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Tube/Tubesheet welding; min. Leak Path

Tube/Tubesheet welding; min. Leak Path

Tube/Tubesheet welding; min. Leak Path

(OP)
Dear all

We are having some troubles qualifying a Tube/Tubesheet PQR acc. to ASME IX and EN ISO 15614-8; more specifically the min. Leak Path.
I know ASME VIII Div.1 has no special rules for it, but EN ISO 15614-8 does.
We have tried many ways to weld the tube/tubesheet connection (ø Fillermetal, amps, weld speed, joint design…) but for some reason when we check the macroscopic test, +/-50% of the welds do not meet the requirements of the min. leak path (for EN ISO this should be min. 0.9 tube THK).
Important: we do the welds manually, first layer without filler metal, second layer with filler metal.
Are there special joint designs that can guarantee a sufficient weld? Or other tips/tricks?

Thanks in advance!

Regards,
PeterMan

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