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Welding electrodes for thermal power plantss

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  • 1. WELDING ELECTRODES FOR THERMAL POWER PLANTS SHIVAJI CHOUDHURY
  • 2. IN THIS PRESENTATION
    • 1.WELDING
    • 2.WELDING JOINTS
    • 3.WELDING MATERIAL SPECIFICATION
    • 4.CLASSIFICATION OF ELECTRODES
    • 5.ELECTRODE IDENTIFICATION , WELDING ELECTRODES CLASSIFICATION
    • 6.COMMON BOILER MATERIALS
    • 7.SELECTION OF SMAW ELECTRODES FOR BUTT WELDS IN POWER PLANTS
    • 8.BOILER MATERIALS FOR 500 MW
  • 3. 1.WELDING
    • The purpose of a weld is to join two metals by fusing them at their interfaces.
    • A metallurgical bond is formed that provides smooth, uninterrupted microstructural transition across the weldment.
    • The weldment should be free of significant porosity and nonmetallic inclusions, form smoothly flowing surface contours with the section being joined, and be free of significant residual welding stresses.
  • 4. 2.WELDING JOINTS
    • ASME design code generally does not describe the strength of weld joints, such as a full penetration butt weld, separate to the strength of base metal in the pressure component.
    • This implies that the weld joint is expected to have equal or greater strength than the base metal.
    • A large, utility-size boiler may contain more than 50,000 welds.
  • 5. 3.WELDING MATERIAL SPECIFICATION
    • Reliable welding and brazing materials are required to produce sound joints using one of the many welding and brazing processes available.
    • The ASME B&PV Code provides the Welding Material Specifications acceptable for Code fabrication in Section II, Part C (Specification for Welding Rods, Electrodes, and Filler Metals).
    • These are the welding filler metal specifications of the AWS adopted for use by the ASME.
    • In this respect, Section II, Part C is comparable to Sections II, Parts A and B that contain the ASTM Material Specifications adopted by the ASME.
  • 6. 4.CLASSIFICATION OF ELECTRODES ASME-adopted ANSI/AWS Specification
    • SFA-5.01, Filler Metal Procurement Guidelines
    • SFA-5.02: Specification for Filler Metal Standard Sizes, Packaging, and Physical Attributes
    • SFA-5.1, Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
    • SFA-5.4, Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding
    • SFA-5.5, Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
    • SFA-5.11, Specification for Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding
    • SFA-5.13, Specification for Solid Surfacing Welding Rods and Electrodes
  • 7. 5.0.ELECTRODE IDENTIFICATION WELDING ELECTRODES CLASSIFICATION
    • Arc welding electrodes are identified using the A.W.S , ( American Welding Society ) numbering system and are made in sizes from 1/16 to 5/16 .
    • An example would be a welding rod identified as an 1/8 " E6011 electrode.
    • The electrode is 1/8" in diameter
    • The " E " stands for arc welding electrode.
    • Next will be either a 4 or 5 digit number stamped on the electrode. The first two numbers of a 4 digit number and the first 3 digits of a 5 digit number indicate the minimum tensile strength (in thousands of pounds per square inch) of the weld that the rod will produce, stress relieved.
    • E60xx would have a tensile strength of 60,000 psi E110XX would be 110,000 psi
  • 8. 5.1.WELDING ELECTRODES CLASSIFICATION (MIN TENSILE STRENGTH) 107000 psi 120000 psi E120XX 7 95000 psi 110000 psi E110XX 6 87000 psi 100000 psi E100XX 5 77000 psi 90000 psi E90XX 4 67000 psi 80000 psi E80XX 3 57000 psi 70000 psi E70XX 2 50000 psi 62000 psi E60XX 1 MIN YIELD STRENGTH MIN TENSILE STRENGTH CLASS S.N
  • 9. 5.2.WELDING ELECTRODE CLASSIFICATION WELDING POSITIONS FLAT,HORIZONTAL,OVERHEAD,VERTICAL EXX3X 3 FLAT ,HORIZONTAL EXX2X 2 FLAT,HORIZONTAL,VERTICAL(UP),OVERHEAD EXX1X 1 DESCRIPTION WELDING POSITION S.N
  • 10. 5.3.WELDING ELECTRODES CLASSIFICATION ELECTRODE COATING,PENETRATION,CURRENT TYPE AC,DCEP,DCEN MEDIUM IRON OXIDE,RUTILE,POTASSIUM EXXX9 10 AC,DCEP MEDIUM LOW HYDROGEN,IRON POWER EXXX8 9 AC,DCEN MEDIUM IRON POWDER IRON OXIDE EXXX7 8 AC,DCEP MEDIUM LOW HYDROGEN POTASSIUM EXXX6 7 DCEP MEDIUM LOW HYDROGEN SODIUM EXXX5 6 AC,DCEP,DCEN MEDIUM RUTILE IRON POWDER EXXX4 5 AC,DCEP,DCEN LIGHT RUTILE ,POTASSIUM EXXX3 4 AC,DCEN MEDIUM RUTILE ,SODIUM EXXX2 3 AC,DCEP DEEP CELLULOSE POTESSIUM EXXX1 2 DCEP DEEP CELLULOSE, SODIUM EXXX0 1 CURRENT TYPE PENETRATION ELECTRODE COATING CLASS S.N
  • 11. 5.4.WELDING ELECTRODE CLASSIFICATIONS Suffix Additional Requirement
    • -M Meets most military requirements
    • Diffusible hydrogen limits for weld metal.
    • -H4 ,H8,H16- Indicates the maximum diffusible hydrogen limit measured in millimeters per 100 grams (mL/100g). The 4, 8, and 16 indicates what the limit is. Example: -H4 = 4mL per 100 grams
    • 1 - Increased toughness (impact strength ) for electrodes.
  • 12. 5.5.WELDING ELECTRODES CLASSIFICATION ( Suffix Steel Alloy Type Suffix Number Description)
    • -A1 Carbon-Molybdenum 0.40 - 0.65 Mo
    • -B1 Chromium-Molybdenum 0.40 - 0.65 Cr 0.40 - 0.65 Mo
    • -B2 Chromium-Molybdenum 1.00 - 1.50 Cr 0.40 - 0.65 Mo
    • -B2L Chromium-Molybdenum Lower Carbon B2
    • -B3 Chromium-Molybdenum 2.00 - 2.50 Cr 0.90 - 1.20 Mo
    • -B3L Chromium-Molybdenum Lower Carbon B3
    • -B4L Chromium-Molybdenum 1.75 - 2.25 Cr 0.40 - 0.65 Mo
    • -B5 Chromium-Molybdenum 0.40 - 0.60 Cr 1.00 - 1.25 Mo
    • -B6 was E502 4.6 - 6.0 Cr 0.45 - 0.65 Mo
    • -B8 was E505 8.0 - 10.5 Cr 0.8 - 1.2 Mo
    • -C1 Nickel Steel 2.00 - 2.75 Ni
    • -C1L Nickel Steel Lower Carbon C1
    • -C2 Nickel Steel 3.00 - 3.75 Ni
    • -C2L Nickel Steel Lower Carbon C2
    • -C3 Nickel Steel 0.80 - 1.10 Ni
    • -NM Nickel-Molybdenum 0.80 - 1.10 Ni 0.40 - 0.65 Mo
    • -D1 Manganese-Molybdenum 1.00 - 1.75 Mn 0.25 - 0.45 Mo
    • -D2 Manganese-Molybdenum 1.65 - 2.00 Mn 0.25 - 0.45 Mo
    • -D3 Manganese-Molybdenum 1.00 - 1.80 Mn 0.40 - 0.65 Mo
    • -W Weathering Steel Ni, Cr, Mo, Cu
    • -G No required chemistry
  • 13. 5.6.What is the 8018 welding electrode meaning?
    • The correct name of the electrode is E8018.
    • E stands for electrode,
    • the 80 stands for 80000 psi minimum as welded tensile strength,
    • the 1 stands for all position,
    • the 8 is the number associated with the ingredients of the flux, which in this case is low hydrogen and increased amounts of iron powder.
  • 14. 5.7.What is a low-hydrogen electrode?
    • The reason that the electrode must be kept dry is to reduce water in the coating which injects hydrogen into welds.
    • In some welding applications especially thick metals, hydrogen collects under the weld in the heat affected zone.
    • Enough of it will cause hydrogen induced cracking.
  • 15. 6.COMMON BOILER MATERIALS
  • 16. 7.SELECTION OF SMAW ELECTRODES FOR BUTT WELDS IN POWER PLANTS
    • 7.1.WELDING ELECTRODES FOR MATERIALS (P1)-Carbon steel
    • 7.2.WELDING ELECTRODES FOR MATERIALS (P3)-Low alloy steel
    • 7.3.WELDING ELECTRODES FOR MATERIALS (P4)- Low alloy steel
    • 7.4.WELDING ELECTRODES FOR MATERIALS (P5)-Low alloy steel
    • 7.5.WELDING ELECTRODES FOR MATERIALS
    • 7.6.WELDING ELECTRODES FOR MATERIALS (P8)-Stainless steel
    • 7.7.WELDING ELECTRODES FOR DESSIMILAR MATERIALS
  • 17. 7.1.WELDING ELECTRODES FOR MATERIALS (P1)-Carbon steel
    • BASE MATERIALS (P 1/Gr2)
    • SA 106 Gr C
    • SA 210 Gr C
    • SA 210 GrA1
    • SA 216 WCC
    • SA 516 Gr 70
    • SA 299
    • WELDING ELECTRODES
    • For base materials (P1/Gr2 to P1/Gr2)- E7018 - 1
    • For base materials (P1/Gr2 to P1/Gr2) and dia of tube /pipe less than 127 mm - E7018 - A1
  • 18. 7.2.WELDING ELECTRODES FOR MATERIALS (P3)-Low alloy steel
    • BASE MATERIALS (P 3/Gr 1)
    • SA 209 T1
    • SA 209 T1a
    • SA 209 T1b
    • WELDING ELECTRODES for base materials (P3/Gr 1 to P3/Gr)- E7018 – A1
  • 19. 7.3.WELDING ELECTRODES FOR MATERIALS (P4)- Low alloy steel
    • BASE MATERIALS (P 4/Gr1)
    • SA 335 P11
    • SA 335 P12
    • SA 213 T11
    • SA 213 T12
    • SA 217 WC 6
    • SA 182 F11 CLASS 3
    • SA 182 F12 CLASS 2
    • DIN B Gr Mo4
    • WELDING ELECTRODES for base materials (P4/Gr1 to P4/Gr1)- E8018B2
  • 20. 7.4.WELDING ELECTRODES FOR MATERIALS (P5)-Low alloy steel
    • BASE MATERIALS (P 5/Gr 1)
    • SA 335 P22 Pipe
    • SA 213 T22
    • SA 217 WC 9
    • DIN 10 CrMo910
    • A387 Gr 22 plate
    • WELDING ELECTRODES for base materials (P5/Gr 1 to P5/Gr 1)- E9018B3
  • 21. 7.5.WELDING ELECTRODES FOR MATERIALS (ALLOY STEEL)
    • BASE MATERIALS (P 15)
    • SA 335 P91
    • SA 213 T91
    • SA 182 F91
    • SA 387 Gr 91
    • WELDING ELECTRODES for base materials (P15 to P15)- E9018B9
  • 22. 7.6.WELDING ELECTRODES FOR MATERIALS (P8)-Stainless steel
    • BASE MATERIALS (P 8/Gr 1)
    • SA 213 TP 304H
    • SA 213 TP 347H
    • SA 351 CF8
    • SA 315 CF8M
    • WELDING ELECTRODES for base materials (P8/Gr1 to P8/Gr1)- E 347
  • 23. 7.7.WELDING ELECTRODES FOR DESSIMILAR MATERIALS SFA 5.4 E347-16 TP 304H to TP 347H 6 SFA 5.11 ENiCrFe 2 T22 to TP 304H 5 SFA 5.5 E8018 B2 T 11 to T1 4 E 7018 A1 CS to T-1A 3 E9018 B2 CS to T22 2 E 8018-B2 CS to T1 1 ELECTRODE BASE MATERIALS SN
  • 24. 7.8.WELDING ELECTRODES FOR NON PRESSURE PARTS OF BOILER SFA 5.5 E 8018 B2 CARTON STEEL TO CARTON STEEL 2 SFA 5.1E 6013 SFA 5.1E 7018 BUTT WELD UPTO 6 mm OVER 6 mm CARBON STEEL TO CARBON STEEL 1 ELECTRODES DESCRIPTION BASE MATERIAL S.N
  • 25. 8.BOILER MATERIALS FOR 500 MW SA210GrA1,SA210GrC ECONOMIZER 6 SA213T22,SA213T91, SA213TP347H REHEATER 5 SA213T11,SA213T22, SA213T91,SA213TP347H SUPER HEATER 4 SA213T11 LTSH 3 SA210GrC WATER WALL 2 SA210GrC BURNER PANELS 1 MATERIAL SPECIFICATION DESCRITION S.N
  • 26. THANKING