Welding electrodes for thermal power plantss

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Welding electrodes for thermal power plantss

  1. 1. WELDING ELECTRODES FOR THERMAL POWER PLANTS SHIVAJI CHOUDHURY
  2. 2. IN THIS PRESENTATION <ul><li>1.WELDING </li></ul><ul><li>2.WELDING JOINTS </li></ul><ul><li>3.WELDING MATERIAL SPECIFICATION </li></ul><ul><li>4.CLASSIFICATION OF ELECTRODES </li></ul><ul><li>5.ELECTRODE IDENTIFICATION , WELDING ELECTRODES CLASSIFICATION </li></ul><ul><li>6.COMMON BOILER MATERIALS </li></ul><ul><li>7.SELECTION OF SMAW ELECTRODES FOR BUTT WELDS IN POWER PLANTS </li></ul><ul><li>8.BOILER MATERIALS FOR 500 MW </li></ul>
  3. 3. 1.WELDING <ul><li>The purpose of a weld is to join two metals by fusing them at their interfaces. </li></ul><ul><li>A metallurgical bond is formed that provides smooth, uninterrupted microstructural transition across the weldment. </li></ul><ul><li>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. </li></ul>
  4. 4. 2.WELDING JOINTS <ul><li>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. </li></ul><ul><li>This implies that the weld joint is expected to have equal or greater strength than the base metal. </li></ul><ul><li>A large, utility-size boiler may contain more than 50,000 welds. </li></ul>
  5. 5. 3.WELDING MATERIAL SPECIFICATION <ul><li>Reliable welding and brazing materials are required to produce sound joints using one of the many welding and brazing processes available. </li></ul><ul><li>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). </li></ul><ul><li>These are the welding filler metal specifications of the AWS adopted for use by the ASME. </li></ul><ul><li>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. </li></ul>
  6. 6. 4.CLASSIFICATION OF ELECTRODES ASME-adopted ANSI/AWS Specification <ul><li>SFA-5.01, Filler Metal Procurement Guidelines </li></ul><ul><li>SFA-5.02: Specification for Filler Metal Standard Sizes, Packaging, and Physical Attributes </li></ul><ul><li>SFA-5.1, Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding </li></ul><ul><li>SFA-5.4, Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding </li></ul><ul><li>SFA-5.5, Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding </li></ul><ul><li>SFA-5.11, Specification for Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding </li></ul><ul><li>SFA-5.13, Specification for Solid Surfacing Welding Rods and Electrodes </li></ul>
  7. 7. 5.0.ELECTRODE IDENTIFICATION WELDING ELECTRODES CLASSIFICATION <ul><li>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 . </li></ul><ul><li>An example would be a welding rod identified as an 1/8 &quot; E6011 electrode. </li></ul><ul><li>The electrode is 1/8&quot; in diameter </li></ul><ul><li>The &quot; E &quot; stands for arc welding electrode. </li></ul><ul><li>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. </li></ul><ul><li>E60xx would have a tensile strength of 60,000 psi E110XX would be 110,000 psi </li></ul>
  8. 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. 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. 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. 11. 5.4.WELDING ELECTRODE CLASSIFICATIONS Suffix Additional Requirement <ul><li>-M Meets most military requirements </li></ul><ul><li>Diffusible hydrogen limits for weld metal. </li></ul><ul><li>-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 </li></ul><ul><li>1 - Increased toughness (impact strength ) for electrodes. </li></ul>
  12. 12. 5.5.WELDING ELECTRODES CLASSIFICATION ( Suffix Steel Alloy Type Suffix Number Description) <ul><li>-A1 Carbon-Molybdenum 0.40 - 0.65 Mo </li></ul><ul><li>-B1 Chromium-Molybdenum 0.40 - 0.65 Cr 0.40 - 0.65 Mo </li></ul><ul><li>-B2 Chromium-Molybdenum 1.00 - 1.50 Cr 0.40 - 0.65 Mo </li></ul><ul><li>-B2L Chromium-Molybdenum Lower Carbon B2 </li></ul><ul><li>-B3 Chromium-Molybdenum 2.00 - 2.50 Cr 0.90 - 1.20 Mo </li></ul><ul><li>-B3L Chromium-Molybdenum Lower Carbon B3 </li></ul><ul><li>-B4L Chromium-Molybdenum 1.75 - 2.25 Cr 0.40 - 0.65 Mo </li></ul><ul><li>-B5 Chromium-Molybdenum 0.40 - 0.60 Cr 1.00 - 1.25 Mo </li></ul><ul><li>-B6 was E502 4.6 - 6.0 Cr 0.45 - 0.65 Mo </li></ul><ul><li>-B8 was E505 8.0 - 10.5 Cr 0.8 - 1.2 Mo </li></ul><ul><li>-C1 Nickel Steel 2.00 - 2.75 Ni </li></ul><ul><li>-C1L Nickel Steel Lower Carbon C1 </li></ul><ul><li>-C2 Nickel Steel 3.00 - 3.75 Ni </li></ul><ul><li>-C2L Nickel Steel Lower Carbon C2 </li></ul><ul><li>-C3 Nickel Steel 0.80 - 1.10 Ni </li></ul><ul><li>-NM Nickel-Molybdenum 0.80 - 1.10 Ni 0.40 - 0.65 Mo </li></ul><ul><li>-D1 Manganese-Molybdenum 1.00 - 1.75 Mn 0.25 - 0.45 Mo </li></ul><ul><li>-D2 Manganese-Molybdenum 1.65 - 2.00 Mn 0.25 - 0.45 Mo </li></ul><ul><li>-D3 Manganese-Molybdenum 1.00 - 1.80 Mn 0.40 - 0.65 Mo </li></ul><ul><li>-W Weathering Steel Ni, Cr, Mo, Cu </li></ul><ul><li>-G No required chemistry </li></ul>
  13. 13. 5.6.What is the 8018 welding electrode meaning? <ul><li>The correct name of the electrode is E8018. </li></ul><ul><li>E stands for electrode, </li></ul><ul><li>the 80 stands for 80000 psi minimum as welded tensile strength, </li></ul><ul><li>the 1 stands for all position, </li></ul><ul><li>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. </li></ul>
  14. 14. 5.7.What is a low-hydrogen electrode? <ul><li>The reason that the electrode must be kept dry is to reduce water in the coating which injects hydrogen into welds. </li></ul><ul><li>In some welding applications especially thick metals, hydrogen collects under the weld in the heat affected zone. </li></ul><ul><li>Enough of it will cause hydrogen induced cracking. </li></ul>
  15. 15. 6.COMMON BOILER MATERIALS
  16. 16. 7.SELECTION OF SMAW ELECTRODES FOR BUTT WELDS IN POWER PLANTS <ul><li>7.1.WELDING ELECTRODES FOR MATERIALS (P1)-Carbon steel </li></ul><ul><li>7.2.WELDING ELECTRODES FOR MATERIALS (P3)-Low alloy steel </li></ul><ul><li>7.3.WELDING ELECTRODES FOR MATERIALS (P4)- Low alloy steel </li></ul><ul><li>7.4.WELDING ELECTRODES FOR MATERIALS (P5)-Low alloy steel </li></ul><ul><li>7.5.WELDING ELECTRODES FOR MATERIALS </li></ul><ul><li>7.6.WELDING ELECTRODES FOR MATERIALS (P8)-Stainless steel </li></ul><ul><li>7.7.WELDING ELECTRODES FOR DESSIMILAR MATERIALS </li></ul>
  17. 17. 7.1.WELDING ELECTRODES FOR MATERIALS (P1)-Carbon steel <ul><li>BASE MATERIALS (P 1/Gr2) </li></ul><ul><li>SA 106 Gr C </li></ul><ul><li>SA 210 Gr C </li></ul><ul><li>SA 210 GrA1 </li></ul><ul><li>SA 216 WCC </li></ul><ul><li>SA 516 Gr 70 </li></ul><ul><li>SA 299 </li></ul><ul><li>WELDING ELECTRODES </li></ul><ul><li>For base materials (P1/Gr2 to P1/Gr2)- E7018 - 1 </li></ul><ul><li>For base materials (P1/Gr2 to P1/Gr2) and dia of tube /pipe less than 127 mm - E7018 - A1 </li></ul>
  18. 18. 7.2.WELDING ELECTRODES FOR MATERIALS (P3)-Low alloy steel <ul><li>BASE MATERIALS (P 3/Gr 1) </li></ul><ul><li>SA 209 T1 </li></ul><ul><li>SA 209 T1a </li></ul><ul><li>SA 209 T1b </li></ul><ul><li>WELDING ELECTRODES for base materials (P3/Gr 1 to P3/Gr)- E7018 – A1 </li></ul>
  19. 19. 7.3.WELDING ELECTRODES FOR MATERIALS (P4)- Low alloy steel <ul><li>BASE MATERIALS (P 4/Gr1) </li></ul><ul><li>SA 335 P11 </li></ul><ul><li>SA 335 P12 </li></ul><ul><li>SA 213 T11 </li></ul><ul><li>SA 213 T12 </li></ul><ul><li>SA 217 WC 6 </li></ul><ul><li>SA 182 F11 CLASS 3 </li></ul><ul><li>SA 182 F12 CLASS 2 </li></ul><ul><li>DIN B Gr Mo4 </li></ul><ul><li>WELDING ELECTRODES for base materials (P4/Gr1 to P4/Gr1)- E8018B2 </li></ul>
  20. 20. 7.4.WELDING ELECTRODES FOR MATERIALS (P5)-Low alloy steel <ul><li>BASE MATERIALS (P 5/Gr 1) </li></ul><ul><li>SA 335 P22 Pipe </li></ul><ul><li>SA 213 T22 </li></ul><ul><li>SA 217 WC 9 </li></ul><ul><li>DIN 10 CrMo910 </li></ul><ul><li>A387 Gr 22 plate </li></ul><ul><li>WELDING ELECTRODES for base materials (P5/Gr 1 to P5/Gr 1)- E9018B3 </li></ul>
  21. 21. 7.5.WELDING ELECTRODES FOR MATERIALS (ALLOY STEEL) <ul><li>BASE MATERIALS (P 15) </li></ul><ul><li>SA 335 P91 </li></ul><ul><li>SA 213 T91 </li></ul><ul><li>SA 182 F91 </li></ul><ul><li>SA 387 Gr 91 </li></ul><ul><li>WELDING ELECTRODES for base materials (P15 to P15)- E9018B9 </li></ul>
  22. 22. 7.6.WELDING ELECTRODES FOR MATERIALS (P8)-Stainless steel <ul><li>BASE MATERIALS (P 8/Gr 1) </li></ul><ul><li>SA 213 TP 304H </li></ul><ul><li>SA 213 TP 347H </li></ul><ul><li>SA 351 CF8 </li></ul><ul><li>SA 315 CF8M </li></ul><ul><li>WELDING ELECTRODES for base materials (P8/Gr1 to P8/Gr1)- E 347 </li></ul>
  23. 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. 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. 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. 26. THANKING

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