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WELDED ASSEMBLY
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E-GS-9-5-2
GENERAL SPECIFICATION Rev. D
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CONTENTS
1 INTRODUCTION 3
1.1 Scope of Application 3
1.2 Definitions 3
1.3 Codes, Standards, Regulations and Air Liquide Reference Documents 3
1.4 Contradictions, Omissions, Deviations 4
1.5 Subcontractor's liability 4
2 QUALIFICATION 5
2.1 WPS & PQR realization 5
2.2 Specific requirements for welding procedures 5
2.3 Qualification of Welders, Welding Operators 8
2.4 Filler and metal qualification 9
6 SPECIAL CASES 22
6.1 Backing ring 22
6.2 Reinforcement plate “Saddle” 23
6.3 Repairs to Welds 23
7 BRAZING 24
8 APPENDIX 25
8.1 Appendix 1 25
8.2 Appendix 2 26
8.3 Appendix 3 27
8.4 Appendix 4 28
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WELDED ASSEMBLY
1 INTRODUCTION
This standard sets the general rules applicable for welds on industrial pipes.
Air Liquide Standard E-GS-9-5-1, Prefabrication and Assembly of Pipes, defines the rules applicable to the
construction of industrial pipes.
1.2 Definitions
See standard AIR LIQUIDE E-GS-9-5-1
WPS Welding procedure specification
PQR Procedure qualification record
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WELDED ASSEMBLY
In the following order of precedence: Local Regulations, Recognized National Construction Codes, ASME Code B
31.3, ASME Code B 31.1.
If no codes are laid down by the local regulations, either the European directives and standards or the following
codes will apply:
ASME IX
For the welding of stainless steels: ASME VIII division 1
For the requirements specific to the welding of stainless steels for cryogenic service: UHA 51
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2 QUALIFICATION
The welding procedures selected by the Subcontractor and approved by Air Liquide, must be suitable for the project
assemblies, authorized by the code or contractual standards and allow the inspection required for the construction
category of the concerned piping.
The welding procedures are defined and qualified according to local regulations. If no statutory rules apply, the
welding procedures are defined and qualified according to European standards or the ASME code. The
subcontractor is responsible for his welding work and must therefore carry out the necessary tests (PQR) to qualify
the welding procedures before issuing the WPS.
The welding procedures must cover all dimensions, thicknesses and grades of the materials chosen for the project.
They are specific to each material and must be described in a document written by the Subcontractor, made
available to the Inspection organization.
PQR and WPS must be submitted to Air Liquide one month before the beginning of prefabrication.
2.2.2 Aluminium
All passes are carried out with TIG process
2.2.3 Stainless steel for cryogenic service (ASU network: oxygen, nitrogen, argon etc..)
For work on equipment or piping for cryogenic service made of SS, the PQR must meet the specific requirements
and the additional constraints laid down in the codes concerning the cryogenic service, i.e. (non exhaustive list):
Impact strength at very low temperature -196°C (traceability on the PQR)
Referenced and compatible filler products < 10% on all the weld seam and measurement of ferrite contents.
Welding energy during construction less than or equal to the energies used during qualifications.
Stricter thickness ranges for the qualification of the various processes.
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2.2.7 Heterogeneous welds (carbon steel/stainless steel) are accepted only for non cryogenic services
Heterogeneous welds are accepted on pipe for hot service but are forbidden for cryogenics services.
Filler metal will be 309 L or nuance upper in nickel – TIG process shall be used only one first root pass.
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WELDED ASSEMBLY
o Resilience test shall be done at –20°C – the result shall not be less than 30 J and none of the value
of the three results shall be less than 27 J
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Sb Antimony
Sn Tin
As Arsenic
A complementary analysis by a specialised laboratory shall be done by the subcontractor if the value of the
chemical elements here above are not mentioned in the mill certificate.
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WELDED ASSEMBLY
3.2 Valves
The Subcontractor will remove or protect any unit or accessory which could be damaged by temperature increases
due to welding or chemical treatment (inner Teflon lining of valves, etc…).
While welding the valves bodies the valves flaps will be left open to avoid any damage
Before welding the internal parts are removed from:
o Valves with small cross section
o High tightness valves.
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WELDED ASSEMBLY
The measurement ring must be dismantled and given to Air Liquide before positioning flanges on the pipe.
The use of scribes and compasses with sharp points is prohibited. Markings must be made with chorine free ink
systems.
Any contact with copper, metals containing copper, or mercury (liquid or vapour) is prohibited.
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3.8.3 Aluminum
Thermal (plasma) cutting or sawing is used, the chamfers are prepared:
By machine (milling cutter) or manually with a file.
Grinding with abrasive discs is prohibited, use of saw of mill is obligatory.
If thermal cutting is used, the surfaces will be cleaned by milling or filing to remove any signs of spatter.
The ends are prepared in the same way as the welding method used (geometry and machining means).
3.9 Tapping
If components of different thicknesses need to be assembled, tapping (inner and/or outer) is mandatory.
The thicker part is reduced so that the connection slope does not exceed ¼.
However, with prefabricated elbows of small radius (R = D or R = 1.5 D), the slope can be reduced to 1/3.
For pipes subject to pressure cycle, the connection slope is th. + 10 mm.
3.10.1 Preparation
The sections can be correctly positioned through the use of flanges, with no tension or stress on the parts to be
assembled.
Whether or not the parts to be assembled are positioned or adjusted using temporary parts, the edges are
assembled and prepared according to the welding procedure by qualified personnel.
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m max = 0.5 Th
Th = thinnest thickness of the branch connection with m < 3.2 mm.
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Figure 1
Not acceptable
Acceptable
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On horizontal pipes, the pulse inlets must be fitted on the upper generator of the pipe.
Figure 2
Top
Bottom
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4.1.2 Inerting
Air Liquide accepts inerting with nitrogen for stainless steel lines. If the WPS stipulates inerting with argon, it is
permitted to replace the argon by nitrogen. This is possible since the inerting gas is not an essential variable and its
purpose is to keep the environment free from oxygen.
In case of specific requirements or in the event of inerting difficulty, a mixture of argon or nitrogen with up to 3%
hydrogen is permitted. (H2 simplifies the removal of O2).
SAFETY: During the total or partial inerting the subcontractor will take all necessary measures to detect and
neutralize any leaks of nitrogen / argon, etc. Risk of anoxia.
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Figure 3
< 60°
Interior
< 30°
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6 SPECIAL CASES
6.1.2 The backing ring may be authorized for the following reasons
To protect the weld on the penetration side, to avoid bubbling of the austenitic steel if inerting inside the pipe is
technically impossible.
To maintain the puddle and regularity of the root pass for aluminium only when making closing welds.
Unless otherwise indicated, the support ring must have the same thickness as the tube to be welded (stainless steel
only).
Backing ring can only be used for tube with tube assemblies (same outer diameter) and tube with accessory
assemblies on condition that they have a minimum straight length of 15 mm.
The longitudinal closure weld of the backing ring is made under the same quality conditions as the pipe weld
(approved welding process, carried out by qualified welders). The Air Liquide representative can request, at the
subcontractor's expense, an examination of the longitudinal weld by dye penetration test. The weld is ground down
on the outside to allow insertion and radiographed for possible repair of any faults (spot check).
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7 Brazing
For all this kind of job Air Liquide asks for welder qualification.
Brazing used: 45% Silver
The filler metal must be able to melt and flow freely at the temperature indicated in the brazing procedure and adapt
perfectly to the type of flux.
This metal must wet and adhere perfectly the surfaces to be joined.
The flux is a fluid chemically active at the brazing temperature. It is used to remove any oxidation from the rod and
the surfaces to be joined. It helps the brazing metal to flow between the parts.
To minimize oxidation, the joint to be brazed must be raised to the correct temperature as quickly as possible
without excessive overheating.
Any remaining flux must be brushed or filed off.
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8 APPENDIX
8.1 Appendix 1
Figure 4
ALIGNMENT
FAULTS
BUTT
WELD
e
a and b =< [ e / 13 +0.2]
b
SLOPE
25% max
45° max
1.5e
a =< 0.3mm
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8.2 Appendix 2
Figure 5
ALIGNMENT
DEFECT
A/ Butt Welds
a
e
a and b =< [ e / 50 +0.5]
b
SLOPE
25% max
45° max
1.5e
a =< 0.6mm
SLOPE
a=0,8mm max uniform
25% max
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8.3 Appendix 3
The welding angle is greater than 120 °.
Figure 6
>120°
D
This type of defect most noticeable on thin austenitic steels must remain less than the following limits:
Table 1
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8.4 Appendix 4
Figure 7
a) g 1.5 to 3
g>=0.7e
g 1.5 to 3
b)
g>=0.7e
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