Instrumentation Tubing and Their Connections

15.0 Welding Methods

15.1 300 Series Stainless Steels

May be welded by the TIG, MIG, or stick arc-weld process. TIG welding is recommended as
being best for welding Weld fitting systems because it allows better operator control of heat
penetration and filler material deposition. Stick arc welding is not recommended in many cases
because of the likelihood of excessive burn-through and improper root penetration. In all cases
where stick welding is used, it is recommended that backing gas be used. MIG welding gives the
same characteristics as stick electrode welding with faster deposition of the filler material.

As this process runs hotter than the stick process, the use of a backing gas is mandatory. It
should be noted that in welding the relatively small fitting sizes, filler deposition rate economies
are not a factor and therefore the MIG method is not commonly applied.

15.2 C1018 Steel Fittings

May be welded by the TIG, MIG, stick and oxyacetylene methods. As scale formation remains a
problem, the use of a backing gas is still recommended.

Carbide Precipitation
When un-stabilized stainless steels are heated to 800 - 1500 F during welding, the chromium in
the steel combines with the carbon to form chrome carbides which tend to form along the grain
boundaries of the metal (carbide precipitation). This lowers the dissolved chromium content in
these areas and thus lowers their corrosion resistance, making them vulnerable to intergranular
corrosion. Carbide precipitation is reduced by holding the carbon content of the material to a
very low value. This limits the amount of carbon available to combine with the chromium. The
L series (extra low carbon) stainless steels are often used for this purpose, but their use reduces
system design stress by approximately 15%. Weld fittings are made from a select 316 series with
carbon content in the low range of 0.04 to 0.07 percent. This results in a welded fitting with good
corrosion resistance and a high strength factor. All weld fittings in stainless steel are supplied in
the solution-treated condition, capable of passing ASTM-A-262 Tests for Detecting
Susceptibility to Intergranular Corrosion.

15.3 TIG WELDING

The "TIG" in TIG welding stands for Tungsten Inert Gas. But before it was called TIG" it was
given the name "Heliarc" because helium was the gas that was used when the process was
invented. But then someone discovered that argon worked better and so it was called TIG
because inert gas could refer to either helium or argon. But wait, then someone else discovered
that small additions of hydrogen worked well for some metals. The word "Inert" no longer held
true so it was decided that a new name was required. So nowadays, the technical term for what
used to be called TIG and Heliarc is Gas Tungsten Arc Welding or "GTAW". People still call
it TIG and even Heliarc. In fact more people call it TIG welding than Gas Tungsten Arc
Welding.

TIG welding is akin to gas welding as far as welding technique in that the torch is held in one
hand and the filler rod is manipulated with the other hand. It is considered more difficult than
other arc welding processes because it requires the use of both hands. Often times a foot pedal
amperage control is also used which adds another layer of difficulty.

A TIG torch can be either water cooled or air cooled and is designed to provide shielding gas as
well as welding current through a tungsten electrode. A ceramic nozzle directs the shielding gas
to the weld puddle and internal copper parts like the collet and collet body hold the electrode in
place. The tungsten electrode is sharpened for applications where the arc needs to be pinpointed
and for very low amperage. The heat the melts the metal and makes the weld puddle comes from
the arc that is created between the tungsten electrode and the work piece. The arc is shielded by
argon, helium, or a mixture of the two. Sometimes for certain alloys, hydrogen is added in small
percentages to improve the way the puddle flows. The arc is very smooth and quiet and clean
when DC current is used. When the TIG welding machine is set on Alternating current, it is
slightly more noisy but still clean and smooth.

What Metals can be welded using the TIG process?

Almost any metal can be welded with TIG. Carbon and low alloys steels like 1010 carbon steel
and 4130 chromoly steel, Stainless steels like 304, 321, and 17-7ph, Nickel alloys like inconel
718 and Hastelloy X, Aluminum alloys like 6061, 5052, Magnesium alloys like az31b, Titanium
alloys like commercially pure, and 6al4v, Cobalt alloys like Stellite 6b and l605, copper alloys
like Nibral bronze and pure copper, All can be welding using the TIG welding process.

15.4 ORBITAL TUBE WELDING

Orbital welding was first used in the 1960's when the aerospace industry recognized the need for
a superior joining technique for aerospace hydraulic lines. A mechanism was developed in which
the arc from a tungsten electrode was rotated around the tubing weld joint. The arc welding
current was regulated with a control system thus automating the entire process. The result was a
more precision and reliable method than the manual welding method it replaced.

Orbital welding became practical for many industries in the early 1980's when combination
power supply/control systems were developed that operated from 240 VAC and were physically
small enough to be carried from place to place on a construction site for multiple in-place welds.

Modern day orbital welding systems offer computer control where welding parameters for a
variety of applications can be stored in memory and called up when needed for a specific
application. The skills of a certified welder are thus built into the welding system, producing
enormous numbers of identical welds and leaving significantly less room for error or defects.
15.4.1 Orbital Welding Equipment
In the orbital welding process, tubes/pipes are clamped in place and an orbital weldhead rotates
an electrode and electric arc around the weld joint to make the required weld. An orbital welding
system consists of a power supply and an orbital weldhead.

Power Supply: The power supply/control system supplies and controls the welding parameters
according to the specific weld program created or recalled from memory. The power supply
provides the control parameters, the arc welding current, the power to drive the motor in the weld
head and switches the shield gas(es) on/off as necessary.

Weld Head: Orbital weld heads are normally of the enclosed type and provide an inert
atmosphere chamber that surrounds the weld joint. Standard enclosed orbital weld heads are
practical in welding tube sizes from 1/16 inch (1.6mm) to 6 inches (152mm) with wall thickness'
of up to .154 inches (3.9mm) Larger diameters and wall thickness' can be accommodated with
open style weld heads.

15.4.2 Reasons for Using Orbital Welding Equipment

There are many reasons for using orbital welding equipment. The ability to make high quality,
consistent welds repeatedly at a speed close to the maximum weld speed offer many benefits to
the user:

Productivity. An orbital welding system will drastically outperform manual welders, many times
paying for the cost of the orbital equipment in a single job.

Quality. The quality of a weld created by an orbital welding system with the correct weld
program will be superior to that of manual welding. In applications such as semiconductor or
pharmaceutical tube welding, orbital welding is the only means to reach the weld quality
requirements.
Consistency. Once a weld program has been established an orbital welding system can
repeatedly perform the same weld hundreds of times, eliminating the normal variability,
inconsistencies, errors and defects of manual welding.

Skill level. Certified welders are increasingly hard to find. With orbital welding equipment you
don't need a certified welding operator. All it takes is a skilled mechanic with some weld
training.

Orbital welding may be used in applications where a tube or pipe to be welded cannot be rotated
or where rotation of the part is not practical.

Orbital welding may be used in applications where access space restrictions limit the physical
size of the welding device. Weld heads may be used in rows of boiler tubing where it would be
difficult for a manual welder to use a welding torch or view the weld joint.

Many other reasons exist for the use of orbital equipment over manual welding. Examples are
applications where inspection of the internal weld is not practical for each weld created. By
making a sample weld coupon that passes certification, the logic holds that if the sample weld is
acceptable, that successive welds created by an automatic machine with the same input
parameters should also be sound.

15.4.3 Industrial Applications for Orbital Welding

Aerospace: As noted earlier, the aerospace industry was the first industry to recognize the
requirement for orbital welding. The high pressure systems of a single plane can have over 1,500
welded joints, all automatically created with orbital equipment.

Boiler Tube: Boiler tube installation and repairs offer a perfect application for orbital welding.
Compact orbital weld heads can be clamped in place between rows of heat exchanger tubing
where a manual welder would experience severe difficulty making repeatable welds.

Food, Dairy and Beverage Industries: The food, dairy and beverage industries require consistent
full penetration welds on all weld joints. Most of these tubing/piping systems have schedules for
cleaning and sterilization in place. For maximum piping system efficiency the tubing must be as
smooth as possible. Any pit, crevice, crack or incomplete weld joint can form a place for the
fluid inside the tubing to be trapped and form a bacteria harbor. Nuclear Piping/Tubing: The
nuclear industry with its severe operating environment and associated specifications for high
quality welds has long been an advocate of orbital welding.

Offshore Applications: Sub-sea hydraulic lines use materials whose properties can be altered
during the thermal changes that are normal with a weld cycle. Hydraulic joints welded with
orbital equipment offer superior corrosion resistance and mechanical properties.

Pharmaceutical Industry: Pharmaceutical process lines and piping systems deliver high quality
water to their processes. This requires high quality welds to ensure a source of water from the
tubes that is uncontaminated by bacteria, rust or other contaminant. Orbital welding ensures full
penetration welds with no overheating occurring that could undermine the corrosion resistance of
the final weld zone.

Semiconductor Industry: The semiconductor industry requires piping/tubing systems with

extremely smooth internal surface finish in order to prevent contaminant buildup on the tubing
walls or weld joints. Once large enough, a build up of particulate, moisture or contaminant could
release and ruin the batch process.

Tube/Pipe Fittings, Valves and Regulators: Hydraulic lines, and liquid and gas delivery systems
all require tubing with connector fittings. Orbital systems provide a means to ensure high
productivity of welding and improved weld quality. Sometimes the tubing may be welded in
place to a valve or regulator body. Here the orbital weldhead provides the ability to produce high
quality welds in applications with restricted access to the weld joint.

15.4.4 General Guidelines for Orbital Tube Welding

For orbital welding in many precision or high purity applications, the base material to be welded,
the tube diameter(s), weld joint and part fit -up requirements, shield gas type and purity, arc
length, and tungsten electrode material, tip geometry and surface condition may already be
written into a specification covering the specific application.

Each orbital welding equipment supplier differs slightly in recommended welding practices and
procedures. Where possible, follow the recommendations of your orbital equipment supplier for
equipment set-up and use, especially in areas that pertain to warranty issues.

This section is intended as a guideline for those applications where no specification exists and
the engineer responsible for the welding must create the welding set-up, and derive the welding
parameters in order to arrive at the optimum welding solution.

15.4.5 The Physics of the GTAW Process

The orbital welding process uses the Gas Tungsten Arc Welding process (GTAW) as the source
of the electric arc that melts the base material and forms the weld. In the GTAW process (also
referred to as the Tungsten Inert Gas process - TIG) an electric arc is established between a
Tungsten electrode and the part to be welded. To start the arc, an RF or high voltage signal
(usually 3.5 to 7 KV) is used to break down (ionize) the insulation properties of the shield gas
and make it electrically conductive in order to pass through a tiny amount of current. A capacitor
dumps current into this electrical path, which reduces the arc voltage to a level where the power
supply can then supply current for the arc. The power supply responds to the demand and
provides weld current to keep the arc established. The metal to be welded is melted by the
intense heat of the arc and fuses together. No additional filler material is used in this process of
welding.

15.4.6 Material Weldability

The material selected varies according to the application and environment the tubing must
survive. The mechanical, thermal, stability, and corrosion resistance requirements of the
application will dictate the material chosen. For complex applications a significant amount of
testing will be necessary to ensure the long term suitability of the chosen material from a
functionality and cost viewpoint.

In general, the most commonly used 300 series stainless steels have a high degree of weldability
with the exception of 303/303SE which contain additives for ease of machining. 400 series
stainless steels are often weldable but may require post weld heat treatment.

Accommodation must be made for the potential differences of different material heats. The
chemical composition of each heat batch number will have minor differences in the
concentration of alloying and trace elements. These trace elements can vary the conductivity and
melting characteristics slightly for each heat. When a change in heat number is made a test
coupon should be made for the new heat. Minor changes in amperage may be required to return
the weld to its original profile.

It is important that certain elements of the material be held to close tolerances. Minor deviations
in elements such as sulfur can vary the fluid flow in the weld pool thus completely changing the
weld profile and also causing arc wander.

15.4.7 Weld Joint Fit-Up

Weld joint fit-up is dependent on the weld specification requirements on tube straightness, weld
concavity, reinforcement and drop through. If no specification exists the laws of physics will
require that the molten material flow and compensate for tube mismatch and any gap in the weld
joint.

Tubing is produced according to tolerances that are rigid or loose according to the application for
which the tube was purchased. It is important that the wall thickness is repeatable at the weld
joint from part to part . Differences in tube diameter or out -of-roundness will cause weld joint
mismatch and arc gap variations from one welding set up to another.

Tube and pipe end prep facing equipment is recommended in order to help ensure end
squareness and end flatness. Both the ID and OD should be burr free with no chamfer.

When two tubes are butted together for welding, two of the main considerations are mismatch
and gaps. In general, the following rules apply:
Any gap should be less than 5% of the wall thickness. It is possible to weld with gaps of up to
10% (or greater) of wall thickness, but the resultant quality of weld will suffer greatly and
repeatability will also become a significant challenge.

Wall thickness variations at the weld zone should not be more than 5% of nominal wall
thickness. Again, the laws of physics will allow welding with mismatch of up to 25% of wall
thickness if this is the only challenge but again, the resultant quality of weld will suffer greatly
and repeatability will also become a significant issue.

Alignment mismatch (high-low) should be avoided by using engineering stands and clamps to
align the two tubes to be welded. This system also removes the mechanical requirement of
aligning the tubes from the orbital weldhead.

15.4.8 Shield Gas (es)

An inert gas is required on the tube OD and ID during welding to prevent the molten material
from combining with the oxygen in the ambient atmosphere. The objective of the welder should
be to create a weld which has zero tint at the weld zone ID.

Argon is the most commonly used shield gas (for the OD of the tube)and the purge gas (for the
ID of the tube). Helium is often used for welding on copper material. Mixed gases such as 98%
Argon/2% Hydrogen, 95% Argon/5% Hydrogen, 90% Argon/10% Hydrogen or 75%
Helium/25% Argon may be used when the wall thickness to be welded is heavy (.1" or above).
Using mixtures of 95% Argon/5% Hydrogen is incompatible with carbon steels and some exotic
alloys, often causing hydrogen embrittlement in the resultant weld. As a general rule use 100%
argon gas, for simplicity and reduction of shield gas cost.

Gas purity is dictated by the application. For high purity situations where the concern for micro-
contamination is paramount, such as semiconductor and pharmaceutical applications, the shield
and purge gases must minimize the heat tint that could otherwise be undesirable. In these
applications, ultra high purity gas or gas with a local purifier are employed. For non-critical
applications, commercial
grade argon gas may be used.

15.4.9 Tungsten Electrode

The tungsten welding electrode, the source of the welding arc, is one of the most important
elements of the welding system that is most commonly ignored by welding systems users. While
no one would refute the importance of the ignition device on an automobile airbag, the rip cord
for a parachute, or quality tires for automobiles, the importance of tungsten electrode for quality
welding is often overlooked. Users continue to manually grind and wonder why they produce
inconsistent results. Whether in manual or automatic welding, this is the area where
manufacturing organizations can improve the consistency of their welding output with minor
effort.

The objective for the choice of tungsten parameters is to balance the benefits of a clean arc start
and reduced arc wander with good weld penetration and a satisfactory electrode life.
Electrode Materials: For quite some time, tungsten manufacturers have added an oxide to pure
tungsten to improve the arc starting characteristics and the longevity of pure tungsten electrodes.
In the orbital welding industry, the most commonly used electrode materials are 2% thoriated
tungsten and 2% ceriated tungsten.

Safety: The safety issues of tungsten electrode material are now being looked at more closely.
Many users of the TIG welding process do not realize that the welding electrode they use
contains Thorium, a radioactive element added to the tungsten. While the radioactivity is of a
low level, it brings an issue of danger especially with the radioactive dust generated when
grinding the electrodes to a point for welding.

Alternative, non-radioactive tungsten materials are now available, such as 2% ceriated

electrodes, which often offer superior arc welding. While these materials are commercially
available they have been largely ignored until recently.

Recommended Electrode Materials: Cerium, as a base material, has a lower work function than
thorium, thus it offers superior emission characteristics. Thus, not only do ceriated electrodes
offer an advance in electrode safety, they also improve the arc starting ability of the orbital
equipment. However, as mentioned earlier, it is always best to follow the advice of your orbital
equipment manufacturer. 2%
ceriated and 2% thoriated electrodes are the most commonly recommended materials for orbital
welding equipment.

Electrode Tip Geometry: Given the ever increasing weld quality requirements of the final weld,
more and more companies are looking for ways to ensure that their weld quality is up to par.
Consistency and repeatability are key to welding applications. The shape and quality of the
tungsten electrode tip is finally being recognized as a vital process variable. Once a weld
procedure has been established, it is important that consistent electrode material, tip geometry
and surface condition be used.

15.4.10 Welding Basics and Set-Up

Figure-15-5: Weld Electrode tip diameter

To produce high consistent welds the Tungsten electrode must provide the following:

1. High quality electrode material

2. The electrode tip dimensions shown must be held to close tolerances
3. The surface finish (ground or polished) of the electrode grind must be consistent.
Welders should follow an equipment supplier's suggested procedures and dimensions first,
because they have usually performed a significant amount of qualifying and troubleshooting
work to optimize electrode preparation for their equipment. However, where these specifications
do not exist or the welder or engineer would like to change those settings to possibly improve
and optimize their welding, the following guidelines apply:

A. Electrode Taper - This is usually called out in degrees of included angle (usually
anywhere between 14 and 60). Below is a summary chart that illustrates how
different tapers offer different arc shapes and features:

In addition, to demonstrate graphically how the taper selection will affect the size of the weld
bead and the amount of penetration, below is a drawing that shows typical representations of the
arc shape and resultant weld profile for different tapers.

B. Electrode Tip Diameter - Grinding an electrode to a point is sometimes desirable for certain
applications, especially where arc starting is difficult or short duration welds on small parts are
performed. However in most cases it is best for a welder to leave a flat spot or tip diameter at the
end of electrode. This reduces erosion at the thin part of a point and reduces the concern that the
tip may fall into the weld. Larger and smaller tip diameters offer the following trade-offs:

Tungsten Electrode Grinders and Pre-Ground Electrodes: Using electrodes pre-ground to

requirements or a dedicated commercial electrode grinder to provide electrode tip quality and
consistency offers the following benefits to the user in their welding process:

1. Improved arc starting, increased arc stability and more consistent weld penetration.

2. Longer electrode life before electrode wear or contamination.

3. Reduction of tungsten shedding. This minimizes the possibility of Tungsten inclusions in the
weld.

4. A dedicated electrode grinder helps ensure that the welding electrodes will not become
contaminated by residue or material left on a standard shop grinder wheel.

5. Tungsten electrode grinding equipment requires less skill to ensure that the tungsten electrode
is ground correctly and with more consistency.

Pre-Ground Electrodes: Rather than risk electrode radioactivity issues and also constantly endure
the variability of each operator grinding the electrodes with a slightly different touch, many
manufacturing organizations have chosen to purchase electrodes pre-ground. In addition, since a
small difference in the
dimensions of an orbital electrode can produce a big difference in the weld results, pre-ground
electrodes are the preferred electrode choice to maintain the consistency of your welding. This
low cost option ensures that the electrode material quality, tip geometry and ground electrode
surface input to the welding process is constant.

Consult electrode charts or a pre-ground electrode supplier to obtain the electrode diameter and
tip geometry that is most suitable for your welding application.

Figure-15-7: Using pre -ground electrodes ensure that the elect rode material quality, tip
geometry and ground electrode surface input to the welding process is constant

15.4.11 Welding Parameter Development

Many welding equipment suppliers offer a series of pre-calculated weld programs for a variety of
tube diameters, wall thicknesses and materials. Welders should always follow an equipment
supplier's suggested procedures first, because they have usually performed a significant amount
of qualifying and troubleshooting work to optimize electrode preparation for their equipment.

However, it is impossible for the equipment suppliers to have welding procedures for every
welding application and there will always exist a trade off in maximum weld speed possible
versus weld quality and repeatability. Where weld parameter specifications do not exist or the
welder or engineer would like to change those settings to possibly improve or optimize their
welding, the guidelines noted below
give information on how to modify the welding parameters for a desired result.
Note: The "rules of thumb" noted below are general guidelines only and will not apply to every
welding application and mix of parameters chosen. Although the welding parameters are often
chosen and changed according to the specific needs of the application, there are some industry
standards that have been developed as starting points. Experimentation and experience will
determine the final weld parameters.

Arc Length
The arc gap setting is dependent on weld current, arc stability and tube concentricity/ovality. The
objective of the welding engineer is to keep the electrode at a constant distance from the tube
surface with sufficient gap to avoid stubbing out.

As a "rule of thumb" use a base arc gap of 0.010" and add to this half the penetration required
(usually the tube wall thickness) expressed in thousandths of an inch. Thus if the tube wall is
.030" then a good starting arc gap would be 0.010" + 0.015" = .025". For a wall
thickness/penetration requirement of .154" the arc gap would be 0.010" + .070" = 0.080"

Weld Speed
The weld speed is dependent on flow rate of material to be welded, and wall thickness. The
objective is to weld as fast as possible while still yielding a quality output.

As a starting point the tungsten surface speed should be 4 - 10 inches per minute with the faster
welding speeds used for thinner wall materials and the slower welding speeds used for heavy
wall thickness. As a good starting point, use 5 inches per minute.

Welding Current
The welding current is dependent on the material to be welded, wall thickness, weld speed, and
the shield gas chosen. The objective is to achieve full penetration, defect free welds.

As a starting point use 1 ampere current per 0.001" wall thickness if the material is stainless
steel. Thus for a 0.030" wall tubing the average weld current will be 30 amps in the first level.

Weld Current Levels

Orbital welding normally uses multiple levels of weld current to compensate for heat building up
in the tube during the welding process. If the weld current used to initially penetrate the tubing
was held at the same level for the complete weld, the weld penetration would increase as the
weld progressed around the tube, producing too much penetration.
Figure15-8: A Typical Weld Program current Profile ( This weld profile shows a single level of
weld time). Orbital welding normally uses a minimum of 4 levels of weld time with each level
decreasing in weld amperage as the tube heats up during the welding process

Normally orbital welding uses a minimum of 4 levels of weld time with each level decreasing in
weld amperage Starting parameters: Set weld level 4 to be at 80% of weld level 1 amperages. Set
weld level 2 and weld level 3 to gradually decrease the current from level 1 to level 4.

Figures 15-9 and 15-10 depict a typical weld program current profile for a 10 mm O.D. SS tube.
It may be noted that in the weld program chosen by the welder, the time for each level is same
(Impulse rate) and the average current decreases with each level.

Arc Pulsing
Arc pulsing involves using the welding power supply to rapidly alternate the weld current from a
high (peak current) to a low (background current) value. This creates a seam of overlapping spot
welds. This technique reduces the overall heat input to the base material and can also allow for
increases in weld speed. This welding technique brings many benefits to the welding procedure,
often improving weld quality and repeatability. In some cases materials and weld joints with
poor fit-up that are difficult to successfully weld with a non-pulsed arc can easily be welded with
a pulsed arc technique. The result is improved weld quality and increased output.
Figure 15-9: Weld program data sheet of a typical weld in RAPP-6
In orbital welding, arc pulsing also offers another advantage due to the fact that the gravity pulls
the weld puddle in different directions as the weld is created around the tube. When pulsing at
peak current the base material(s) melt and flow together, at the lower background current the
puddle can solidify before becoming liquid at the next peak current pulse. This diminishes the
effect of gravity on the molten weld, minimizes the weld sagging at the 12 and 6 o clock
positions, and reduces the molten weld puddle running/slumping downhill at the 3 and 9 o'clock
positions and effectively alters the electrode to weld puddle distance. The arc pulsing technique
thus becomes more advantageous as the wall thickness
increases resulting in a larger weld puddle.

Arc Pulsing Parameters: Arc pulsing involves four welding parameters: peak current,
background current, pulse width (duty cycle), and pulse frequency. Here again, opinions vary
from one welding organization to another and indeed from welder to welder. Many welders
arrive at the same welding result having somewhat different welding parameters.

It is important to understand how to choose convenient weld development starting parameters

and the effect on the weld by changing each parameter. The primary objective is to use the
benefits of weld pulsation to improve weld quality and output.

Peak/Background Current Ratios: The peak to background current ratios basically provides a
means for the welding current to pulse from one level to another. Industry usage generally varies
from 2:1 ratios to 5:1 ratios. A good starting point is to use 3:1 ratios, make the required weld
and test other parameters to see if any benefit can be gained.

Pulse Frequency: The pulse frequency is dependent on spot overlap required. Good starting
parameters are to attempt for a 75% spot overlap. Pulse rate for thin wall tube is often equal to
the weld speed in ipm (5 ipm = 5 pps) {pps: pulse per second}
Pulse Width: The pulse width (the percentage of time spent on the peak current) is dependent on
heat sensitivity of material and available current from power supply. Higher heat sensitivity
requires lower pulse width % on peak current. Standard pulse widths are often 20% to 50%. A
good starting parameters would be to set a pulse width of 35%.

Welding Parameter Development Example for 1" Tube/.030" Tube Wall Thickness:

1. Arc Length/Gap = .010" + (0.5 x penetration required)

Starting Parameters: .010" + (0.5 x .030") = .025"

2. Weld Speed = 5 ipm surface speed

RPM = ipm/(3.1415 x dia.)
Starting Parameters: 5/(3.1415 x 1") = 1.59 RPM

3. Welding Current Levels

Level 1 = 1 amp per .001" of wall thickness for level 1 current
Level 4 = 80% of Level 1 current
Levels 2 and 3 gradually decrease the current from Level 1 to Level 4

Starting Parameters:
Level 1 Peak Current = .030" wall thickness = 30 amps
Level 4 Peak Current = 30 amps x 80% = 24 amps
Level 2 Peak Current = 28 amps
Level 3 Peak Current = 26 amps

Background Current will be 1/3rd of peak current. Pulse width/duty cycle is 35%

4. Tungsten Electrode Diameter & Tip Geometry - Use your equipment manufacturer's
specifications or consult your pre-ground electrode supplier

The above data gives starting parameters. On completion of the first test weld, the parameters
will be modified to obtain the final result desired.

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Table of Contents

1.0 INTRODUCTION

1.1 DIFFERENCE BETWEEN A PIPE AND A TUBE

1.2 MAJOR ADVANTAGES OF TUBING OVER PIPING SYSTEMS

1.3 TYPES OF TUBES

1.4 GUIDELINES FOR SELECTION OF INSTRUMENTATION TUBES

1.5 DIFFERENT SIZES OF TUBES

1.6 CRITERIA FOR SELECTING THE SIZE OF A TUBE

1.7 SELECTION AND DESIGN CRITERIA

2.0 DESIGN OF TUBING AND TUBING SYSTEMS

2.1 CLASS-I INSTRUMENTATION TUBING DESIGN

2.2 REQUIREMENTS OF MATERIAL FOR INSTRUMENT TUBING/PIPING AS PER NB-2000

2.3 DESIGN REQUIREMENTS OF INSTRUMENT PIPING/TUBING AS PER SUBSECTION NC (NC 3600)

2.4 PRESSURE DESIGN (INTERNAL PRESSURE) OF INSTRUMENT TUBING/ PIPING

2.5 ANALYSIS CRITERION OF TUBING/PIPING SYSTEM

2.6 ANALYSIS OF SS TUBES USED IN NPCIL

2.6.1 WALL THICKNESS AND PRESSURE RATING OF DIFFERENT SIZES OF INSTRUMENT TUBING

2.6.2 STRESS ANALYSIS OF TUBING SYSTEMS

2.6.2.1 ANALYSIS FOR SUSTAINED MECHANICAL LOADS

2.6.2.2 ANALYSIS FOR OCCASIONAL LOADS (LEVEL A&B SERVICE LIMITS)

2.6.2.3 ANALYSIS FOR STRESS DUE TO THERMAL EXPANSION AND OTHER SUSTAINED LOADS

2.7 CONSIDERATION FOR VARIOUS FORCES

2.8 TUBE BENDING CONSIDERATIONS

2.9 SPECIAL DESIGN ASPECTS TO MEET THE REQUIREMENTS OF CLASS-I TUBING AND TUBING SYSTEMS

2.10 CONCLUSION

3.0 TECHNICAL REQUIREMENTS OF SS TUBES

4.0 PNEUMATIC TUBING

4.1 ADVANTAGES OF USING COPPER TUBES

4.2 DIFFERENT TYPES OF COPPER TUBES

4.3 RECOMMENDATIONS FOR SELECTION OF A TYPE OF COPPER TUBE

4.4 TECHNICAL REQUIREMENTS OF COPPER TUBE

4.5 APPLICABLE INTERNATIONAL STANDARDS FOR COPPER TUBES

5.0 ASTM TUBING SPECIFICATIONS OUTSIDE DIAMETER/WALL THICKNESS

6.0 EMBEDDED PENETRATIONS

7.0 METHODS OF CONNECTION OF INSTRUMENTATION TUBES

7.1 WELDED JOINTS

7.2 FLARED, FLARELESS AND COMPRESSION JOINTS

7.3 THREADED JOINTS

8.0 GUIDELINES FOR TAKE OFF CONNECTIONS FOR SENSING LINES

8.1 LOCATION OF PRESSURE TAPS

8.2 CONSIDERATIONS FOR PRESSURE TAP DESIGN

8.3 RECOMMENDATIONS FOR PRESSURE TAP DESIGN

9.0 GUIDELINES FOR ROOT VALVES

10.0 INSTALLATION OF INSTRUMENTATION TUBING

10.1 BEST PRACTICES FOR IMPULSE TUBE INSTALLATION

10.2 SOME PRACTICAL GUIDELINES FOR TUBE LAYING

AND BENDING

10.3 TUBE BENDING CHECK LIST

10.4 CHARACTERISTICS OF A WELL-MADE TUBING CIRCUIT

10.5 COMMON CAUSES OF IMPERFECT BENDS

10.6 ROUTING OF BENDS

10.7 GUIDELINES FOR COPPER TUBE INSTALLATION

10.8 GUIDELINES FOR COPPER TUBE BENDING

10.9 COPPER TUBE JOINTS

11.0 IMPULSE TUBE/SENSING LINE SUPPORT

12.0 IMPULSE TUBE INSTALLATION THROUGH EPS

13.0 TUBE FITTINGS

13.1 REQUIREMENTS OF A TUBE FITTING

13.2 CONSTRUCTION OF A TUBE FITTING

13.3 TYPES OF TUBE FITTINGS

13.4 FLARED FITTING

13.5 FLARELESS BITE TYPE TUBE FITTING

13.6 FLARELESS COMPRESSION TYPE TUBE FITTING

13.7 SINGLE FERRULE FLARELESS COMPRESSION TYPE TUBE FITTING

13.8 TWIN FERRULE FLARELESS COMPRESSION TYPE TUBE FITTING

13.8.1 FERRULE AND ITS PURPOSE

13.8.2 SWAGING

13.8.3 OPERATION OF A TWIN FERRULE TUBE FITTING

13.8.4 EFFECT OF TUBE THICKNESS ON SWAGING

13.8.5 SAFETY PRECAUTIONS FOR TUBE FITTING INSTALLATION

13.9 REPEATED ASSEMBLY AND DISASSEMBLY OF TUBE FITTING

13.10 SPECIFICATION FOR SS TUBE FITTINGS

13.11 SPECIFICATION FOR BRASS TUBE FITTINGS

14.0 THREADS USED FOR TUBE FITTINGS

14.1 EVOLUTION OF THREADS

14.2 TYPE OF THREADS

14.3 SIZES

14.4 TAPER/PARALLEL THREADED JOINTS

14.5 DRY SEAL NPTF THREADS

15.0 WELDING METHODS

15.1 300 SERIES STAINLESS STEELS

15.2 C1018 Steel FITTINGS

15.3 TIG WELDING

15.4 ORBITAL TUBE WELDING

15.4.1 ORBITAL WELDING EQUIPMENT

15.4.2 REASONS FOR USING ORBITAL WELDING EQUIPMENT

15.4.3 INDUSTRIAL APPLICATIONS FOR ORBITAL WELDING

15.4.4 GENERAL GUIDELINES FOR ORBITAL TUBE WELDING

15.4.5 THE PHYSICS OF THE GTAW PROCESS

15.4.6 MATERIAL WELDABILITY

15.4.7 WELD JOINT FIT-UP

15.4.8 SHIELD GAS (ES)

15.4.9 TUNGSTEN ELECTRODE

15.4.10 WELDING BASICS AND SET-UP

15.4.11 WELDING PARAMETER DEVELOPMENT

16.0 References and Suggested Reading

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