You clearly have the wrong filler metal – you are out of spec for Cr, V, and Nb. This filler metal will have far lower creep strength than the proper 91 chemistry filler metal. You need to remove any weld found with this type chemistry and re-weld with proper filler metal. If this filler metal is mismarked, you need to eliminate the supplier from your approved list. This is a major problem and could have disastrous consequences if it makes it out into the field.
John A. Henning
Welding & Materials
From: materials-welding@googlegroups.com [mailto:materials-welding@googlegroups.com] On Behalf Of mohamed jubair
Sent: Tuesday, August 28, 2012 3:25 AM
To: materials-welding@googlegroups.com
Subject: [MW:15142] Problem about Positive material Identification(PMI)
Dear all,
In our boiler one major problem occurred in Positive Material Identification(PMI) test [Spectrum test].
Description | Reheater finishing outlet(RHFO) coil |
Material | T91 |
Size | ø 63 x 4 |
Process | GTAW only |
Filler wire | ER 90S B9 |
Filler wire Manufacturer | D & H Secheron |
Preheating °C | 185 |
Rate of Heating °C | 100/hr |
Interpass temp °C | 190 |
Post heating °C | 100 |
PWHT °C | 750 |
Soaking Time | 90 minutes |
Around 800 joints welded in the above approved procedure only. Filler wire, header stub, RHFO coil, weld metal undergone PMI test separately and all show positive material results as T91 except weld metal. Weld metal shows the Chromium content only as (4-7%){Reqd is 8-10.5%}. We can’t find how it happened? Our Chinese consultant told to cut and reweld all the joints. But our contractor argued that we followed approved procedure and used approved vendor’s consumable only. Please give a solution. Here I have attached one preheating cum PWHT chart of RHFO joints(for 11 joints,5 thermocouples,1 recorder).All 800 joints are not checked yet. Only 40 joints checked and all 40 weld metals shown low Cr Content.
Please go through the below readings of one RHFO joint.
Description | Filler wire | Header stub | Weld metal | RHFO coil |
Alloy | T91 | T91 | A-2 | T91 |
Cr | 8.94 | 8.34 | 5.19 | 8.68 |
Mo | 0.96 | 0.90 | 0.93 | 0.92 |
V | 0.17 | 0.17 | 0.08 | 0.19 |
Ti | 0.07 | 0.10 | 0.04 | 0.03 |
Mn | 0.60 | 0.40 | 0.54 | 0.63 |
Fe | 87.81 | 88.11 | 90.86 | 87.61 |
Ni | 0.12 | 0.33 | 0.20 | 0.38 |
Cu | 0.02 | 0.16 | 0.20 | 0.16 |
Nb | 0.09 | 0.08 | 0.03 | 0.04 |
W | 0.15 | | 0.00 | |
Waiting for your valuable suggestions.
Thanks & Regards
K Mohamed Jubair
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