Dear Mr.Jubair,
I feel you have got 5Cr 1Mo wire from the supplier whereas they have produced 9Cr1Mo V TC. it is not possible that the filler material chemistry and weld metal chemistry can change like this.
You have no other option but to cut and re-weld. I would suggest that ban the supplier and be vigilant while procuring the consumables.
When you have trusted suppliers for this P91 alloy with long term reputation are in the market there is no need for you to venture with D&H. As such P91 is a critical alloy to deal with ( a lot of attention is required at every stage right from selection of consumables till proper PWHT) and the application is also critical any negligence on this could be disastrous.
regards,
shankar
--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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Shankar
9994562774
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