Air Liquide

OERLIKON Consumables for
Construction and Maintenance in

Thermal Power Stations
- T/P 92 Applications Michael Reimann
Dipl.-Ing. IWE - Product ManagerOERLIKON Switzerland
The 10th Beijing Essen Welding & Cutting Fair in Shanghai, May 25th
28th, 2005
View of different constructions
Thermal power station
- History and general information

- Technical backround
- Welding technology
- Development and present situation
of OERLIKON consumables
History and general information

Energymix
for electricity in EU 25 in 2002
Value of blocks
Age structure of coal-fired power station within EU15
Share of installed power of

Coal-fired power station wihin EU (%)
Effectiveness thermal power stations within EU 15
CO2- reduction of increase power stations efficiency within

EU 15

Development
of power plant efficiency

Material
s Development at high-temperature
power station
P92

10
Technical background
Use
of high-temperature steels in Europe, USA,

and Japan
Year
Europe
USA
Japan
Before the
60's
10 CrMo910
(2 1/2%Cr, 1%Mo)
T/P22
STBA24-STPA24
In the 60's
14MoV6-3
0,5%Cr, 0,5%Mo, 0,25%V
Mid 60's
X20CrMoV12-1
12%Cr, 1%Mo, 0,25%V
EM12 (9%Cr, 2%Mo, V, Nb)
T/P22
STBA24-STPA24
Mid 80's
X10CrMoVNb9-1
(9%Cr, 1%Mo, 0,25%V, Nb)
T/P 91
STBA28-STPA28
Early 90's
7CrMoVTiB10-10
E911
T/P 23
T/P 122
HCM2C
HCM12A
Since 1998
X10CrWMoVNb9-2
9%Cr, 2%W, 0,5%Mo,
0,25%V, Nb
T/P92
STBA29-STPA29
T/P22
STBA24-STPA24
11
International
standards
Specification
and grade
Country
Description
A213 T92
USA
Seamless ferritic and austenitic alloy-steel

boiler, superheater and heat exchanger tubes
A335 P92
USA
Seamless ferritic alloy-steel pipe for hightemperature service
A387 GR92
USA
Pressure vessel plates

Alloy steel Cr, Mo
USA
Forged or rolled alloy steel pipe Flanches,

forged fittings and valves and parts of high
temperature service
USA
Carbon and ferritic alloy-steel,

Forged and bored pipe for high-temperatures
service
A182 F92 in
progress
A369 FP92 in
progress
12
Chemical
composition of choosen materials
13
Creep
rupture strenght of pipes
14
Illustration
of the required pipe wall thickness
15
Thickness
at hot steam escape temperature
16

17
Welding technology
Producing
of P92- Collectors
18
Welding technology
Collector
with Connecting-pipes
19
Welding technology
Typical
heating and welding cycle for T/P92-T/P92
20
Welding technology
Typical
heating and welding cycle for P92-P91
21
Welding technology
Typical
heating and welding cycle for P92-P122
22
Welding technology
Typical heating and welding cycle for P92-austenitic-steel
23

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)
25

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
Mn
Si
Cr
Mo
Ni
Co
Nb
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
<5
0,05
1,71
26

consumables
Charpy V-notch value

Rep
KCV+20C (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

consumables
Creep resisting values 85 MPa, 100 h up to 8000 h
Creep Resistance Tests under 85 Mpa stress value
100000
log tr ( h)
10000
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
10
0.00102
Nip. St. Data Package moy
0.00104
0.00106
-1
1/T( K )
0.00108
0.0011
28

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

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

consumables
Customer s Demand
Increase of AC1
Replace 0,5% Ni by 1% Co
Increase AC1 ~25C
Same level of mechanical properties
is reached with 1% Co electrodes
Same analysis like TIG-rod and SAW
C
Si
Mn
P
S
Cr
Mo
Ni
Al
Co
Cu
Nb
Ti
V
W
B
Oxygne
Azote
ALCROMCORD 92
lot 1002820
0.102
0.17
1.12
0.009
0.009
8.6
0.53
0.47
<0.001
0.011
<0.010
0.052
0.005
0.23
1.76
0.0041
714
354
Cr q.
5.63
5.99
PWHT 760C/4h
Kv +20C (J)
Kv 0C (J)
Kv -20C (J)
Rp0.2 (Mpa)
Rm (Mpa)
A%
T int. 250C
67-67-56 moy:63
48-44-38 moy:43
34-28-18 moy:27
600
747
18.7
74-86-44 moy:68
40-58-44 moy:47
45-47-32 moy:41
555
717
20.6
Ref.
R109-050
0.097
0.18
1.05
0.008
0.008
8.7
0.52
0.05
0.001
0.95
0.012
0.048
0.004
0.25
1.64
0.0025
592
397
30

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 )
test
stopped
test
stopped
test
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

consumables
32

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

consumables
Creep resisting values 85 MPa, 100 h up to 8000 h
Submerged arc (after PWHT)
100000
logtr ( h)
10000
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
-1
1 / T ( K
0.00108
0.0011
34

consumables
Creep resistance test - Cored wire and Flux combinations (after PWHT)
Constrain ( MPa )
1000
100
10
34000
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
34500
35000
35500
36000
36500
37000
37500
38000
38500
39000
Larson-Miller parameter ( C = 36,10999 )
35

consumables
1000
LOG SIGMA ( MPa )
test
stopped
test
stopped
test
stopped
100

Results ALCROMO SF92 / LEXAL F500 - Pure weld
Results ALCROMOCORD 92 - Pure weld
10
32000
33000
34000
35000
36000
37000
38000
39000
36

consumables
LOG SIGMA ( MPa )
1000
100

Results ALCROMO SF92 / LEXAL F500 - Cross weld
10
32000
33000
34000
35000
36000
37000
38000
39000
37

consumables
38

consumables
Conclusion
aConsumables for T/P92

ALCROMOCORD 92 ( SMAW )
ALCROMO WF 92 ( GTAW )
ALCROMO SF 92 / LEXAL 500 ( SAW )
39

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OERLIKON Consumables for

Construction and Maintenance in

View of different constructions

Thermal power station

- History and general information

History and general information

for electricity in EU 25 in 2002

History and general information

Age structure of coal-fired power station within EU15

Share of installed power of

History and general information

Effectiveness thermal power stations within EU 15

History and general information

CO2- reduction of increase power stations efficiency within

History and general information

of power plant efficiency

History and general information

Thermal power station

- History and general information

of high-temperature steels in Europe, USA,

Seamless ferritic and austenitic alloy-steel

Seamless ferritic alloy-steel pipe for hightemperature service

Pressure vessel plates

Forged or rolled alloy steel pipe Flanches,

Carbon and ferritic alloy-steel,

composition of choosen materials

rupture strenght of pipes

of the required pipe wall thickness

at hot steam escape temperature

Thermal power station

- History and general information

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

heating and welding cycle for P92-P91

heating and welding cycle for P92-P122

Typical heating and welding cycle for P92-austenitic-steel

Thermal power station

- History and general information

Development and present situation of P92

Based on these results and based on target that

Based on the present situation out of the industry, we

Development and present situation of P92

a Development of three different electrodes

Chemical composition ( All-weld-metal )

0,01 0,055 1,94

0,94 0,051 1,77

Development and present situation of P92

Charpy V-notch value

96, 103, 106

Good charpy V-notch values

Gammagene elements decrease slightly AC1

AC1 is high enough, PHTW Industrial application

Development and present situation of P92

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

Nip. St. Data Package moy

Development and present situation of P92

0%Ni ; 1%Co ; 0ppm B

Larson-Miller Parameter ( C = 36,10999 )

Development and present situation of P92

Development and present situation of P92

: MEANS THAT TEST SYMBOLIZED BY DOT BELOW IS IN PROGRESS

LOG SIGMA ( MPa )

Nippon Steel Data Package

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

Development and present situation of P92