ABSORPTION WELDING INSTRUCTIONS

SERVICE Supersedes: 155.17-M3 (694) Form 155.17-M3 (204)

MAJOR CUTTING AND WELDING GUIDELINES

NO CUTTING TORCHES after temporary closures have been welded on to remove
air and recharge with a slight positive charge of Nitrogen
Oxy-Acetylene cutting torches will or Argon. A small hole can be made with a pencil point
blow molten metal particles into the in the plastic to provide a positive purge of nitrogen. Set
unit. Some of these will adhere to the the regulator for only a small flow (detectable on a wet
the copper alloy tube surfaces causing wrist) and insure that the Nitrogen or Argon bottle has
pitting corrosion to occur later. The a sufficient quantity of gas remaining if the unit will be
loose particles will plug spray nozzles left unattended. If necessary, manifold several bottles of
and cause pump bearing failures. inert gas together. If available, a liquid nitrogen bottle
will supply a sufficient quantity of gas to last for long
periods of time.
Hole saws, reciprocating saws or the like should be used
whenever possible. The preferred method of entry at
YORK’s manufacturing facilities is to skim gouge or FIRST AND SECOND PASS (ROOT AND HOT
PASS) MUST BE TIG WELDED.
air-arc the metal so that only a thin skin of metal remains
and then to grind the metal away using a disk grinder. Stick welding is not allowed on the first pass due to the
Final grinding is done with a slight positive pressure need for a smooth internal weld surface. Chill rings or
in the unit so that grinding residue does not fall into backup rings are not allowed due to the crevice they
the unit. Any entry method should be performed with will provide for corrosion to occur. See Welding Details
a slight positive pressure in the unit so that all cutting section for more specific welding information.
debris is blown outward. See Cutting Details section
for more specific information. ALL CUTTING AND WELDING OF UNITS
UNDER WARRANTY MUST BE 100% YORK
NEVER LEAVE THE UNIT OPEN TO THE SUPERVISED.
ATMOSPHERE
Under no circumstances should non-YORK personnel
Keep a constant purge of Nitrogen or Argon on the unit be given sole responsibility to cut or weld on a YORK
when it is open. Tightly tape any openings with plastic Absorption unit. Absorption units require specialized
or use test plugs to close openings. If a unit has to be cut handling when cutting or welding. Only trained YORK
apart for installation purposes, weld temporary closures personnel are considered qualified to supervise or
over the openings. Evacuate the unit as soon as possible perform this work.

CUTTING DETAILS
1. Cutting into a YORK Absorption unit should only until only a thin layer of metal remains, then grind
be done after careful study of assembly drawings. that metal away using a disk grinder. Be sure a
Precautions should be taken to avoid damaging slight positive pressure remains in the unit during
internal items in the unit such as tubes, etc. this operation.
Complete removal of solution or refrigerant may
be required to avoid loss of Lithium Bromide. 3. Keep a slight positive pressure on the unit at all times
so that cutting dirt and air does not enter the unit.
2. Whenever possible, use circular hole saws or
reciprocating saws to cut access holes. Do not 4. If major repairs are necessary, it may be beneficial
use cutting torches. Where extensive cutting is to perform a Lithium Hydroxide wash first. Consult
necessary, skim gouge (See Gouging Procedure) YORK Factory Service prior to this procedure.
 FORM 155.17-M3 (204)

HAND HELD ELECTRODE of carbon electrode used. For extra heavy duty work
HOLDER
water cooled holders are used.
CARBON
ELECTRODE The air pressure is not critical but should range from 80
to 100 psi (550 to 690 kPa). The volume of compressed
AIR STREAM
air required ranges from as low as 5 cu ft/min (2.5 liter/
DIRECTION OF min) to 50 cu ft/min (24 liter/min) for the largest size
TRAVEL WORK LEAD
electrodes. A one horsepower compressor will supply
sufficient air for smaller size electrodes. It will require
up to a ten-horsepower compressor when using the
largest size electrodes.

The carbon graphite electrodes are made of a mixture

LD09443 of carbon and graphite plus a binder which is baked
FIG. 1 - SKIM GOUGING
to produce a homogeneous structure. Electrodes come
in several types. The plain uncoated electrode is less
GOUGING
expensive, carries less current and starts easier. The
Air carbon arc gouging is an arc gouging process in copper coated electrode provides better electrical
which metals to be gouged are melted by the heat of a conductivity between it and the holder. The copper
carbon arc and the molten metal is removed by a blast coated electrode is better for maintaining the original
of air. A high velocity air jet traveling parallel to carbon diameter during operation; it lasts longer and carries
electrode strikes the molten metal puddle just behind a higher current. Copper electrodes are of two types,
the arc and blows the molten metal out of the immediate the DC type and the AC type. The composition ratio of
area. Fig. 1 shows the operation of the process. It shows the carbon and graphite is slightly different for these
the arc between the carbon electrode and the work and two types. The DC type is more common. The AC
the air stream parallel to the electrode coming from the type electrode contains special elements to stabilize
special electrode holder. the arc. The AC type electrode is used for direct current
electrode negative when cutting cast irons. For normal
The air carbon arc cutting process can also be used to use, the electrode is operated with the electrode positive.
cut metal and to gouge out defective metal, to remove Electrodes range in diameter from 5/32 in (4.0 mm) to
old or inferior welds, for root gouging of full penetration 1 in (25.4 mm). To make a cut or a gouging operation
welds, and to prepare grooves for welding. Air carbon the cutter strikes an arc and almost immediately starts
arc cutting is used when slightly ragged edges are not the air flow. The electrode is pointed in the direction of
objectionable. The area of the cut is small, and since the travel with a push angle approximately 45 degrees with
metal is melted and removed quickly, the surrounding the axis of the groove. See the following Carbon Arc
area does not reach high temperatures. This reduces Gouging Procedure (Air Arc) WPS No. 135-015-001
the tendency towards distortion and cracking. The air for the prescribed procedure.
carbon arc cutting process can be used in all positions.
It can also be used for gouging in all positions. Use in The speed of travel, the electrode angle and the
the overhead position requires a high degree of skill. electrode size and current determine the groove depth.
Electrode diameter determines the groove width. See
The electrode holder is designed for the air carbon Table 2 for specific details.
arc process. The electrode holder and a copper coated
electrode are shown in Fig 1. The holder includes a Carbon Arc Gouging is a very noisy
small circular grip head which contains the air jets for process and ear protection should be
directing the compressed air along the electrode. It also worn.
has a groove for gripping the electrode. This head can
be rotated to allow different angles of electrode with
respect to the holder. A heavy electrical lead and an
air supply hose are connected to the holder through a Carbon Arc Gouging creates large
terminal block. A valve is included in the holder for amounts of molten metal that will
turning the compressed air on and off. Holders are be falling in the surrounding area.
available in several sizes depending on the duty cycle Combustible materials and personnel
of the work performed, the welding current and the size should be suitably protected.
2 YORK INTERNATIONAL
 FORM 155.17-M3 (204)

CARBON ARC GOUGING PROCEDURE 3. Connect the electrode from the power supply and
(AIR ARC) WPS NO. 135-015-001 air supply to holder lead.
Arcair Manual Torch K-3 and K-5 4. The D.C. power supply should be set to operate in
The Arcair manual torches are designed to operate with reverse polarity and amperage depending on elec-
a supporting power source and shop air supply (100 trode size (See Table 1).
psi). The K-3 model is designed to operate with 5/32"
(4 mm) to 3/8" (10 mm) diameter carbon electrode, the 5. With the power and air supply turned on, press the
K-5 model is designed to operate with 5/16" (8 mm) to torch valve button to turn on the air. Position the
5/8" (16 mm) diameter carbon electrode. torch for a leading angle with the air jets in holder
trailing the arc, strike arc and travel at a speed to
SET-UP AND OPERATING INSTRUCTIONS maintain the depth of gouging required.
FOR MANUAL TORCH K-3 AND K-5 MODELS

1. Select the size electrode to be used based on the Electrode Size 1/4 5/16 3/8 1/2
recommended amperage range and carbon size in Minimum Amps 200 250 350 600
Table 1.
Maximum Amps 400 450 600 1000

2. The electrode should be gripped in the holder to that TABLE 1 - RECOMMENDED ELECTRODE SIZE
a maximum of 6" (15 cm) extends from the holder AND AMPERAGE RANGE
to work.

GROOVE WIDTH GROOVE DEPTH ELECTRODE AMPERES VOLTS ELECTRODE ELECTRODE TRAVEL SPEED
(IN) (IN) DIAMETER (IN) (DC) POSITIVE FEED (IPM) (IPM)
1/4 1/16 3/16 200 43 6.2 82
5/16 3/16 3/16 190 42 6.7 27.2
3/8 1/8 5/16 320 40 3 65.5
3/8 1/4 5/16 420 42 3.8 31.2
7/16 3/16 3/8 560 42 2.6 41
7/16 1/4 3/8 560 42 3 29.5

TABLE 2 -

WELDING DETAILS
Every field weld on a YORK Absorption unit should be When possible, finish weld any repair weld inside seam
a full penetration weld. Most welds can be butt welds. prior to closing up the unit. This is especially true when
Butt welds are preferable because of their strength. All working on the generator or any area of strong solution
weld root passes and hot passes must be made using concentration within the unit.
Gas Tungsten-Arc Welding, commonly called TIG.
Do not weld a unit while that unit
The purpose of using TIG for the first two passes is
is under vacuum. A slight positive
primarily to provide a smooth crevice free surface on
the inside of the pipe or shell. It is impossible to get
pressure should be present whenever
such a surface using Shielded Metal Arc Welding welding.
(conventional stick). It must be remembered that any
cracks or crevices will later be places for corrosion
cells to form. A weld with porosity, holes, or crevices Weld joints should be prepared as shown in Fig. 2. See
on the inside surface will quickly corrode and develop the following Gas Tungsten Arc Welding Procedure
leaks. Every effort should be made to leave a smooth (TIG) WPS No. 135-006-030 for the prescribed
inner surface when making weld repairs. procedure.

YORK INTERNATIONAL 3
 FORM 155.17-M3 (204)

Most of the steel shell material of a YORK Absorption welding pipe, aligning should be done with some type
unit is mild steel with a nominal thickness of 3/8" (10 of aligning fixture. Root opening and root face should
mm). Almost all piping is Schedule 40 grade steel. If be controlled to specified dimensions as illustrated in
there is any doubt as to the exact metallurgy of an area Fig. 2. Tacks shall be small and equally spaced to insure
of the unit, contact YORK Factory Service for the proper root opening during welding. A welder equipped
specific details. with remote amperage control should be used to decay
arc at end of weld. When remote amperage is not used,
the arc should be moved to the side wall before ending
GAS TUNGSTEN ARC WELDING weld. The end of tacks should be ground to a beveled
PROCEDURE (TIG) WPS NO.135-006-030 end for starting and stopping points. The weld is started
by holding the torch at a 90 to 75 degree angle with
Specifications pipe or plate. The filler rod is positioned close to joint
an arc in preparation for insertion. Filler rod is inserted
JOINTS SEE FIG 2
in short strokes, at the same time moving the torch in
GAS TUNGSTEN-ARC
PROCESS
WELDING (GTAW) MANUAL
the direction of the filler rod. To stop weld, hold torch
SPEC. NO SFA 5.18
over puddle for a few seconds until puddle cools.
CLASS ER70S-2
When welding single welded pipe joints with 1/8"
PREHEAT TEMP. RANGE 60° F MINIMUM
(3 mm) root opening, the weld should be stopped
INTERPASS TEMPERATURE 350° F MAXIMUM
approximately 1/4" (6 mm) from a tack and the tack
SHIELDING GAS WELDING GRADE ARGON beveled by grinding or burring tool. Before starting to
% COMPOSITION 100 weld, the end of the weld or start of a tack should be
FLOW RATE 15 - 20 C.F.H. beveled for easier starts. The travel speed and filler
WELD PASS THICKNESS 1/4" MAXIMUM rod must be controlled to maintain a key-hole opening
STRINGER OR WEAVE BEAD EITHER of 3/16" (5 mm) maximum. For better torch control
ORIFICE OR GAS CUP SIZE NO. 4 - 8 when welding root pass, the nozzle or cup can be placed
OSCILLATION UP TO 1/4" against the beveled surface and the electrode adjusted
2% THORIATED TUNG- to proper distance from puddle.
ELECTRODE STEN 1/16", 3/32", OR 1/8"
DIA. CONE POINT
CURRENT DC
POLARITY STRAIGHT 75˚
AMPERAGE RANGE 75-250
ELECTRODE EXTENSION 3/16" TO 3/8"

PROCEDURE

Surfaces to be welded and an area of at least 1/2" (13

1/16" MAX
mm) from the weld joint preparation shall be smooth, MISMATCH
clean and free from rust, scale and any other surface
impurities. Cleaning shall be done by shot blasting, 3/32 - 5/32"
GAP
grinding, machining or wire brushing. Cleaning is LD09444
required prior to welding and after each pass. FIG. 2 - WELD JOINT SET-UP

The shape of the tungsten is very important and should

be shaped on a fine grinding wheel. The included
angle of the point should be ground back about 22 to
23 degrees or to a distance equal to 2-1/2 times the
electrode diameter. The tip should be blunted slightly
less than 1/64" (1 mm).
Aligning of the weld joint is very critical and when

4 YORK INTERNATIONAL
 FORM 155.17-M3 (204)

SHIELDED METAL ARC-MANUAL

1/8 PROCEDURE (STICK) WPS NO.135-003-015

Use for Cap (3rd Pass and Remainder of Passes)

SUPPORT
ELECTRODE SFA5.1/E7018
PIPE
CURRENT
1/8 Direct Current - Constant Current
TYPE
POLARITY Reverse Polarity - Electrode Positive
VOLTAGE 22 to 27 Volts
3/32 Flat - 90-115 amps; Out of Position-80-100 amps
1/8 Flat - 140-160 amps; Out of Position-110-130 amps
AMPERAGE
5/32 Flat - 185-220 amps; Out of Position-155-190 amps
LD09447
3/16 Flat - 220-300 amps
FIG. 3 - WELDING PIPE SUPPORTS MIN. PREHEAT
60°
TEMP.
MAX.
INTERPASS 500° F
TEMP.
Welding Pipe Less than 2-1/2"
MAX. PASS
1/4"
THICKNESS
Slight weaving is permitted but bead width
1/8 OSCILLATION shall not exceed six (6) times electrode
PIPE diameter.
The surface of parts to be welded shall be
75° cleaned by machining, grinding, wire brushing,
grit blasting, vapor degreasing, and/or solvent
INITIAL
cleaning to remove scale, rust, oil, grease or
CLEANING
other detrimental foreign material from the
weld point and 1.0 inch of the base material
adjacent to the weld preparation.
When weld material is to be deposited over
a previously welded surface, all slag shall be
NOTE: Root pass TIG, when welding removed by a slag pick, pneumatic slagger,
pipe larger than 2-1/2". INTERPASS wire brush, grinding, or other suitable means
CLEANING so as to prevent inclusions or impurities
LD09448 in the weld metal. Any cracks, porosity or
undercutting which is evident shall be removed
FIG. 4 - WELDING PIPE subsequent to any additional welding.

YORK INTERNATIONAL 5
 FORM 155.17-M3 (204)

SPECIAL INSTRUCTIONS FOR FIELD the first stage generator are examples of these welds.
WELDING NEW UNITS All other welds should be soap tested for leaks as a bare
minimum. Refer to ES Service Information Letter
Air should not be allowed to contact the internal SI0045 for leak detection procedures.
surfaces of the unit. Every effort must be made to
prevent air (oxygen) from entering the unit at all Follow assembly drawings and welding symbols for
times (this applies to any Absorption unit). During reassembly of units. If there are any doubts concerning
reassembly procedures, keep a constant purge of inert the proper procedure to use for assembling a knock
gas (Nitrogen or Argon) going through all sections of down unit, consult YORK Service, York, PA for
the unit. Since it is virtually impossible to prevent all additional information.
air from entering the unit while it is being assembled,
as soon as possible evacuate the unit and recharge it
with inert gas. Under no circumstances should a
non-knockdown Absorption unit be
Welds that cannot be pressure tested must be dye cut open for installation purposes
penetrant tested prior to closing. Solution pipes within without prior approval from YORK
pipes such as between the solution heat exchanger and Factory Service.

SYMBOLOGY

FINISH SYMBOL GROOVE ANGLE; INCLUDED

ANGLE OF COUNTERSINK
CONTOUR SYMBOL
FOR PLUG WELDS
ROOT OPENING; DEPTH OF FILLING
FOR PLUG AND SLOT WELDS
GROOVE WELD SIZE F LENGTH OF WELD
PITCH (CENTER-TO-CENTER
DEPTH OF PREPARATION; SIZE OR
STRENGTH FOR CERTAIN WELDS
A SPACING) OF WELDS
FIELD WELD SYMBOL
)

R }L
s }
) ) OTHER
SIDES )

SIDE

SPECIFICATION, PROCESS, ARROW CONNECTING

OR OTHER REFERENCE (E) P REFERENCE LINE TO
T ARROW SIDE MEMBER OF

}
( BOTH

TAIL

} JOINT OR ARROW SIDE

) ARROW
SIDE

OF JOINT
(TAIL OMITTED
WHEN REFERENCE
IS NOT USED) WELD-ALL-AROUND-SYMBOL
(N) REFERENCE LINE
NUMBER OF SPOT, STUD
OR PROJECTION WELDS
BASIC WELD SYMBOL
OR DETAIL REFERENCE
ELEMENTS IN THIS
AREA REMAIN AS
SHOWN WHEN
TAIL AND ARROW
MELT - THROUGH SYMBOL ARE REVERSED

LD09445

FIG. 5 - SYMBOLOGY

6 YORK INTERNATIONAL
 FORM 155.17-M3 (204)

MELT-THROUGH SYMBOL

1/16

1/16

DESIRED SYMBOL

75°
6-030 (ROOT)
3-015/3-039
1/8

75°

INSIDE OF PIPE
1/8

DESIRED SYMBOL

LD09446
FIG. 6 - SYMBOLOGY

NON-DESTRUCTIVE TESTING (NDT)

BASIC SYMBOLS GENERAL PROVISIONS

Basic nondestructive testing symbols shall be as Location of Testing Symbol

follows:
When nondestructive testing symbols have no arrow
TYPE OF TEST SYMBOL
or other side significance, the testing symbols shall be
RADIOGRAPHIC RT
centered on the reference line as follows:
MAGNETIC PARTICLE MT
PENETRANT PT
RT PT MT

When nondestructive tests are to be made on the arrow

side, other side or both sides of the part, the testing
symbols shall be indicated as follows:

PT MT
RT MT

YORK INTERNATIONAL 7
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by York International Corporation 2004 www.york.com ALL RIGHTS RESERVED
Form 155.17-M3 (204)
Supersedes: 155.17-M3 (694)