11the heating treatment manual of p91 after welding

RPSCL ROSA POWER SUPPLY COMPANY LIMITEDLUCKNOW, UTTAR PRADESH

2 x 300 MW - Stage - I

Rosa Thermal Power Project

Rosa, Shahjahanpur (U.P.)

DOCUMENT TITLE：

The heating treatment manual of P91 after welding

DOCUMENT NO: 28/X-TEPC-HJZ011-2008

UEEPL

Utility Energytech and Engineers Pvt. Ltd.

Ground Floor, H-146/147

Sector-63

Noida – 201 307

Uttar Pradesh

DEVELOPMENT CONSULTANTS PRIVATE

LIMITED CONSULTING ENGINEERS

24B, PARK STREET, KOLKATA - 700 016, INDIA

TPSC (INDIA) PRIVATE LIMITED

A-1 Module, D-Quadrant, 2nd Floor

Cyber Towers, Hi-Tec City, Hyderabad-81

Shanghai Electric Group Co. Ltd.

No. 8 , Xingyi Road.

Shanghai

China - 200336

Tianjin Electric Power Construction Company

The 26th floor, Harbor Centre ,No. 240

Zhangzizhong Road, Heping district, Tianjin

P.R.China p.c:300041

The heating treatment

manual of P91 after

welding

2×300 MW Rosa

Thermal Power Project

DOCUMENT CONTROL SHEET

PROJECT : 2×300 MW ROSA THERMAL POWER PROJECT

CLIENT : ROSA POWER SUPPLY COMPANY LIMITED

DOCUMENT TITLE :THE HEATING TREAMENT MANUAL OF P91 AFTER

WELDING

DOCUMENT NO. : 28/X-TEPC-HJZ011-2008

REV. NO. :

ENDORSEMENTS :

0

Rev

NoDate Description

Initials Sgn. Initials Sgn. Initials Sgn. Initials Sgn.

Prepared by Reviewed by Approved byIssue

Authorization

DOCUMENT NO. : 28/X-TEPC-HJZ011-2008 Page 1 of 14


manual of P91 after

welding

2×300 MW Rosa


CONTENTS

1.Work preparation:................................................................................................................3

1.1 Drawings and equipment instruction:...............................................................................3

1.2 main T & P and inspection instruments:...........................................................................3

1.3 the construction conditions...............................................................................................3

1.4 safety proceeding..............................................................................................................3

2. working procedure and methods.........................................................................................5

2.1 Construction art flow........................................................................................................5

3. Appendix...........................................................................................................................12

1.Work preparation:

1.1 Drawings and equipment instruction:

1.1.1 Drawing instruction

Drawing for main steam pipe

1.1.2 Equipment instruction and work quantity: main steam pipe ID368.3*41.275,



manual of P91 after

welding

2×300 MW Rosa


ID273.05*30, ID368.3*47.04, HP bypass steam pipeφ241.3*27, material is SA335-P91.

1.2 main T & P and inspection instruments:

1.2.1 Main T & P and inspection instruments

SN. Description Model Num. Remarks

1

Heating treatment

temperature control

carbine

DLWK-12-360 2 PCS Acceptance

2 Crawler heater 60 SETS Acceptance

3 Line type heater 30m 10 pieces Acceptance

4 Infrared thermometer TI120EL 1 block Acceptance

5Leeb’s hardness

testerHT-2000A 1 block Acceptance

6 Thermocouple K type 6 pieces Acceptance

1.3 the construction conditions

1.3.1 the power shall be arranged and ensured that during heating treatment, the

power could not be cut off.

1.3.2 The operator shall have the certification.

1.4 safety proceeding

1.4.1 On the heating treatment area, the protection and alarm board shall be hanged.

1.4.2 There shall have two men on duty during electrical heating. Before remove the

heating device, ensure the power has been cut off. After the heating treatment, check

the site, leaving without the fire hidden danger.

1.4.3 Helmet and safety belt shall be worn correctly during working.

1.4.4 The scaffolds shall be fastened with adequate light.



manual of P91 after

welding

2×300 MW Rosa


2. working procedure and methods

2.1 Construction art flow


Operator shall have the certification

Receive the commission from construction team


manual of P91 after

welding

2×300 MW Rosa



Check whether there has the work condition

Bind up the heater

Pre-heating

Heating treatment after welding

Hardness checking

Report

Data hand overwelding

The heating treatment manual of P91

after welding

2×300 MW Rosa Thermal Power

Project

Heating treatment construction methods

SN. Description Note Content and methods

Requirements Results

Witness Checking index

Quality standard

Checking instruments

and methods

Checking results

1

Operator shall have the certification

Heating operator shall have the certification as per the IBR requirements.

IBR Acceptance R

2

Receive the commission from construction team

The written commission shall be given to heating technician, and shall be signature by heating technician.

Legible Handwriting

R

3

Check whether the conditions have been prepared

The heating technician shall confirm the working conditions after receiving the commission, the technician shall contract the construction team immediately if the working conditions could not be met the requirements.

The scoffed shall be fastened

W

4Bind up the heater

The welding joint on the commission list shall be bound up, the cover area shall

The relative specialty T & P

23R



after welding


Project

be met the heating requirements during using crawler heater and line type heater. In any heating condition, the heater could not be cross and overlapped. And the material could not touch heating wire. The heater shall be close to the pipe without kink and uneven, the insulation material on heater shall be intact. From the center of welding joints, the heating width shall be not less than 3 times of the thickness of pipe wall and shall the minimum heating width is 60mm. if the outer diameter is more than 219mm or the thickness of pipe wall more than or equal to 20mm, the heating width shall be 3 times more than the thickness of pipe wall and meanwhile, the



after welding


Project

minimum heating width is 100mm.According to the temperature difference and conduction, it can be divided into two parts, from top to under part, from thin part to thick part with tightness and fastness bound up. For example: for Y-connection, on the straight pipe, the insulation was thin and short, on the leveling pipe, from top to under part, the thickness of the wall was increased. (Thin and thick is comparative)

5 Pre-heating

The temperature increasing speed = 250×25 ÷ wall

thickness （ ℃ /h ） , and

also, the temperature shall not be exceeded 300 /h. Before℃ welding, the pre-heating

“The heating treatment code for fire power plant”

DL/T 819-

R



after welding


Project

temperature is 100 － 150℃

before back welding, and the temperature between wall shall less than 300 , the pre-℃

heating temperature is 200－

300 while SMAW, and the℃ temperature between wall shall l less than 300 , and℃ the heating technician shall monitor in time, if the temperature between wall is more than 300 , and welder℃ shall stop welding till the

temperature down to 200 －

300 .℃During heating, the K type armoured thermo-couple as the temperature control element to monitor the temperature. While temperature reach to the pre-

2002



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heating temperature, the infrared thermometer shall be applied to measure the temperature of groove root, if it reaches to the pre-heating temperature, welding started, if not, the thermo insulation shall be adopted till the temperature reaches to the pre-heating temperature. 2pc thermo-couples and vertical pipe type (2G) thermo-couples were arranged at two side of groove. And leveling pipe type (5G) thermo-couple was arranged as per the photo 1. And between thermo-coupler and heater, there shall have the heating insulation device.



after welding


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6Heating treatment

Before heating treatment, check the appearance quality of welding joints, and then the welding joints shall be subjected to the heating treatment after acceptance.

After welding, while the temperature become 100-200 of welding seam, the℃ stabilize the temperature for 1 hour, and then improve the

temperature to 750 － 770℃

as the speed of 140 /h, and℃ then stabilize the temperature for 4 hours, and then low down the temperature to 300 as the speed of℃ 140 /h, after this, the℃ welding seam become cold on the nature condition without control.During heating treatment, the thermo-couple is moved to the

“The heating treatment code for fire power plant”DL/T 819-2002

R



after welding


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center of welding seam, and the arrangement method is the same as pre-heating.For the heating treatmen tcurve, please refer to appendix 3.

7Hardness checking

The welding seam shall be subjected to the 100% hardness test during heating treatment, after the treatment, the hardness of welding seam shall be not more than HB hardness of original material +100, and less than HB350. If the test result was not confirmed to the requirement, the heating treatment shall be redone.

R

8 ReportAfter the hardness accepted, the report shall be issued.

R



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9Data handover

Tidy up the heating treatment curve and hardness report etc.

R

R: Record the point (PETRON done)

W: witness (PETRON and REL)

H: Stop working to inspect (PETRON, REL and SEC)

3. Appendix

Appendix 1： The binding up method for straight pipe



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3-5 倍壁厚宽度： The width is 3-5 times of wall thickness

绳状加热器： Rope type heater

履带式加热器： Crawler type heater



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加热器中心线： Heater center line

焊缝中心线： Seam center line

Appendix 2: The binding up method for “T” type pipe

3-5 倍壁厚宽度： The width is 3-5 times of wall thickness



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NOTE: A) For A, the heating area shall be 3-5 times than welding seam thickness, and the insulation material shall be covered the

whole area.

B) For B, the heater 3 shall be used crawler heat, and for the other, any heater can be applied, and the insulation materials

shall be covered on the whole welding seam and other place affected by the heater.

Appendix 3: heating treatment curve



after welding


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11the heating treatment manual of p91 after welding

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