Abstract
Steels are subjected to many time-dependent degradation mechanisms when they are applied in electric power plants. They are exposed to high temperatures, multi-axial stresses, creep, fatigue, corrosion, and abrasion during such services. Used under these threatening conditions, those materials could develop various damages or failures or even form cracks. Therefore, it is desirable to prevent in-service failures, improve reliability, and extend the plant's operational life. The efficiency of the electric power plant, among other processes, depends on effective maintenance. The paper presents the evaluation of advanced procedures and knowledge in the field of steel repair welding in the maintenance of the power plants. Most repair welding of low alloy steels requires high-temperature post-weld heat treatment (PWHT), but in certain repairs, however, this is not always possible. Application of the nickel-based filler metal could also be an alternative to performing post-weld heat treatment (PWHT). The repair work expenses could be reduced if the repair is performed on-site. The novel developed repair welding procedures presented in this paper were applied for emergency weld repairing of the steel pipelines in thermal power plant, repairing without disassembling the working wheel of the coal mill in thermal power plant and "on-site" repairing turbine shaft of the hydropower plant. For all the presented repair welding procedures, weldability analysis based on the analytical equations and technological ''CTS'' and ''Y'' tests to determine the sensitivity to cold and hot crack forming were applied. Tensile tests, absorbed energies tests, banding tests, and hardness measurements were performed on trial joints, which were used to develop and verify the applied methodologies. Presented advanced weld repair technologies enable repairs for a shorter time and at lower costs compared to conventional procedures.
Highlights
Systems operating at high temperatures and high pressures in power, petrochemical, and refinery plant are subjected to innumerable degradation mechanisms
In the first part of the study, the trial welds and repair welding were performed for low alloy Cr-Mo steels applied at elevated temperatures as well as for 13CrMo4-5 steel applied in hot-rolled conditions
Considering structural and mechanical properties of the parent material and assumed quality requirements, geometric shape of the shaft flange, construction solution, technological possibilities conditioned by possible on-site repair welding and availability of repair welding equipment, metal arc welding process (MMA - 111) with covered Ni-based electrode without post-weld heat treatment (PWHT) was selected
Summary
Systems operating at high temperatures and high pressures in power, petrochemical, and refinery plant are subjected to innumerable degradation mechanisms. Plant operation can lead to damage and cracking in homogeneous metal materials due to time-dependent processes such as creep, fatigue, oxidation, corrosion, and abrasion. One of the most popular manufacturing processes for joining metals is arc welding, and it is used in structural applications such as pipelines, equipment, and components in thermal and hydro power aggregates. The actual life of homogeneous components of the systems, especially in power plants, will be in excess of the design life, and there are advantages from an economic point of view if the plant life can be safely extended beyond the originally designed life. The efficiency of the power plants, among other processes, depends on effective maintenance [1,2,3,4,5,6,7,8]
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