F [SPECIFICATION FOR INSTALLATION OF TUDES [ENGINEERING SPECIFICATION, SCIENTIFIC DESIGN Jax stRENGTH WELDING OF TUBE ENDS FOR E-106 COMPANY, INC, | CARBON AND AUSTENITIC STAINLESS STEEL [PapecT at oe Date, 28-72 Rov. 1 3-12-74 Rev, 2 SCOPE ‘This specification covers procedures for installing tubes and for strength welding of tube ends to tubecheets on reactors and shell-and-tube heat exchangers fabricated of carbon steel or austenitic stainless steel. 's Rosponstbiltt 2, The Fabricator ts responsible for furnishing a sound, leak-free vessel, The fabrication Procedures contained in this specification are for the purpose of outlining procedures which when used with proper workmanship, will produce leak-free vessels. Applicable Specifications 3, AWS-ASTM Standards (latest edition). Standards of Tubular Exchanger Manufacturers As¢ociation (TEMA ~ latest edition), Sctentific Design Company Specification E-110, Halide Leak Testing Procedure. Sctentific Design Company Engineering Standard EA-2-3. latertal of Construction 4, Materials of construction for tubes and tubesheets shall be in strict accordance with the material specifications listed on the Scientific Design Company design draviings, specifications sheets and specifications. Carbon steel used for tubes and tubesheets shall be killed steel with the carbon content limited to the percentages specified on the design drawing and/or material specification, In addition, when carbon steel 1s used for tubes and tubesheets and only when specifically called for on the design drawing, the cover side of the tubesheets shall be overlayed with @ nominal 3/16" of low carbon steel, It is important that the metallurgy of this weld overlay contain 0,15 percent meximum carbon, The cladding shall be machined to 1/8" minimum thickness and ultrasonically tested per ASTM A~435, Machining and Dring 8, Machining and drilling of tubesheets and baffles shall be done strictly n accordance with Sotentific Design Company design drawings and specifications, Tube holes in tubesheets shall be not more than 0.010" (-0.002") larger in diameter than the nominal tube diameter. ‘The Interlor surface of the tube holes shall have a smooth fintsh and be free from spiral eeratches and scores, Gleantna. 6, Tubesticet faces, tube holes, and tubes (particularly tube ends) must be thoroughly cleaned before welding of tube ends commences and cleanliness must be maintained until welding has been completed. All ofl, grease, rust, scale, dirt and other foreign matter including the protective coating on tubes as received from the mill, must be completely removed. Tube- sheets shall initially be cleaned mechanically by either wire brushing or sandblasting. Following this the tubesheets, tube holes and tube ends shall be cleaned with a solvent Bolutton, A cleaning solution consisting of one part methylene chloride and two parts xylol tg recommended. This solution shall be sprayed with an atr-pressured gun, on the tubesheets, {nto the tube holes and on the tube ends which will be within the tubesheets. Other solvents Buch as acetone or methanol are satisfactory except that they are inflammable and must be used with caution. Before welding begins, the tubesheets shall be heated to a temperature ‘as required to remove any last traces of motsture or solvent which may remain after the Cleaning operation,ENGINEERING SPECIFICATION | SPEGIFIGATION FOR INSTALLATION OF TUBES T= 106 AND STRENGTIE WELDING OF TUBE ENDS ror] SCIENTIFIC DESIGN Poge:__2___ of 4] GARSON AND AUSTENITIC STAINLESS STEEL] gQMPANY, INC. Date: 2-8-72 Rev. ‘ PTET te sitiontng ‘The tubes shall be positioned in the tubesheets by means of @ 30° tapered drift pin. Position- ing by roller expanding the tubes into the tubesheets {s not permitted. sted M: Welding Tube Ends 8, It 4s recognized that fabricators will have various and differing tube-end welding procedures which they have developed and which have proven sucessful in service. It 1s expected, however, that the procedures to be used shall be basically in accordance with the suggested general methods outlined below. In any event, bidders are required to submit with their quotations, complete and detatled descriptions of the tube end welding procedures which they propose to employ. Tw i. Gas Shielded Arc (TG) Manual Weldin This 5 the orc welding process wherein 9 weldment is produced by the melting of the tube end and tubesheet metal by means of a non-consumable tungsten electrode, Filler metal shall be added to produce welds of the proper cross-sectional thickness. Two (2) weld passes shall be deposited, Shielding is accomplished by an inert gas of welding purity fed through the welding torch, Care shall be taken to insure that a complete melt has been made on both the tubesheet and tube wall, Roll-over of weld metal into the tube which will restrict the inside diameter of the tube cannot be tolerated. This method may be used for elther carbon steel or austenitic stainless steel welding. A.typical tube joint preparation for this welding method is shown on Scientific Design Company Engineering Standard EA-2-3, Figure 2. s Metal=Are Manual Weldin This 1s the arc welding process wherein a weldment 1s produced by the melting of the tube metal and the tubesheet metal by means of a consumable coated metal electrode. Itis suitable for use on carbon steel. Shielding is obtained from the decomposition of the electrode coating. After the first pass, the slag shall be removed and the weld eened before proceeding with the second pass, Care shall be taken to be certain that 2 complete melt has been accomplished on both the tubesheet as well as the tube wall ‘and that adequate penetration has been obtained, In order to insure welds without Porosity and to reduce the possibility of underbead cracking, a high quality low hydrogen electrode such as AWS-ASTM 7016 or 7018 shall be used. Diameter of electrode shall be 3/32”. A typical tube Joint preparation for this method is shown on Setentific Design Company Engineering Standard EA~2-3, Figure 1 or 2, Electrodes must be stored in a humidity free room and protected from motsture pick-up by being kept in closed heated containers until just before use, ¢. Combination Automatic Gun Welding and Shielded Metal~Arc Manual Welding This method uses a first fuston pass made with an automatic Tungsten Inert Gas welding gun ond a second pass using shielded metal-are welding per method 8b. It {8 recommended for use on carbon steel only. A typical tube Joint preparation for this method 1s shown on Setentific Design Company Engineering Standard Eh-2-3, Figure 1 4. Combination Automatic Gun Welding and Tungsten Inert Gas Shielded Are (116) Manval Welding This method uses a first pass made with an automatic Tungsten Gas welding gun and a Second pass using Tungsten Inert Gas shtelded are (TIG) manual welding with filler metal added per method 8a. This method ts adaptable to both carbon steel and austenitic stainless steel welding. A typical tube joint preparation for this method 1s shown on Scientific Design Company Standard EA-2-3, Figure 2.| SPECIFICATION FOR INSTALLATION OF TUBES | ENGINEERING SPECIFICATION SENTING DEO |p smeicr waubinc of uRE ribs For geigg COMPANY, INC, | caRoow anD AUsTeNTnre staves srbet aoe a Date, 2-878 T I=12-78 Rev. 2 Suggested Methods of Welding Tube Ends ~ (Cont'd) 9, The throat thickness of the completed welds made by any one of the proceduré under paragraphs (82, @b,8¢ and 8d) shall not be less than 1.5 X "t" where " wall thickness, described 15 the tube 10, Tube Joint welding shalll be performed in the flat downhand position with the tubesheets horizontal wherever possible. Each tube end shall be welded individually. Welding techniques such as figure eight welding or other complex welding patterns which involve welds crossing over each other are not recommended, Weld Samples 11, At least two weeks before the scheduled beginning of production welding of tube ends, the fabricator must furnish for approval, a sample of welded tube ends fabricated exactly in accordance with the welding procedures which he proposes to employ. The semple shall Consist of at least six (6) tubes welded and expanded into @ tubesheet of the same thickness ‘as that required for the reactor or heat exchanger. The tubes and tubesheet material used for the sample welds shall be taken from the material which will be used for the fabrication of the reactor or heat exchanger. The following pertinent data shall be furnished with the weld samples: 2. Complete details of welding procedure employed. b, Mechanical properties and chemical composition of tubesheet, tubes and filler metal, ©. The hardness of the weld, the tube, the tubeshest heat affected zone and the tubesheet base metal after one weld pass is made, d. The hardness of the weld, the tube, the tubesheet heat affected zone and the tubesheet base metal, after the second weld pass ts made, @. section 1/2" thick containing the six tube end welds shall be sawed from this sample and radiosraphed for weld quality, This radiograph shall be submitted for Sctentific Design examinations, At least three (3) tubes shall be sectioned, polished, etched and mlerophotographed for examination of depth of weld penetration and definition of boundaries, The above weld samples must be furnished for all reactors. For shell-and-tube heat ex- changers they are not required unless specifically called for on the drawing or Purchase Order, Air Soap Test 12. Atest shall be made after completion of the first weld pass with 20 psig of alr on the shell side and a bubble forming solution applied to the tubesheets to test the tightness of the first Pass. Procedures outlined in ASME Section V, Article 10, T,1030 Gas and Bubble Formation Testing, shall be followed. Eirst Liquid Penetrant Exemination 13, After tube end welding has been completed, a liquid penetrant examination of the tube end welds shall be performed in accordance with Methods for Liquid Penetrant Examination, ASME Section VIL, Division 1, Appendix VIII and Liquid Penetrant Examination, ASME Section V, Article 6. Before conducting'thts test, the faces of carbon steel tubesheets shall be sand= blasted to remove all weld slag, must and scale. * First Halide Test 14, After the first Uquid penetrant examination has been successfully completed and before the tubes are expanded, the welds shall be tested for leaks per Scientific Design Company Specification E-110, Halide Leak Testing Procedure and ASME Section V, article 10, T-1040 Halogen Diode Detector Testing.ENGINEERING SPECIFICATION | SPEGIFIGATION FOR INSTALLATION OF TUDES E106 AND STRENGTH WELDING OF TUBE ENDs ror] SCIENTIFIC DESIGN a ar CARBON AND AUSTENITIG STAINLESS STEEL] ” COMPANY, INC, Date: 20-72 Rov. 1 | F107 ube r 18. After the first halide test has been successfully completed and all leaking welds repatred, the tubes shall be "contact expanded” with a parallel type expander, Contact expanding 45 intended to bring the tube O,D, into contact with the tube hole without displacement of metal, 4n order to prevent cold working of the tube welds as might be caused by vibrations uring shipping or operation and to minimize the probability of crevice corrosion, Contact ‘expanding shall begin 1/2 inch (12mm) from the front face of the tubesheet and extend to 1/8 inch (3mm) from the back face, Second Liquid Penetrant Examination 16, After the tube rolling has been completed, the vessel shall be given a second liquia penvirant ‘examination In accordance with ASME Section VII, Division 1 Appendix VIIT and Liquid Penetrant Examination, ASME Section V Article 6. Bavelope Test 17, Next, as a further test for leaks, the tubesheets shall be securely wrapped in plastic sheets ‘and the vessel allowed to remain under test pressure with the halogen tracer on the shell side for a period of 10 to 12 hours. ‘Then with the detector set at a maximum sensitivity, the probe shall be Inserted through the plastic cover at the bottom of the tubesheets and readings taken to observe if any leakage has occurred. Hydrostatic Test 18, The equipment shall finally be hydrostatically tested for at least one hour at the test pressure indicated on the drawing and/or in the specification sheet. Shop Repatr Procedures 19, If leaks are found during any of the above testing procedures, repairs shall be made by re~ moving the defects down to sound parent metal and repeating the weld procedure per paragraph 8. All weld repairs must be retested in accordance with thetest procedures outlined above, Test and Repair Reports 20, The Fabricator shall furntsh certification that the tests required under paragraphs 12, 13414, 16,17 and 18 have been successfully completed, Included with these certifications shall be a description of the number of leaks discovered on each test and the extent of the repair required.