John C. Stennis Space Center Standard WELD PROCEDURE FOR WELDING COPPER TUBE

Transcription

1 Revision February 2010 National eronautics and Space dministration John C. Space Center Space Center, MS John C. Space Center WELD PROCEDURE FOR WELDING COPPER TUBE Original signed by: Michael F. Killam for Robert Heitzman 02/03/10 NS SSC Center Operations Directorate Date Operations & Maintenance Division Issued by: _Issued CEF Central Engineering Files 02/05/10 Date

2 Responsible Office: NS Center Operations Directorate Page 2 of 12 Document History Log Revision Date Originator/ Phone Basic 2/25/05 Doug Dike /09/10 Doug Dike Initial Release. Description Updated references. Corrected typographical and grammatical errors. dministrative changes only, no changes to technical meaning or content.

3 Responsible Office: NS Center Operations Directorate Table of Contents Page 3 of PURPOSE PPLICBILITY REFERENCED DOCUMENTS RESPONSIBILITIES PROCEDURES GENERL BSE MTERIL FILLER MTERIL SHIELDING GS POSITION ELECTRODE PREPRTION OF BSE MTERIL JOINT DESIGN HET TRETMENT PREHET FINL WELD TRETMENT INSPECTION TESTING POST HET RECORDS ND FORMS CRONYMS ND BBREVITIONS... 7 TTCHMENTS QW-482 WELDING PROCEDURE SPECIFICTION (WPS)...8 QW-483 PROCEDURE QULIFICTION RECORDS (PQR)...10 CERTIFICTE OF NLYSIS...12

4 Responsible Office: NS Center Operations Directorate Page 4 of PURPOSE This John C. (SSTD) specifies the procedure for Gas Tungsten rc Welding (GTW) of seamless copper tube P No. 31 at John C. Space Center (SSC). 2.0 PPLICBILITY This SSTD applies to contractor and subcontractor personnel involved in the GTW welding of seamless copper tube P No REFERENCED DOCUMENTS Referenced documents shall be the latest edition unless otherwise specified. SME Boiler and Pressure Vessel Code: Section II, Materials SME Boiler and Pressure Vessel Code: Section IX, Welding and Brazing Qualifications NSI/WS 5.7M, Copper and Copper-lloy Welding Bare Rods and Electrodes STM B-88, Specification for Seamless Copper Water Tube NSI/WS 5.12, Specification for Tungsten and Oxide Dispersed Tungsten Electrodes for rc Welding and Cutting SCWI , John C. Space Center Personal Protective Equipment SPR , John C. Space Center Safety and Health Procedural Requirements SSC , Introduction of Welding s SSC , Classes of Welding Inspection SPR , John C. Space Center Document Preparation, ing and Management SSTD WELD, Qualifying Welders and Welding Procedures 4.0 RESPONSIBILITIES a. It is the responsibility of SSC personnel performing the procedure specified herein to follow the requirements set by this SSC. b. Responsibilities for the qualification of the welder and the performance of the welding procedure are defined in Section PROCEDURES 5.1 GENERL a. ll procedures shall be performed in compliance with applicable requirements in SPR , SSC Safety and Health Procedural Requirements, and SCWI ,

5 Responsible Office: NS Center Operations Directorate Page 5 of 12 Personal Protective Equipment. If ever there is a conflict between this standard and the SPR, the SPR shall take precedence. b. Welders shall be qualified in accordance with SSTD WELD, Qualifying Welders and Welding Procedures and SME Section IX. c. Inspection methods for the welds shall be in accordance with SSC , Classes of Welding Inspection. 5.2 BSE MTERIL The base metal shall be seamless copper tube as per STM B-88, Specification for Seamless Copper Water Tube. 5.3 FILLER MTERIL The filler metal shall conform to NSI/WS 5.7M-2007, Copper and Copper-lloy Welding Bare Rods and Electrodes. 5.4 SHIELDING GS The shielding gas shall be 99.9% argon gas (welding). 5.5 POSITION The welding shall be in the 5G position with the axis horizontal and fixed during welding. 5.6 ELECTRODE The electrode shall be 2 percent thoriated tungsten as per NSI/WS 5.12, Specification for Tungsten and Tungsten-lloy Electrodes for rc Welding and Cutting. 5.7 PREPRTION OF BSE MTERIL a. The area of the base metal to be welded shall be cleaned of any grease and dirt using a detergent. b. Rinse off the detergent with water. c. Remove oxides by either pickling the areas to be welded using an acid solution or abrasion clean with Scotch Brite pads or equivalent until a bright metal surface is obtained.

6 Responsible Office: NS Center Operations Directorate Page 6 of 12 d. If acid is used then do a final rinse with water and dry. e. Prior to welding, the surface area is to have a final cleaning with an emery cloth. 5.8 JOINT DESIGN Joint design shall be nominal V groove, as illustrated on the attached Welding Procedure Specification (WPS) form. 5.9 HET TRETMENT No heat treatment is required PREHET a. Preheat shall be 350 F minimum. b. Interpass shall be 550 F maximum FINL WELD TRETMENT The complete area shall be smooth and free from undercutting in excess of 1/32 (inch), provided the minimum wall thickness is maintained INSPECTION Dye-penetrant inspect final layers of all welds in accordance with approved procedures TESTING Testing shall be per SME Section IX POST HET No post heat is required. 6.0 RECORDS ND FORMS a. Records and forms required by the procedures of this standard shall be maintained in accordance with SPR ll forms are assumed to be the latest edition unless

7 Responsible Office: NS Center Operations Directorate Page 7 of 12 otherwise specified and may be obtained from the SSC Electronic Forms repository or from the NS SSC Forms Management Officer. b. In accordance with SSC , the original, signed WPS/PQR forms, and the corresponding Certificate of nalysis reports (copies of which are provided as attachments) shall be maintained, together with the original signed hard copy of this, in Central Engineering Files (CEF). 7.0 CRONYMS ND BBREVITIONS NSI SME STM WS CEF merican National s Institute merican Society of Mechanical Engineers merican Society for Testing and Materials merican Welding Society Central Engineering Files Degrees F GTW MSFC NS PQR SCWI SPR SSC SSTD WPS Fahrenheit Gas Tungsten rc Welding Marshall Space Flight Center National eronautics and Space dministration Procedure Qualification Record John C. Space Center Work Instruction Procedural Requirements John C. Space Center John C. Space Center Technical Welding Procedure Specification

8 Responsible Office: NS Center Operations Directorate Page 8 of 12 QW-482 SUGGESTED FORMT FOR WELDING PROCEDURE SPECIFICTION (WPS) (See QW-200.1, Section IX, SME Boiler and Pressure Vessel Code) Company Name Mississippi Space Services By: Richard Nyberg Welding Procedure Specification No. Date Supporting PQR No.(s) -BSIC Revision No. Basic Date 2/2/05 Welding Process(es) GTW Type(s) Manual (utomatic, Manual, Machine, or Semi-uto) JOINTS (QW-402) Joint Design V Groove Backing (Yes) (No) X Backing Material (Type) N/ (Refer to both backing and retainers.) Details Metal Nonmetallic Nonfusing Metal Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified. (t the option of the Mfgr., sketches may be attached to illustrate joint design, weld layers and bead sequence, e.g., for notch toughness procedures, for multiple process procedures, etc.) *BSE METLS (QW-403) P-No. 31 Group No. to P-No. 31 Group No. OR Specification type and grade STM B-88 P-31 to Specification type and grade STM B-88 P-31 OR Chem. nalysis and Mech. Prop. to Chem. nalysis and Mech. Prop. Thickness Range: Base Metal: Groove to Fillet ll Pipe Dia. Range: Groove 2 7/8 and above Fillet ll *FILLER METLS (QW-404) Spec. No. (SF) WS No. (Class) F-No. 31 -No. 5.7 ERCu 5.7 ERCu Size of Filler Metals 3/32 to 1/8 Weld Metal Thickness Range: Groove to Fillet ll Electrode-Flux (Class) Flux Trade Name Consumable Insert N/ N/ N/ ERCu *Each base metal-filler metal combination should be recorded individually. (7/00) This form (E00006) may be obtained from the Order Dept., SME, 22 Law Drive, Box 2300, Fairfield, NJ

9 Responsible Office: NS Center Operations Directorate Page 9 of 12 QW-482 (Back) WPS No. Basic POSITIONS (QW-405) POSTWELD HET TRETMENT (QW-407) Position(s) of Groove ll Temperature Range N/ Welding Progression: Up uphill Down Time Range N/ Position(s) of fillet ll PREHET (QW-406) Preheat Temp. Min. 350 F Interpass Temp. Max. 550 F Preheat Maintenance 350 F (Continuous or special heating where applicable should be recorded.) GS (QW-408) Percent Composition Gas(es) (Mixture) Flow Rate Shielding rgon 99.9% up to 30 CFH Trailing Not Required Backing rgon 99.9% up to 30 CFH ELECTRICL CHRCTERISTICS (QW-409) Current C or DC DC Polarity straight mps (Range) Volts (Range) (mps and volts range should be recorded for each electrode size, position, and thickness, etc. This information may be listed in a tabular form similar to that shown below.) Tungsten Electrode Size and type 3/32 or 1/8 2% thoriated (Pure Tungsten, 2% Thoriated, etc.) Mode of Metal Transfer for GMW GTW (Spray arc, short circuiting arc, etc.) Electrode Wire feed speed range N/ TECHNIQUE (QW-410) String or Weave Bead Stringer & Weave Orifice or Gas Cup Size Initial and Interpass Cleaning (Brushing, Grinding, etc.) chemical clean, grinding, Scotch Brite, and wire brush(ss) Method of Back Gouging N/ Oscillation Contact Tube to Work Distance Multiple or Single (per side) Multiple or Single Electrodes Travel Speed (Range) Peening Yes N/ Multiple Single 2-8 IPM as required Filler Metal Current (e.g., Remarks, Comments, Hot Wire Weld Layer(s) Process Class Dia. Type Polar. mp. Range Volt Range Travel Speed Range ddition, Technique, Torch ngle, Etc.) ll GTW ERCu 3/32 to 1/8 DC straight IPM Forehand technique

10 Responsible Office: NS Center Operations Directorate Page 10 of 12 QW-483 SUGGESTED FORMT FOR PROCEDURE QULIFICTION RECORDS (PQR) (See QW-200.2, Section IX, SME Boiler and Pressure Vessel Code)Record ctual Conditions used to Weld Test Coupon. Company Name Mississippi Space Services Procedure Qualification Record No. -BSIC Date 2/23/05 WPS No. Welding Process(es) GTW Types (Manual, utomatic, Semi-uto) Manual JOINTS (QW-402) Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall be recorded for each filler metal or process used.) BSE METLS (QW-403) Material Spec. STM B-88 Type or Grade P-No. 31 to P-No. 31 Thickness of Test Coupon Diameter of Test Coupon 4 pipe FILLER METLS (QW-404) SF Specification 5.7 WS Classification 5.7 Filler Metal F-No. 31 Weld Metal nalysis -No. Size of Filler Metal 3/32 Weld Metal Thickness POSITION (QW-405) Position of Groove 5G Weld Progression (Uphill, Downhill) PREHET (QW-406) Preheat Temp. 350 F Interpass Temp. 550 F ERCU ERCU Uphill POSTWELD HET TRETMENT (QW-407) Temperature N/ Time N/ GS (QW-408) Percent Composition Gas(es) (Mixture) Flow Rate Shielding rgon 99.9% up to 30 CFH Trailing Not Required Backing rgon 99.9% up to 30 CFH ELECTRICL CHRCTERISTICS (QW-409) Current DC Polarity straight mps. Volts Tungsten Electrode Size 3/32 or 1/8 TECHNIQUE (QW-410) Travel Speed 2 to 8 IPM String or Weave Bead string & weave Oscillation N/ Multipass or Single Pass (per side) Single or Multiple Electrodes Single Multipass This form (E00007) is from SME Boiler and Pressure Vessel Code and may be obtained from the SME Order Dept..

11 Responsible Office: NS Center Operations Directorate Page 11 of 12 QW-483 (Back) PQR No. -BSIC Tensile Test (QW-150) Ultimate Total Load lb. Ultimate Unit Stress psi Type of Failure & Location Specimen No. Width Thickness rea T ,230 34,308 Base T ,580 32,250 weld Guided-Bend Tests (QW-160) Type and Figure No. Face Bend FB-1 QW 462.3() Face Bend FB-2 QW 462.3() Root Bend RB-1 QW 462.3() Root Bend RB-2 QW 462.3() Result 180 satisfactory 180 satisfactory 180 satisfactory 180 satisfactory Toughness Tests (QW-170) Specimen No. Notch Location Specimen Size Test Temp. Impact Values Drop Weight Break (Y/N) Ft. lbs. % Shear Mils Fillet-Weld Test (QW-180) Result Satisfactory: Yes No Penetration into Parent Metal: Yes No Macro Results Tests Type of Test Deposit nalysis Welder s Name Charles Hariel Clock No. Stamp No. MSS-10 Tests conducted by: Tech Weld Laboratory Test No We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the SME Code. Manufacturer Mississippi Space Services Date 2/24/05 By (Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by the Code.)

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