Beruflich Dokumente
Kultur Dokumente
APPROVED BY:
MFG Tim Driver DATE 01/25/99 ENGRG Peter J. Ditzel DATE 01/20/99
MFG DATE ENGRG D. J. Buquoi DATE 03/24/99
ESD QA DATE ENGRG DATE
ESD QA DATE TECH REC C. J. Buzard DATE 03/25/99
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1.0 SCOPE
This process specification describes the requirements for welding 12% chromium steel (type 403),
12%Cr4%Ni-1%Mo steel (type 41500), 12Cr-1Mo-W-V steel (type 422) and 12 Cr-V-Nb-N (H46) blades
for LP, IP, and HP diaphragms by machine GMAW and SAW processes.
Type 422 stainless steels are not ASME pressure vessel materials and therefore are not listed in QW-422 as
P6 materials. For the purpose of this specification, Type 422 steels and 10705Z2 will be considered an
“unassigned material” which requires separate Procedure Qualification Record (PQR). On the WPS
documents in this specification, the material will be considered as a P6 Modified. The Steam Turbine
Materials Engineering considers that procedures qualified with this material qualify for welding this and
other P6 materials, however, qualification with regular P6 materials does not qualify for welding type 422.
As the specified minimum elongation is 14%, the special rules of QW-466.1 and QW-462.3(b) shall be used
in qualification guided bend testing.
This specification is written in the following Parts for various types of diaphragms:
*If the Process Specification 600466 is called out on a drawing or other document and neither Part I nor
Part II is specified, Part I requirements will be followed. If Part III is specified, follow PS 82121MS.
2.0 SAFETY
2.1 Applicable Material Safety Data Sheets (MSDS) and Safe Practice Data Sheets (SPDS) must be
available and reviewed for all solvents and materials used in this specification.
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600466 WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
Rev. 22 03/25/99 Process Specification
2.2 All precautions related to the use, handling, storage, and disposal of the solvents and materials
used in this process specification, as specified in the appropriate MSDS and SPDS, must be
observed.
2.3 Where applicable, eye protection, gloves, protective clothing, safety shoes, and hard hats must be
used. Wash thoroughly after handling and before eating, drinking, or smoking. All safety
precautions related to the handling of and working around electrical equipment must be observed.
Proper fire protection must be in the immediate work area. The work area must have adequate
ventilation and be free of open flames and sparks. Local exhaust or hoods, respirators, masks,
filters and other appropriate breathing devices must be used when necessary. Approved safety
containers are required.
2.4 Waste disposal must be conducted in accordance with all federal, provincial, state, and local
government environmental regulations.
The following documents, current revision, shall form a part of this specification to the extent referenced
herein.
3.4 Drawings
3.5 Others
4.0 EQUIPMENT
4.5 Furnace, controls, and thermocouples capable of controlling the postweld heat treatment as
specified.
5.0 MATERIALS
6.0 QUALIFICATION
As steam turbines and electrical generators and their associated equipment are not covered by the scope of
the ASME B & PV Codes or ASME B3 1. 1, the welding operations described in this specification are not
specifically governed by ASME Code (Book Section) requirements. The procedure and performance
qualifications, however, follow Section IX rules, wherever practicable, as they are considered industry
standards on qualification. ASME Code rules shall be followed where this procedure is used on ASME
B & PV Code or ASME B3 1.1 fabrication. In non-Code applications (W) Engineering may waive specific
WPS variable rules by use of the FAR system or MDR, if processed through Turbine/Generator Materials.
6.1 The following PQR’s support the welding called out in this process specification:
Thickness of
Range of
Deposited
Thickness of Base
PQR’s P# to P# F# PWHT Gas/Flux Weld Metal
Metal Qualified
Qualified (t)
(T) (inches)
(inches)
Thickness of
Range of
Deposited
Thickness of Base
PQR’s P# to P# F# PWHT Gas/Flux Weld Metal
Metal Qualified
Qualified (t)
(T) (inches)
(inches)
The WPS documents which follow are written to meet the intent of the ASME Section IX Welding
Variable rules. Supplementary Manufacturing Information or Supplementary Welding Information in this
or other documents shall not have precedence over the WPS requirements. Waivers of the WPS
requirements for field welding shall only be authorized by Engineering on FAR documents. This document
supersedes and has precedence over the Supplementary Welding, General Welding Information
documents, MIL-, and ESD Field Welding - documents.
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WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
600466
Process Specification Rev. 22 03/25/99
Siemens Westinghouse Welding Procedure Specification
(WPS in Sec IX QW-482 Format)
***********************************************************************************
ORIGINAL WPS
(W)WELDING PS (WPS) NO. 600466 PARTS I & II ISSUE DATE 12/10/97
WPS REV 0 DATE 12/10/97 SUPPORTING PQR’S C4318, C4320
ADDITIONAL MFG. INFO. SEE PROCESS SPEC.
WELDER QUAL
WELDING PROCESS (ES) GMAW TYPE Machine TEST (WPQ) PQ 51003
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600466 Siemens Westinghouse Power Corporation
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Page 7 of 27 Use this document solely for the purpose given. Do not disclose, reproduce, or
use this otherwise without the written consent of Siemens Westinghouse Power
Corporation. Copyright © 1999 by Siemens Westinghouse Power Corporation.
WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
600466
Process Specification Rev. 22 03/25/99
Siemens Westinghouse Welding Procedure Specification
(WPS in Sec IX QW-482 Format)
***********************************************************************************
ORIGINAL WPS
(W)WELDING PS (WPS) NO. 600466 PARTS I & II ISSUE DATE 12/10/97
WPS REV 0 DATE 12/10/97 SUPPORTING PQR’S C3040, C3041, C6860
ADDITIONAL MFG. INFO. SEE PROCESS SPEC.
WELDER QUAL
WELDING PROCESS (ES) SAW TYPE Machine TEST (WPQ) PQ 61403
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JOINTS (QW-402) POSITIONS (QW-405)
GROOVE DESIGN U Groove POSITION OF GROOVE Flat
BACKING YES X NO WELDING PROGRESSION N/A
BACKING MATL. (TYPE) P6 or P6 Mod OTHER
OTHER
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use this otherwise without the written consent of Siemens Westinghouse Power
Corporation. Copyright © 1999 by Siemens Westinghouse Power Corporation.
WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
600466
Process Specification Rev. 22 03/25/99
Siemens Westinghouse Welding Procedure Specification
(WPS in Sec IX QW-482 Format)
***********************************************************************************
************************************************************************************
JOINTS (QW-402) POSITIONS (QW-405)
GROOVE DESIGN U Groove POSITION OF GROOVE All Positions
BACKING YES X NO WELDING PROGRESSION Vertical Up
BACKING MATL. (TYPE) P6 OTHER
OTHER
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Page 11 of 27 Use this document solely for the purpose given. Do not disclose, reproduce, or
use this otherwise without the written consent of Siemens Westinghouse Power
Corporation. Copyright © 1999 by Siemens Westinghouse Power Corporation.
WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
600466
Process Specification Rev. 22 03/25/99
Siemens Westinghouse Welding Procedure Specification
(WPS in Sec IX QW-482 Format)
***********************************************************************************
************************************************************************************
JOINTS (QW-402) POSITIONS (QW-405)
GROOVE DESIGN U Groove POSITION OF GROOVE All Positions
BACKING YES X NO WELDING PROGRESSION Vertical Up
BACKING MATL. (TYPE) P6 OTHER
OTHER
OTHER
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use this otherwise without the written consent of Siemens Westinghouse Power
Corporation. Copyright © 1999 by Siemens Westinghouse Power Corporation.
WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
600466
Process Specification Rev. 22 03/25/99
Siemens Westinghouse Welding Procedure Specification
(WPS in Sec IX QW-482 Format)
***********************************************************************************
ORIGINAL WPS
(W)WELDING PS (WPS) NO. 600466 PART I ISSUE DATE 12/10/97
WPS REV 0 DATE 12/10/97 SUPPORTING PQR’S C822
ADDITIONAL MFG. INFO. SEE PROCESS SPEC. PS 600943 (Ref. Only)
WELDER QUAL
WELDING PROCESS (ES) SMAW TYPE Manual TEST (WPQ) PQ 60110
************************************************************************************
JOINTS (QW-402) POSITIONS (QW-405)
GROOVE DESIGN U Groove POSITION OF GROOVE All Positions
BACKING YES X NO WELDING PROGRESSION Vertical Up
BACKING MATL. (TYPE) P6 OTHER
OTHER
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Page 15 of 27 Use this document solely for the purpose given. Do not disclose, reproduce, or
use this otherwise without the written consent of Siemens Westinghouse Power
Corporation. Copyright © 1999 by Siemens Westinghouse Power Corporation.
WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
600466
Process Specification Rev. 22 03/25/99
Siemens Westinghouse Welding Procedure Specification
(WPS in Sec IX QW-482 Format)
***********************************************************************************
ORIGINAL WPS
(W)WELDING PS (WPS) NO. 600466 PART I ISSUE DATE 12/10/97
WPS REV 0 DATE 12/10/97 SUPPORTING PQR’S C8084
ADDITIONAL MFG. INFO. SEE PROCESS SPEC. PS 600943 (Ref. Only)
WELDER QUAL
WELDING PROCESS (ES) SMAW TYPE Manual TEST (WPQ) PQ 50103
************************************************************************************
JOINTS (QW-402) POSITIONS (QW-405)
GROOVE DESIGN U Groove POSITION OF GROOVE All Positions
BACKING YES X NO WELDING PROGRESSION Vertical Up
BACKING MATL. (TYPE) P6 OTHER
OTHER
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Orlando, FL U.S.A. -- Proprietary Information
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use this otherwise without the written consent of Siemens Westinghouse Power
Corporation. Copyright © 1999 by Siemens Westinghouse Power Corporation.
600466 WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
Rev. 22 03/25/99 Process Specification
8.0 OPERATIONS
8.1.1 Assemble blades on 360° welding fixture, shim between last and first blade to ensure good
fit for weld grooving. Check fit and radial orientation. Do not fit blades overly tight. If
blades are overly tight, they will not lay flat on assembly fixture.
8.1.2 Machine weld grooves, ID first, then OD. Machine grooves to dimensions specified in
diaphragm fabrication drawing. Check dimensions.
8.1.3 Prepare blades for reinforcement pocket welds as per fabrication drawing and alteration
drawing 883C862.
8.1.4 Clean blades of all grease, oil or other foreign matter. Clean welding fixture components
to remove machining chips, grease and oil by spraying with a detergent or solvent solution
and rinsing clean. Check blades and fixture to ensure cleanliness.
8.1.5 Place cover plate on fixture and bolt assembly to welding positioner. The cover plate is
placed on top of the diaphragm to hold it in place when the assembly is lifted into position
and placed on the positioner. The diaphragm assembly during welding consists of a base
or jig plate, the diaphragm blades, and the cover plate. The cover plate also provides a
clamping surface.
8.1.6 Rotate turntable and check blades for tightness to assure they will not move during
welding. Verify that shims are still in place and tight.
8.2.1 Diaphragm assembly shall be preheated to and maintained at the temperature specified in
the applicable welding specifications. Check temperature with temperature indicating
crayon or other method approved by the welding engineer. Do not use temperature
indicating crayon in weld groove.
8.2.2.1 For GMAW process, using direct current welding equipment with reverse polarity
and M 10730SA0P3 wire, join the blades using the parameters specified in the
WPS.
8.2.2.2 Visible stick-out wire extension 1/2 inch to 5/8 inch from guide tube.
8.2.2.3 Maintain shielding cup 1/2 inch above surface except when welding in a groove
deeper than 1/2 inch. In this case maintain shielding cup 1/8 inch above top of
groove.
8.2.3.1 Welding of diaphragms using submerged arc welding shall adhere to the variables
specified in the WPS.
8.2.3.2 Using weld wire 10730SA0EB with carbon content not to exceed 0.095% for
10705BC blades, using weld wire 10730SA0EB with carbon content not to
exceed 0.090% for Type 422 and H46 blades.
8.2.3.4 Flux shall be baked at 400°F for 4 hours prior to use. Flux warmers shall be used
around flux recovery hoppers to help drive off moisture. Unfused flux may be
reused provided that it is clean and warm and has not been contaminated by
foreign material or moisture.
8.2.3.5 All flux/wire combinations shall be tested and documented prior to use in
production.
8.2.4 Position work and make welds in the flat position. Bead placement shall be specified by
the welding or manufacturing engineer for each joint style as necessary.
8.2.5 Welding the Reinforcement Pocket may be done using the machine GMAW, SAW, and
manual GTAW processes with 10730SA filler wire and the parameters specified in
Table I, or using the SMAW process using electrode M 10765DA and parameters
specified in Table I.
8.2.6 Grind pocket weld smooth. Visually inspect the welded assembly for cracks, voids or
burn through and verify that the pockets are welded and ground flush.
8.3.1.1 It is important that the diaphragms be flat following stress relief. Manufacturing
has the option to stack multiple diaphragms as shown in Figure 4 or stress relieve
a single diaphragm.
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600466 WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
Rev. 22 03/25/99 Process Specification
8.3.1.2 Diaphragms manufactured with non-parallel sides shall be shimmed as necessary
so all faces are supported, see Figure 5.
8.3.1.3 Load so that the thickest diaphragm is on the bottom of the stack against the base
plate.
8.3.2 Heat in a calibrated furnace at a rate not exceeding 100°F per hour from 600°F to the
PWHT holding temperature. To monitor the temperature, place at least three
thermocouples on the base plate near the diaphragms with equal spacing around the
circumference. Start to count PWHT holding time when the entire diaphragm is heated to
the PWHT holding temperature.
10705BA, 10705BC, 1150°F ± 25°F 3 hours plus 1 hour per 2” Thick Diaphragm
10711AD, 10725AF, inch of weld thickness of 3 hours + (2 x 1) =
10719BD the thickest diaphragm 5 hours total
10705BL, BM, BR, 1175°F ± 25°F 3 hours plus 1 hour per 2” Thick Diaphragm
BT, Z2 inch of weld thickness of 3 hours + (2 x 1) =
the thickest diaphragm 5 hours total
8.3.2.2 Cool at a rate not exceeding 200°F per hour from the PWHT holding temperature
to 200°F, then air cool.
8.3.3 Following stress relief, place diaphragm on flat surface in a relaxed position, i.e., no
clamps or weights to hold it down. Diaphragm must be flat within 0.060 inches. If not flat
within 0.060 inch or as directed otherwise by Engineering, re-stress relieve diaphragm per
paragraph 8.3 of this specification.
8.3.4 Diaphragms can be stress relieved a maximum of three (3) times (with a maximum
cumulative holding time of 18 hours) without additional Engineering approvals.
Measure and record the base diameter at the horizontal and vertical center lines.
8.6 All welds shall be inspected per paragraph 10.0 and evaluated to the acceptance criteria in
paragraph 11.0.
9.1.1 Repair welding may be done by machine GMAW, machine SAW, manual GTAW or
manual SMAW at the discretion of Manufacturing.
Repair all unacceptable indications by grinding and rewelding using Tables I and II.
Postweld heat treat as required. Reinspect according to original criteria except that areas
welded with Inconel shall be penetrant examined using PS 84350KD instead of magnetic
particle examination.
9.2 Repair Welding of Damaged Blades Minor Repair, No Complete Blade Severing
9.2.1 Clean the damaged area of the blade by hand or power stainless steel wire brush to sound
bright metal.
9.2.2 Dye penetrant examine damaged areas for cracks in accordance with PS 84350KD, Part C.
9.2.3 Blade thicknesses to 1/16 inch do not require any joint or edge preparation for either blade
repair or crack repair. When the thickness exceeds 1/16 inch, chamfer the crack with a
rotary file to a depth that will provide a remaining root thickness of 1/32 inch to 1/16 inch
to obtain a full penetration weld. Chamfer minimum root diameter 1/8 inch and maximum
wall slope 30 ° when depth of chamfer exceeds 1/8 inch.
9.2.4 Clean the area to be welded with alcohol or cleaner M 53513CM. Wipe component dry.
9.2.5 For preheat requirements, see Table II Sections B and C. Cover repaired area immediately
after welding to slow down cooling rate.
9.2.6 Repair weld with GTAW process using filler metals shown in Table II Sections B and C,
maximum current 80 amperes, and an Argon shielding gas flow of 15-20 CFH. The exact
amperage will depend on the material thickness and undercut prevention.
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600466 WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
Rev. 22 03/25/99 Process Specification
9.2.7 Use a tight fitting copper backing plate when repairing cracks and depressions in thin
blade sections.
9.2.8 A bead temper technique as shown in Figure 6 is required for all Inconel repairs.
9.2.9 Grind and polish repair areas to original contour as determined by contour gage and
straight edge. No undercut is permitted.
9.2.10 Postweld heat treat as indicated in Table II and per paragraph 8.3.
9.2.11 If re-inspection after postweld heat treatment per above procedure reveals new or
unrepaired damage, Step 9.2.1 through 9.2.10 must be repeated.
QCI (Quality Control Instruction) documents are generated as needed and provide the plan necessary to
verify that the requirements of this specification have been met.
10.1 Quality Engineering shall be responsible to develop an audit plan that will ensure the final product
meets this Process Specification and drawing requirements.
10.2 Magnetic particle examination, where required, shall be in accordance with PS 84350KC, Part I,
with the exception of that to detect radial circumferential indications, AC magnetization shall be
used instead of DC. The AC yoke is the preferred AC magnetization method but, a coil may be
used if the coil method is demonstrated to show sufficient field strength as verified with the field
strength indicator.
10.3.1 Repairs made with Inconel weld wire shall be penetrant examined in accordance with
PS 84350KD, Part C.
10.3.2 Repairs made with 12% Cr stainless steel weld wire shall be magnetic particle examined
in accordance with PS 84350KC, Part I.
10.4 Visually inspect the saw cut cross-sectional area for defects per PS 84353MA. No unacceptable
indications are permitted. All unacceptable indications shall be removed, weld repaired and
blended as appropriate.
11.1.1 Porosity
Axial and circumferential - Axial indications are acceptable except for those indications
associated with a blade joint that extend completely across the transverse section of the
weld. An axial indication may be defined as any indication oriented greater than 10° from
the circumferential direction.
Magnetic particle examine per paragraph 10.2 (PS 84350KC, Part I).
11.2.1 Porosity
Aligned porosity is acceptable provided the sum of the diameters of the pores is
no more than 1/2 inch in a 6 inch length and provided that each pore is separated
from an adjacent pore by a minimum of 1/8 inch.
Axial and circumferential - Repair all linear axial indications. Circumferential indications
less than 1/2 inch long and not associated with a blade joint are acceptable. Each
acceptable indication shall be separated by a distance equal to twice the longer of the two
adjacent indications. Circumferential indications longer than 1/2 inch or any indication
associated with a blade joint shall be repaired.
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600466 WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
Rev. 22 03/25/99 Process Specification
TABLE I - POCKET AND REPAIR WELDING PARAMETERS
Filler Shielding
Voltage
Diameter Amperage Gas CFH
B. Repair of Damaged 12%Cr, Type 403 and 12%Cr-4%Ni1% Mo Blades, Type 41500, Paragraph 9.2
Minor repair on inner and outer shrouds only, no air foil repairs allowed.
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600466 WELDING - MACHINE GMAW AND SAW -
OF STATIONARY 12% CR STAINLESS STEEL BLADES
Rev. 22 03/25/99 Process Specification
FIGURE 6
Temper bead technique to be used for Inconel repair welds (per section 9.2.8)
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