1.

WELDING ELECTRODES FOR THERMAL POWER PLANTS

2. IN THIS PRESENTATION
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1.WELDING
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2.WELDING JOINTS
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3.WELDING MATERIAL SPECIFICATION
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4.CLASSIFICATION OF ELECTRODES
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5.ELECTRODE IDENTIFICATION , WELDING ELECTRODES CLASSIFICATION
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6.COMMON BOILER MATERIALS
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7.SELECTION OF SMAW ELECTRODES FOR BUTT WELDS IN POWER PLANTS
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8.BOILER MATERIALS FOR 500 MW
3. 1.WELDING
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The purpose of a weld is to join two metals by fusing them at their interfaces.
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A metallurgical bond is formed that provides smooth, uninterrupted microstructural transition across the weldment.
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The weldment should be free of significant porosity and nonmetallic inclusions, form smoothly flowing surface contours with the section being
joined, and be free of significant residual welding stresses.
4. 2.WELDING JOINTS
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ASME design code generally does not describe the strength of weld joints, such as a full penetration butt weld, separate to the strength of
base metal in the pressure component.
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This implies that the weld joint is expected to have equal or greater strength than the base metal.
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A large, utility-size boiler may contain more than 50,000 welds.
5. 3.WELDING MATERIAL SPECIFICATION
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Reliable welding and brazing materials are required to produce sound joints using one of the many welding and brazing processes available.
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The ASME B&PV Code provides the Welding Material Specifications acceptable for Code fabrication in Section II, Part C (Specification for
Welding Rods, Electrodes, and Filler Metals).
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These are the welding filler metal specifications of the AWS adopted for use by the ASME.
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In this respect, Section II, Part C is comparable to Sections II, Parts A and B that contain the ASTM Material Specifications adopted by the ASME.
6. 4.CLASSIFICATION OF ELECTRODES ASME-adopted ANSI/AWS Specification
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SFA-5.01, Filler Metal Procurement Guidelines
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SFA-5.02: Specification for Filler Metal Standard Sizes, Packaging, and Physical Attributes
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SFA-5.1, Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
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SFA-5.4, Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding
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SFA-5.5, Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
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SFA-5.11, Specification for Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding
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SFA-5.13, Specification for Solid Surfacing Welding Rods and Electrodes
7. 5.0.ELECTRODE IDENTIFICATION WELDING ELECTRODES CLASSIFICATION
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Arc welding electrodes are identified using the A.W.S , ( American Welding Society ) numbering system and are made in sizes from 1/16 to 5/16
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An example would be a welding rod identified as an 1/8 " E6011 electrode.
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The electrode is 1/8" in diameter
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The " E " stands for arc welding electrode.
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Next will be either a 4 or 5 digit number stamped on the electrode. The first two numbers of a 4 digit number and the first 3 digits of a 5 digit
number indicate the minimum tensile strength (in thousands of pounds per square inch) of the weld that the rod will produce, stress relieved.
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E60xx would have a tensile strength of 60,000 psi E110XX would be 110,000 psi
8. 5.1.WELDING ELECTRODES CLASSIFICATION (MIN TENSILE STRENGTH) 107000 psi 120000 psi E120XX 7 95000 psi 110000 psi E110XX 6 87000 psi 100000 psi
E100XX 5 77000 psi 90000 psi E90XX 4 67000 psi 80000 psi E80XX 3 57000 psi 70000 psi E70XX 2 50000 psi 62000 psi E60XX 1 MIN YIELD STRENGTH MIN TENSILE
STRENGTH CLASS S.N
9. 5.2.WELDING ELECTRODE CLASSIFICATION WELDING POSITIONS FLAT,HORIZONTAL,OVERHEAD,VERTICAL EXX3X 3 FLAT ,HORIZONTAL EXX2X 2
FLAT,HORIZONTAL,VERTICAL(UP),OVERHEAD EXX1X 1 DESCRIPTION WELDING POSITION S.N
10. 5.3.WELDING ELECTRODES CLASSIFICATION ELECTRODE COATING,PENETRATION,CURRENT TYPE AC,DCEP,DCEN MEDIUM IRON OXIDE,RUTILE,POTASSIUM
EXXX9 10 AC,DCEP MEDIUM LOW HYDROGEN,IRON POWER EXXX8 9 AC,DCEN MEDIUM IRON POWDER IRON OXIDE EXXX7 8 AC,DCEP MEDIUM LOW HYDROGEN
POTASSIUM EXXX6 7 DCEP MEDIUM LOW HYDROGEN SODIUM EXXX5 6 AC,DCEP,DCEN MEDIUM RUTILE IRON POWDER EXXX4 5 AC,DCEP,DCEN LIGHT RUTILE
,POTASSIUM EXXX3 4 AC,DCEN MEDIUM RUTILE ,SODIUM EXXX2 3 AC,DCEP DEEP CELLULOSE POTESSIUM EXXX1 2 DCEP DEEP CELLULOSE, SODIUM EXXX0 1
CURRENT TYPE PENETRATION ELECTRODE COATING CLASS S.N
11. 5.4.WELDING ELECTRODE CLASSIFICATIONS Suffix Additional Requirement
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-M Meets most military requirements
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Diffusible hydrogen limits for weld metal.
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-H4 ,H8,H16- Indicates the maximum diffusible hydrogen limit measured in millimeters per 100 grams (mL/100g). The 4, 8, and 16 indicates
what the limit is. Example: -H4 = 4mL per 100 grams
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1 - Increased toughness (impact strength ) for electrodes.
12. 5.5.WELDING ELECTRODES CLASSIFICATION ( Suffix Steel Alloy Type Suffix Number Description)
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-A1 Carbon-Molybdenum 0.40 - 0.65 Mo
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-B1 Chromium-Molybdenum 0.40 - 0.65 Cr 0.40 - 0.65 Mo
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-B2 Chromium-Molybdenum 1.00 - 1.50 Cr 0.40 - 0.65 Mo
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-B2L Chromium-Molybdenum Lower Carbon B2
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-B3 Chromium-Molybdenum 2.00 - 2.50 Cr 0.90 - 1.20 Mo
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-B3L Chromium-Molybdenum Lower Carbon B3
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-B4L Chromium-Molybdenum 1.75 - 2.25 Cr 0.40 - 0.65 Mo
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-B5 Chromium-Molybdenum 0.40 - 0.60 Cr 1.00 - 1.25 Mo
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-B6 was E502 4.6 - 6.0 Cr 0.45 - 0.65 Mo
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-B8 was E505 8.0 - 10.5 Cr 0.8 - 1.2 Mo
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-C1 Nickel Steel 2.00 - 2.75 Ni
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-C1L Nickel Steel Lower Carbon C1
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-C2 Nickel Steel 3.00 - 3.75 Ni
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-C2L Nickel Steel Lower Carbon C2
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-C3 Nickel Steel 0.80 - 1.10 Ni
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-NM Nickel-Molybdenum 0.80 - 1.10 Ni 0.40 - 0.65 Mo
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-D1 Manganese-Molybdenum 1.00 - 1.75 Mn 0.25 - 0.45 Mo
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-D2 Manganese-Molybdenum 1.65 - 2.00 Mn 0.25 - 0.45 Mo
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-D3 Manganese-Molybdenum 1.00 - 1.80 Mn 0.40 - 0.65 Mo
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-W Weathering Steel Ni, Cr, Mo, Cu
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-G No required chemistry
13. 5.6.What is the 8018 welding electrode meaning?
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The correct name of the electrode is E8018.
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E stands for electrode,
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the 80 stands for 80000 psi minimum as welded tensile strength,
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the 1 stands for all position,
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the 8 is the number associated with the ingredients of the flux, which in this case is low hydrogen and increased amounts of iron powder.
14. 5.7.What is a low-hydrogen electrode?
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The reason that the electrode must be kept dry is to reduce water in the coating which injects hydrogen into welds.
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In some welding applications especially thick metals, hydrogen collects under the weld in the heat affected zone.
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Enough of it will cause hydrogen induced cracking.
15. 6.COMMON BOILER MATERIALS

16. 7.SELECTION OF SMAW ELECTRODES FOR BUTT WELDS IN POWER PLANTS

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7.1.WELDING ELECTRODES FOR MATERIALS (P1)-Carbon steel
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7.2.WELDING ELECTRODES FOR MATERIALS (P3)-Low alloy steel
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7.3.WELDING ELECTRODES FOR MATERIALS (P4)- Low alloy steel
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7.4.WELDING ELECTRODES FOR MATERIALS (P5)-Low alloy steel
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7.5.WELDING ELECTRODES FOR MATERIALS
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7.6.WELDING ELECTRODES FOR MATERIALS (P8)-Stainless steel
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7.7.WELDING ELECTRODES FOR DESSIMILAR MATERIALS
17. 7.1.WELDING ELECTRODES FOR MATERIALS (P1)-Carbon steel
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BASE MATERIALS (P 1/Gr2)
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SA 106 Gr C
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SA 210 Gr C
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SA 210 GrA1
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SA 216 WCC
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SA 516 Gr 70
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SA 299
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WELDING ELECTRODES
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For base materials (P1/Gr2 to P1/Gr2)- E7018 - 1
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For base materials (P1/Gr2 to P1/Gr2) and dia of tube /pipe less than 127 mm - E7018 - A1
18. 7.2.WELDING ELECTRODES FOR MATERIALS (P3)-Low alloy steel
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BASE MATERIALS (P 3/Gr 1)
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SA 209 T1
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SA 209 T1a
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SA 209 T1b
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WELDING ELECTRODES for base materials (P3/Gr 1 to P3/Gr)- E7018 A1
19. 7.3.WELDING ELECTRODES FOR MATERIALS (P4)- Low alloy steel
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BASE MATERIALS (P 4/Gr1)
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SA 335 P11
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SA 335 P12
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SA 213 T11
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SA 213 T12
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SA 217 WC 6
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SA 182 F11 CLASS 3
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SA 182 F12 CLASS 2
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DIN B Gr Mo4
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WELDING ELECTRODES for base materials (P4/Gr1 to P4/Gr1)- E8018B2
20. 7.4.WELDING ELECTRODES FOR MATERIALS (P5)-Low alloy steel
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BASE MATERIALS (P 5/Gr 1)
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SA 335 P22 Pipe
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SA 213 T22
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SA 217 WC 9
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DIN 10 CrMo910
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A387 Gr 22 plate
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WELDING ELECTRODES for base materials (P5/Gr 1 to P5/Gr 1)- E9018B3
21. 7.5.WELDING ELECTRODES FOR MATERIALS (ALLOY STEEL)
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BASE MATERIALS (P 15)
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SA 335 P91
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SA 213 T91
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SA 182 F91
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SA 387 Gr 91
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WELDING ELECTRODES for base materials (P15 to P15)- E9018B9
22. 7.6.WELDING ELECTRODES FOR MATERIALS (P8)-Stainless steel
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BASE MATERIALS (P 8/Gr 1)
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SA 213 TP 304H
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SA 213 TP 347H
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SA 351 CF8
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SA 315 CF8M
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WELDING ELECTRODES for base materials (P8/Gr1 to P8/Gr1)- E 347
23. 7.7.WELDING ELECTRODES FOR DESSIMILAR MATERIALS SFA 5.4 E347-16 TP 304H to TP 347H 6 SFA 5.11 ENiCrFe 2 T22 to TP 304H 5 SFA 5.5 E8018 B2 T 11 to
T1 4 E 7018 A1 CS to T-1A 3 E9018 B2 CS to T22 2 E 8018-B2 CS to T1 1 ELECTRODE BASE MATERIALS SN
24. 7.8.WELDING ELECTRODES FOR NON PRESSURE PARTS OF BOILER SFA 5.5 E 8018 B2 CARTON STEEL TO CARTON STEEL 2 SFA 5.1E 6013 SFA 5.1E 7018 BUTT
WELD UPTO 6 mm OVER 6 mm CARBON STEEL TO CARBON STEEL 1 ELECTRODES DESCRIPTION BASE MATERIAL S.N
25. 8.BOILER MATERIALS FOR 500 MW SA210GrA1,SA210GrC ECONOMIZER 6 SA213T22,SA213T91, SA213TP347H REHEATER 5 SA213T11,SA213T22,
SA213T91,SA213TP347H SUPER HEATER 4 SA213T11 LTSH 3 SA210GrC WATER WALL 2 SA210GrC BURNER PANELS 1 MATERIAL SPECIFICATION DESCRITION S.N
26. THANKING