INDUSTRIAL TRAINING PHASE- 1 AT LARSEN & TOUBRO LTD.

, HAZIRA COMPLEX HEAVY ENGINEERING DIVISION

A MINOR REPORT ON WELDING AND FABRICATION TECHNOLOGY ROYAL COLLEGE OF TECHNOLOGY INDORE, PREPARED BY: RAJNIKUMAR KOLADIYA ENR. NO: - 0836ME091019

CERTIFICATE
This is to certify that MR. RAJNIKUMAR KOLADIYA . Enrolment no. 0836ME091019 of Dept. of Fabrication Technology has successfully completed his Minor report on WELDING during his training period of first phase 05/07/2012 to 20/07/2012 in L&T Hazira, Surat.

APPROVED BY:

GUIDED BY :

Dr.SUJIT MEMON (INCHARGE OF HFS-3A)

Dr.JAIRAJ GOHIL (CO-ORDINATOR OF HFS 3A)

Sr.NO. TOPIC PAGE NO. 1. Job Detail 4 2. P no. 5 Low Alloy Steel 6 3. Characteristics 6 4. Chemical composition 6 5. Effect of Chromium 6 6. Effect of Vanadium 7 7. Cr-Mo-V steels 7 8. Comparison 7 9. Comparison of reactor steels 8 10. Enhanced Tensile Strength 8 11. Creep 8 12. Temper Embrittlement 9 13. Hydrogen Embrittlement 9 14. Hydrogen Induced Overlay Disbonding 10 15. Weldability of Cr-Mo Steel 10 16. Preheating 11 17. Inter-Pass Temperature 12 18. DHT (De-Hydrogenation Treatment) 12 19. Intermediate Stress Relieving (ISR) 12 20. Why ISR?? 13 21. ISR Requirement 13 22. Critical Weldability issues 13 Reheat, or stress-relief cracking Solidification, or hot cracking
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 Hydrogen-induced, or cold cracking 23. Welding Training 21

AIM: To investigation the slag inclusion in PETROBRAS job JOB DETAILS:-

NAME OF JOB:- DIESEL HYDROTREATING REACTOR PROJECT NO.:- 45537/2 CUSTOMER:

PETROLEO BRASILEIRO (PETROBRAS)

JOB DIMENSION:
4916 mm I.D., 23346 mm LENGTH, (150 mm THK+8 mm OVERLAY)

JOB MATERIAL:
- FOR HEADS: SA 542M TYPE .D CL. 4a (Quenched + Tempered) + (SS 309 L+ SS 347 overlay - 8 mm THK.) - FOR NOZZLE: SA 336M GR. F22 V. - Y-RING : SA 336 GR. F22 V (Q+T)+(SS 309L +SS 347O/L8THK). - MANHOLE : SA 542M TYPE .D CL. 4a (Quenched + Tempered) +(SS 309 L+ SS 347 overlay) - BOLTING:SA193M Gr. B16/ SA 194 M Gr.4 - GASKATE : SA182M Gr. F347
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 DESIGN TEMPERATURE (INT/EXT.)

430/30 0C

DESIGN PRESSURE (KG/CM2)

- INTERNAL: 134 - EXTERNAL: 1.05

SHELL: 9 shells + 2 D end. FABRICATED WEIGHT: - 560000 kg.

HYDRO TEST PRESSURE : 16.26 M pa horizontal : 5.988 M pa vertical HYDRO TEST TEMP. : 27 to 50 0C CHEMICAL COMPOSITION : Carbon 0.05 to 0.15 Manganese 0.30 t0 0.60 Phosphorus 0.035 max. Sulphur 0.035 max. Silicon 0.50 Chromium 2.00 to 2.50 Molybdenum 0.90 to1.10

CODE REFERENCE: ASME SEC: VIII, DIV: - 2 ED.-2007.

P no. 5 Low Alloy Steel Characteristics Used up to 650oC Operating Temp.
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 Resistance to H2 attack Better creep ruptures properties and high temp. strength than carbon steels Resist oxidation and sulphidation High hardenability Chemical composition A: 2.25Cr 1Mo SA 508 Gr. 22, CL. 3 Forgings SA 541 Gr. 22 CL.3 Forgings SA 542 TYPE B CL.4 Forgings B: 2.25Cr 1 Mo -2.25V (LAS) SA 336 Gr. F22V Forgings SA 182 Gr. F22V Forgings SA 541 Gr. 22V Forgings SA 542 TYPE D CL.4a plates SA 832 Gr.22V plates. C: 3Cr 1Mo V-Ti-B (LAS) SA 182 Gr. F3V Forgings SA 542 TP C CL. 4A Plates SA 832 Gr.21V Plates SA 541 Gr.3V Forgings SA 508 Gr.3V Forgings SA 336 Gr.F3V Forgings CODE :- ASME SEC.8, DIV.-2, PART:3, Material requirements part content table-3.18.

Chromium
Increases resistance to corrosion and oxidation Increases hardenability Adds some strength at high temperatures
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 Resist abrasion and wear (with high carbon) Molybdenum Molybdenum is a potent hardenability agent and is a constituent of many heat treatable alloy steels. It raises grain coarsening temperature of austenite It retards softening at elevated temperatures and is therefore used in boiler and pressure vessel steels, as well as several grades of high speed and other tool steels.

Vanadium
Enhance tensile strength at elevated temperatures (above 400oC) Enhance creep rupture strength Improve resistance to in-service degradation like temper embittlement, high temp. hydrogen attack, hydrogen embrittlement, hydrogen induced overlay disbonding Lower unit weight of the reactors at a comparable cost by increase of steel strength.

Cr-Mo-V steels
2.25Cr - 1Mo - 0.25V Element C Mn P S Si Cr Mo V

% Composition 0.11 0.30 0.015 0.010 0.10 2.00 0.90 0.25 0.15 2.50 1.10 0.35 0.60

Tensile Strength 585 780 MPa

Yield Strength Elongation in 2 Brinell hardness no. 415 MPa 18.0% 174-237

Comparison

Material

Tensile Strength

Yield Strength Elongation in 2 260 MPa 242 MPa 415 MPa 21.0% 22.0% 18.0%

C.S (SA 516 Gr.485 620 MPa 70) SA 387 Gr. 11 415 585 MPa SA 182 Gr. F22V 585 780 MPa

Comparison of reactor steels Steel Grade 2.25Cr-1Mo Max. allowed temp. ASME482oC VIII 2 Min. Tensile Strength 517 Min. Yield Strength 310 Design Stress Intensity Value,At 454oC 150 MPa ASME VIII-2 At 482oC 117 MPa Wall Thickness At 454oC 338mm At 482oC 442mm 454oC Design Reactor1038MT Weight; Typical Cost Rs 45.2x107 482oC Design Reactor1359MT Weight; Typical Cost Rs 59.1x107 2.25Cr-1Mo-0.25V 482oC 586 414 At 454oC 169 MPa At 482oC 163 MPa At 454oC 298mm At 482oC 310mm 916MT Rs 44.0x107 953MT Rs 45.7x107

Enhanced Tensile Strength In service behavior of steels strongly depend on the type and morphology of carbide phase Vanadium modification provides fine, vanadium rich carbides, evenly distributed in the metal matrix Four types of carbides formed: M7C3, M23C6, M6C and M2C All contained vanadium with differentiated amounts of Cr, Fe and Mo Thermodynamic stability of carbides is much greater than V free precipitates
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Creep Creep is defined as the process by which plastic flow occurs when constant stresses are applied to metal for prolonged period of time at high temp. It occurs at all stress levels at higher temp. Creep rate with stress at given temp. Effect of Vanadium on creep resistance Heat application leads to carbide growth Coarse carbides distort the grains and lead to smaller grains More Sliding & Dislocations in smaller grains Vanadium resist carbide growth at elevated temperature

Temper Embittlement Caused by: Grain boundary segregation of impurities and tramp elements Watanable No. (J Factor) To limit the impurity /tramp elements content in reactor steels J factor = 104(P+Sn)(Mn+Si) Resistance of steel to temper embrittlement will be sufficient when J factor is limited to a value of less than 100 Carbide formation is accompanied by microstructural and microchemical change. The addition of Cr in steels enhances the impurities, such as P, Sn, Sb, and As, segregating to grain boundaries and induces temper embrittlement.
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 A delay in carbide formation, precipitation or thickening usually leads to delay in embrittlement Hydrogen Embrittlement At typical hydro processing temperatures and hydrogen partial pressures, hydrogen diffuses easily through reactor walls When reactor is cooled down rapidly, delayed hydrogen cracking may occur Fine, evenly distributed vanadium rich carbides trap the diffusible hydrogen in steel So lesser hydrogen is available at the tips of the crack High Temperature Hydrogen Attack Diffused hydrogen reacts with carbides to form methane Leads to decarburization of the material with formation of cavities, fissures or cracks Higher thermodynamic stability of carbides leads to reduced methane pressure Precipitation of vanadium rich carbides in the modified steel enhances the resistance to hydrogen attack. Hydrogen Induced Overlay Disbonding Hydrogen reactors must be protected from high temperature sulphide corrosion caused by hydrogen sulphide present in processed steam. Hydrogen concentration increases at the interface of both the steels. Hydrogen is trapped in the fine vanadium containing carbides So, Hydrogen has low diffusivity in vanadium steels Weldability The capacity of a metal to be welded under the fabrication conditions imposed into a specific, suitably designed structure, and to perform satisfactorily in the intended service Depends on, - Composition of weld metal - Circumstances in which weld freezes Weldability of Cr-Mo Steel
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 Hardened when Quenched from Austenitizing temperature Sensitive -Hydrogen Induced Cracking -Solidification Cracking To avoid Cracking -Preheat Maintenance -Use of appropriate Welding Consumables -Heat Treated to improve Toughness -Carbon Content of weld Metal Ultra High Strength material Air Hardenable Form Hard Martensite when quenched from Hardening temperature of around 1000 C Hard Martensite will form unless proper Preheat and PWHT procedure is followed HAZ portion Highly susceptible Under bead Cracking To avoid Cracking: Proper Preheat is required Preheat Temperature: above Ms temperature Preheating Preheating promotes slow cooling of weld and HAZ Slow cooling softens or prevents hardening of weld and HAZ Soft material not prone to crack even in restrained condition Removes moisture, oil, etc. Temp = 35 X [CE(1 + 0.5t) 0.25]^0.5 Where t = thickness CE = carbon equivalent CE = C + Mn/6 + (Cr+Mo+V)/5+ (Ni+Cu)/15 Width of preheating material should be equal to plate thickness or 75mm whichever is less on each side (but not less than 25mm) P-NUMBERS

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1 2 3 4 5 6 7 8 9 to 11 21-25 31-35 41-45 51-53

Carbon-Manganese steel Carbon-1/2%Mo 1%Cr-0.5%Mo 2.25%Cr-1%M Ferritic stainless steel. Martensitic stainless steel. Austenitic stainless steel. Nickel steel. Quenched & Tempered steel Al & Al base alloys Cu & Cu base alloys Ni & Ni base alloys Ti & Ti base alloys

PREHEATING TABLE Material/ P.No. Groove & Fillet (Preheat) Base Metal Thickness (mm) <25 25 to50 to75 50 75 100 C-Mn P1 Gr 1& 2 20 100 125 C-1/2 Mo P3 Gr1 & 2 100 125 150 175 P3 Gr 1 100 150 175 11/4Cr-1/2Mo P4 Gr1 & 2 150 21/4Cr-1 Mo P5A Gr 1 150 200 5Cr-1/2 Mo P5B Gr 1 200 21/4Cr1MoP5C Gr 1 200 -1/4V Q & T Steel P11 AS 150 Inter-Pass Temperature Control on inter pass temperature avoids over heating, there by
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to>=100 150 200 200

 Refines the weld metal with fine grains Improves the notch toughness properties Minimize the loss of alloying elements in welds Reduces the distortion Inter-Pass required for Cr-Mo-V is about 250Oc DHT (De-Hydrogenation Treatment) SMAW introduces hydrogen in weld metal Entrapped hydrogen in weld metal induces delayed cracks unless removed before cooling to room temperature Retaining the weld at a higher temperature for a longer duration allows the hydrogen to come out of weld

Material/ P.No.

C-Mn

P1 1& 2 C-1/2 Mo P3 Gr1-&2 P3 Gr 1 -11/4Cr1/2Mo P4 Gr1-&2

Groove (DHT) Fillet (DHT) Base Metal Thickness (mm) Fillet Size <25 25 to50 to75 to>=100 50 75 100 Gr-- --------300-350oC hrs /3(>=50 CFW) 300-350oC hrs (>=35 CFW) 300-350oC hrs (>=35 CFW) 300-350oC hrs (>=15 CFW) 350-400oC hrs (>=10 CFW) 350-400oC
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/3 /3 /3 /4 /4

300-350oC /3 hrs 300-350oC /3 hrs

21/4Cr-1 P5A Gr-Mo 1 5Cr-1/2 Mo P5B Gr-1

350-400oC /4 hrs 350-400oC /4 hrs

21/4Cr1Mo -1/4V

P5C Gr350-400oC /4 hrs 1

hrs ALL 350-400oC hrs

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Intermediate Stress Relieving (ISR) Heat treating a subassembly in a furnace to a predetermined cycle immediately on completion of critical restrained weld joint / joints without allowing the welds to go down the pre heat temperature. Rate of heating, Soaking temperature, Soaking time and rate of cooling depends on material quality and thickness Applicable to -Highly restrained air hardenable material

Why ISR?? Restrained welds in air hardenable steel highly prone to crack on cooling to room temperature. Cracks due to entrapped hydrogen and built in stress Intermediate stress relieving relieves built in stresses and entrapped hydrogen making the joint free from crack prone ISR Requirement For 2.25Cr-1Mo-0.25V material, all L/S & C/S having thickness >100 mm, all nozzle # Shell/head welds and support ring/nub attachment to shells, shall undergo an ISR at 690oC for minimum 1hr or 650670oC for 2hrs. Critical Weldability issues Hydrogen-induced, or cold cracking Reheat, or stress-relief cracking Solidification, or hot cracking Hydrogen-Induced Cracking (HIC)
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 Hydrogen dissolved in molten weld pool (e.g., wet coatings, poor gas shield, grease/rust on component surface) high solubility in liquid During rapid solidification of weld deposit, some hydrogen is trapped supersaturated condition In Cr-Mo/Cr-Mo-V steels, greater hardenability increases the risk of lower bainite/martensite formation in the weld and HAZ Hydrogen diffuses preferentially to these highly stressed regions of the weldment structure e.g., the coarse-grained HAZ increasing the risk of cracking Necessary Components for HIC to Occur Sufficient quantity of trapped hydrogen in weldment -Total vs diffusible hydrogen (residual hydrogen remains) Susceptible microstructure -Structures with high internal stress/lower transformation products Stress-Residual stresses, influence of stress concentrators Temperature of susceptibility -Limited range of susceptibility reflecting the influence of hydrogen mobility (must be high enough to allow concentration, but not so high to allow escape) Potential Sources of Hydrogen in Weld Metal Welding consumable -Coatings and fluxes (cellulosic vs basic) Atmosphere -High humidity -Ineffective gas shield Base metal -Trapped hydrogen in heavy sections -Surface moisture, grease, oil, etc. -Rust, other surface corrosion products Solubility of Hydrogen in Weld Metal

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Typical Features of Hydrogen-Induced Cracking Can occur in weld metal or HAZ Can occur at weld root, weld toe, sub-surface (underbead) Can show features of intergranular, transgranular, or ductile fracture Can occur hours after welding is complete controlled by diffusion rates Exacerbated by restraint Can propagate in service and lead to failure Hydrogen-Induced Cracking In HAZ

Hydrogen-Induced Cracking in Weld Deposit

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Prevention of HIC Minimize hydrogen in the weld metal Low hydrogen electrodes (proper storage, baking) Steel cleanliness Preheat Match temperature to alloy Allow sufficient time for diffusion Microstructure control Isothermal transformation Use austenitic or nickel base filler metal Hydrogen sink & residual stress mitigation Reheat Cracking Reheat Cracking is defined as cracking that occurs in the heataffected zone (HAZ) or weld metal during the exposure of a welded assembly to PWHT or elevated temperature service. Reheat cracking is also referred to PWHT cracking or stressrelief cracking. Common in Cr-Mo steels containing less than 3%Cr. Characteristics Of Reheat Cracking Low rupture ductility. Intergranular fracture along prior austenite grain boundaries.. Heat-to-heat crack susceptibility varies dependent on residual elements
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 Bulk chemistry of a material may not be reliable predictor of cracking susceptibility The time-to-failure exhibits a C-curve behavior as a function of temperature. Reheat Cracking --- C-Curve Behavior

Position of Curve Dependant on Alloy And Heat Chemistry.

Mechanism of Reheat Cracking A balance of intergranular and intragranular carbide precipitation controls the reheat cracking susceptibility. Cracking can initiate at prior austenite grain boundaries by cavitation on incoherent, Fe-rich M3C carbides. The grain matrix is resistant to plastic deformation due to precipitation strengthening by alloy carbides. Impurities have significant effect on susceptibility to reheat cracking. Reheat Cracking Susceptibility Parameters G parameter: - G = Cr + 3.3Mo + 8.1V 2 - If G > 0, the material is considered to be susceptible. PSR parameter: - PSR = Cr + Cu + 2Mo + 10V + 7Nb + 5 Ti 2
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- If PSR > 0, the material is deemed to be susceptible Effect of Cr and Mo According to G & PSR, Cr increases reheat cracking susceptibility. According to Nakamura & Ito, steels containing >1.5Cr are not susceptible. According to Tamaki, effect of Cr varies with Mo content (right figure) Molybdenum: Mo increases reheat cracking susceptibility In early stage of tempering, Mo2C carbides precipitate first and cause hardening in grain matrix In presence of V, Nb & Ti (more affinity for C than Mo), there exists a tendency to form more stable carbides.

Effect of Vanadium Vanadium V increases reheat cracking susceptibility.

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 V forms uniform and fine V4C3 carbide in the matrix. At temperatures of 930-1020 F, coherent precipitates of V4C3 occur in ferrite lattice similar to M2C formation. z

Solidification Crack Cracking that forms during solidification of the molten weld pool hence the term hot cracking Lack of sufficient feed of hot metal into the area of final solidification (e.g., crater cracking) Unfavorable orientation of the final freezing zone relative to the direction of solidification Factors Promoting Solidification Cracking Composition Long freezing range High levels of carbon, sulfur, phosphorus, etc. Bead Shape High depth : width ratio Joint Profile Root condition Thickness mismatch

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Influence of Composition on Solidification Cracking Long freezing range: The risk of cracking is a direct function of the magnitude of the difference in solidification temperature between the solvent-rich and solute-rich components of the molten weld metal Stresses that develop during solidification due to contraction must be borne by the solute-rich metal that solidifies last Elevated levels of impurities and some alloying elements: Elements that promote low-melting eutectics, such as S, B, and Cb, increase the risk of solidification cracking Differences in solubility of certain elements, such as sulfur, in austenite vs ferrite can have a potent effect on susceptibility: Carbon and other austenite formers that promote solidification as austenite increase the risk of solidification cracking Role of carbon can be critical, particularly weld roots and when using high dilution processes, such as SAW Bead Shape Depth:Width ratio affects solidification pattern High depth:width ratio promotes concentration of lowest melting material at the centerline (by heat extraction) of the weld deposit

Shape of the weld bead will be influenced by: Welding current (lower current reduces depth:width ratio)
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 Welding speed (lower speed reduces depth:width ratio) Polarity (dc positive vs ac/dc negative) Reducing Susceptibility to Solidification Cracking Change bead shape (depth:width ratio) by reducing penetration Reduce dilution, particularly in root pass (lower C and S) Buttering of higher carbon steels Reduce length of molten weld pool (easier fill of final solidification zone with hot metal), use backfill techniques Control weld metal chemistry within specification Reduce root gaps; maintain gap dimension along full length of long welds

Welding Training Welding training includes the training given to welders, L&T Supervisor & Contractors Welding Engineer by Welding Engineering. 1. Welding parameter understanding Preheating Temperature Interpass Temperature DHT Temperature & Time Checking of Preheating on Base Metal Checking of Interpass Temperature on Bead Maintenance of preheat temperature until DHT SMAW Welding Parameters: Current, Voltage, Bead Length GTAW Welding parameters: Current, Voltage, Travel Speed Temper Bead understanding Interpass Cleaning
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 Understanding of Detrimental effect due to Arc Strike, Precautionary actions to avoid Arc-Strike on base metal. Critically of Cr-Mo-V with respect to welding, handling, etc. Practical Training: Before Starting on job- SMAW Bead on Practice to achieve required bead length in various positions.

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