Air Liquide

OERLIKON Consumables forConstruction and Maintenance in

Thermal Power Stations- T/P 92 Applications -

Michael ReimannDipl.-Ing. IWE - Product Manager-

OERLIKON Switzerland

The 10th Beijing Essen Welding & Cutting Fair in Shanghai, May 25th 28th, 2005

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View of different constructions

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Thermal power station

- History and general information

- Technical backround

- Welding technology

- Development and present situationof OERLIKON consumables

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History and general information

Energymix for electricity in EU 25 in 2002

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Age structure of coal-fired power station within EU15Sh

are

ofin

stal

led

pow

erof

Coa

l-fire

dpo

wer

stat

ion

wih

inEU

(%)

Valu

eof

bloc

ks

6


Effectiveness thermal power stations within EU 15

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CO2- reduction of increase power stations efficiency withinEU 15

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Development of power plant efficiency

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Material s Development at high-temperaturepower station

P92

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Technical background

Use of high-temperature steels in Europe, USA,and Japan

STBA29-STPA29T/P92X10CrWMoVNb9-2

9%Cr, 2%W, 0,5%Mo,0,25%V, Nb

Since 1998

HCM2CHCM12A

T/P 23T/P 122

7CrMoVTiB10-10E911Early 90's

STBA28-STPA28T/P 91X10CrMoVNb9-1(9%Cr, 1%Mo, 0,25%V, Nb)Mid 80's

STBA24-STPA24T/P22X20CrMoV12-1

12%Cr, 1%Mo, 0,25%VEM12 (9%Cr, 2%Mo, V, Nb)

Mid 60's

STBA24-STPA24T/P22

14MoV6-30,5%Cr, 0,5%Mo, 0,25%VIn the 60's

STBA24-STPA24T/P2210 CrMo910(2 1/2%Cr, 1%Mo)Before the

60's

JapanUSAEuropeYear

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International standards

Carbon and ferritic alloy-steel,Forged and bored pipe for high-temperatures

serviceUSAA369 FP92 inprogress

Forged or rolled alloy steel pipe Flanches,forged fittings and valves and parts of high

temperature serviceUSAA182 F92 inprogress

Pressure vessel platesAlloy steel Cr, MoUSAA387 GR92

Seamless ferritic alloy-steel pipe for high-temperature serviceUSAA335 P92

Seamless ferritic and austenitic alloy-steelboiler, superheater and heat exchanger tubesUSAA213 T92

DescriptionCountrySpecificationand grade

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Chemical composition of choosen materials

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Creep rupture strenght of pipes

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Illustration of the required pipe wall thickness

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Thickness at hot steam escape temperature

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Welding technology

Producing of P92- Collectors

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Welding technology

Collector with Connecting-pipes

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Welding technology

Typical heating and welding cycle for T/P92-T/P92

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Welding technology

Typical heating and welding cycle for P92-P91

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Welding technology

Typical heating and welding cycle for P92-P122

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Welding technology

Typical heating and welding cycle for P92-austenitic-steel

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Development and present situation of P92consumables

Based on these results and based on target thatapplication, we have to find an acceptable trade-off,between creep resistance and toughness after PWHT

Based on the present situation out of the industry, wemust find the best solution for the consumables as follows:

aMetal-coredwire (GTAW welding process)

aCoated electorde (SMAW welding process)

aFlux / Fluxcored wire combination (SAW welding process)

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Coated electrode

aDevelopment of three different electrodesWith 0,5% NiWith 1% CoWith 2% Co

Chemical composition ( All-weld-metal )

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Charpy V-notch value

86579196, 103, 1062 Co

905818106, 99, 961 Co

893795119, 103, 840,5Ni

Ac3 (C)Ac1 (C)KCV+20C (Jcm2)Rep

Conclusions

- Good charpy V-notch values

- Gammagene elements decrease slightly AC1

- AC1 is high enough, PHTW Industrial application

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Creep Resistance Tests under 85 Mpa stress value

10

100

1000

10000

100000

0.00102 0.00104 0.00106 0.00108 0.00111 / T ( K-1 )

log

tr (

h )

0,5%Ni;0%Co;40ppmB

0,5%Ni;0%Co;0ppmB

0%Ni;2%Co;0ppmB

0%Ni;1%Co;0ppmB

0,5%Ni;0%Co;40ppmB moy

0,5%Ni;0%Co;0ppmB moy

0%Ni;2%Co;0ppmB moy

0%Ni;1%Co;0ppmB moy

Nip. St. Data Package moy

Creep resisting values 85 MPa, 100 h up to 8000 h

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Creep Resistance Test on Coated Electrode (after PWHT)

10

100

1000

34000 34500 35000 35500 36000 36500 37000 37500 38000 38500 39000Larson-Miller Parameter ( C = 36,10999 )

Con

trai

nte

( MPa

)

Nip. St. Data Package0,5%Ni ; 0%Co ; 25ppm B0,5%Ni ; 0%Co ; 0ppm B0%Ni ; 1%Co ; 0ppm B0%Ni ; 2%Co ; 0ppm B

Creep resistant test on coated electrode

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Ref. ALCROMCORD 92lot 1002820 R109-050

C 0.102 0.097Si 0.17 0.18Mn 1.12 1.05P 0.009 0.008S 0.009 0.008Cr 8.6 8.7Mo 0.53 0.52Ni 0.47 0.05Al

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CREEP TEST PLAN Filler Metal ALW P92status as of Jan.6, 2005

10

100

1000

32000 33000 34000 35000 36000 37000 38000 39000

LARSON-MILLER PARAMETER LMP = (T + 273) x [36,11 + log(t)]

LOG

SIG

MA

( M

Pa )

Nippon Steel Data Package

Results ALCROMO SF92 / LEXAL F500 - Pure weld

Results ALCROMOCORD 92 - Pure weld

: MEANS THAT TEST SYMBOLIZED BY DOT BELOW IS IN PROGRESS

teststopped

teststopped

teststopped

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Flux and Core Wire Combination

aBasic flux ( low oxygen level)aGood arc stabilityaGood slag removal

Chemical composition

aDevelopment of three different core wiresWith 0,5% Ni + 25 ppm BWith 1% CoWith 2% Co + 25 ppm B

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Submerged arc (after PWHT)

10

100

1000

10000

100000

0.00102 0.00104 0.00106 0.00108 0.00111 / T ( K-1 )

log

tr ( h

)

1% Co 25 ppm B

1% Co 0 ppm B

0,5% Ni 25 ppm B

1%Co 25ppm B moy

1%Co 0ppm B moy

Nip. St. Data Pack. moy

0,5%Ni 25ppm B moy

Creep resisting values 85 MPa, 100 h up to 8000 h

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Creep resistance test - Cored wire and Flux combinations (after PWHT)

10

100

1000

34000 34500 35000 35500 36000 36500 37000 37500 38000 38500 39000Larson-Miller parameter ( C = 36,10999 )

Con

stra

in (

MPa

)

Nippon Steel Data Package 1%Co ; 0%Ni ; 25ppm B

1%Co ; 0%Ni ; 0ppm B 0%Co ; 0,5%Ni ; 25ppm B

0%Co ; 0,6%Ni ; 0ppm B 0%Co ; 0,6%Ni ; 0ppm B en cours

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10

100

1000

32000 33000 34000 35000 36000 37000 38000 39000


LOG

SIG

MA

( M

Pa )


Results ALCROMO SF92 / LEXAL F500 - Pure weld

Results ALCROMOCORD 92 - Pure weld


teststopped

teststopped

teststopped

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10

100

1000

32000 33000 34000 35000 36000 37000 38000 39000


LOG

SIG

MA

( M

Pa )


Results ALCROMO SF92 / LEXAL F500 - Cross weld


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Conclusion

aConsumables for T/P92

ALCROMOCORD 92 ( SMAW )

ALCROMO WF 92 ( GTAW )

ALCROMO SF 92 / LEXAL 500 ( SAW )

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