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    Welding of P91

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    Welding of P91

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
    134 views23 pages

    Fabrication Guidelines For P91

    Uploaded by

    Srinivasa
    Welding of P91

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    of 23
    Wi coneanr Cacoryu7) Bharat Heavy a Electricals Limited PC: Q:A: SIM P9 01.06.2000 PIPING CENTRE ‘ARR COMPLEX +41, NORTH USMAN ROAD, 7.NAGAR, CHENNAI - 600 017. INDIA. To Shri.U.R. Khosla Teux : oct PHONE: ezotoot SM / QA Co-ordinator ( Simhactri Project) Fax: of 044 e202560 Engineering Office Complex II floor, National Thermal Power Corporation Ld., A~8A, Sector 24 NOIDA — 201 301. Dear Sir, Sub:- Simhadri 2X500 MW Main Plant Package P91 Welding Ref:- MOM dt 25.05.2000 We are enclosing a copy of the Doc No. QCP : 11:01 dt 25.05.2000. “Fabrication Guidelines for SA 335 P91 material at HPBP shop”. Please note that the points agreed on 25.05.2000 have been incorporated. Thanking you Yours truly DGM / QUALITY cc: Shri. G.J.P. Narayanan / DGM / IS -NTPC / BHEL Campus / Trichy Shri.M.Kannappan / Sr.DGM / OP&C / BHEL / HPBP / Trichy Shri. V.Ravindran / Sr.Mgr / WTC 2&4 Building / BHEL / HPBP / Trichy > Shri. J. Kannan / DGM / Quality Control /2 & 4 Building /BHEL / HPBP / Trichy Shri. C.R. Raju / DGM / Quality Assurance Central Lab / BHEL / HPBP / Trichy Shri. S. Jeyakumar / DGM / Engg / PC Shue Tayole bin ~ Llopre- Shu To Kanvaygar long Regd. Office : BIEL HOUSE, Siri Fort, New Delhi - 110 049 i a BHARAT HEAVY ELECTRICAL LIMITED PIPING CENTRE : CHENNAI - 600 017 Doc NO: QCP:11 :01 DATE:25.05.2000 FABRICATION GUIDELINES FOR FOR SA 335 P91 MATERIAL AT HP BP-SHOP Name Signature Prepared / Revised by Sri. JeyasinghPaul, Manager/ QA Piping Centre ea Reviewed by Senior DGM/OP&C HPBP/Trichy 77 DB h— ‘Senior Manager] WTC HPBP/Trichy ela.) DGM/QCc HPBP/Trichy TJ ham — DGM/QA HPBP/Trichy DGM/ Engineering Piping Centre. Approved by DGM/Quality Piping Centre cael | Laat RA__ BHARAT HEAVY ELECTRICALS LIMITED PIPING CENTRE, CHENNAL PAGE 1 OF 22 FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 AT HPBP-SHOP Doc NO : QCP:11 : 04 DATE : 25.05.2000 REV 01 CI 10.0 to Cl 14.0:- Appearing from page 17 to 22 renumbered as CI 114.0 to Cl 15.0 ( typographical error) In the following Clauses NTPC comments are incorporated. C1 4.2.3b,Cl 4.3.2.¢, Cl 4.3.4 a, b,Cl 5.1,C15.3, C1 7.3, Cl 11.3 ¢, Cl 12.2, C114.1_v added. Cl 4.3.4.e. deleted and subsequent point renumbered. wdop AA BHARAT HEAVY ELECTRICALS LIMITED __ PIPING CENTRE CHENNAL PAGE 2 OF 22 RO a FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 AT HPBP-SHOP Doc NO : QCP:11: 011 DATE : 25.05.2000 1.0 2.0 2.0 3.0 34 3.2 33 INTRODUCTION The new material SA 335P91 (P91)is normally used in place of P22 in the main steam and high pressure bypass upstream piping systems. This material P91 is a high strength creep resistant ferritic steel exhibiting very high creep rupture strength properties at elevated temperature justifying its application for the above systems replacing SA 335 P22 material. The butt and fillet joints will be welded both at shop and site. SCOPE Ee This procedure highlights the important requirements to be ensured during fabrication and inspection of P91 Piping products at shop. REFERENCE DOCUMENTS Relevant ASME standards Indian Boiler Regulations (IBR) Collaborator's recommendations Good engineering practices used in BHEL MATERIALS The P91 pipes and fittings are procured from the BHEL approved Vendors, with necessary test certificates. All P91 pipe bends are either procured or manufactured at BHEL - HPBP shops as per the drawing and applicable Quality Plan. Material Specifications Pipes and Bends SA 335 P91 Fittings SA 234 WP91 Forgings SA 182 F91 All materials are checked for specification, grade, size and identified by hard stamping and colour code and stored properly to avoid any mix up with other materials. a BHARAT HEAVY ELECTRIGALS LIMITED PIPING CENTRE CHENNAL PAGE 3 OF 22 & Doc NO : QCP:11 : 04 FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 ATH PBP-SHOP DATE : 25.05.2000 40 44 4.2 4.24 4.2.2 4.23 WELDING Welding is performed as per the systems and practices developed at BHEL over the years. All welding procedures are qualified as per ASME Sec. IX and all welding personnel are qualified in accordance with IBR. The welding systems developed at BHEL covers the controls exercised for procurement, inspection, storage and issue of consumables, procedure and personnel qualifications and surveillance of welding activities. Welding Consumable Control Welding consumables are selected and procured as per the applicable Welding Procedures Specifications (WPS). All welding consumables are verified for compliance to the test certificates and taken into stock with proper identification. Storage, Issue & Control of welding consumables Storage Welding consumables are received with proper packing and marking which includes the relevant batch number for easy identification. Electrodes are stored in their original sealed containers / packages until issue and kept in dry and clean environment taking care of shelf life. Welding filler wires are received with proper packing and marking which includes the relevant batch number for easy identification. The filer wires are stored in their original packages until issue and kept in dry and clean environment. The Welding Technology Centre (WTC) authorises the issue of required welding consumables from Stores, based on the requisitions from Manufacturing, and stores them at the Intermediate Store in the respective Shop. Prior to issue at Shop, the electrodes are removed from the packages and transferred to the drying oven. The drying ovens are provided with separate ‘compartments to prevent mix up of consumables. toy NE BHARAT HEAVY ELECTRICALS LIMITED PIPING CENTRE, _CHENNAL PAGE 4 OF 22 ATH P BP- SHOP FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 Doc NO : QCP:11 : 01 DATE : 25.05.2000 Consumable pre-treatment and Issue a. Electrodes are to be dried in an oven at 250 - 300°C for a minimum period of 2 hours. b. After drying the electrodes are transferred to the holding ovens and are maintained at temperature of 150°C to prevent moisture absorption. c. The temperature indicators of the drying and holding ovens are periodically calibrated to ensure valid calibration at any time. d. Issue of electrodes at any time to the welders shall be restricted to 20 i o numbers maximum. The issue is done through authorised issue slips. ©. Unused electrodes are retumed to the intermediate stores after the completion of the job or at the end of every shift. f, _Allreturned electrodes are transferred in the drying oven for re-drying prior to re-issue. 9. Allldrying, holding and issue controls are done as per the above instructions issued by WTC and records maintained. 43 PROCESS CONTROL 4.3.1. Definitions Welding Procedure Specification (WPS) & Qualified WPS alone is to be used for welding. Applicable WPS Nos are to be indicated in the OPS. The WPS comprises of the details of Welding consumable, Pre &Post heat temp, PWHT temp, Purging & Shielding gas, weld parameter details. Procedure Qualification Record (POR) The Procedure Qualification Record (PQR) is a record of welding: data used during the welding of test coupon. The PQR contains variables recorded during welding and also the test results of the tested specimen. The PQR will be as per ASME Sec IX. Welder's Performance Qualification (WPQ) Welders who are qualified as per IBR on alloy steel welding will bé trained, on P91. ph BHARAT HEAVY ELECTRICALS LIMITED PIPING CENTRE. _ CHENNAI PAGE 5 OF 22 oe FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 ATHPBP-SHOP Doc NO : QCP:11 : 04 DATE : 25.05.2000 4.3.2 a. 43.3 Sequence of Operations ‘The sequence of operations is defined in the Operation Process Sheets (OPS), which shall be followed for forming, fabrication, welding, inspection/ testing and heat treatment. All the relevant stages shall be checked by Quality Control (QC) as per the OPS / applicable Quality Plan(QP) and inspection records maintained. QC shall coordinate for obtaining clearance from Customer/IBR during their inspection of the applicable stages. The following are to be ensured by Shop/QC/NDTL, as indicated in the opsiaP: Material verification Dimensions and weld bevel check Weld joint alignment and fit-up Arrangement for purging, heating and temperature measurement Attesting the heating cycle chart in case of induction heating Welding clearance after completion of welding Nondestructive examination Heat treatment clearance Attesting the chart after completion of PWHT Final inspection including NDT Surface Preparation, Painting and Work order / DU identification Despatch clearance after external inspection clearance Caution:- No LPI/ Wet MPI shall be carried out on weld before PWHT. EDGE PREPARATION AND FIT-UP Edge preparation shall be done by machining as per drawing requirements. During fit-up, it is essential that the inside diameter are matched and the outside surface shall be suitably maintained with sufficient cylindrical portion for carrying out UT examination. It shall be ensured that sufficient straight portion at the lip, as indicated in the drawing, is provided for UT examination. In case where the above straight portion is not possible at both ends, UT scanning may be done only at one end covering full weldment or suitably supplemented with shop radiography as decided during the fabrication. NK AL BHARAT HEAVY ELECTRICALS LIMITED Piping Centre Chennai Page 6 0f 22 FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 ATHPBP-SHOP Doc NO : QCP:11: 01 DATE : 25.05.2000 d. Branch openings and Carrier attachments shall be prepared as per drawing e. The fit-up tolerance of pipe to pipe or pipe to bend / fitting shall be as indicated in the drawing. Wherever it is not specified in the drawing it shall be as follows; RootGap 2-4mm Mismatch at root 1mm (max.) f, Weld build up shall be avoided as far as possible. In case any weld build up becomes unavoidable, a separate procedure shall be established and issued by QA ® 9. During the fit-up of joints it is essential to verify the exact dimensions measured at the weld joint area; suitable reference punch marks (at 200 mm from the EP) on both the pipes at atleast four axis locations shall be made to facilitate UT. This is to enable NDT/UT operators to examine the root defect echos as in most of the cases the misalignment at root may cause geometrical defects and lead to misinterpretation of root defects. | h. The weld fit-up for any type of butt joint or branch joint or attachment shall have suitable arrangement like mechanical fixture/ clamping or partial root weld of minimum 20 mm length. Bridge pieces shall be avoided. 4.3.4 PURGING ARRANGEMENT : a. Argon gas with requisite purity shall be used for purging of the root side weld. The purging dam (blank) shall be fixed on either side of the weld bevel prior to pre-heating. The dam shall be fixed inside the pipe and it ‘ shall be located away from the heating zone. Purging is to be done for root ' welding (GTAW) followed by two filler passes of SMAW in case of butt welds. Purging is not required in the case of nozzle and attachment welds when they are not full penetration joints. b. The flow rate is to be maintained during purging is 10 to 25 litres/minute and for shielding during GTAW is 8 to 14 litres/minute. A minimum fiow rate as per welding procedure specification (WPS) shall be maintained. c, Start purging from inside of pipe when root temperature reaches 220°C. Provide continuous and adequate Argon Gas to ensure complete purging in the root area. —A_ BHARAT HEAVY ELECTRICALS LIMITED PIPING CENTRE, CHENNA PAGE 7 OF 22 i FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 ATHPBP-SHOP Doc NO : QCP:14 : 01 DATE : 25.05.2000 d. The minimum pre-flushing time for purging before start of welding shall be 5 minutes, irrespective of the pipe size. e. Wherever possible, solid purging gas chambers are to be used which can be removed after welding. If tt is not possible, only water-soluble paper is to be used. Plastic foils that are water-soluble are NOT acceptable. 4.3.5. Arrangements for argon purging Using Metal Dam arrangement MS sheets shall be used on either side of the weld in the ID of the pipe to create a purging chamber as shown in the sketch. Asbestos material can be used to seal the spacing further between the MS sheet and pipe ID. Suitable rods can be welded to keep the dam in position and also to retrieve after completion of purging requirement. * AkGoN GAs PuxGing ARRANGE MENT £08 PU WELDING (BUT? JOINT re oorvet CAUTION : ENSURE REMOVAL OF PURGING ARRANGEMENTS AFTER WELDING, ~dop AA GHARAT HEAVY ELEGTRIGALS UMITED PIPING CENTRE, CHENNAL pacenorz: oan Doc NO : QCP:11: 01 DATE : 25.05.2000 FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 ATH P B P— SHOP USING ALUMINIUM DAM ARRANGEMENT: In order to retain the Argon gas at the inside of the pipe near root area of the weld joint, the purging dams made of Aluminium and permanite gaskets may be provided during the weld fit-up work as indicated in the sketch. The Aluminium discs shall be firmly secured with a thin wire rope. After completion of the root welding followed by two filler passes, the disc may be pulled outwards softly SKETCH: 2 oil h Vom es THE [oP i . PRAMANITE GASKET Jom ae ~ aA = 7 ANG \ cree ene ~p— Using water soluble paper The dams can be made of water-soluble paper for creating the purging chamber. The advantage in such dam arrangement is that dissolving in water can flush the dams. The following are different methods used. BHARAT HEAVY ELECTRICALS LIMITED PIPING CENTRE, _ CHENNAI PAGE 9 OF 22 FABRICATION GUIDELINES FOR PIPING TO SA 335 P 91 ATHPBP-SHOP Doc NO : QCP:11 : 01 DATE : 25.05.2000 1 For smal diameter pipes, simply Ruff water soluble paper into each scction joined. (refer sketch) ae fobs el. “_ For larger pipes, cut out a circular disc slightly larger than the diameter and shape it to the inside pipe ciroumference. (A small hole may be punched in the paper to ensure ‘complete evacuation of air when purging) (Refer Sketch) skate 2 Position the disc within the pipe and tape in place with water soluble paper. Repeat procedure for the other section. Insert the backing gas into the joint with a needie valve and ‘make root pass in the usual manner. (Sketch) SKETCH-S For pipes larger than 508 mm diameter , simply splice two sheets of water soluble paper together with water soluble wat. and repeat procedure in picture 2 and 3. (Skeich) Zo) KETC HA YP 7

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