6.

5 Tube-to-Tubesheet Welding Procedures

Tube-to-tubesheet welds have many factors affecting weld quality that are different than that for conventional groove and fillet welds. These factors result mainly from the unique geometry of the welds. Therefore, a demonstration mockup in accordance with ASME IX QW-193 may be required by the construction code or proprietary company specifications.

6.5.1

Essential Variables

The types of essential variables listed in ASME IX QW-288, in addition to those listed in Section 6.2.1 above, include:

Joint configuration Tube and tubesheet thickness Ligament thickness Multi versus single pass Welding position Interpass temperature Tube expansion Cleaning method Electrode or filler metal diameter Inserts Specific requirements for explosive welding l. Weld process and type m. Vertical position progression n. P# and A# o. Preheat p. PWHT q. Weld current level

r. Polarity or current type s. Welding type t. F Number u. Shielding gas v. Gas flow rate

6.5.2

Procedure Qualification Test

The procedure qualification test requirements for tube-to-tubesheet welds are specified in ASME IX QW-193. The tests include:

Visual Dye penetrant Macro examination of weld cross sections

Other testing that may be specified by the construction code or proprietary company specifications include:

Hardness testing Shear load test in accordance with ASME VIII, Div. 1, Appendix A

7.0 Welding Materials 7.1 General Welding materials refers to the many materials involved in welding including the base metal, filler metal, fluxes, and gases, if any. Each of these materials has an impact on the WPS and the weldment properties. An understanding of the conventions used by the ASME Section IX is necessary to adequately review qualified welding procedures. 7.2 P-Number Assignment to Base Metals Base metals are assigned P-numbers in ASME Section IX to reduce the number of welding procedure qualifications required. For ferrous base metals having specified impact test requirements, group numbers within P-numbers are assigned. These

assignments are based on comparable base metal characteristics such as composition, weldability, and mechanical properties. Table 1 lists the assignments of base metal to P-numbers. A complete listing of P-number, S-number, and group number assignments are provided in QW/QB-422 of ASME Section IX. This list is an ascending sort based on specification numbers. Specification numbers grouped by P-number and group number are also listed in ASME Section IX nonmandatory Appendix D. Within each list of the same P-number and group number, the specifications are listed in an ascending sort. 7.3 F-Number Assignment to Filler Metals Electrodes and welding rods are assigned F-numbers to reduce the number of welding procedure and performance qualifications. The F-number groupings are based essentially on their usability characteristics, which fundamentally determine the ability of welders to make satisfactory welds with a given process and filler metal. Welders who qualify with one filler metal are qualified to weld with all filler metals having the same F-number, and in the case of carbon steel SMAW electrodes, may additionally qualify to weld with electrodes having other F-numbers. For example, a welder who qualified with an E7018 is qualified to weld with all F-4 electrodes, plus all F-1, F-2, and F-3 electrodes (with backing limitations). The grouping does not imply that base metals or filler metals within a group may be indiscriminately substituted for a metal, which was used in the qualification test. Consideration should be given to the compatibility of the base and filler metals from the standpoint of metallurgical properties, post-weld postweld heat treatment, design and service requirements, and mechanical properties. A complete list of F-numbers for electrodes and welding rods is given in ASME Section IX, Table QW-432. 7.4 AWS Classification of Filler Metals An AWS classification number identifies electrodes and welding rods. The AWS classification numbers are specified in ASME Section IIC under their appropriate SFA specification number. ASME Section IX Table QW-432 lists the AWS classification numbers and SFA specification numbers included under each of the Fnumbers. Note that the Xs in the AWS classification numbers represent numerals, i.e. the AWS classifications E6010, E7010, E8010, E9010, and E10010 are all covered by F-number 3 (EXX10). Appendix A contains additional details on the conventions used in identification of filler metals for the welding processes. 7.5 A-Number To minimize the number of welding procedure qualifications, steel and steel alloy filler metals are also grouped according to their A-number. The A-number grouping in ASME Section IX, Table QW-442 is based on the chemical composition of the deposited weld metal. This grouping does not imply that filler metals may be

indiscriminately substituted without consideration for the compatibility with the base metal and the service requirements. 7.6 Filler Metal Selection Inspectors should verify the filler metal selection is appropriate for the base metal being welded. Some considerations in selection include: a. Chemical composition of filler metal. b. Tensile strength of filler metal and base metal. c. Dilution of alloying elements from base metal. d. Hardenability of filler metal. e. Susceptibility to hot cracking. f. Corrosion resistance of filler metal. Appendix D provides a guide of common filler metals for base metals most often used in petrochemical plants. In addition, there is a table comparing the current AWS filler metal classification to the previous ones for low-alloy steels. AWS modified the classifications for several common low-alloy filler metals. 7.7 Consumable Storage and Handling Welding consumable storage and handled guidelines should be in accordance with the consumable manufacturers instructions and guidelines and as given in the AWS A5.XX series of filler metal specifications. Covered electrodes exposed to moisture can become unstable due to moisture pickup by the coating. Particularly susceptible to moisture pickup are coatings on low-hydrogen electrodes and stainless steel electrodes. Moisture can be a source of hydrogen. To reduce exposure to moisture, certain welding consumables should be stored in warm holding ovens after they have been removed from the manufacturers packaging. Low-hydrogen SMAW electrodes supplied in non-hermetically sealed containers must be baked according to manufacturers instructions prior to use. Lowhydrogen electrodes They should be stored separately from other types of electrodes with higher hydrogen content, as this can be another source for hydrogen pickup. Some welding consumables that are slightly damp can be reconditioned by baking in separate special ovens. Ovens should be heated by electrical means and have automatic heat controls and visible temperature indications. Ovens should only be used for electrode storage as using them for food storage or cooking could cause electrode coatings to absorb moisture. Any electrodes or fluxes that have become wet should be discarded.

8.0 Welder Qualification

8.1 General Welder performance qualification is to establish the welders ability to deposit sound weld metal. Similar to welding procedure qualification, this section reflects the parameters in the referencing code or typically referenced to ASME Section IX. Other codes exist which utilize other means for welder qualification. The term welder is intended to apply to both welders and welding operators for the purpose of the following descriptions. The welder qualification is limited by the essential variables given for each process. A welder may be qualified by radiography of a test coupon or of an initial production weld or by bend tests of a test coupon. Some end users and codes limit or restrict the use of radiography radiography. Welding operators making a groove weld using SMAW, SAW, GTAW, PAW, EGW, and GMAW (except short-circuiting mode) or a combination of these processes, may be qualified by radiographic examination, except for P-No. 21 through P-No. 25, P-No. 51 through P-No. 53, and P-No. 61 through PNo. 62 metals. Welding operators making groove welds in P-No. 21 through P-No. 25 and P-No. 51 through P-No. 53 metals with the GTAW process may also be qualified by radiographic examination for this purpose such as radiography is not allowed for GMAW-S by ASME Section IX. The responsibility for qualifying welders is typically restricted to the contractor or manufacturer employing the welder and cannot be delegated to another organization. However, some codes such as B31.3 may modify this rule and generally it is permissible to subcontract test specimen preparation and NDE. 8.2 Welder Performance Qualification (WPQ) The WPQ addresses all essential variables listed in QW-350 of ASME Section IX. The performance qualification test coupon is to be welded according to the qualified WPS, and the welding is supervised and controlled by the employer of the welder. The qualification is for the welding process used, and each different welding process requires qualification. A change in any essential variable listed for the welding process requires the welder to re-qualify for that process. QW-352 through QW-357 in ASME Section IX, list the essential variables and referencing code paragraphs for different welding processes. The variable groups addressed are: joints, base metals, filler metals, positions, gas, and electrical characteristics. The record of the WPQ test includes all the essential variables, the type of test and test results, and the ranges qualified. The format of the WPQ is not fixed provided it addresses all the required items. An example form is available in ASME Section IX Form QW-484 in nonmandatory Appendix B. Mechanical tests performed on welder qualification test coupons are defined in ASME Section IX, QW-452 for type and number required. If radiographic exam is used for qualification, the minimum length of coupon to be examined is 6 in. (152.4 mm), and includes the entire weld circumference for pipe coupons. Coupons are required to pass visual examination and physical testing, if used. Rules for

qualification of welding operators using radiography require 3 ft (0.91 m) length to be examined. There are rules (e.g. ASME Section IX) for the immediate retesting of welders or welding operators who fail a qualification test and is commonly referred to as the two for one rule whereby the welder/operator must be tested on twice the original extent of tests. Welders or welding operators who fail the second test typically have to be sent for retraining but no clear guidance is provided to inspectors on what constitutes retraining. The reality is that for most standard materials and welding processes a welder/operator who cannot pass a test in two attempts is significantly deficient and one has to ask the question would you want that individual welding on pressure equipment. Inspectors should insist that clear documented evidence of retraining and production of acceptable practice welds has been achieved Documented evidence of retraining and production of acceptable practice welds should be presented to the inspector before allowing a further test.

Welder performance qualification expires if the welding process is not used during a six-month period. The welders qualification can be revoked if there is a reason to question their ability to make welds. A welders log or continuity report can be used to verify that a welders qualifications are current. 8.3 Reviewing a WPQ 8.3.1 Review Prior to Welding Prior to any welding, inspectors should review welders WPQ to verify they are qualified to perform the welding given its position and process. When reviewing a WPQ, items to check include: a. Welders name and stamp number. b. Welding process and type. c. Identification of WPS used for welding test coupon. d. Backing (if used). e. P-number(s) of base metals joined. f. Thickness of base metals and diameter if pipe. g. Filler metal SFA number. h. Filler metal F-number. i. Consumable insert (if used). j. Deposited thickness (for each process used).

k. Welding position of the coupon. l. Vertical weld progression. m. Backing gas used. n. Metal transfer mode (if GMAW). o. Weld current type/polarity (if GTAW). p. If machine weldedrefer to QW-484 for additional values required. q. Guided bend test type and results, if used. r. Visual examination results. s. Additional requirements of the construction code. t. Testing organization identification, signature, and date. u. X-ray Radiographic results (if used) if used. 8.3.2 Verifying the Qualification Range The following ASME Section IX references should be used to verify the qualification range: a. Base metal qualificationQW- 423.1 and QW-403.15. b. BackingQW-350 and QW-402.4. c. Deposited weld metal thickness qualificationQW-452.1 (if transverse bend tests) and QW-404.30. d. Groove weld small diameter limitsQW-452.3 and QW-403.16. e. Position and diameter limitsQW-461.9, QW-405.3 and QW-403.16. f. F-numberQW-433 and QW-404.15. Welder Qualifications for Tube to Tubesheet Welding

When a demonstration mockup in accordance with ASME IX QW-193 is required by the construction code or proprietary company specifications the welder qualification requirements have the same essential variables and acceptable ranges as in the welding procedure qualification (WPQ) requirements used to support the welding procedure specification (WPS).

9.0 Non-destructive Examination 9.1 Discontinuities Non-destructive Examination (NDE) is defined as those inspection methods, which allow materials to be examined without changing or destroying their usefulness. NDE is an integral part of the quality assurance program. A number of NDE methods are employed to ensure that the weld meets design specifications and does not contain defects. The inspector should choose an NDE method capable of detecting the discontinuity in the type of weld joint due to the configuration, and required sizes as demanded by the accept/reject criteria. Table 2 and Figure 11 list the common types and location of discontinuities and illustrates their positions within a butt weld. The most commonly used NDE methods used during weld inspection are shown in Table 3. Table 4 lists the various weld joint types and common NDE methods available to inspect their configuration. Table 5 further lists the detection capabilities of the most common NDE methods. Additional methods, like alternating current field measurement (ACFM), have applications in weld inspection and are described in this section but are less commonly used. The inspector should be aware of discontinuities common to specific base metals and weld processes to assure these discontinuities are detectable. Table 6 is a summary of these discontinuities, potential NDE methods and possible solutions to the weld process.