a risk of inadequate weld throat
by the fillet weld. The advantage of this design is thickness as the fillet leg length cannot exceed
that the overall weld volume is reduced and there the tube wall thickness. As a result of this
is less chance of burning through the tube wall. ISO 15614-8 table 4 item 16 has a weld throat
acceptance criterion for the macrosections of 0.9t
There is a risk of lack of fusion at the weld root on instead of the 1t that would be expected for a full
the tube-plate due to the larger wall thickness, strength joint.
particularly for manual and semi-automatic
welding. Push-through tensile tests are more likely to fail in
the weld as a result of this reduced throat thickness
t (see clause 3.4 Weld Strength Tests).
L
a = t b + 0.7L a
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A U-Groove is machined into the tube-plate to A U-Groove is machined into the tube-plate to
provide a joint that appears to be a concentric provide a joint that appears to be a matching tube
tube outside the tube. The advantage of this on the tube side of the tube-plate. This allows a
configuration is that the heat sink on the full penetration weld to be performed from the
tube-plate side is reduced to be comparable with inside of the tube and will normally require an
the tube. Furthermore, welding distortion of the additional shielding gas to be applied from the
tube-plate is minimised. outside of the tube. The preferred geometry on the
right includes a recess that centres the tube and
A disadvantage of this joint configuration is that provides additional weld metal for autogenous
the weld bead profile becomes critical to achieving welds (though see clause 8.4 of this Publication).
sufficient weld throat.
Although this configuration is shown without a
t root gap, a gap can be incorporated to allow filler
metal addition by fed wire or consumable insert
ring.
t <= D <= 2t
W=t
Figure 6 Castellated
Figure 7 Full penetration internal butt weld
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MACHINED HIGH TENSILE ROD
(SLIP FIT IN TUBE BORE)
SUPPORT
RING
MACHINED d
PLUG
BED PLATE
MACHINED HIGH TENSILE ROD The transverse sections of welds, including weld
(SLIP FIT IN TUBE BORE) craters, shall be free from cracks, fissures and lack of
fusion. Slag inclusions and gross porosity shall not
exceed the limits of ISO 15614-8 Tables 2 and 3.
LOAD IS APPLIED SLOWLY TO ENSURE NO SHOCK LOADING Hardness tests shall be carried out in accordance
IS APPLIED AND TEST CONTINUED UNTIL FAILURE OF TUBE
OR WELD RESULTS with ISO 15614-8 section 8.1.6 for all materials.
Acceptance criteria for metals that do not have
Figure 8 Weld strength tests a specified maximum in EN ISO 15614-1 shall be
as-specified for the base material specification or as
agreed between the Purchaser and Manufacturer.
The Purchaser may specify additional limits based
on application requirements.
50 mm x 50 mm x 25 mm
TENSILE
WITH TEST WELDS
M/C GRIPS
AT EACH END
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6. Tube location
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8. Welding
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9.1 General
The post-weld heat treatment of complex
assemblies such as welded tube end connections
may present difficulties. Where acceptable,
consideration should be given to methods of
eliminating the need for post-weld heat treatment,
eg. finite element analysis coupled with a fracture
mechanics assessment.
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11.1 General
After welding the tube-plate face, the welds and
the internal tube surface to a distance of at least
3mm beyond the fusion line must be cleaned
thoroughly by wire brushing and examined
carefully for surface defects. Defects such as cracks,
gross porosity, slag inclusions and lack of fusion
shall be remedied.
11.3 Other
Other examination techniques may be applied
subject to the Purchaser’s agreement. For critical
applications, as defined by the Purchaser, micro-
radiography shall be applied.
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13. Repairs
13.1 Leaks
On completion of a gas leak test, any leaks
discovered shall be repaired and retested until
all faults are remedied. The maximum number of
repairs permitted shall be agreed between the
Purchaser and Manufacturer.
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Tube expansion after welding shall lie within the Difference (Internal
zone from approximately 10mm from the weld expansion of tube): ID2-ID1
junction to 3mm from the back of the tube-plate. Initial thickness of tube: t
Tube wall thinning: ((ID2-ID1)-(IDh-OD))
* 100%
14.3 Equipment 2t
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16.1 General
The vessel shall be drained thoroughly after testing
and where specified a suitable dewatering fluid
may be used.
16.2 Heating
If the heat exchanger is required to be completely
dry, e.g. for SO2 duties, the assembly should be
heated by an appropriate method to a temperature
that is sufficiently high to remove all water,
particularly from the interstices between the tubes
and the tube-plate. If the bundles are of stainless
steel, the heat exchanger should be washed out
with water containing not more than 10ppm
chloride before heating.
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18. Records
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References
Specifications and Standards 12. ISO 3834-5 (2015) Quality requirements for
fusion welding of metallic materials - Part
1. ANSI Z49.1 (2012) / AWS Z49.1 (2012) Safety in 5: Documents with which it is necessary to
Welding, Cutting and Allied Processes conform to claim conformity to the quality
2. ASTM E562 (2011) Standard Test Method for requirements of ISO 3834-2, ISO 3834-3 or
Determining Volume Fraction by Systematic ISO 3834-4 - Second Edition
Manual Point Count 13. ISO 5172 (2006) Gas welding equipment
3. ASTM G48 (2011/R 2015) Standard Test Blowpipes for gas welding, heating and
Methods for Pitting and Crevice Corrosion cutting Specifications and tests - Third Edition
Resistance of Stainless Steels and Related Alloys (including amendments 1 & 2, 2015)
by Use of Ferric Chloride Solution
4. EN ISO 14731:2006 Welding coordination - Other References
Tasks and responsibilities
5. IEC 60974-x IEC standards for “Arc welding 14. TEMA Standards of Tubular Exchanger
equipment” - Parts 1-13 Manufacturers Association. 5th Edition, 1968.
6. ISO 11611 (2015) Protective clothing for use in 15. IIS/IIW recommendations International
welding and allied processes - Second Edition Institute of Welding “Recommended Welded
7. ISO 14114 (2014) Gas Welding Equipment Connections for Pressure Vessels”.
- Acetylene Manifold Systems for Welding, I.I.S./I.I.W. -237-66.
Cutting and Allied Processes - General
Requirements - Second Edition
8. ISO 15614-1:(2004) Specification and
qualification of welding procedures for metallic
materials — Welding procedure test — Part 1:
Arc and gas welding of steels and arc welding
of nickel and nickel alloys (+ later amendments
1 & 2)
9. ISO 15614-8:2016 Specification and
qualification of welding procedures for metallic
materials — Welding procedure test —Part 8:
Welding of tubes to tube-plate joints
10. ISO 3834-1 (2005) Quality requirements for
fusion welding - of metallic materials - Part 1:
Criteria for the selection of the appropriate level
of quality requirements - Second edition
11. ISO 3834-2 (2005) Quality requirements for
fusion welding of metallic materials - Part 2:
Comprehensive quality requirements - Second
edition
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