POWER SECTOR

SOUTHERN REGION
QUALITY DEPARTMENT

TECHNICAL DIRECTIVE
---------------------------------------------------------------------------------------------------------------------------------REF: PSSR-QLY-TD-PP-03-01, DATED 02.07.2003. ISSUED BY : K. PANDI, Sr. ENGINEER-QUALITY Sheet no.: 1 of 1 ----------------------------------------------------------------------------------------------------------------------------------

ALIGNMENT OF PRESSURE PARTS MISMATCHING OF WELD JOINTS IN TUBES/ COILS Of late we have come across weld joint failure in tubes and coils with Header stub, in some of the sites. The main reason for these failure appears to be improper root matching and surface alignment of the butt welded joints resulting DOG LEGGED JOINT. Fit-up of the joints shall be ensured as per drawing. The surface alignment (mismatch) in case of Butt welds shall be within t, where t is the tube thickness. In the case of welds in coils, tubes and with Header stubs, the maximum misalignment at the root for butt welds shall not exceed 0.5 mm . Where additional requirements are specified in the drawing, the same shall be followed. Welding area covering the base material to approximately 15mm on either side shall be thoroughly cleaned and ensured free from oil, grease, rust, scales, etc. Parts to be joined by welding shall be fitted, aligned and retained in position during welding operation, by the use of bars, jacks, clamps, tack welds, temporary attachment or other appropriate means. Ensure that dog legged joints are avoided by mechanical means/ hot correction/ introducing spool piece. Tack welds used to secure alignment shall either be removed completely when they have served their purpose or properly prepared by grinding or by other suitable means so that they may be incorporated into the final weld. Tack weld shall be done using qualified procedure and personnel to a sufficient length (25mm minimum) and width. Tack weld found defective during visual examination shall be removed. Other requirements like Preheating, PWHT, NDE, etc shall be followed as per WPS/ EWS/ Drawing. Strict adherence to this procedure is essential to avoid failure of weld joints during operation. In case deviations from the said procedure is desired, approval for the desired deviation must be obtained from HEAD-QUALITY, PSSR or Quality Engg. Dept., BHEL, Trichy.
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