Open Access Open Access  Restricted Access Subscription Access
Open Access Open Access Open Access  Restricted Access Restricted Access Subscription Access

Development of Welding Procedures for Critical Applications in Nuclear and Fossil Power Plants


Affiliations
1 Scientific Officer-F Metallurgy and Materials Group, Indira Gandhi Centre for Atomic Research, Kalpakkam 603102, Tamilnadu,, India
     

   Subscribe/Renew Journal


I am involved in the several projects for development of materials, welding procedures and welding consumables for nuclear and Advanced Ultra Super Critical (AUSC) coal-fired power plants. As it is difficult to cover the entire work, I am presenting here some of the important and unique welding activities in this prestigious Prof. Placid Rodriguez Memorial lecture.

As a national mission program, research organizations and industries are working together for the development of new materials, fabrication technology, designing and construction of Indian Advanced Ultra Super Critical (AUSC) thermal power plant of 800 MWe capacity with steam parameters 710oC/720oC/310 bar. Indigenously developed Alloy 617M (a chemistry control variant of Alloy 617) and 304HCu SS are materials of choice for AUSC boiler tubes. Welding procedure has been developed and qualified for similar and dissimilar metal welding of Alloy 617M and 304HCu SS boiler tubes. Repair welding procedure for service exposed Alloy 617M has also been established. The dissimilar metal welding between 10Cr ferritic martensitic steel and nickel-base Alloy 617M rotor forgings for AUSC high pressure (HP) and intermediate pressure (IP) steam turbines is unique and first of its kind. For this, welding procedure, weld groove design and post weld heat treatment has been optimized using hot-wire narrow-gap TIG welding process, and mock-up weld joints are qualified as per ASME Section IX requirements. Root pass argon gas purging methodology in the localized cavity of solid welded rotor has also been established and qualified. Both NG-TIG welding procedure and root pass argon gas purging methodology has been successfully implemented in the fabrication of full-size welded rotor for AUSC project.

Similar and dissimilar welding of commercially pure titanium and 304L SS are required for the reprocessing of Fast Breeder Reactor nuclear spent fuel. The dissimilar metal joint between titanium and 304L stainless steel (SS) was carried out by explosive cladding process. The explosive cladded plates were qualified by ultrasonic examination, shear test, bend test and three phase (liquid, vapour, and condensate phase) corrosion test in 11.5M boiling nitric acid. The activated flux has been formulated in-house for autogenous TIG welding of titanium. The activated flux TIG weld joint fabricated using 6 mm thick titanium plate passed as per ASME section IX requirements and 11.5M boiling nitric acid test. This paper highlights some of the critical welding procedures developed for AUSC and nuclear power plants.


Keywords

10Cr Steel, Alloy 617M, Titanium, 304L SS, 304HCu SS, Welding, ATIG, Narrow-Gap TIG, Welded Rotor.
User
Subscription Login to verify subscription
Notifications
Font Size

  • R.Viswanathan, R. Purgert, S.Goodstine, J.Tanzosh, G.Stanko, J. P. Shingledecker, B.Vitalis,U.S. Program on materials technology for Ultra super-critical Coal-fired Boilers, Advances in Materials Technology for Fossil Power Plants, Proceedings of the 5th International Conference, ASM International (2008)
  • T. Jayakumar, A.K. Bhaduri and S.C. Chetal, Development of improved high temperature boiler materials for the Indian advanced ultra super-critical thermal power plant technology, Proceedings of the 10th Liege Conference on Materials for Advanced Power Engineering, Belgium, eds. J.Lecomte-Beckers, O.Dedry, J. Oakey and B. Kuhn (2014) 51-60.
  • C. Berger, R. B. scarlin, K.H. Mayer, D.V. Thornton, S.M. Beech; Steam Turbine materials: High Temperature Forgings, D. Coutsouradis et al. (eds.), Materials for Advanced power engineering, Part I, pp 47-72.
  • H.C. Dey, S.K. Albert, A.K. Bhaduri and T. Jayakumar; Post Weld Heat Treatment (PWHT) of 10% Cr Steel /Alloy 617 Dissimilar Metal Welded Rotor for AUSC Project, IGCAR Internal Report, January 2014.
  • Andreas Pirscher; Alstom Steam Turbine Designs for AD700 Power Plant, Source: www.alstom.com.
  • Barbara K. Henon (2010); Hot wire narrow groove welding and cladding with nickel-based alloys, Focus on Nuclear Power Generation, pp. 20-23.
  • Jean-Pierre BARTHOUX; Narrow Gap Welding of Heavy Wall Thickness Materials in Nuclear and Fossil Fuel Industries,source: www.polysoude.com
  • H. C. Dey, V. Shankar, A. K. Bhaduri: Titanium/304L Stainless Steel Dissimilar metal Joint for FRFRP, IGC Report No: IGC/MTD/MJS/2004/02 May 2004.
  • U. Kamachi Mudali, BM Anand Rao, K Shanmugam, R Natarajan and Baldev Raj: Journal of Nuclear Materials 321 (2003) 40-48.
  • B. M. Ananda Rao, K Shanmugam, UK Muduli, AK Bhaduri, K Balachander, R Natarajan: Proc. International Welding Conference, Ind Inst of Welding, New Delhi (1999) 959-964.
  • H. C. Dey, S. K. Albert, A. K. Bhaduri, U. Kamachi Mudali, “Activated Flux TIG Welding of Titanium”, Welding in the World (2013), DOI 10.1007/s40194-013-0084-9.

Abstract Views: 37

PDF Views: 2




  • Development of Welding Procedures for Critical Applications in Nuclear and Fossil Power Plants

Abstract Views: 37  |  PDF Views: 2

Authors

Harish Chandra Dey
Scientific Officer-F Metallurgy and Materials Group, Indira Gandhi Centre for Atomic Research, Kalpakkam 603102, Tamilnadu,, India

Abstract


I am involved in the several projects for development of materials, welding procedures and welding consumables for nuclear and Advanced Ultra Super Critical (AUSC) coal-fired power plants. As it is difficult to cover the entire work, I am presenting here some of the important and unique welding activities in this prestigious Prof. Placid Rodriguez Memorial lecture.

As a national mission program, research organizations and industries are working together for the development of new materials, fabrication technology, designing and construction of Indian Advanced Ultra Super Critical (AUSC) thermal power plant of 800 MWe capacity with steam parameters 710oC/720oC/310 bar. Indigenously developed Alloy 617M (a chemistry control variant of Alloy 617) and 304HCu SS are materials of choice for AUSC boiler tubes. Welding procedure has been developed and qualified for similar and dissimilar metal welding of Alloy 617M and 304HCu SS boiler tubes. Repair welding procedure for service exposed Alloy 617M has also been established. The dissimilar metal welding between 10Cr ferritic martensitic steel and nickel-base Alloy 617M rotor forgings for AUSC high pressure (HP) and intermediate pressure (IP) steam turbines is unique and first of its kind. For this, welding procedure, weld groove design and post weld heat treatment has been optimized using hot-wire narrow-gap TIG welding process, and mock-up weld joints are qualified as per ASME Section IX requirements. Root pass argon gas purging methodology in the localized cavity of solid welded rotor has also been established and qualified. Both NG-TIG welding procedure and root pass argon gas purging methodology has been successfully implemented in the fabrication of full-size welded rotor for AUSC project.

Similar and dissimilar welding of commercially pure titanium and 304L SS are required for the reprocessing of Fast Breeder Reactor nuclear spent fuel. The dissimilar metal joint between titanium and 304L stainless steel (SS) was carried out by explosive cladding process. The explosive cladded plates were qualified by ultrasonic examination, shear test, bend test and three phase (liquid, vapour, and condensate phase) corrosion test in 11.5M boiling nitric acid. The activated flux has been formulated in-house for autogenous TIG welding of titanium. The activated flux TIG weld joint fabricated using 6 mm thick titanium plate passed as per ASME section IX requirements and 11.5M boiling nitric acid test. This paper highlights some of the critical welding procedures developed for AUSC and nuclear power plants.


Keywords


10Cr Steel, Alloy 617M, Titanium, 304L SS, 304HCu SS, Welding, ATIG, Narrow-Gap TIG, Welded Rotor.

References





DOI: https://doi.org/10.22486/iwj.v54i3.209783