Welding Filler Metals for

Power Generation

voestalpine Böhler Welding

voestalpine Böhler Welding
www.voestalpine.com/welding
 Agenda

• Key Account Management Role

• Types of Power Plants
• Power Plant Components
• Typical Technical Questions to Ask
• Material Types
• Bohler Premium and Quality Filler Metals
• Customer Sales Process
• Key Account Review
• Next Steps

voestFaelbpruinarey Böhler
2 Corporate Presentation
18, 2021
Welding
Key Account Management Role
• High Level Direct Relationships
• Owner/Operators, EPC’s, Fabricators
• Specification/Qualification of Bohler Products
• Own Pricing Guidelines and Negotiate Pricing Contracts with
Key Direct Accounts
• Project Level Support at Site Locations
• Coordinate Training on Segment Focused Products
Supported by WeldingAcademy
• Provide Technical Support
• Representation at Industry Organizations
• ASME, API, EPRI, AWS, etc.
• Manage Inventory of Premium Products Supported by
Material Management
• Understand Industry Trends
voestFaelbpruinarey Böhler
3 Corporate Presentation
18, 2021
Welding
voestalpine Böhler Welding Austria
Kapfenberg

Others
 International specialist for
the production of high quality Solid wire
stick electrodes and cored
wires
 Group Competence center for Stick
Electrodes & Cored Wire located in
Kapfenberg / Austria Stick electrodes
Cored wire

voestalpine Böhler Welding

voestalpine Bohler Welding Germany
Hamm

Facts and Figures

Europe's biggest welding consumables production
plant

Focus of Production
 Solid wire
 Flux

voestalpine Böhler Welding

5 June 2015 Corporate Presentation
Bohler Filler Metals for Power Generation

Products
 A full line of alloys in GTAW, SMAW,
GMAW,SAW and FCAW
 Preferred manufacturer by many
major
EPC’s and fabricators
 European-made, world leading
quality
 Stock of full line in North America

Training/Support
 Welding Academy road show
 In field technical support
 Product training across the USA
 Regional point of contact

voestalpine Böhler Welding

6 2/18/2021
Corporate Presentation
Thermal Power Generation – Types of Plants
• Coal Fired:
• Uses Coal to generate heat to boil water to create super
heated steam
• Natural Gas:
• Uses Natural Gas to heat the boiler to create super heated
steam
• Combined Cycle:
• Uses Natural Gas to heat the boiler to create super heated
steam
• A Heat Recovery Steam Generator (HRSG) captures exhaust
heat
from the gas turbine that would otherwise escape through the
exhaust stack.
• The HRSG creates steam from the gas turbine exhaust heat
and delivers it to the steam turbine.
• Plant Size is determined by Megawatt (mW)
voestalpine Böhler Welding
7 26.01.2016 Welding of unalloyed steels.
Thermal Power
Welding solutions for a high demanding industry

voestalpine Böhler Welding

Thermal Power
Welding solutions for a high demanding industry

voestalpine Böhler Welding

Thermal Power Industry
welding solutions for a high demanding industry

voestalpine Böhler Welding

Ferritic Creep resistant Steels
Application in fossil fueled thermal power plants

voestalpine Böhler Welding

11
Higher Operating Temperatures
Improved power plant efficiency

voestalpine Böhler Welding

Components
Boiler tubes – heat exchanger, super heater, reheater, instrumentation

Pipes – steam header, steam piping, feed water piping

voestalpine Böhler Welding

Components
Water walls – tube to fin connections

Cladding – water walls , super heater tubes, etc.

voestalpine Böhler Welding

Questions To
Ask:
• What are the base materials?
• What arc process(es) are being used?
• What diameters?
• What shielding gas is being used?
• What positions are being welded?
• What mechanical properties are required?
• Yield, Tensile, Elongation, CVN’s, Hydrogen
• Are there any additional electrode requirements?
• PWHT, X-factor, Chemistry, Approval Organizations
• Additional Welding Procedure Considerations?
• Material Thickness, joint design, material condition
voestalpine Böhler Welding
 Flowchart
• Carbon Steel?
What • High Strength Steel?
Materials Are • Chrome-Moly?
Being • Stainless?
Welded? • High Alloy/Nickel Base?
• Stick Electrode?
• Wire:
What • Solid Wire?
Processes Are • Flux Cored?
Being Used? • Metal Cored?
• Subarc/TIG?

If Flux Cored • Shielding Gas?

– What • 100%CO2
Position and • Mixed Gas – 75Ar/25CO2
Gas? • Flat or All Position?

• Strength
What AWS • Elongation
Class and/or • CVN's
Mechanical • Hydrogen
Properties?
• Other Requirements

voestalpine Böhler Welding

Premium/Quality Product Groups
 Grade P11 (1 1/4% Chrome - .5% Moly) (B2 Filler Metal)
 SMAW – Bohler FOX E8018-B2 / Bohler FOX DCMS Kb (E8018-B2)
 GTAW/GMAW – Union ER80S-B2 (ER80S-B2)
 FCAW – Bohler DCMS Ti-FD (E81T1-M21PY-B2 H8))
 SAW – T Union SA EB2 + UV 400 (F8PZ-EB2-B2)

 Grade P22 (2 ¼%Chrome – 1% Moly) (B3 Filler Metal)

 SMAW – Bohler FOX E9018-B3 / Bohler FOX CM 2 Kb (E9018-B3)
 GTAW/GMAW – Union ER90S-B3 (ER90S-B3)
 FCAW – Bohler CM 2 Ti-FD (E91T1-M21PY-B3 H8))
 SAW – T Union SA EB3 + UV 400 (F9PZ-EB3-B3)

 Stainless Steel
 SMAW – Bohler 308L-16, Bohler 316L-16
 GTAW – Avesta ER308L, Avesta ER316L
 FCAW – Avesta FCW 308L PW, Avesta FCW 316L PW

 Carbon Steel
 SMAW – Bohler E7018, Bohler FOX EV 50
 GTAW – Bohler ER70S-2, Bohler EMK 5 (ER70S-3), Bohler EMK 6 (ER70S-6)
 FCAW – Bohler Ti 52 T-FD Bohler, Ti 52 T-FD HP (E71T1-M21AP5-CS2-H4)
voestalpine Böhler Welding
Premium/Quality Product Groups
 Grade 91 (9% Chrome – 1% Moly with Vanadium) (B9 or B91 Filler Metal)
 SMAW – Thermanit Chromo 9V Mod (E9015-B91 H4)
 GTAW/GMAW – Thermanit MTS 3 LNi (ER90S-B9)
 FCAW – Thermanit MTS 3 PW (E91T1-M21PY-B91)
 SAW – Thermanit MTS 3 LNi + Marathon 543 (F9PZ-EB91-B91)

 Grade 92 (9% Chrome, .5% Moly with Tungsten & Vanadium) (B92 Filler Metal)
 SMAW – Thermanit Chromo MTS 616 (E9015-B92 H4)
 GTAW/GMAW – Thermanit MTS 616 (ER90S-G)
 FCAW – Thermanit MTS 616 PW (E91T1-M21PZ-B92)
 SAW – Thermanit MTS 616 + Marathon 543 (F9PZ-EG-G)

 Grade T23 (2 ¼% Chrome with Tungsten and Vanadium) (B23 Filler Metal)
 SMAW – Thermanit P23 (E9015-B23)
 GTAW – Union I P 23 (ER90S-G)

 Super 304 H (304 alloy with Copper, Nitrogen, Niobium)

 SMAW – Thermanit 304 H Cu
 GTAW – Thermanit 304 H Cu
voestalpine Böhler Welding
 Summary of Premium/Quality Products
SMAW GTAW SAW
ThermanitFCAW
617 Thermanit MTS 616 BÖHLER CM 2 Ti-FD Wires:
Thermanit Nicro 82 Thermanit Nicro 82 BÖHLER DCMS Ti- Union S 2
Thermanit MTS 616 Thermanit MTS 5 CrMo Union S
FD
Thermanit 263 P24 Union S
CoT Thermanit 304 BÖHLER DMO Ti-FD
Thermanit Chromo 9 V P23
HCu BÖHLER DCMS Kb T-
mod Thermanit P23 Thermanit MTS 3 L
Thermanit 617 FD Ni Thermanit MTS
Thermanit P24 Thermanit MTS 3 BÖHLER DCMV Kb T- 616
BÖHLER FOX P22 FD
LNi Union I P24 Thermanit Nicro
(LC)
Union I P23 BÖHLER DMO Kb T- 82 Fluxes :
Thermanit MTS 5 Co
Union ER 80S- FD BÖHLER P92 Ti- UV 420 TTR
1 BÖHLER FOX E 308
B2 Union ER FD BÖHLER DCMS Ti Marathon 543
H Union S 2 Mo - UV 420 TTR
90S-B3GMAW T-FD
BÖHLER FOX E 347 H Union S 1 CrMo 2 - UV 420
BÖHLER FOX DCMS BÖHLER DCMV Ti T-
Thermanit 617 TTR Union S 2 CrMo - UV 420
Kb FD BÖHLER DMO Ti
Thermanit Nicro 82 TTR
RED Fox
Bohler = Premium
CM 2 Kb T-FD
Thermanit MTS 3 Thermanit MTS 3 L Ni - Marathon
Böhler DCMS Ti T- 543 Thermanit MTS 616 - Marathon
GREEN = Quality LNi Thermanit MTS FD Böhler CM 2 Ti 543 UV305 - Union S P23 and S P24
616 Union ER 80S- T-FD
B2 Union ER 90S-B3
1v9oestal2p6i.n01e2. B0ö16hler WeWd
l eilndigng of unalloyed steels.
Additional Material Requirements
 X-Factor
 Calculation to determine the potential for temper embrittlement of the
material
 Calculated by weight % of (4) key elements Phosphorus, Arsenic, Antimony,
and Tin
 Typically <15 is the requirement
 Step Cooling
 Test where the material is cooled, held at temperature, cooled again, etc.
 Gives an indication of temper embrittlement resistance
 Mn + Ni Ratio
 Typically < 1.2 for P11, P22
 <1.0 for P91, P92
 Creep Data – Contact Person
 Creep - the movement of material under loads less than the yield point which
typically increases with temperature
 Minimum test time is 10,000 hrs

voestalpine Böhler Welding

Extended Creep Data
Creep tests on all weld metal an d welded joints

Weld metal Cumulated tested Longest single

time [h] test
[h]
P22 type 1.800.800 > 60.000

Creep test laboratory of Salzgitter-

P91 type 2.724.000 > 175.000
Mannesmann Forschung G mb H
P92 type 1.114.000 > 75.000
VM12 SHC type 665.500 > 39.000
CB2 type 554.000 > 61.000
Super 304 type 277.400 > 43.000
…

voestalpine Böhler Welding

Creep Resistant Flux Cored Wire
Bohler P92 Ti-FD

Dissimilar Welding of CB2 and P92 with P92 Flux Cored

Wire

Semi-automatic welding of CB2 cast

component with P92 pipe in position PC (2G) wall thickness 300 mm
voestalpine Böhler Welding
Who Are Our Customers?

voestalpine Böhler Welding

 “Ideal” Customer Sales Path

Bohler Customer Customer Requires

Only Bohler Products
Product to be used at all
Qualified/Specified locations, sub
component
fabricators, field
services, etc.

Site Location Fabricators Field Services

Distribution

voestFaelbpruinarey Böhler
24 Corporate Presentation
18, 2021
Welding
Journey to Customer – Discussion
• Where to start?
• What is the Best Path to the Right Contact?
Corporate Office Relationship?
Distributor?
Welding Engineer?
Purchasing?
Quality Manager?
Site Manager?
• Want to Create Pull
Through Distributor!!!!
• What To Do/Not To Do?
• Which Product Range
To Lead With?
• Field vs. Plant
Fabrication?
voest a l p in e Böhler
F e b ru ar y

•Welding
25
Customized for Atlantic
18, 2021
Corporate Presentation
 Leading the Industry

Main steam header / Dayton Power / USA

First application P91 – 1989
Pipe delivered by Mannesmann
Filler metal deliver by Böhler (Thyssen)
Welding To date operation approx. 180,000
hours
First new Power Plant in Europe with
P91 (X10CrMoVNb9-1)
First application: 1992
Start up: 1994
Main steam piping system

voestalpine Böhler Welding

Thank you!
Russel Fuchs/Keith Packard
Regional Application Engineering

voestalpine Böhler Welding

voestalpine Böhler Welding
www.voestalpine.com/welding