________________________________________________________________________________________________________________________

ISSUED BY NUMBER

R.C. Niss 2009

ENGINEERING FIRST ISSUED

APPROVED BY
December 2, 1960
C.M. Kotansky APPARATUS INSTRUCTIONS
SUPERSEDES

ELECTRO MOTIVE
B.Fliss LaGrange, Illinois

SUBJECT Welding specifications for joining pipe to pipe fittings and welding of flanges
AFFECTS MODELS

PART NOS AFFECTED

REF DRAWINGS EMS-874, EMS-899, AI 2208, AI 1651, AI 1046

A. Welding Specification

1. All pipe assemblies and assemblies that weld pipe that are used for liquid or gas will have this
A.I. (Apparatus Instruction) added to the "For Manufacturing Block". For other applications this
A.I. may be added at the discretion of Welding Engineering.

2. All welded pipe assemblies must be pressure tested to the minimum pressure listed in A.I1651 (K)
Section 2, unless otherwise specified on the Engineering drawing.

3. Stainless steel and aluminum pipe assemblies will have the electrodes designated on the
engineering drawings. For mild steel pipe assemblies, electrodes are defined in this A.I. and are
not to be designated on the engineering drawing.

4. Commercial steel pipe fittings of all types are manufactured to a specification that allows up to
.35% carbon content. This factor makes the use of low hydrogen welding techniques mandatory.

5. The acceptable options for welding mild steel pipe to pipe fittings are:

• Use AWS Class E7016 or E7018 SMAW (Shield Metal Arc Welding) welding electrode.

• Use AWS Class ER70S-X, E7XC-X, E7XT-X filler metal for the GMAW (Gas Metal Arc
Welding), Metal Core or FCAW (Flux Core Arc Welding) processes.

B. Welding of Flanges (Fabricated from Plate with Square or Round Shapes)

1. Although flanges are generally machined to obtain a suitable gasket surface, they may be
distorted by welding; therefore, they must be checked for flatness after the welding operation is
completed. This applies to all flanges that are arc-welded or brazed into an assembly. To obtain
a satisfactory seal, the gasket surface is to be flat within 0.004" for an area around the center
hole of the assembly extending radially to the inner edges of the bolt holes, or 1/2 inch,
whichever is smaller. The balance of the area is to be flat within 0.015", measured in a radial
direction, i.e., away from the sealing area, and free of weld spatter.
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WELDING SPECIFICATIONS FOR JOINING MILD STEEL PIPE TO PIPE FITTINGS & WELDING OF FLANGES

2. It is recommended that, wherever possible, the inside weld of the flange to the pipe be
completed before the outside weld is made. This will help to minimize the amount of distortion
and reduce the amount of subsequent dressing of the flange to obtain the required degree of
flatness.

3. Welding flanges of this type may be welded to mild steel pipe per the options given in section “A”
or with A.W.S. Class E6010 or E6011 SMAW welding electrode.

C. Welding of Radiator Header Flanges (Fabricated from Plate with a Rectangular Shape)

1. Although radiator header flanges are machined to obtain a suitable gasket surface, they may be
distorted by welding; therefore, they must be checked for flatness after the welding operation is
completed. To obtain a satisfactory seal, the machined surface is to be flat within 0.020", in all
directions and free of weld spatter.

2. It is recommended that the weld of the pipe protruding through the gasket side of the flange be
completed before the outside weld is made. This will minimize the amount of distortion and
reduce the amount of subsequent dressing of the flange to obtain the required degree of
flatness.

3. One end of the pipe should protrude at least 0.38 inches through the flange on the machined
side as shown in Figure 1.

Machined
side of flange

0.38"

Figure 1. Radiator Flange Assembly

D. Socket and ANSI type flange pre-weld gap

1. There must be a minimum of 0.06" (1.5 mm) clearance (gap) between the pipe and the bottom of
the socket fitting before welding. This is in compliance with ASME Boiler and Pressure Vessel
Code Section VIII and AAR standard S-402. See Figure 2.

Figure 2.
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WELDING SPECIFICATIONS FOR JOINING MILD STEEL PIPE TO PIPE FITTINGS & WELDING OF FLANGES

2. The pre-weld 0.06" (1.5 mm) min. gap can be accomplished by either of the following options.
Note: this gap allowance is designed into EMD pipe assemblies.

1. Insert the pipe into the fitting and scribe a mark on the pipe using the edge of the fitting.
Then pull the pipe out until a minimum of 0.06" (1.5 mm) dimension is achieved between the
scribed line and the edge of the fitting. Tack and weld the fitting joint.

2. Applying of a gap ring. Insert a metallic (stainless steel) contraction gap ring into the fitting
prior to inserting the pipe before welding. A product such as GAP-A-LET® when applied will
achieve the required pre-weld gap. Refer to chart 40151313 for EMD part numbers for gap
rings. See Figures 3 & 4 for application.

1. Fit gap ring into the socket fitting. Gap ring must be held in place by spring
tension from the gap ring itself, ring must not be loose. Seat the gap ring all
the way to the bottom of the fitting.

2. Insert the pipe into the socket fitting until pipe touches the gap ring. Do not
compress the gap ring between the fitting and the pipe, a touch contact is all
that is required for proper installation and function. See Figure 4. Tack and
weld the fitting joint.

Figure 3 Figure 4

3. During tack welding and finish welding, the pipe assembly must be supported to minimize
loading of the weld joints as the welds are solidifying.

E. Qualification of Pipe Welders

Pipe welders must be qualified per AI 2208.

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