19-04-2023

NTPC R&R Colony, Darlipali NTPC Bhadla NTPC Kudgi

Presentation on
Grade 91/92 welding
NTPC Koldam NTPC Kayamkulam NTPC Rojmal

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Presentation on
Fabrication Aspects Of Advanced
Materials
For Super Critical Units
Welding of Gr-91/92

Rajeev Kumar Jain

[email protected]
9650997939
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Pre-test

Importance of Al to N ratio for

What is Grade 91 material?
Gr 91 material

What is P91/T91/F91/ SA387-91-2/ Importance of Ni for Gr 91

WP 91? material

What are the various types of

PWHT requirement for Gr 91
Grade 91 material available?

In your area whether Type 1 or Whether welding of Gr 91 with

type 2 is being used! Gr11 possible!

Difference between grade 91 Welding of Gr 91 with Gr 92-

and 92 dissimilar weld or similar weld!

Contents of Presentation
Together we did Together we will

 Various grades of Materials used in Boiler

 Development of Grade 91 Material

 Grade 91 welding

 Grade 91-Post Weld Heat Treatment requirements

 Precautions with Grade 91 welding

 Grade 92 welding

 Dissimilar welding of 91 with 22/Super304H

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Advanced Cr-Mo steels

High Temperature Application Materials: Possibilities!!!!

Grade 91 With
Grade22 9Cr1MoV (P15E)
2¼ Cr 1Mo
(P5A) Grade 92 (like 91
with 9Cr ½Mo
1¾W (P15E)

Grade23 (like 22 with

2¼ Cr ½1.6% W V Nb)
(P5A)

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Chemical Composition
Material C Max/ Mn P S Max Si Cr. Mo. W Ni
Min Max
P22 0.30 1.90 0.87
0.15 0.60 0.03 0.03 0.50 2.60 1.13
P91 Type I 0.07 0.30 0.20 8.00 0.85 0.40

0.14 0.60 0.02 0.01 0.50 9.50 1.05

P91 Type II 0.08 0.30 0.20 8.00 0.85 0.20
0.12 0.50 0.02 0.005 0.40 9.50 1.05 N/Al>= 4.0
P92 0.07 0.30 0.50 8.50 0.30 1.5-2.0 0.40
0.13 0.60 0.02 0.01 9.50 0.60
TP304H 0.04 18.0 8.0

0.10 2.0 0.04 0.03 0.75 20.0 11.0

SA335 P91 Type 1 & Type 2 have differences mainly in elements Mn, S, Si, N, Sn and Sb
content, and Type 2 has stricter requirements on element content than Type 1

Effect of Ni + Mn on AC1 Temperature

Ni + Mn Limit for Filler Metal

Relation between Ni + Mn limit and maximum
PWHT temperature
 P-No. 15E Group No.1 (no chemistry) 775℃
 Ni＋Mn > 1.5% 775℃
 1.5% > Ni＋Mn > 1.0%，Ni > 0.4% 775℃
 1.5% > Ni＋Mn > 1.0%，Ni < 0.4% 790℃
 Ni＋Mn < 1.0%，Ni > 0.4% 790℃
 Ni＋Mn < 1.0%，Ni < 0.4% 800℃

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Mechanical Properties at room temperature

0.2% Y.S., U.T.S., Elongation % Hardness Max
Material Min. Min. minimum
KSI/ MPa KSI/ MPa (Gauge Length 2” )
170HV/ 85HRB/163HBW
T12 32 /220 60/ 415 30

T22 30/ 205 60/ 415 30

230HV/ 97HRB/220HBW
T23 58/ 400 74/ 510 20

T91 196-265HV/ 190-250HBW

60/ 415 85/ 585 20
Type I & II
265HV/ 25HRC/250HBW
T92 64/ 440 90/ 620 20
200-230HV
TP 304H 30/ 205 90/ 620 20

A minimum hardness of 190 HB

is considered as a reliable
indication to get tempered
martensitic structure without
ferrite

Maximum hardness of 250 HB

so that the final structure will
consist of Tempered Martensite

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SA 335 SPECIFICATION FOR SEAMLESS FERRITIC ALLOY-STEEL PIPE FOR HIGH-TEMPERATURE SERVICE

• SA 335 is specification for various grades of ferritic steels. Ferritic steels in this
specification are defined as low and intermediate- alloy steels containing up to and
including 10 % chromium.
• Grade 91 consists of two types. Type 2 is differentiated from Type 1 by requiring
restricted composition for the enhancement of creep resistance.
• All repair welds in P91 shall be made with one of the following welding processes and
consumables: SMAW E90XX-B9; SAW EB9 + neutral flux; GTAW ER90S-B9; FCAW
E91T1-B9.
• In addition, the sum of the Ni+Mn content of all welding consumables used to weld repair
P91 Type 1 and Type 2 shall not exceed 1.0 %.
• Pipe of Grade P91 Type 1 and Type 2 shall have a hardness within the range of 190 to
250 HBW or 196 to 265 HV or 91 HRBW to 25 HRC.

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 Note for P-91 consumables Ni+Mn factor which is not addressed by Sec-IX (but covered in
Sec VIII & I).
 Total Ni+Mn in the weld metal should not exceed 1.5%
 Both Sec-I (PW-39) and B-31.1(Table -132) specifies that:-
• If Ni + Mn < 1.50% but ≥ 1.0%, the maximum PWHT temperature is 1,450°F (790°C).
• If Ni + Mn < 1.0%, the maximum PWHT temperature is 1,470°F (800°C).
 It is advisable to stick to the approved WPS and preferably approved brand/make of
welding consumable which is used for procedure qualification.
 If the change of welding consumable becomes an absolute necessity, in addition to normal
ASME Sec-II Part -C requirements , you need to see the the Ni+Mn content in the MTC and
the results of mechanical testing following PWHT before making the change.

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E90XX-B91, E90XX-B92, E90XX-B23

The E90XX-B9 classification has been changed to E90XX-B91 to better conform to industry standards and practices.
ASME SECTION II C 2021 table A4

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Typical Heating Cycle for Welding P91

• Soaking at 80-100C, Necessary
after welding to ensure complete
transformation of the austenite
formed during welding heat to
martensite so that complete
hydrogen get removed
• Not allow the temperature below
80-100 deg c before PWHT to
keep the weld region dry and also
increase the mobility of the
hydrogen atoms
• PWHT using induction method is
adopted for ensuring uniform
heating in the welding zone and
consequent reduction of hardness
values

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PREHEATING AND PWHT BY INDUCTION HEATING

760+/-10

350

Temp
in C

220
100

80

RT 1 2 3 4 5 6 7 8
Time

No Operation Temp degree C Rate of Cooling/Heating

1 Preheat 220 C 100 C/hr
2 Welding GTAW+SMAW 220 C-350 C
3 Cooling 80-100 C 100 C/hr
4 Holding at 80-100 C for min. 1 hr. Holding shall continue till the start of PWHT
5 Heating to PWHT Reach 745+/- 15C As per above
745+/-15 at 2.5 Mts./mm
6 Soaking at PWHT
(Minimum 2 hrs)
7 Cooling under insulation Cooling to 350 C As per above
8 Cooling to RT
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Hydrogen Bake with PWHT at later time …..

• If it is not possible to perform post weld heat
treatment immediately (at the most within 8
hours) after the completion of the weld, a
hydrogen bake shall be performed on the
weld joint (to remove all dissolved hydrogen).

• Hydrogen bake shall NOT be interpreted as a

post-weld heat treatment.

• The temperature shall be raised to 260-400C

and held for one hour per inch of thickness, up
to a maximum of four hours and then allowed
to cool in still air to ambient temperature.

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Welding & PWHT Requirements for P91 AND P22

Parameter P22 P91
Filler Wire (GTAW) ER90S-B3 ER90S-B9
E9018-B9 or
Electrode (SMAW) E9018-B3
E9015-B9
Preheat Temp. deg.C 150 220
Inter pass Temp. deg. C 300 350
Post heat (Preheat 80-100
Maintenance ) deg. C (Min 1 HR.)
PWHT Temp. deg. C 680-750 745 +/- 15C
Minimum Soaking time 2.5Min/mm 2.5Min/mm
Minutes Min 30 for tube, 60 for pipe Min 60
Shielding gas Argon Argon
Purging Gas (Root Pass) Nil Argon
B3- 2-¼% Cr 0.9-1.2 % Mo: B9- 9% Cr 1 % Mo

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Factors that decide good welding

Consumable should have proper chemistry with
 Low impurities
 low hydrogen content in the weldment - less than 4ml/100gm
 Preferably E 9015-B91 type of electrodes (SMAW). The usage of E 9015-
B91 is recommended over E 9018-B91/E 9016-B91 for the following reasons:
 E 9018-B91 is a basic coated low hydrogen electrode with iron powder coating : iron
powder is considered to be one of the source of bringing contamination mainly S & P to
the weldment that are not desirable in P91 welding. These impurities are to be controlled
to avoid hot cracking.
 E 9015-B91 offers pure weld without iron powder as compared to E 9018-B91 hence the
impact toughness is better with E-9015-B91.

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Minimizing time between completion of welding & PWHT

• Codes does not offer any rule or guidelines about the time between welding & PWHT,
however,
High Hardness & little ductility makes it susceptible to SCC
Should be protected from moist environment
Avoid unnecessary handling & lifting until PWHT is complete

• Untempered martensite hardness is 429Hv10

• While tempering the weld to temp of 810, 800, 790C (i.e. AC1-10, AC1-20, AC1-30C), it is
observed that tempered martensite having hardness above 290Hv.
• While Tempering the weld at Ac1-50 i.e., 770C shows optimum hardness of 250Hv and has
typical tempered martensite structure.
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To Prevent Crack Formation Following Precautions Are To Taken

• Intermediate cooling after welding at 80-100 deg C before PWHT to complete
transformation of the austenite formed during welding to martensite.
• Not allow the temperature below 80-100 deg c before PWHT to keep the weld
region dry and to increase the mobility of the hydrogen atoms to completely comes
out
• Immediate Post Heat (Hydrogen Bake) or PWHT
• Post heating at 300- 400C to avoid cold crack. However, Post heating not reduces
chances of SCC
• PWHT at 760C using induction method to ensure uniform heating in the welding
zone and consequent reduction of hardness values
• Not to exceed AC1 in PWHT

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Types of Cracking

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PRECAUTIONS WITH P91 WELDING

• No temporary attachment should be welded with pipe/tube for erection
or holding purpose.

• Arc strike on this material is to be totally avoided, well insulated

welding holders and welding cables should be used.

• No bridges or rods should be welded to pipe for weld joint fit-up.

• Special clamps are to be made for the fit-up.

• Repair of edges by build-up is not recommended.

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PRECAUTIONS WITH P91 WELDING

• Cutting and edge preparation to be done at site by mechanical means only.

• During grinding, avoid localized over heating of metal.

• Ensure baking & holding temperature of welding electrodes as recommended.

• Ensure DG supply before starting the preheating of weld joint or other alternate
arrangements.

• Suitable punch mark shall be made on both pipes at 200mm from EP for UT & at 1000mm
from EP for identifying weld during PWHT

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STEPS FOR SUCCESSFUL CR-MOLY WELDING

• Selection of suitable filler alloy (TIG root/SMAW…etc.)

•Proper re-baking of electrode & fluxes

•Verification of preheating & Inter-pass temperature

•Setting of (Electrical) welding parameters

•Weld bead sequence & Verification of heat treatment temp

Qualified procedure by qualified welder

ISSUES IS ONLY DUE TO NON-OBSERVANCE OF ABOVE

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Induction Heating
• Induction heating is caused by alternating low voltage, high current
when applied to coils wrapped around the pipe.
• The magnetic field associated with the current passing through the coil,
penetrate the pipe.
• Since the current is alternating, the magnetic field also alternates in
phase with it.
• A current is induced in the pipe and resistance to this induced current,
heats the pipe.
• Advantage: 1. High rate of Heating is possible
2. Temp can be controlled within narrow range
3. Localized over heating is not produced
4. The Coils have longer life & so they do not fail during heat treatment.

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CLEANING OF PIPE ENDS WITH BUFFING WHEEL

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PUNCH MARK MADE AT 200 mm FROM WELD CENTRE FOR UT REFERENCE

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SURFACE MARKED WITH METAL MARKER FOR UT

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MECHANICAL PIPE CLAMP BEING FIXED ON PIPE FOR JOINT FITUP

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JOINT ROOT GAP CHECKED USING TAPER GAUGE

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THERMOCOUPLE: K –TYPE
No preheating is required for fixing
T/C with resistance Spot welding

CAPACITOR DISCHARGE M/C FOR THERMOCOUPLE

WELDING ON PIPE

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JOINT WRAPED WITH ANNEALING CABLE ON CERAMIC CLOTH COVERING WOOL INSULATION

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Argon Purging
• Argon gas shall be used for purging of root side of weld.
• Purging dam (blank)/purge paper shall be fixed on either side of the weld bevel prior
to preheating & it shall be located away from heating zone.
• Purging to be done for root welding (GTAW) followed by two filler passes of SMAW in
case of butt welds.
• Purging is not required for nozzle & attachment welds when they are not full
penetration welds.
• Flow rate to be maintained during purging is 20-25 Litres/minutes.
• Flow rate to be maintained for shielding during GTAW is 10 Litres/minutes .
• The Minimum pre-flushing time for purging before start of welding shall be 5 minutes.
• When ever possible solid purging gas chambers are to be used which can be removed
after welding. If not possible only water-soluble paper is used.

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ARGON PURGING ARRANGEMENT

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VISUALLY INSPECT ROOT WELDING THROUGH WINDOW OPENING PROVIDED AT BOTH SIDES
OPPOSITELY.

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PWHT
• Pipes: A minimum of 4 thermocouples shall be placed such that at least
two are on the weld & other two on the base metal on either side of
the weld within the heating band at 180 deg apart about 50mm from
weld joint.
• Two standby T/C shall be provided on the weld in case of failure of T/C.
• The width of heated circumferential band on either side of weld must
be at least 5 times the thickness of the weld.
• An insulation of about 10mm thick shall be provided between cable &
weld joint.
• The width of insulation band beyond heating band shall be at least two
times the heating band width on either side of weldment.

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Dissimilar Welds

Dissimilar weld
between P/T91 &
P/T22 as well as
austenitic steel can be
produced
successfully.

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Dissimilar Welds
There is a phenomenon knoiwn as carbon
migration due to difference is Cr & C
content
carbon diffuses during welding/PWHT
from low Cr material into high Cr partner
steel.
As a result, carbon depleted zone evolves
in low Cr & a carbon enriched zone in
high Cr material. De-carburized zone
means loss in strength and toughness
It is not possible to avoid this
phenomenon unless Ni based
consumables are used.
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91 to 11 joint not possible……

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Dissimilar weld between P/T91 & P/T22

(NTPC practice)

GTAW : ER 90S B3
SMAW : E9018 B3
Preheat : 220⁰C
Interpass : 350 ⁰C
PWHT : 745 +/- 15 ⁰C

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Grade 92 material

 The Creep strength enhanced ferritic (CSEF) P92 steel was developed in Japan by Nippon steel.
 P92 steel offers enhanced creep strength, which results from the combination of precipitation and solid-
solution hardening.
 The P92 steel microstructure is tempered martensitic structure.
 During the welding process, P92 steel showed a great tendency for δ ferrite formation due to the
presence of ferrite stabilizers like V, Nb, W, Mo, and Cr.
 The presence of δ -ferrite gives a negative effect on mechanical properties due to notch sensitivity of
the δ –ferrite. It makes material brittle.
 It is possible to control the formation of retained austenite and δ -ferrite by optimizing the base and
filler metal composition.
 The high number of ferrite-forming elements resulted in excessive formation of δ -ferrite

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Heat control during welding and PWHT- condition for P92

1000

+ 0

800 760°C - 10
Temperature [°C]

2-4h
Heating rate Cooling rate
600 80 - 120°C/h 100 - 150°C/h

400 slow
250 - 300°C cooling rate
< 400°C
200 cooling in still air
·
20 - 100°C
· ·
0
0 0,51 welding
preheating 1,52 2,53 3,54 4,55 5,56
and soaking 6,57
necessary 7,588,59
cooling down after9,51010,5
welding 1soaking
or 111,51212,51313,5
Time

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Together we did Together we will

Thank You

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