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QW-193 Tube to Tube-sheet

Mock up and Macro (Etching)
Examination
Published on December 5, 2019

Author owns the copyrights of the photo.

Libin Babu, P.E, CMQ/OE, CWI

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ASME Certifying Engineer

ASME Section IX has recently added a new requirement to qualify a

procedure for every Strength weld (calculated as per UW-20.6). The
method to qualify the procedure is explained in QW-193 and Essential
variables under consideration is explained in QW-288.

Basically, the acceptance criteria includes only visual tests that ensure a
complete weld. No mechanical tests like Bending test or Tensile test
involved in the Procedure Qualification. However, a calculation as per
UW-20.6 have to be performed to determine the weld thickness in order
to qualify it as a "Strength Weld". This calculation will take care of the
mechanical strength aspects. In combination with this calculation, QW-
193 procedure will complete the Code requirements of Strength weld
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qualification.

QW-193.1.1 explains the Visual Examination Criteria. Basically

inspector will check for complete fusion, burn through, porosity and
cracking without any Magnification. This could be performed by
anyone who has experience in finding weld defects. ASME doesn't
mandate any qualification requirement to perform this.

QW-193.1.2 requires an Liquid Penetrant Examination as per Section V

and Article 6. It has to be performed by a qualified individual.

QW-193.1.3 requires a Macro-Examination using a 10 to 20 times

Magnifying glass. Code don't explain this in details except that the
inspector is supposed to check the Minimum leakage path, Complete
Fusion, Crack etc. Minimum Leakage Path mentioned is the thickness
calculated in UW-20 (ar). The maximum value for this thickness is the
tube wall thickness.

The Four Surfaces mentioned in the Code are the weld profiles created
when cutting a Tube to Tubesheet Joint through its Diameter. Minimum
Ten (10) tubes are to be welded to the tubesheet and verified as per the
Code in order to qualify a mock up procedure.

QW-470 explains how to perform etching and suggests a few preferred

Etching solutions. But there are many more Etchants available in the
market. The only purpose is to create a sharp and clear contrast
between the weld metal and base metal in order to facilitate a complete
inspection as per the Code.

It is advised to use chemical protection gloves when the Macro

examination is performed. Keep clean water near the test set up for
rinsing eyes or skin in case of any spill of Etchant happens. Some
Etching solutions works best when the base metal is slightly heated to
about 100-150F. Some shall never be heated. Always follow the
instructions on the label. Cotton sticks are preferred to apply the
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Etching solution on the weld. Preferred light intensity over the test set
up is 100 foot candles.

First clean the surface with water and dry well. Apply the Etching
solution with Cotton Sticks over the weld profile for about 30 seconds
or until sufficient color contrast between the weld and basemetal
become available for inspection. Sometimes rinsing off the Etching
solution with clean water and wiping it clean will enable a better view
of the weld profile.
Use a Magnifying glass from 10 to 20 times Magnification to look at
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each weld profile and examine if it meets the Code acceptance criteria
as per QW-193.1.3. A Map or Drawing of the Tube to Tubesheet Mock
up piece will help to mark the results quickly as the inspection
progresses. It is important to trace back which tube joint is defective if
there is any.

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Published by
Libin Babu, P.E, CMQ/OE, CWI 12 articles Follow
ASME Certifying Engineer
Published • 2y

ASME Tube to Tubesheet Mock up as per QW-193

#ASME #heatexchangers #Strengthweld # #mockup #tube #BoilerCode #SectionIX

#Macroexamination #Etching #UW-20 #QW-193 #ASMEBPVC
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Brandan Langlinais •
3rd+ 8mo
Operations Manager at Faircloth Metallurgical Services, LLC

The minimum leak path is the distance from the root of the weld to the surface
nearest the root. This is not the thickness calculated in UW-20. We have performed
hundreds of these macro exams. See the photomicrograph pictured below of a
macro exam with a measurement of the minimum leak path.

Like Reply

Arun Ramu •
3rd+ 10mo
Founder & CEO @ MachineMaze - Print to Part | MAAS - Manufacturing as a Service

Libin, Interesting!

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Libin Babu, P.E, CMQ/OE, CWI

ASME Certifying Engineer

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