Tube To Tube Sheet Mock Up

Tube-to-Tube sheet Welding
Tube to tube sheet welding is a special kind of welding, both process and technique
wise. Essentially the parameters, techniques adopted for a groove weld will not work
for this type of weld joint. Tube-to-Tube sheet welding is a critical weld and a very
specific weld joint, whose integrity cannot be assured by groove welding qualification
alone. The failure of a tube-to-tube sheet weld may cost more and whole exchange will
be waste.
Important Terminology for Tube-to-Tube sheet:
Tube Hole, D: It is the through hole in tube sheet in which tube is inserted.
Ligament, L: It is the shortest distance between edge of the adjacent tube hole in the
tube sheet.
Pitch, P: It is the centre to centre distance of tube holes.
Minimum Leak Path: It is the distance from the root of the weld to the surface nearest
the root (red line show in below figure 3, is the shortest way i.e. MLP). MLP must
equal that required by the design or by the Construction Code or client requirement.
For the strength weld joint MPL is the minimum distance required by a fluid from
root side of the weld to get leaked from face side i.e. tube sheet side.
While designing the heat exchanger, critical and potential leak path of the fluid is tube
to tube sheet joint. Hence, tube-to-tube sheet joint design is considered as the most
important factor.
Minimum leak path, Tube-to-tube sheet, Tube-to-tube sheet welder qualification,

Welder qualification, tube to tube sheet ligament
Figure 3- Tube-to-tube sheet Minimum Leak Path
Tube-to-Tube sheet Welder Qualification
1. The mock-up assembly shall essentially duplicate the tube-to-tube sheet weld joint
design to be used in production, within the limits of the essential variables of QW-350
in addition to the variables of Table QW-388.
2. A minimum of 5 mock-up tube-to-tube sheet welds are required to qualify each

welder or welding operator. (Refer QW-193.2)
3. PWHT may be omitted (Refer QW-193.2)
Tube sheet Thickness Limit for Welder Qualification (Refer QW-193.1)
Minimum leak path, Tube-to-timesheet, Tube-to-tube sheet welder qualification,

Tube-to-Tube sheet Welder & Welding Operator Qualification (QW-387)
1. When the applicable Code Section requires the use of QW-193 for tube-to-tube
sheet demonstration mock up qualification tests, QW-193.2 shall apply.
–ASME BPVC Section VIII Division 1 does not stipulate as a mandatory requirement
to apply QW-193, it is manufacturer’s option to choose between QW-193 or normal
welder qualification in accordance with QW-303.1.
–However, in case of ASME BPVC Section VIII Division 2, application of QW-193 is

mandatory in accordance with para. 6.3.4.
2. If specific qualification test requirements are not specified by the applicable Code
Section, welders and welding operators shall be qualified with one of the following
methods:
–Demonstration mock-up per the requirements of QW-193.2, as described above.
–A groove-weld qualification as per the requirements of QW-303.1
The welder or welding operator who pass the required test for groove weld shall be
qualified for the welding of tube-to-tube sheet joint and in addition welding position,
diameter restrictions and essential variable of QW-350 or QW-360 shall also
applicable.
Essential Variables for Tube-to-Tube sheet Performance Qualification.
Minimum leak path, Tube-to-tube sheet, Tube-to- tube sheet welder qualification,
Testing Required for Tube-to-tube sheet Performance Qualification:
Visual Examination: The weld shall show complete fusion, be free from crack or
porosity and have no evidence of burning through the tube wall thickness.
Liquid Penetrant Examination: Shall meet the requirement of ASME Section V,
Article 6.
Acceptance Criteria:
-No relevant linear indication
-Rounded indication shall not be greater than 5 mm
-Three or less rounded indication in a line separated by 1.5 mm are acceptable.

Figure 4- Tube-to-tube sheet weld root run PT
Macro Examination: The mock-up welds shall be sectioned through the centre of the
tube for macro examination. The four exposed surfaces shall be smoothed and etched
to give clear definition of the weld and HAZ. Using magnification of 10X to 20X.
Acceptance Criteria:
-Must achieve minimum leak path (MLP) dimension required by the design.
-No Cracking
-Complete fusion of the weld deposit into the tube sheet and the tube wall thickness.
Figure 5- Macro Image of Tube-to-tube sheet


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Tube-to-Tube sheet Welding

Important Terminology for Tube-to-Tube sheet:

Pitch, P: It is the centre to centre distance of tube holes.

Minimum leak path, Tube-to-tube sheet, Tube-to-tube sheet welder qualification,

Figure 3- Tube-to-tube sheet Minimum Leak Path

Tube-to-Tube sheet Welder Qualification

2. A minimum of 5 mock-up tube-to-tube sheet welds are required to qualify each

3. PWHT may be omitted (Refer QW-193.2)

Tube sheet Thickness Limit for Welder Qualification (Refer QW-193.1)

Minimum leak path, Tube-to-timesheet, Tube-to-tube sheet welder qualification,

Tube-to-Tube sheet Welder & Welding Operator Qualification (QW-387)

–However, in case of ASME BPVC Section VIII Division 2, application of QW-193 is

–Demonstration mock-up per the requirements of QW-193.2, as described above.

–A groove-weld qualification as per the requirements of QW-303.1

Essential Variables for Tube-to-Tube sheet Performance Qualification.

Testing Required for Tube-to-tube sheet Performance Qualification:

-No relevant linear indication

-Rounded indication shall not be greater than 5 mm

-Three or less rounded indication in a line separated by 1.5 mm are acceptable.

Minimum leak path, Tube-to-timesheet, Tube-to-tube sheet welder qualification,

Figure 4- Tube-to-tube sheet weld root run PT

Minimum leak path, Tube-to-timesheet, Tube-to-tube sheet welder qualification,

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