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Welding of P91
Welding of P91
P5A P5B
Siddhartha Sankar Bharali M6B194
Composition of X20
12 Cr 1Mo 1/4V
operating at temperatures of 530 0C and higher for power generating sets of 150MW and more. X20 material was first used in India for high-temperature steam piping around 1970. The use of X20 allowed wall thickness reductions of about 50%. These reductions resulted in easier handling; less energy needed for preheating and postweld heat treatment , faster start-up and shutdown of the unit. However, two factors limited its use: - The extreme care needed for its fabrication and welding. - Its noninclusion in the American Society of Mechanical Engineers (ASME).
Siddhartha Sankar Bharali M6B194
middle 1970s to bridge the gap between ferritic P22 and austenitic steels with respect to creep rupture strength for hightemperature service from 540 to 600 0C. As a result of these developmental efforts, a new material, designated P91, was introduced in the U.S. in the 1980s by Oak Ridge National Laboratory. It has very high strength at elevated temperatures and good fabrication properties. These features have made P91 the material of choice for high-temperature steam piping.
Siddhartha Sankar Bharali M6B194
P91 DETAILS
P NO. COMPOSITION FILLER USED ELECTRODE P 5A GR 2 9 Cr 1 MoV 90 S- B9 E9018- B9
Cooling
Purging
Preheating
PWHT
Soaking
hacksaw / machining / grinding only. Edge preparation (EP) shall be done only by machining. The weld fit-up shall be carried out properly to ensure proper alignment and root gap . Neither tack welds nor bridge piece shall be used to secure alignment. Partial root weld of minimum 20mm length by GTAW and fit-up by a clamping arrangement is recommended. Use of site manufactured clamps for fit up is acceptable .
The fit-up shall be as per drawing. Root gap shall be 2 to 4 mm; root mismatch shall be within 1-mm.
Siddhartha Sankar Bharali M6B194 9
ELECTRODE NOMENCLATURE
Prefix E : Arc Welding Electrode First two or three digits : Strenght in ksi
For example : E-90xx is 90ksi Second last digit: Welding position For example : E-xx1x = All positions : E-xx2x = Horizontal and Flat : E-xx3x = Flat Last digit : E-xxx1: Type of Coating and other Characteristics For example : E-xxx3 = Rutile Coated : E-xxx8 = Basic Coated (Low hydrogen) Suffix A-1,B-2,B-3 etc. : Alloying Element For example : E-xxxx A-1 = 0.5Mo : E-xxxx B-2 = 1.25Cr & 0.5Mo : E-xxxx B-3 = 2.25Cr & 1.0Mo
Siddhartha Sankar Bharali M6B194 10
PURGING
Reason for purging
It is generally carried out on the backside of the weld to
eliminate oxygen and other atmospheric gases from mixing with hot metal. Oxygen have a stronge tendency to combine with hot metal which will lead to the formation of thin films of oxide layers on the weld surface. It prevents the joining of two pieces by welding. Argon is commonly used as purging gas.
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WHY ARGON ?
Argon is chemically inert, heavy, monatomic gas available in
large quantity at reasonable cost. Argon is used for shielding and backing purpose.
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Purging Details
Purging should be start from inside of the pipe when root
temperature reaches 2200C . Adequate amount of Argon should be purged in the root area. Minimum pre-flushing time for purging before the start of welding is 5 min irrespective of pipe thickness. The min flow rate to be maintained during purging is 10-26 litres/min. For shielding during GTAW welding, flow rate is 814 litres/min.
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PREHEATING
Prior to the start of
preheating the surface should be clean from oil, grease and dirt. Preheating temperature should be maintained at 2200C.
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P1 Gr 1 & SA106 Gr C
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Contd.
P No. of Material Thickness (mm)
All
Butt Weld
Preheat C 220 PWHT C 750-770
All
220
730- 760
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Preheating Methods
3 common methods of preheating:
Electrical resistance heating. Induction heating. Oxy- acetylene heating.
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including the entire weld and adjacent area of base metal, by induction or electrical resistance heating.
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DETAILS OF PWHT
PWHT temperature for P91 : (76010)0 C
Soaking time : 2.5 minutes/ mm of weld thickness
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> 75mm
Siddhartha Sankar Bharali M6B194
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SL NO 1
2 3 4 5 6
OPERATION
PREHEAT WELDING BY GTAW/ SMAW COOLING
TEMPERATURE
220 220-350 80-100
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HOLDING AT 80-100 FOR MIN 1 HR . HOLDING SHALL CONTINUE TILL THE START OF PWHT HEATING TO PWHT SOAKING at PWHT 760 +/- 10 760 +/- 10 at 2MIN / mm COOLING TO 350 COOLING TO ROOM TEMPERATURE
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COOLING COOLING
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temperature at 80 to 100C up to a length of 50 mm on either side from weld centre line along the complete circumference of the pipe. Root welding shall be continued after power is restored and preheating temperature is raised to 220C.
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Contd.
Argon purging should be continued until the GTAW root
welding followed by minimum two filler passes of SMAW, is completed. GTAW wires are kept in absolutely clean condition and free from oil , rust, etc. SMAW electrodes are baked to proper temperature. Interpass temperature should be less than 350C. Argon purging arrangements should be removed after welding.
Siddhartha Sankar Bharali M6B194 35
Contd.
Don'ts No Tack welding or Bridge piece welding is permitted. Argon purging is continued till the completion of GTAW root welding and two layers of SMAW. Oxy-Acetylene flame cutting is avoided. Do not allow moisture, rain, water, cold wind, cold draft etc. to come in contact with the weld zone or heating zone during the entire cycle from preheat to PWHT. Use unidentified TIG wires or electrodes is not permitted.
Siddhartha Sankar Bharali M6B194 36
THANK YOU
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