RPSCL

ROSA POWER SUPPLY COMPANY LIMITED LUCKNOW, 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

2300 MW Rosa Thermal Power Project

DOCUMENT CONTROL SHEET

PROJECT

: 2300 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

Rev No

Date

DescriptionInitials Sgn. Prepared by

Initials

Sgn.

Initials

Sgn.

Initials Sgn. Issue Authorization

Reviewed by

Approved by

CONTENTS
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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

1.Work preparation:................................................................................................................2 1.1 Drawings and equipment instruction:...............................................................................2 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.........................................................................................4 2.1 Construction art flow............................................................................................................4 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, ID273.05*30, ID368.3*47.04, HP bypass steam pipe241.3*27, material is SA335-P91.
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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

1.2 main T & P and inspection instruments:

1.2.1 Main T & P and inspection instruments SN. Description Model Num. Remarks

1 2 3 4 5 6

Heating treatment temperature control carbine Crawler heater Line type heater Infrared thermometer Leebs hardness tester Thermocouple

DLWK-12-360

2 PCS 60 SETS

Acceptance Acceptance Acceptance Acceptance Acceptance Acceptance

30m TI120EL HT-2000A K type

10 pieces 1 block 1 block 6 pieces

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.

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The heating treatment manual of P91 after welding

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2. working procedure and methods 2.1 Construction art flow

Operator shall have the certification Receive the commission from construction team
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The heating treatment manual of P91 after welding

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Check whether there has the work condition Bind up the heater

Pre-heating

Heating treatment after welding

Hardness checking

Report

Data hand over welding

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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

Heating treatment construction methods

SN. Description Note Content and methods Checking index 1 Operator shall have the certification Receive the commission from construction team Check whether the conditions have been prepared Bind up the heater Heating operator shall have the certification as per the IBR requirements. The written commission shall be given to heating technician, and shall be signature by heating technician. 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 welding joint on the commission list shall be bound up, the cover area shall be met the heating requirements during using crawler heater and
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Requirements Quality standard IBR Checking instruments and methods

Results Checking results Acceptance

Witness

Legible Handwriting

The scoffed shall be fastened

The relative specialty T &P

23R

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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

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 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
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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

Pre-heating

up. For example: for Yconnection, 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) The temperature increasing speed = 25025 wall thickness /h , and also, the temperature shall not be exceeded 300/h. Before welding, the pre-heating temperature is 100 150 before back welding, and the temperature between wall shall less than 300, the preheating 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
28/X-TEPC-HJZ011-2008

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

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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

down to 200300. During heating, the K type armoured thermo-couple as the temperature control element to monitor the temperature. While temperature reach to the preheating 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
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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

the heating insulation device.

Heating 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 100200of 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 center of welding seam, and the arrangement method is the same as pre-heating.
28/X-TEPC-HJZ011-2008

R The heating treatment code for fire power plant DL/T 8192002

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The heating treatment manual of P91 after welding

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Hardness checking

Report

For the heating treatmen tcurve, please refer to appendix 3. 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. After the hardness accepted, the report shall be issued. Tidy up the heating treatment curve and hardness report etc.

Data handover

R: Record the point (PETRON done) W: witness (PETRON and REL) H: Stop working to inspect (PETRON, REL and SEC)
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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

3. Appendix

Appendix 1

The binding up method for straight pipe

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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

3-5

The width is 3-5 times of wall thickness

Rope type heater Crawler type heater Heater center line Seam center line

Appendix 2: The binding up method for T type pipe

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The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

3-5

The width is 3-5 times of wall thickness

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

T/

70 0 6 1 4 h 1 0 / h 5 30 5 1 h =0 m 2m 1 0 /h 5 1 h 10 2 0 -1 0 1 0 / h 5 20 0 0 -3 0 30 0

1 0 / h 5 10 5 0 -1 0 20 0 0 -3 0

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R T

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t(h ) P9 PH PWT g h 1 & H rap

The heating treatment manual of P91 after welding

2300 MW Rosa Thermal Power Project

T/

760 10 4h 150/ h 350 1h = m 20m 150/ h 1h 100- 120 R T 150/ h 200- 300 300

150/ h 100- 150 200- 300

t ( h) P91 PH PWT graph & H

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