APPENDIX 28
ALTERNATIVE CORNER WELD JOINT DETAIL FOR
BOX HEADERS FOR AIR-COOLED HEAT
EXCHANGERS
28-1 GENERAL
For box headers for air-cooled heat exchangers using
a multipass corner weld joint constructed in accordance
with Fig. 28-1, the rules of UW-13(e)(4) and Fig. UW-
13.2 shall be supplemented as described below.
28-2 SUPPLEMENTARY
REQUIREMENTS
This Appendix only replaces the requirement, “a +
b not less than 2ts” of UW-13(e)(4) and the weld joint
geometry of Fig. UW-13.2. All other rules in the Code
pertaining to welded joints shall apply.
In addition, the following shall apply.
28-2(a) A sample corner weld joint shall be prepared
to qualify the weld procedure; and a sample corner
weld joint shall be prepared to qualify each welder or
welding operator. The Manufacturer shall prepare the
sample corner weld joint with nominal thickness and
configuration matching that to be employed with the
following tolerances:
28-2(a)(1) the sample thinner plate shall match
the thickness of the production thinner plate within
±1⁄4 in.;
28-2(a)(2) the sample thicker plate shall be at
least 1.5 times the thickness of the sample thinner plate.
The sample shall be sectioned, polished, and etched
to clearly delineate the line of fusion. Acceptability
shall be determined by measurements of the line of
fusion for use in the calculations for compliance with
Fig. 28-1. The sample shall be free from slag, cracks,
and lack of fusion. A sample corner weld shall be
prepared for each P-Number, except that a sample
prepared to qualify a joint made from material with a
given value for K [see 28-2(d)] may be used to qualify
a joint made from material having an equal or higher
value for K but not vice versa.
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28-2(b) This sample corner weld joint is an addition
to the Welding Procedure Specification Qualification
and the Welder and Welding Operator Performance
Qualification requirements of Section IX. The following
essential variables apply for both the procedure and
performance qualification, in addition to those of Sec-
tion IX:
28-2(b)(1) a change in the nominal size of the
electrode or electrodes used and listed in the PQR;
28-2(b)(2) a change in the qualified root gap
exceeding ±1⁄16 in. (±1.6 mm);
28-2(b)(3) addition or deletion of nonmetallic re-
tainers or nonfusing metal retainers;
28-2(b)(4) a change in the SFA specification filler
metal classification or to a weld metal or filler metal
composition not covered in the specifications;
28-2(b)(5) the addition of other welding positions
than those qualified;
28-2(b)(6) for fill passes, a change in amperage
exceeding 25 amp, change in voltage exceeding 3 v;
28-2(b)(7) a change in contact tube to work distance
exceeding 1⁄4 in. (6 mm);
28-2(b)(8) a change from single electrode to multi-
ple electrodes, or vice versa;
28-2(b)(9) a change in the electrode spacing;
28-2(b)(10) a change from manual or semiauto-
matic to machine or automatic welding or vice versa.
28-2(c) After production welding, the back side of
the weld shall be subjected to a visual examination to
assure that complete fusion and penetration have been
achieved in the root, except where visual examination
is locally prevented by an internal member covering
the weld.
28-2(d) K, the ratio of through-thickness (Z direction)
tensile strength to the specified minimum tensile
strength, shall be taken as 0.6. Higher values for K,
but not higher than 1.0, may be used if through-
thickness tensile strength is determined in accordance
 Fig. 28-1 2001 SECTION VIII — DIVISION 1

Construction line
for a2 and
= 45 deg min.
Weld preparation

Line of fusion a2 / ts
not less
K than
0.6 0.29
a2 0.7 0.23
ts 0.8 0.17
0.9 0.09
1.0 0

Positive penetration but

need not exceed 1/8 in. (3.2 mm)
Z - Direction

(a) Details for One Member Beveled

Construction line
for a2 and
= 45 deg min.
Weld preparation

Line of fusion

a2
ts
a (Ref.)

Positive penetration but

Z - Direction need not exceed 1/8 in. (3.2 mm)

b (Ref.)

See sketch (a) above for table with values of K and a2 / ts

(b) Details for Both Members Beveled

FIG. 28-1

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 28-2 APPENDIX 28 — MANDATORY
with Specification SA-770. The test results, including
the UTS in addition to the reduction in area, shall be
reported on the Material Test Report, in addition to
the information required by Specification SA-20 when
the testing in accordance with Specification SA-770 is
performed by the material manufacturer. If the testing
is performed by the vessel Manufacturer, the test result
shall be reported on the Manufacturer’s Data Report.
See UG-93(b) and UG-93(c).
28-2(e) The maximum value of ts (see Fig. 28-1)
shall be limited to 3 in. (76 mm).
01 28-2(f) Both members may be beveled as shown in
Fig. 28-1 sketch (b). When the bevel angle (␣) is large
enough to satisfy the UW-13(e)(4) requirements, the
alternative rules of this Appendix do not apply. When
the bevel angle (␣) results in weld fusion dimensions
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28-2
that do not satisfy the UW-13(e)(4) requirement that
a + b is not less than 2ts, the following shall be
satisfied.
28-2(f)(1) The angle (␣) shall be equal to or
greater than 15 deg.
28-2(f)(2) The dimension a2 shall be measured
from the projected surface of the plate being attached
as shown in Fig. 28-1 sketch (b).
28-2(f)(3) The angle (␤) shall be equal to or
greater than 15 deg.
28-2(f)(4) All other requirements of this Appendix
shall be applied.
28-2(g) When all the requirements of this Division
and the supplemental requirements of this Appendix
have been met, the following notation shall be entered
in the Manufacturer’s Data Report under Remarks,
“Constructed in conformance with Appendix 28.”