BRAZING PROCEDURE SPECIFICATION NO
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1 NATIONAL CERTIFIED PIPE WELDING BUREAU BRAZING PROCEDURE SPECIFICATION NO FOR TORCH BRAZING OF ALLOYS 102, 120, 122, 142, 192 OF TUBE, VALVES, FITTING AND FLANGES USING BcuP-3 THROUGH-7 FILLER METALS WITHOUT FLUX This document is the property of (NCPWB Member Company Name) This Brazing Procedure Specification (BPS) and Procedure Qualification Records (PQRs) are issued by the NCPWB for adoption by its members. Reproduction or use of this BPS and PQRs by anyone other than Members of the NCPWB is prohibited NCPWB
2 Brazing Procedure Specification (BPS) BPS Number Revision 7 Date issued: (Previously BPS ) Supporting PQRs: 89010, 9901 Brazing Process: Torch Brazing, Manual Base Metals Joints Joint Design: Socket joint with clearance between tube and fitting of to inches. Overlap: Minimum of 3 times the thickness of the thinner member but not less than ¼ inch. It is not necessary to insert tube to the bottom of the socket as long as the minimum overlap has been achieved. There is no maximum overlap except for the maximum overlap for which the brazer is qualified. Filler Metals and Flux P-Number 107 to to P- Number 107 This BPS is for brazing of Alloys 102, 120, 122, 142 and 192 (unalloyed wrought copper) Base Metal Thickness Range to Postbraze Heat Treatment Temperature: None Max. Holding Time: N/A Positions Positions permitted: All Flow Direction: Upflow or downflow Specification Number: SFA 5.8 AWS Classification: BCuP-3 through BCuP-7 F-number: 103 Filler Form: Preformed ring or Face Fed, 1/16 to 1/8 in. Drawn wire, or both. Flux type or Trade Name: Flux is not permitted Gas Fuel Gas: Acetylene, propylene, propane or MAPP Flame Type: Neutral if used with oxygen Recommended Brazing Temperature: For BCuP-3, -5 and 6, 1400 to 1500 F (dull to light cherry color.) For BCuP-4, 1275 to 1375 F (dull cherry color) For BCuP-7, 1300 to 1400 F (cherry color.) Do not exceed 1600 F (yellow-red color) to avoid excessive oxidation. Technique and other information Initial Cleaning: Remove grease or oil with solvent followed by wiping with a clean cloth. Use sandpaper or Scotch-Brite to achieve a bright finish. Emery cloth is not recommended since it may contain oils. Do not polish so hard that grooves are formed. Flux Application: Flux is not permitted Fixturing: No special fixtures. Tube shall be supported by temporary supports during brazing as necessary Torch Tip Sizes: Acetylene: 54 up to ¾ inch OD, 51 for ¾ to 1-1/4 In. OD, 48 to 44 for 1-1/2 to 2-1/2 in. OD For other gases, torch tips shall be in accordance with the torch manufacturer s recommendations. Multi-flame torches are encouraged when brazing sizes over 2 inch OD. TurboTorch is permitted for all sizes. Final Cleaning: Use a wet rag and stainless steel wire brush to remove external oxide. Inspection: Visually examine completed joint. No linear indications are permitted. Outside surfaces shall be free of excessive braze metal. The undersigned contractor, a member of the National Certified Welding Bureau, hereby adopts this jointly developed brazing procedure and certifies that it has been qualified as shown in the referenced Procedure Qualification Records. Title: Date: NCPWB Form QB-482 BPS 107-1
3 Figure 1 Typical Brazed Joint Terminology D C A B A is the outside diameter of the tube B is the wall thickness of the tube C is the inside diameter of the socket D is the wall thickness of the socket E is the socket depth F is the overlap length (depth of insertion of the pipe into the socket) Joint Clearance is one-half of the difference between the outside diameter of the tube and the inside diameter of the socket Joint Clearance = (C-A) / 2 The Overlap (F) shall not be less than the overlap specified in the BPS. The overlap may be less than the depth of the socket (E) when permitted by the applicable construction code. F E
4 Brazing Procedure Qualification Record (PQR) BPS followed during brazing of test coupon: 107A-1, Rev 3, 5/30/95 PQR No: 9901 Brazing Process(es) used: Torch Brazing, Manual Date coupon was Brazed: Base Metal Specification: SB-111, Grade 122 to Base Metal Specification: B16.22, Alloy 22 coupling P-Number: 107 to P-Number: 107 Plate/Pipe Diameter: 1-1/2 Nominal Base Metal Thickness (in.): tube to socket Joint Type: Socket Filler metal specification: SFA 5.8 AWS Classification: BCuP-5 F-No.: 103 Overlap used (in.): 0.25 Clearance between parts: to in. Filler metal size: 1/8 square rod Method of supplying filler: Face fed Flux Type or Trade Name: None Gas Backing: Nitrogen at 5 cfh Position and flow direction: Three coupons each vertical upflow and horizontal flow Fuel Gas: Acetylene and TurboTorch Flame type: Neutral Postweld Heat treatment (ºF): None Postbraze heat treatment time (hr.): N/A Cleaning prior to brazing: Stainless steel wire brushing followed by wiping with clean rag Cleaning after brazing: water wash followed by stainless steel wire brushing Other: Each coupon consisted of two pipes and one coupling. Reduced Section Tensile Tests Rectangular Turned X Full Section Specimen Width/Dia (in.) Thickness (in) Area (sq in.) Ultimate load (lb.) Ultimate Stress (psi) Failure Location 1VU ,800 34,200 Base Metal, tube side 2VU ,800 33,600 Base Metal, tube side 1H ,900 34,600 Base Metal, tube side 2H ,900 34,000 Base Metal, tube side Bend Tests Transverse Face and Root Side Longitudinal Face and Root Peel Tests X Section Test Horizontal Section Acceptable Horizontal Section Acceptable Vertical Section Acceptable Vertical Section Acceptable Other tests: Visual Examination acceptable. Interior surface was free of surface oxides. Brazer s name: David A. Kaminski Stamp: DK Brazing Witnessed by: Bill Spohn, Coleman Spohn Corp Tests conducted by: Total Quality Testing, Inc. Laboratory test number: We hereby certify that the statements in this record are correct and that the test welds were prepared, brazed and tested in accordance with the requirements of Section IX of the ASME Boiler and Pressure Vessel Code. National Certified Pipe Welding Bureau Date: Chairman, Technical Committee NCPWB Form QB-483 PQR Number 9901
5 PROCEDURE QUALIFICATION RECORD (PQR) BPS followed during brazing of test coupon: BPS , Rev 1 PQR Number: Brazing Process(es) Used: Manual Torch Brazing, H-101 Date Test Coupon Was Brazed: 2/11/85 Base Metal Specification: SB-75, Grade 122 to Base Metal Specification: SB-75, Grade 122 P Number: 107 to P Number: 107 Joint Type: Socket Thickness (in.): Plate Diameter, if Pipe: 2-1/2" Type M Length of Overlap: 1.30 Clearance: 0.004" Filler Metal Specification: SFA 5.8 Classification: BCuP-5 F-No.: 103 Filler Metal Product Form: 1/8" Flat Wire Flux Type/Trade Name: None Used Brazing Temperature ( F) N/A Brazing Flow Positions Flat/Horizontal Flow, Vertical Upflow If Face Fed or Preplaced, Major Flow: X Does Does Not Occur. Furnace Atmosphere: N/A Fuel Gas: Propane Flame Type: Neutral Torch Tip Size: 54 Cleaning Method Before Brazing: Sandcloth followed by wiping with a clean cloth. Cleaning Method After Brazing: Water Wash followed by drying Additional Brazing Processes: None Postbraze Heat Treatment ( F): None Heat Treatment Time (hr.): N/A Other: X Reduced Section Tensile Tests Full-Section tensile Tests Specimen Width/Dia. (in) Thickness (in) Area (sq in) Ult.imate Load (lbs) Ultimate Stress (psi) Failure Location H ,250 34,600 Tubing H ,250 34,600 Tubing VU ,250 34,600 Tubing VU ,250 34,600 Tubing Guided Bend Tests: Trans. Root and Face (QB462.2(a)) Long. Root and Face (QW-462.3b) Peel or Section Test QB (peel) X QB (Section) Horizontal Acceptable (0%, 5% unbrazed) Vertical Acceptable (5%, 5% unbrazed) Horizontal Acceptable (0%, 0% unbrazed) Vertical Acceptable (5%, 5% unbrazed) Brazer's Name: Jerry Elson Stamp Number: E-1 Brazing Witnessed Gary Eff, Wm. Ferrel, Inc. Tests Conducted by: Gary Eff, Wm. Ferrel, Inc. Laboratory Test Number: NCPWB-195 We Certify that the statements in this record are correct and that the test brazments were prepared, brazed and tested in accordance with the requirements of Section IX of the ASME Code. National Certified Pipe Welding Bureau BY: Date Chairman, Technical Committee NCPWB Form QB /91 PQR Number 89010
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