Minimum Leak Path for Tube-to-Tubesheet joint

ASME Sec IX code specifies the requirement to section the Tube-to-Tubesheet weld mock-up and
ensure by macro examination that the Minimum Leak Path (MLP) required by design is available in
the actual weld. Refer below extract from the code.

This check is required because of following practical aspects in welding which would affect the MLP.

i. The profile/ geometry of fillet weld varies (convex/ concave based on the fluidity of weld
pool, welding position/ technique, geometry at junction of parts, etc.) w.r.t. 45° straight line
fillet weld specified on drawing. Sometimes, the fillet leg length needs to be increased to
achieve the required throat dimension.
ii. The weld may contain some porosity and under penetration at the root within the permissible
limits in the code.

TTJ mock-up block

Section of tubesheet mock-up

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However, the term MLP is not defined clearly in ASME Sec VIII and Sec IX codes. Hence, in this
article the term MLP is explained in detail for various tube-to-tubesheet joint configurations.

The value of MLP depends on tube-to-tubesheet joint configuration (only fillet/ only groove/ groove +
fillet) and not on its type (strength/ partial strength/ seal welds).

Definition:
MLP is defined as the distance in any direction from the root of the weld to the surface nearest the
root.

One should not confuse MLP with the weld failure path. (Refer sketches and table below for clarity)

For evaluating the MLP, fillet and groove welds are treated as separate welds as done while
evaluating the nominal thickness of weld joint for PWHT requirement in UW-40(f)(3).

Weld joint
MLP Weld Failure Path
configuration
Fillet weld throat of fillet weld throat of fillet weld
45° groove weld depth of groove depth of groove
J groove weld depth of groove depth of groove
Groove + Fillet Minimum(MLP for fillet weld, throat of fillet weld +
weld MLP for groove) depth of groove

MLP = throat dimension ‘a’ = the radius of the largest circle totally inscribed in the weld whose centre
is situated at the root of weld.

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 Root of weld
Root of weld

As incomplete penetration up to 0.4 mm from the root of weld is permissible, the groove depth and
throat (leg) of fillet on drawing shall be increased to compensate for this provision.

E.g.: For 2 mm thk tube with strength weld TTJ with only fillet weld configuration, the fillet leg on
drawing shall be calculated as below.

Required throat of fillet = tube thk + 0.4 = (2 + 0.4) mm

Leg size = √2 * 2.4 = 3.39 mm

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