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.} ~How-to-Align-Flange-Holes
I-I How to Align Flange Holes
(1) Place a flange so that two of its holes become on a level with each other, insert a bolt in
each of them, and lay a welding rod on the top of these bolts. (A welding rod may be
secured using a clamp.)

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Check visually
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C clamp

(2) Do the same thing to another flange, and look straight at these welding rods from the
front side of the flange faces.
Two electrodes overlaps one another

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Turn the flange

Two electrodes are parallel to each other

(3) Turn either flange until two rods become parallel to each other. When in parallel, apply
tack- welding to the flanges.

e Chapter 7
 111
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- J )-!o~' to Align Flange Holes

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1.2How to Align Straight Pipe and Flange

(1)With the end of pipe retreated from flange face by apporoximately 5 mm, tack weld the
flange.
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New pipe I

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Square
Flange square I' J
Flange shall be right angle to the pipe.

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5mm 5mm
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(2)Holesof the right flange witch is to be tack welded shall be aligned with those of left
flange which is regular welded.

Regular welding shall be done on both sides.

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Keep a 5 mm clearance.

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2-Modeling-of-a-Bent-Pipe- - -- - --

(1)

Old pipe to be replaced

Temporary tightening with 2 bolts

Spare flange

Height and sideway positioning of

(2) the old pipe with an L-shaped bar
Fixing the flange ~
with a band iron

Temporary
welding to
the bed

Deck

Temporary
(3) About 5 mm in clearance welding
between the flange face
and the pipe end

Final welding after removing

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Temporary welding (4 points)
----- New flange

welding ----- 1st layer; contact welding

2nd layer; weave welding on a small scale

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Temporary welding between the bent pipe and the
straight pipe, and between the straight pipe and

J the flange; then fixing with a

all parts after removing bolts
band iron; Finally weld
and nuts.

.
0 Chapter 7
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 ~ 1,1
Modeling .of a- Bent-Pipe-with-a-Branch-ripe
A bent pipe can be made in accordance with the above procedures (modeling). Even when
a bent pipe is fitted with branch pipes, it can be made by similar method (by modeling the
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flanges of branch pipes).

Fix

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Weld on welding deck I,j

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Regularwelding after firmly fixing

onthe main pipe Regular welding

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It is important to firmly fix the branch pipes to the main pipe so that they are not
deformed in the course of a final welding.

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Chapter7 8 I
--- .. id -_.--------

4 -Modeling-of-a-Pipe T
A pipe can be modeled at site using a #8 steel wire.

#8 steel wire

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Stretch a #8 steel wire along the center line of a pipe to be modeled; the length shall bea
little longer than the actual pipe length; apply a mark to the wire at flange positions.

e Chapter 7
 I li,\.
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Bending of a Pipe Filled with-Sand-by-Heating
~lFilling Sand
Sand gravel of 5 mm or smaller in size is ideal but fine sand can also be used. Avoid using
wetsand which is easily solidified by heat.
Withthe bottom of the pipe plugged with a wood block, fill sand in the pipe while giving II

hammer-tapping to the periphery of the pipe from the bottom and upward (Area to be bent
shallbe positioned on the lower side).

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~2 Modeling the Bent Angle with a #8 Steel Wire

Mark "A", "B" and "e" at the position where #8 steel wire begins to be bent.
Trace the points "A", "B", "e" on the pipe.

Wood plug

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B

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Point Point Point
A B e

Chapter7 G
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5-3 Heating
Apply heat evenly to the section of a pipe to be bent (Defective bending resulting from
uneven heating can hardly be corrected). Do not heat any section other than the curved
section from "A" to "C". Heat the section which only becomes inside of the curvature (2/3
of the circumference of the pipe), and do not heat the section which becomes outside of
the curvature (1/3 of the circumference of the pipe). Heating the outer plate of the
curvature will result in thinner wall thickness and a dent in the pipe.
When the bending angle approaches 90 deg., the pipe may create a dent on the outer
plate of the curvature. In such a case, give an additional bend to the pipe for about 10
deg., then burn that portion until the surface turn red, and return the bending angle back to
90 deg. On the other hand, the inner plate sometimes becomes wavy before the bending
angle reaching 90 deg. In such a case, give hammer-tapping to such portion to regain its
normal shape, and then resume burning to increase the bending angle until the surface
turns red.

~estore to the original shape

by tapping
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G Chapter 7
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Emergency Repair-of-€racked-Pipe
Remove the rust by disc grinder and clean.

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Pipe is thinner around the cracking. i
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4 mm thick Cut out a piece of 4 mm
steel plate thick steel plate which is I
a little larger than the crack. I
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Weld Burn with a gas cutting torch II
until the surface turns red.
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When the surface turns

red, tap and bend the steel
plate along the pipe.

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