Lalitpur Power Generation Company Limited

3x 660 MW - STPP

WELDING & PWHT

REQUIREMENT OF
VARIOUS MATERIAL
USED AT SITE IN
PRESURE PARTS

1 | Page

Prepared By- Navneet Singh(FQA)

Lalitpur Power Generation Company Limited

3x 660 MW - STPP

WELDING
Welding is a materials joining process which produces coalescence of materials by heating them
to suitable temperatures with or without the application of pressure or by the application of
pressure alone, and with or without the use of filler material.

COMMANLY USED WELDING PROCESSESS AT SITE FOR WELDING PRESSURE

PARTS.

SMAW SUBMERGED METAL ARC WELDING

Shielded
metal
arc
welding (SMAW),
also
known
as manual
metal
arc
[1]
welding (MMA or MMAW), flux shielded arc welding or informally as stick welding, is a
manual arc welding process that uses a consumable electrode covered with a flux to lay the
weld.
An electric current, in the form of either alternating current or direct current from a welding
power supply, is used to form an electric arc between the electrode and the metals to
be joined. The workpiece and the electrode melts forming the weld pool that cools to form a
joint. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that
serve as a shielding gas and providing a layer of slag, both of which protect the weld area from
atmospheric contamination.

(a) SMAW - Welding Circuit

2 | Page

(b) SMAW Welding Process

Prepared By- Navneet Singh(FQA)

Lalitpur Power Generation Company Limited

3x 660 MW - STPP
GTAW GAS TUNGESTUN ARC WELDING
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc
welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area
is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler
metal is normally used, though some welds, known as autogenous welds, do not require it.
A constant-current welding power supply produces electrical energy, which is conducted across the
arc through a column of highly ionized gas and metal vapors known as a plasma.

(a) GTAW - Welding Circuit

3 | Page

(b) GTAW Welding Process

Prepared By- Navneet Singh(FQA)

Lalitpur Power Generation Company Limited

3x 660 MW - STPP
LIST OF MATERIAL USED IN PRESSURE PARTS WITH P.NO

P.NO
P1

Group
No.
1

Common
Name
Carbon
Steel
Carbon
Steel

Tubes

Pipes

Forgings

Castings

SA 106 Gr B

P1

P4

P5A

P15E

1Cr1/2Mo
Steels
21/4
Cr1Mo
Steel
9Cr1MoV

SA 213 T12

P15E

9Cr2W

P8

18Cr-8Ni

SA 210 GR C

SA 213 T22

SA 213 T91

Fittings

SA 234
WPB
SA 106 Gr C SA 216 SA 105,
SA 670 Gr
WCB ,
SA 234
B70
SA 216 WPC
WCC
SA 335 P12 SA 182 SA 217 SA 234
F12
WC6
WP12
SA 335 P22 SA 182 SA 217 SA 234
SA 691 Gr22 F22
WC9
WP22
SA 335 P91

SA 182
F91
SA 213 T92 SA 335 P92 SA 182
F92
SA
213 SA 312 TP AISI 321
TP304H
304 H
SA
213
TP347H

SA 217 SA 234
C12A
WP 91
SA 351 SA 403
CF8

Note:- IS 1239 , IS 3589 , API 5L Gr B are considered under P.No -1 & Group No :-1

4 | Page

Prepared By- Navneet Singh(FQA)

Lalitpur Power Generation Company Limited

3x 660 MW - STPP
WELDING & PWHT REQUIREMENTS PRESUURE PARTS- TUBES
Welding

Material

Proces
s

Reference

GTAW
Filler

SMAW
Electrode

PWHT
Soaking
Temp(C)

Soaking
Time
(Mins)

Remark

P1 Gr 2
+
P1 Gr 2

A 210 Gr C
+
A 210 Gr C

GTAW
+
SMAW

WPS-1002/EWS

ER 80S-D2

E 7018-A1

620-650

Min 30
Mins

Eco Hanger
Tubes

P1 Gr 2
+
P1 Gr 2
P1 Gr 2
+
P4 Gr 1
P4 Gr 1
+
P4 Gr 1

A 210 Gr C
+
A 210 Gr C
A 210 Gr C
+
A 213 T 12
A 213 T 12
+
A 213 T 12
A 213 T 12
+
A 182 F 12

GTAW
+
SMAW
GTAW
+
SMAW
GTAW
+
SMAW

WPS-1002

ER 80S-D2

E 7018-1

WPS-1017

ER 80S-D2

E 7018-1

WPS-1009

ER 80S-B2

E 8018-B2

P4 Gr 1
+
P5A Gr 1

A 213 T 12
+
A 213 T 22

GTAW
+
SMAW

WPS-1011

ER 80S-B2

E 8018-B2

Eco Coils,1st
Pass Bottom
Header Joint
Hopper Panel &
Bottom Header
Tube
Water Wall
Panels
,Intermediate
Header Joints,
Back Pass
Panels,LTRH
Inlet Header
Joints , LTRH
Coils Assembly,
Roof Header &
Joints
LTRH Coil Int
Assembly

P5A Gr 1
+
P5A Gr 1

A 213 T 22
+
A 213 T 22

GTAW
+
SMAW

WPS-1014

ER 90S-B3

E 9018-B3

680-750

Min 30
Mins

P5A Gr 1
+
P5A Gr 1

A 213 T 22
+
A 213 T 22

GTAW
+
SMAW

WPS-1013

ER 90S-B3

E 9018-B3

P15E Gr 1
+
P15E Gr 1

A 213 T 91
+
A 213 T 91

GTAW
+
SMAW

WPS-1050,1036

ER 90S-B9

E 9015-B9

750-770

90 Mins

P15E Gr 1
+
P15E Gr 1

A 213 T 92
+
A 213 T 92

GTAW
+
SMAW

WPS-1058

ER
9CRWV

Thermanit
MTS-616

730-770

30 Mins

FSHIC , FSHOA
,RHOA Joints

P15E Gr 1
+
P15E Gr 1

A 213 T 91
+
A 213 T 92

GTAW
+
SMAW

WPS-1059

ER 90S-B9

E 9015-B9

730-770

30 Mins

FSHIB 98
Joints,
SHPOB -32
Joints

P8 Gr 1
+
P8 Gr 1

A 213 TP 304H
+
A 213 TP 304H

GTAW

WPS-1054

YT304H

RHOB Joints

P8 Gr 1
+
P8 Gr 1

A 213 TP 347H
+
A 213 TP 347H

GTAW
+
SMAW

WPS-1016

ER 347

E347

RHIB Joints,
FSHOB Joints,
FSHID Joints

5 | Page

Rear Arch
Panel, Rear
Hanger with
Rear Header
Joints
,LTRH Upper
Assembly,RHIA,
SHPIA,SHPIB
Joints
SHPOA ,
SHPOB,FSHIA ,
FSHIB

Prepared By- Navneet Singh(FQA)

Lalitpur Power Generation Company Limited

3x 660 MW - STPP
WELDING & PWHT REQUIREMENTS- PIPES

BHEL DOC-4-80-999-93172 (WPS, HT, NDT)-Pipes

6 | Page

Prepared By- Navneet Singh(FQA)

Lalitpur Power Generation Company Limited

3x 660 MW - STPP
Rate of Heating & Rate of Cooling During PWHT
Thickness of Material
25 mm
> 25 50 mm
> 50 75 mm

> 75mm

Maximum Heating Rate

Above 300C
220C/hour
110C/hour
75C/hour
55C/hour

Maximum Cooling
Rate Upto 300C
220C/hour
110C/hour
75C/hour
55C/hour

Typical SR/PWHT Chart T-91 & T-92

7 | Page

Prepared By- Navneet Singh(FQA)