SIPAT

FIELD QUALITY ASSURANC DEPARTMENT

Weld repair procedure for SA213T22 tubes in 660MW Boiler

Marking :
 Mark cutting location on leak tubes.

Leak point

Cutting & Beveling :

 Cut the leakage tube and neighbouring Fin.
 Perform Beveling the both tubes of the new tube and cut tubes.

Insert the tube and preheating:

 Insert the new beveling tube.

 Perform Preheating with min Temp.200℃.
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Preheating Area
(Min 200℃)

Butt weld : Perform Tube butt welds.

 Amperage should be diminished gradually at final weld area and be stop
arc with backward direction.
 Crater should be ground at every pass.
 No permission of crater treatment on the same location at each pass.

 Welding Process : GTAW

 Welding Rod: ER80S-B2(1’st root Pass),ER90S-B3 for rest pass.
 Amp Range: 120~160
 Volt Range: 10~20
 Preheat Temp : Min 200.
 Inter pass Temp: Max.350
 Gas Back Purging: Argon (Recommend)
 Final W/D Split(3’d & 4’d weld)
RT: Perform RT(2 shots) on welding positions at 90° angle.
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Insert the fin And preheating:
 Insert the fin between tubes & keep 2mm gap then Perform Preheating with
min temp.200℃ .

New insert piece

200mm

 Preheating Area (Min 200℃)

 Preheating around fin area widely within
200mm area.

Fin welding:
 Only with GTAW(ER90S-B3)
 Min. 2 pass applied.
 Final pass should be welded on fin side.

Min.2pass
2
1
1 Fin
2

PT: Perform PT test on butt weld and fin welds

Final Inspection: Identify tube weld surface visually.

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Recommendation:
ER80S-B2 welding rod on root pass(1’ st pass) is recommended due to following
reasons.
 At the initial design stage, T12 material also was recommended for vertical
wall considering design temp.Therefore usage of welding rod (ER80S-
B2 )equivalent to T12 base material is possible.
 In case of urgent repair such as inserting the tube , It is so difficult to apply
back shielding and also increase risk for oxidation and crater crack on welds.
 Welding Rod (ER80S-B2) is relatively less sensitive about the SCC than
welding rod(ER90S-B3) considering chemical composition.
 As welding Rod (ER80S-B2) is applied on only root pass(1’st Pass) and
balances are filled with ER90S-B3, enough thickness equivalent to base metal
could be formed.
 There is no effect on the boiler life cycle because the stress to circumferential
direction on weld area is half of the longitudinal stress.
 DHI have used ER80S-B2 on the same repair welds in domestic power plants

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