MANUFACTURING STANDARD FOR Handling and Manufacturing of Grade 91 Material

THIS DOCUMENT IS THE PROPERTY OF ALSTOM Power Inc. WINDSOR, CT 06095-0500 USA Tl HS DOCUMENT CONTAINS PROPRIETARY INFORMATION AND MAY NOT BE REPRODUCED OR DISCLOSED WITHOUT THE PERMISSION OF ALSTOM Power Inc. THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL PAGES ARE THE SAME REVISION LEVEL AS INDICATED IN THE TITLE BLOCK

ALSTOM
Handling and Manufacturing of Grade 91 Material
INITIALS BY: RRP CHK'D EMO DATE
11/16/06 11/16/06

DOCUMENT #

REV

MS-H RSG-0002

23

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Table of Contents

Paragraph

Page 1.0 PURPOSE .................................................................................................................................................................... 3 2.0 REFERENCES .............................................................................................................................................................. 3 2.1 ASME Boiler and Pressure Vessel Code: ............................................................................................................ 3 2.2 ASME Code for Pressure Piping, B31.1, Power Piping ........................................................................................... 3 2.3 ALSTOM Power Manufacturing Standard MS-HRSG-0006 ...................................................................................... 3 2.4 ALSTOM Power Purchase Order .............................................................................................................................. 3 3.0 TRAINING .................................................................................................................................................................... 3 4.0 WELDING .................................................................................................................................................................... 3 4.1 WELDING PROCESSES .......................................................................................................................................... 3 4.2 PROCEDURE QUALIFICATION RECORDS (PQR) ................................................................................................. 3 4.3 WELDER PERFORMANCE QUALIFICATION ......................................................................................................... 3 4.4 WELDING MATERIALS ............................................................................................................................................ 3 4.5 WELDING PREPARATIONS .................................................................................................................................... 4 4.6 PREVENTION OF HYDROGEN INDUCED CRACKING ......................................................................................... 4 4.7 POST-WELD HEAT TREATMENT ........................................................................................................................... 5 4.8 ALIGNMENT, ADJUSTMENT, OR STRAIGHTENING ........................................................................................... 6 4.9 WELD INSPECTION ................................................................................................................................................. 6 5.0 BENDING ..................................................................................................................................................................... 6 5.1 GENERAL REQUIREMENTS ................................................................................................................................. 6 6.0 HEAT TREATMENT OF GRADE 91 BENDS ............................................................................................................... 7 7.0 IDENTIFYING GRADE 91 MATERIAL ......................................................................................................................... 7 8.0 POST WELD HEAT TREAT DIAGRAMS ..................................................................................................................... 8 9.0 REVISION LOG.... .................................................................................................................................................. 8

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1,0 PURPOSE

The purpose of this specification is to provide additional information and requirements for the fabrication of boiler components from 9 chrome 1 molybdenum vanadium (Grade 91) material beyond what is specified in other documents such as the ASME Boiler and Pressure Vessel Code. The processes included are welding, bending, heat treating and testing. This document shall be used in conjunction with Manufacturing Standard MS-HRSG0006. Any variations between this standard and the Customer Specification shall be addressed in the ALSTOM Power Purchase Order.
2.0 REFERENCES

2.1 2.2

ASME Boiler and Pressure Vessel Code: Section I, Power Boilers Section II, Material Specifications, Parts A, C, and Section V, Nondestructive Examination Section VIII, Pressure Vessels, Division Section IX, Welding and Brazing Qualifications ASME Code for Pressure Piping, B31.1, Power Piping

2.3 ALSTOM Power Manufacturing Standard MS-HRSG-0006 2.4 ALSTOM Power Purchase Order
3.0 TRAINING

3.1

No welding of Grade 91 Material shall take place until the Fabricator has been trained and indoctrinated to this standard. Training shall be conducted by ALSTOM and provided to the Fabricators Management, Supervisors, Welding Engineers, Welding Inspectors, and Quality Personnel. The Fabricator shall train their welders to this standard prior to the start of welding. Fabricator welder training shall be documented on an attendance sheet, which shall include, the date of training, the welder's signature and symbol. The Fabricator shall include the following hold points on their Inspection and Test Plan (1TP): 3.2.1 3.2.2 ALSTOM Grade 91 Training of the Fabricator prior to the start of pressure part welding. ALSTOM First Article inspection (FAI) at the start of Grade 91 pressure part welding.

3.2

4.0 WELDING

4.1 WELDING PROCESSES 4.1.1 The acceptable welding processes for welding Grade 91 materials are Shielded Metal Arc, Submerged Arc, and Gas Tungsten Arc. No other welding processes can be used without specific approval from ALSTOM Power, Inc. The Supplier shall furnish a copy of each Welding Procedure Specification (WPS), with supporting Procedure Qualification Records (PQR's), for each procedure used in fabrication to ALSTOM Power Inc. No welding shall be performed prior to review and ALSTOM Power's acceptance of the Welding Procedure Specifications. AU Procedure Qualification Records shall be in accordance with ASME Code Section IX, and meet any other requirements imposed by ASME Code Sections 1, VIII, ASME B31.1, etc. These particular construction codes apply to specific types of fabrication and ALSTOM Power Inc. may impose additional welding requirements or exemptions to Section IX qualifications. ALSTOM Power Inc. reserves the right to evaluate and reject any welding procedure specification, welder performance qualifications, and welding procedure qualification records.

4.1.2

4.2 PROCEDURE QUALIFICATION RECORDS (PQR) 4.2.1

4.3 WELDER PERFORMANCE QUALIFICATION 4.3.1 All welders and welding operators shall be qualified to ASME Code, Section IX requirements. 4.3.2 It shall be the Supplier's responsibility to assure that all welders and welding operators have successfully completed the required tests and have welded with a process within 6 months prior to being assigned to production welding. Welder continuity records shall be the Supplier's responsibility. MS-HRSG-0002 Rev 23.doc Page 3 of 9

4.4 WELDING MATERIALS 4.4.1 The filler metals for welding of Grade 91 material to Grade 91 material shall be E9015-69, E901669, and E9018-69 for the Shielded Metal Arc Welding process; ER90S-B9 for the Gas Tungsten Arc Welding process; and EB9 for the Submerged Arc Welding process. Grade 91 filler materials shall be purchased with the combined nickel and manganese content not exceeding 1.5% and the ratio of nitrogen to aluminum shall be at last 4. The use of the "G" grade electrodes or bare wires is prohibited. Other welding materials are also prohibited unless approved by ALSTOM Power, Enc. prior to use. See MS-HRSG-0006 for filler metal requirements for welding Grade 91 to other grades of material. 4.4.2 The Supplier's quality system shall have a procedure in place for the procurement, receiving, handling and storage of welding materials. The procedure shall limit access to welding materials to authorized personnel only. 4.4.3 Welding material certification shall consist of actual chemistry certification documents for all Grade 91 consumables, bare wire, and coated electrodes. 4.4.4 The Supplier's quality control procedure for material certification and welding material control shall be submitted to ALSTOM Power, Inc. for approval prior to the start of any welding. 4.5 WELDING_PREPARATIONS. 4.5.1 All surfaces to be welded shall be free of any contaminants (paint, loose rust, oil, grease, dirt and debris). Grit blasting, if employed, shall be performed using non-silica media. 4.5.2 The controls and parameter display devices on welding machines shall be calibrated annually. The Supplier's quality system shall have provisions for incorporating data regarding this requirement into their records. 4.5.3 Grounding cables from welding machines shall be attached directly to the parts being welded. 4.5.4 Butt joints in tube or piping fabricated of Grade 91 material shall have the root pass welded using the gas tungsten arc welding process and the interior of the component shall be purged with 100% argon gas. The inert gas environment shall be maintained until the first two layers of weld metal have been deposited. The procedure for the root side purging shall be described in detail and submitted with the welding procedures to ALSTOM Power, Inc. for approval. 4.5.5 Preheating shall be applied using_Electric Resistance Elements, except as noted in 4.5.8. The preheat temperature shall be a minimum of 400F (205C) for pipe and headers. A preheat of 300F (150C) is acceptable for tube-to-header welds or tube-to-tube welds using the GTAW process only. Results of preheat must be documented. 4.5.6 Preheat shall be maintained throughout the entire welding cycle, including tack welds. If preheat is interrupted and the weidment is allowed to cool below the preheat temperature, an extended preheat / hydrogen bake shall be performed immediately as described in 4.6.2. 4.5.7 The interpass temperature shall not exceed 750F (400C). 4.5.8 The preheat temperature shall be measured and monitored within three inches of the weld groove, and the interpass temperatures shall be measured and monitored at the last deposited weld layer of the weld joint. The temperatures shall be measured by the use of temperature indication crayons, optical pyrometers, thermocouples with calibrated chart recorders, potentiometers or an equivalent method that does not harm the base metal or deposited weld metal. The use of manually operated heating torches (flame heating) is prohibited without approval of ALSTOM Power, Inc., except for the automatic SAW welding process. and for preheating assist on the tubes when welding tube-to-header welds. Cutting torches are not to be used for preheating. 4.6 PREVENTION OF HYDROGEN INDUCED CRACKING 4.6.1 After all welding is completed or if preheat is interrupted before welding is completed, an extended preheat/hydrogen bake shall be performed as outlined in 4.6.2. using Electric Resistance Elements. However, this extended preheat/hydrogen bake can be eliminated under the conditions specified in 4.6.3. Also refer to Charts 1 and 2 located in section 8 of this procedure. 4.6.2 Extended Preheat/ Hydrogen Bake 4.6.2.1 Components up to and including 1" (25 mm) thick 4.6.2.1.1 Prior to performing the extended preheat / hydrogen bake, the weldment shall be cooled in still air, (outside the furnace), to below 325F (165C), but not below 200F (95C) MS-HRSG-0002 Rev 23.doc Page 4 of 9

4.6.2.1.2 The temperature shall be raised to 600-750F (315-400C) and held for one hour minimum before being allowed to cool in still air (outside furnace) to at least 325F (165C). 4.6.2,1.3 After Extended Preheat/Hydrogen Bake has been completed, the temperature of the component may be dropped below 200F (95C) 4.6.2.2 Components over 1" (25 mm) thick 4.6.2.2.1 Prior to performing the extended preheat / hydrogen bake, the weldment shall be cooled in still air, (outside the furnace), to below 275F (135C), but in not below 200F (95C). 4.62.2.2 The temperature shall be raised to 600-750F (315-400C) and held for three hours minimum before being allowed to cool in still air (outside furnace) to at least 275F (135C). 4.6.2.2.3 After Extended Preheat/Hydrogen Bake has been completed, the temperature of the component may be dropped below 200F (95C) 4.6.2.3 The extended preheat shall be monitored by thermocouples with calibrated chart recorders, optical pyrometers or temperature indicating crayons. Results of extended preheat must be recorded. . 4.6.2.4 Following any extended preheat, components shall be kept in a moisture-free area until post-weld heat treatment has been performed. CAUTION: If Liquid Penetrant Testing is to be performed prior to post-weld heat treatment, the solvent type method is preferred over the water-soluble method. It is important that all residue be removed from the component after the testing is completed. 4.6.3 4.6.3.1 Extended Preheat/Hydrogen Bake may be eliminated only under the following conditions: Components up to and including 1" (25 mm) thick

4.6.3.1.1 After welding is completed the component must be allowed to cool in still air, (outside the furnace), to below 325F (165C), but not below 200F (95C). 4.6.3.2 Components over1" (25 mm) thick 4.6.3.2.1 After welding is completed the component must be allowed to cool in still air, (outside the furnace), to below 275F (135C), but not below 200F (95C). 4.6.3.3 4.7.1 The component must then be post weld heat heated as outlined in 4.7. Components up to and including 1" (25 mm) thick 4.7 POST-WELD HEAT TREATMENT 4.7.1.1 Prior to Post-weld heat treatment, all welds shall be allowed to cool in still air, (outside furnace), to below 325F (165C), but not below 200F (95C), unless an Extended Preheat/Hydrogen Bake has been performed per 4.6.2 above. Also refer to Charts 1 and 2 located in section 8 of this procedure. 4.72 Components over 1" (25 mm) thick 4.7.2.1 Prior to Post-weld heat treatment, all welds shall be allowed to cool in still air, (outside furnace), to below 275F (135C), but not below 200F (95C), unless an Extended Preheat/Hydrogen Bake as been performed per 4.6.2 above. Also refer to Charts 1 and 2 located in section 8 of this procedure. 4.7.3 Post-weld heat treatment of Grade 91 material shall be either by furnace or localized heating. If localized Post-weld heat treatment is utilized, the resistance pads shall be wrapped completely around the entire circumference of the component. 4.7.4 Post-weld heat treatment shall consist of heating to the temperature of 1350-1450F (730790C) for one hour per inch of thickness, 30 minutes minimum, and then allowed to cool in still air (outside furnace). For components greater than 3" (76mm) thickness, forced air cooling or oil quenching from the normalizing temperature to below 1000F (540C) shall be performed. Heating and cooling shall be recorded with appropriate equipment. 4.7.5 if the purchase order requires hardness readings to be taken of the weld metal after Post Weld Heat Treatment, the hardness readings shall be made as described in ALSTOM Power specification MS-HRSG-0008. 4.7.6 See MS-HRSG-0006 for post-weld heat treatment requirements for Grade 91 welded to other grades of material. MS-HRSG-0002 Rev 23.doc Page 5 of 9

4.7.7 After initial Post-weld heat treatment of one hour per inch of thickness for the Grade 91 material, additional welding may be required. Subsequent additional welding, such as seal welds and socket welds or other attachment welds of .375" (10 mm) or less shall be heat-treated to the temperature of 1350-1420F (730-770C) for a minimum of 30 minutes. if localized Post-weld heat treatment is utilized, the resistance pads shall be wrapped completely around the entire circumference of the component. 4.7.8 Exothermic or direct flame heating for post-weld heat treatment shall not be permitted. 4.7.9 A detailed post-weld heat treatment procedure shall be submitted to ALSTOM Power, Inc. for evaluation prior to welding. 4.7.10 Appropriate calibrated recording devices shall be used to record the time at temperature during all post-weld heat treatments. 4.8 ALIGNMENT, ADJUSTMENT, OR STRAIGHTENING 4.8.1 All P-5B, Grade 91 components that have been welded shall not be subjected to any forces to align; adjust, or straighten before a post weld heat treatment has been completed: Harp headers that are completed and subject to straightening prior to tube-to-header welds being started shall be given an interim post weld heat treatment at 1350-1400F (730-760C) for one hour per inch of thickness, 30 minutes minimum. 4.8.2 Minor alignment, adjustment, or straightening operations to meet specification requirements or facilitate fabrication are permitted without a subsequent heat treatment provided care is taken to minimize strain. Examples regarding this strain limit would be keeping the mid-span deflection of a header loaded in three-point bending below 0.0025L2/D, where "L" is the bending span length and "0" is the part diameter. 4.8.3 If possible, all aligning, adjusting, and straightening should be performed without heating the affected part. 4.8.4 if heating is required for aligning, adjusting, and straightening, the metal temperature must be kept below 1250F (675C) and documented. 4.8.5 Any heating to facilitate aligning, adjusting, and straightening must be accomplished using electric resistance heating devices controlled by thermocouples; torches must not be used for heating. The heating devices must be appropriately sized and positioned so that strains from straightening or aligning are distributed evenly and are not concentrated in small areas or at the toes of welds. 4.8.6 Fixtures used during aligning, adjusting, and straightening must be appropriately sized and shaped to preclude causing local distortion or damage where contact is made with the affected component. 4.9 WELD INSPECTION In addition to weld examination requirements of ASME Section I or ASME 831.1, the Supplier shall comply with the following: 4.9.1 All root and final weld passes shall be 100% visually inspected. inspection shall be performed using suitable means. Inspection records shall be completed for all visual inspections. 4.9.2 As a minimum, 10% of all completed butt welds shall be non-destructively examined by radiography (RT) or ultrasonic testing (UT). Acceptance criteria shall be as outlined in ASME Code, Section I and ASME B31.1. 4.9.3 100% of all completed attachment welds shall be non-destructively examined by magnetic particle testing (MT) or by liquid penetrant testing (PT). Acceptance criteria shall be as outlined in ASME Code, Section 1 and ASME B31.1. 4.9.4 For inspection criteria of tube-to-header, nipple-to-header or tube-to-tube welds, see Manufacturing Specification MS-HRSG-0001 or MS-HRSG-0004, as applicable. 4.9.5 All personnel performing visual and other non-destructive testing shall be certified to the latest Code accepted edition and addenda of SNT-TC-1A or CP-189. In lieu of SNT-TC-1 or CP-189 visual inspectors may have current certification to AWS-CWI/CAWI or to ASME 931.1 or equivalent. Applicable NOT procedures for VT, PT, MT, RT, UT, and certification of personnel shall be submitted to ALSTOM Power, Inc., for review prior to use. 4.9.6 Additional NDT requirements may be imposed in the ALSTOM Power, Inc., purchase order.

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5.0 BENDING

5.1 GENERAL REQUIREMENTS 5.1.1 The process of producing Grade 91 bends can involve hot and/or cold bending processes. Any hot process and any cold process with an R/ Da (mean bend radius divided by actual outside diameter - in other words, actual tube or pipe outside diameter, not nominal pipe diameter) of less than 4.0 shall be followed by a heat treatment of the entire part, including normalizing and tempering phases. Cold bent parts with an R/Da of 4.0 or greater need not receive any post bending heat treatment. 5.1.2 5.1.3 Prior to any bending, each bend shall be marked with a permanent unique identifier to maintain material control. After cooling of hot formed bends, removal of external loose scale, and installation of the necessary instrumentation of the entire length, shall be subjected to a normalizing and tempering heat treatment process given below and to the acceptance/rejection assessment procedure defined by the ALSTOM Power Inc., Purchase Order.

6.0 HEAT TREATMENT OF GRADE 91 BENDS

6.1

The heat treatment of Grade 91. is critical and therefore sufficient bends in each furnace charge shall be instrumented with thermocouples to demonstrate that all components stay within the required temperature limits. Particular care shall be taken to ensure that enough thermocouples are installed to account for furnace thermal profiles and shadowing effects resulting from close packing and layering of the components. In a production situation, and with the approval of ALSTOM Power Inc., advantage may be taken of data from the first few heat treatments to reduce the number of thermocouples but there shall never be less than three. In this situation, any change in the charge configuration shall be considered the start of a new production run with no advantage being taken of previous history. The thermocouples and their instrumentation shall be calibrated and their output permanently recorded throughout the heat treatment cycle. The records shall be part of the components' quality record and shall form one of the bases for acceptance or rejection of the batch of bends that makes up a furnace charge. Normalizing shall consist of heating the components to 1920-1975F (1050-1080'C), carefully controlling the heat-up rate as this temperature is approached to ensure no overshoot, holding for one hour per inch (2 minutes per mm) with a minimum time of 30 minutes and air cooling (outside furnace) to below 200F (95C). Accelerated cooling will be required for components having sections over 3 inches (76 mm) thick and special procedures will have to be developed and submitted for approval in such instances. Tempering shall consist of heating the components tol 350-1450'F (730-790C), again taking care not to overshoot, holding for one hour per inch (2 minutes per mm), and air cooling (outside furnace). After the heat treatment is completed the necessary physical checks and hardness measurements shall be made. Hardness shall be 190-300 VHN. Subsequent to acceptance, unique identifying marks may be removed as part of fabricating the overall component provided that a quality process is established and implemented to ensure that only bends that have been accepted are used in production. Refer MS-HRSG0008, procedure for hardness testing with portable instrument.

6.2

6.3 6.4

7.0 IDENTIFYING GRADE 91 MATERIAL

Prior to shipping the Grade 91 material, all headers, piping and elbows shall be identified by painting the components with the following words: Grade 91 Material, DO NOT STRIKE ARC.

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8.0 POST WELD HEAT TREAT DIAGRAMS

CHART
EXTENDED BAKE WITH PWHT AT LATER TIME

TEMPERATURE - DEG F 1350 INTERPASS NOT TO EXCEED 750F 60Q 400

POST WELD HEAT TREATMENT EXTENDED PRE-HEAT OF 600 TO 750 7

70

/PREHEAT TEMPERATURE MAINTAINED

COOL TO NOT LESS THAN 200 F

CHART

TEMPE TUBE - DEG F 1350

POST WELD HEAT TREATMENT

INTERPASS NOT TO EXCEED 750F 4 0 0 PREHEAT TEMPERATURE MAINTAINED 2 0 0 7 0 COOL TO NOT LESS THAN 200F

PWHT IMMEDIATELY AFTER WELDING AND COOLING

Temperature Conversions: 1350F (730C) 750F (400C) 600F (315C) 400F (205C) 200F (95C) 70F (21C)

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9.0 REVISION LOG

REV 0 1 2 3 4 5 6 7 8 9 10 11 12 13 . 14 15 16 17 18 19 20 21 22 23

DATE 11/24/01 02/15/02 02/19/02 06/05/02 09/12/02 09/27/02 10/16/02 11/02/02 4/21/03 10/7/03 11/24/03 12/23/03 01/14/04 02/10/04 7/07/04 9/1/04 7/25/05 8/2/05 5/19/06 7/12/06 8/9/06 9/11/06 10/3/06 11/16/06

BY AP RRP RRP RRP RRP EMO RRP EMO RRP RRP RRP RRP EMO RRP RRP RRP RRP RRP RRP RRP RRP EMO RRP RRP

CHK'D TPM TPM TPM TPM TPM TPM EMO TPM . JNI-1 RWM RWM RWM RWM RWM RWM RWM RWM RWM RWM RWM RWM RRP EMO EMO

DESCRIPTION Initial Issue Added 3.7.1.1 Formatted 3.7.1.1 Par. 3.5.5, 3.5.7, 3.7.1 Par 3.7.1 Reformatted document, changed document number Rev. 3.5.5, and 3.5.7 Revised reference to manufacturing standards (1.0 and 2.3) Revisions are shown in red. Revisions are shown in red. Added 3.0 Training. Revisions are shown in red. _ Added 4.7.1.1 and 4.7.1.2 'Revised 4.7.2 and 4.7.2.1, added 4.7.1.3. Moved hardness comment from 4.7.2 to 4.7.1.2 Revised 4.8.1, various editorial as shown in red Revised various sections Deleted Hot Bending Temperatures in 5.0 ( 5.1.3) and Revised 6.2 Revised various.sections Revised Paragraphs 4.7.5 and 4.7.6 Revised Paragraph, 6.4, hardness readings Revised Interpass Temp. to 750F and revised charts 1 & 2 Revised 2.1,4.4.1, 4.4.3, 4.5.6, 4.7.5, 4.7.5.1 and editoraf Revised 1.0, 2.1, 44.1, 4.5.5, 4.6.2., 4.6.3, 4.7, 4.8.1, 4.8.4, 4_9.6, 5.1.1, 6.0, 6.2, 6.3, 6.4 and 8.0 Charts 1 and 2. Revised, 4.6.2, 4.6.3, 4.7.1, 4.7.2 and Charts 1 and 2 Revised 4.5.5 4.5.8 and 4.6.1

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