OERLIKON Consumables for

Construction and Maintenance in

Thermal Power Stations
- T/P 92 Applications -

Michael Reimann
Dipl.-Ing. IWE - Product Manager-
OERLIKON Switzerland

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

2
Thermal power station

- History and general information

- Technical backround

- Welding technology

- Development and present situation

of OERLIKON consumables

3
History and general information

¢ Energymix for electricity in EU 25 in 2002

4
History and general information

¢ Age structure of coal-fired power station within EU15

Coal-fired power station wihin EU (%)
Share of installed power of

Value of blocks
5
History and general information

¢ Effectiveness thermal power stations within EU 15

6
History and general information

¢ CO2- reduction of increase power stations efficiency within

EU 15

7
History and general information

¢ Development of power plant efficiency

8
History and general information

¢ Material
s Development at high-temperature
power station

P92

9
Thermal power station

- History and general information

- Technical backround

- Welding technology

- Development and present situation

of OERLIKON consumables

10
Technical background

¢ Useof high-temperature steels in Europe, USA,

and Japan

Year Europe USA Japan

Before the 10 CrMo910
T/P22 STBA24-STPA24
60's (2 1/2%Cr, 1%Mo)

14MoV6-3
In the 60's STBA24-STPA24
0,5%Cr, 0,5%Mo, 0,25%V T/P22

X20CrMoV12-1
Mid 60's 12%Cr, 1%Mo, 0,25%V T/P22 STBA24-STPA24
EM12 (9%Cr, 2%Mo, V, Nb)

X10CrMoVNb9-1
Mid 80's T/P 91 STBA28-STPA28
(9%Cr, 1%Mo, 0,25%V, Nb)

7CrMoVTiB10-10 T/P 23 HCM2C

Early 90's
E911 T/P 122 HCM12A

X10CrWMoVNb9-2
Since 1998 9%Cr, 2%W, 0,5%Mo, T/P92 STBA29-STPA29
0,25%V, Nb

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Technical background

¢ International standards
Specification
Country Description
and grade

Seamless ferritic and austenitic alloy-steel

A213 T92 USA
boiler, superheater and heat exchanger tubes

Seamless ferritic alloy-steel pipe for high-

A335 P92 USA
temperature service
Pressure vessel plates
A387 GR92 USA
Alloy steel Cr, Mo
Forged or rolled alloy steel pipe Flanches,
A182 F92 in
USA forged fittings and valves and parts of high
progress
temperature service
Carbon and ferritic alloy-steel,
A369 FP92 in
USA Forged and bored pipe for high-temperatures
progress
service

12
Technical background

¢ Chemical composition of choosen materials

13
Technical background

¢ Creep rupture strenght of pipes

14
Technical background

¢ Illustration of the required pipe wall thickness

15
Technical background

¢ Thickness at hot steam escape temperature

16
Thermal power station

- History and general information

- Technical backround

- Welding technology

- Development and present situation

of OERLIKON consumables

17
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

21
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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Thermal power station

- History and general information

- Technical backround

- Welding technology

- Development and present situation

of OERLIKON consumables

24
Development and present situation of P92
consumables

¢ Based on these results and based on target that

application, we have to find an acceptable trade-off,
between creep resistance and toughness after PWHT

¢ Based on the present situation out of the industry, we

must find the best solution for the consumables as follows:

a Metal-coredwire (GTAW welding process)

a Coated electorde (SMAW welding process)

a Flux / Fluxcored wire combination (SAW welding process)

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Development and present situation of P92
consumables
¢ Coated electrode

a Development of three different electrodes

With 0,5% Ni
With 1% Co
With 2% Co

¢ Chemical composition ( All-weld-metal )

REP C Mn S P Si Cr Mo V N Ni Co Nb W B

0,5Ni 0,11 1,06 0,005 0,013 0,17 9,6 0,55 0,20 530 0,52 0,01 0,055 1,94 <5

1 Co 0,10 1,03 0,07 0,013 0,17 9,1 0,52 0,19 550 0,08 0,94 0,051 1,77 <5

2 Co 0,10 1,05 0,007 0,013 0,17 9,1 0,51 0,19 490 0,06 2,0 0,05 1,71 <5

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Development and present situation of P92
consumables

¢ Charpy V-notch value

Rep KCV+20°C (Jcm2) Ac1 (°C) Ac3 (°C)

0,5Ni 119, 103, 84 795 893

1 Co 106, 99, 96 818 905

2 Co 96, 103, 106 791 865

Conclusions

- Good charpy V-notch values

- Gammagene elements decrease slightly AC1
- AC1 is high enough, PHTW Industrial application

27
Development and present situation of P92
consumables

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

Creep Resistance Tests under 85 Mpa stress value

100000

10000
log tr ( h)

1000

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

0,5% Ni;0% Co;0ppmB
0% Ni;2% Co;0ppmB
100 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
10
0.00102 0.00104 0.00106 0.00108 0.0011
-1
1/T( K )

28
Development and present situation of P92
consumables

Creep resistant test on coated electrode

Creep Resistance Test on Coated Electrode (after PWHT)

1000

Nip. St. Data Package

0,5%Ni ; 0%Co ; 25ppm B
0,5%Ni ; 0%Co ; 0ppm B
0%Ni ; 1%Co ; 0ppm B
Contrainte ( MPa )

0%Ni ; 2%Co ; 0ppm B

100

10
34000 34500 35000 35500 36000 36500 37000 37500 38000 38500 39000
Larson-Miller Parameter ( C = 36,10999 )

29
Development and present situation of P92
consumables
ALCROMCORD 92
Customer s Demand Ref.

C
lot 1002820
0.102
R109-050

0.097

Increase of AC1 Si
Mn
0.17
1.12
0.18
1.05
P 0.009 0.008
S 0.009 0.008
Cr 8.6 8.7
Mo 0.53 0.52
Ni 0.47 0.05
Al <0.001 0.001
Replace 0,5% Ni by 1% Co Co
Cu
0.011
<0.010
0.95
0.012
Nb 0.052 0.048
Increase AC1 ~25°C Ti 0.005 0.004
V 0.23 0.25
W 1.76 1.64
Same level of mechanical properties B 0.0041 0.0025
Oxygène 714 592
Azote 354 397
is reached with 1% Co electrodes
Cr éq. 5.63 5.99

Same analysis like TIG-rod and SAW PWHT 760°C/4h T int. 250°C
Kv +20°C (J) 67-67-56 moy:63 74-86-44 moy:68
Kv 0°C (J) 48-44-38 moy:43 40-58-44 moy:47
Kv -20°C (J) 34-28-18 moy:27 45-47-32 moy:41
Rp0.2 (Mpa) 600 555
Rm (Mpa) 747 717
A% 18.7 20.6

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Development and present situation of P92
consumables

CREEP TEST PLAN Filler Metal ALW P92

status as of Jan.6, 2005
1000 : MEANS THAT TEST SYMBOLIZED BY DOT BELOW IS IN PROGRESS

test
stopped test
test
stopped
LOG SIGMA ( MPa )

stopped

100

Nippon Steel Data Package

Results ALCROMO SF92 / LEXAL F500 - Pure weld

Results ALCROMOCORD 92 - Pure weld

10
32000 33000 34000 35000 36000 37000 38000 39000
LARSON-MILLER PARAMETER LMP = (T + 273) x [36,11 + log(t)]

31
Development and present situation of P92
consumables

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Development and present situation of P92
consumables
¢ Flux and Core Wire Combination

a Basic flux ( low oxygen level)

a Good arc stability
a Good slag removal

¢ Chemical composition

a Development of three different core wires

With 0,5% Ni + 25 ppm B
With 1% Co
With 2% Co + 25 ppm B

33
Development and present situation of P92
consumables

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

Submerged arc (after PWHT)

100000

10000
logtr ( h)

1000

1% Co 25 ppm B
1% Co 0 ppm B
100
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
10
0.00102 0.00104 0.00106 0.00108 0.0011
-1
1 / T ( K )

34
Development and present situation of P92
consumables

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

1000
Constrain ( MPa )

100

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

10
34000 34500 35000 35500 36000 36500 37000 37500 38000 38500 39000
Larson-Miller parameter ( C = 36,10999 )

35
Development and present situation of P92
consumables

CREEP TEST PLAN Filler Metal ALW P92

status as of Jan.6, 2005
1000 : MEANS THAT TEST SYMBOLIZED BY DOT BELOW IS IN PROGRESS

test
stopped test
test
stopped
LOG SIGMA ( MPa )

stopped

100

Nippon Steel Data Package

Results ALCROMO SF92 / LEXAL F500 - Pure weld

Results ALCROMOCORD 92 - Pure weld

10
32000 33000 34000 35000 36000 37000 38000 39000
LARSON-MILLER PARAMETER LMP = (T + 273) x [36,11 + log(t)]

36
Development and present situation of P92
consumables

CREEP TEST PLAN Filler Metal ALW P92

status as of Jan.6, 2005
1000 : MEANS THAT TEST SYMBOLIZED BY DOT BELOW IS IN PROGRESS
LOG SIGMA ( MPa )

100

Nippon Steel Data Package

Results ALCROMO SF92 / LEXAL F500 - Cross weld

10
32000 33000 34000 35000 36000 37000 38000 39000
LARSON-MILLER PARAMETER LMP = (T + 273) x [36,11 + log(t)]

37
Development and present situation of P92
consumables

38
Development and present situation of P92
consumables

¢ Conclusion

aConsumables for T/P92

ALCROMOCORD 92 ( SMAW )

ALCROMO WF 92 ( GTAW )

ALCROMO SF 92 / LEXAL 500 ( SAW )

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