Ramco Institute of Technology, Rajapalayam

Department of Mechanical Engineering

One Day Workshop on Welding of Emerging Power Plant Materials (03.02.2020)

Department of Mechanical Engineering, Ramco Institute of Technology and RIT - Indian

Welding Society Students Forum jointly organized a One day Workshop on Welding

Emerging Power Plant Materials on 3rd

February 2020 (Monday) to RIT – IWS students

Members at Mechanical Seminar Hall, RIT, Rajapalayam. Dr.S.Rajakarunakaran,

HOD/Mech, Mr.S.Maharajan, AP/Mech, Mr.J.Jeorld John Britto, AP(S.G)/Mech coordinated

the event. The program started with invocation “Tamil Thai Valthu”. Mr.S.Maharajan,

AP/Mechanical and RIT – IWS coordinator welcomed the gathering. Dr.P. Suresh Kumar,

Associate Professor/Mechanical presides over the function. The chief Guest of the Event

Mr.N.Rajasekaran, Hon. Secretary (IWS) & DGM (Unit II), Bharat Heavy Electricals

Limited, Tiruchirappalli has delivered the inaugural address. He narrated about RIT IWS and

its unique function in organizing technical talk and lectures in the past and assured that RIT

IWS will organize technical talks, workshops and seminars to students in future by assisting

and providing eminent resource persons from BHEL and WRI for conducting events. He

mentioned the importance of welding in specific applications like defense, boiler industries,

constructions, railways, aircraft industry, under water welding. He also explained the

following privileges from IWS to RIT – IWS students’ forum.

Student Forum Certificate from IWS to the institution

IWS Membership ID Cards to all Student Members

Financial Assistance of Rs. 10,000/- for one day Programme and Rs. 15,000/-

for two days programme on First Come First Served basis.

IWS Journal with technical articles as E-Journal for all Members

5 free delegates for the International events of IWS from your student forum.

Faculty Support for Seminars/Conferences/Workshops/ all lecture programmes

from the panel of Experts of IWS

Support for Projects Works of the student

Participation in lecture programme of Zones/Centres, free of cost/Highly

subsidised rate by the student members

One copy of the Proceedings of IWS Events as complimentary copy to the

library of the Institute.

Fig.1. Inaugural Address by Chief Guest Mr.N.Rajasekaran

The sessions are planned and handled by three resource persons from BHEL, Trichy. The

resource persons details are as follows:

S.No Name of the Expert and their Designation Topics to be delivered

1.

Mr.S.Singaravelu,

Consultant and Former AGM, WTC, BHEL.

Vice Chairman, IWS (South Zone)

Advanced Materials for Power Plant

Industries

2.

Mr.N.Parameswaran,

Former DGM, BHEL.

Zonal Executive Committee Member,IWS (

South Zone)

Testing and Weldability of Stainless Steel

3. Mr.N.Rajasekaran, DGM, BHEL,Hon.

Secretary, IWS.

Processing of 9Cr-1Mo Steel and Welding

Defects

Session 1: Advanced Materials for Power Plant Industries, Handled by Mr.S.Singaravelu,

Fig.2. Advanced Materials for Power Plant Industries, Handled by Mr.S.Singaravelu,

The following concepts are delivered to students,

Power plant working principle and Evolution of modern power plant industries from

conventional boiler power plant in the olden days. To meet the consumption of

electrical energy, the up gradation of power plant accessories and machineries by

innovating materials that can be withstand high pressure and high temperature.

Explain the working of Ultra Super critical boilers, steam generators, turbine blades,

and other machineries in industries. Under normal atmospheric pressure [0.101

MPa], water boils at 100ºC. As pressure increases, the boiling temperature of water

also increases. When the pressure is increased to 22.12 MPa, and at a temperature of

374ºC, water does not boil but is directly converted into steam. This is called the

critical point, and the pressure above this critical point is called supercritical

pressure. Supercritical pressure with a temperature equal to or more than 593ºC is

called ultra-supercritical pressure. The materials should withstand the high pressure

and temperature.

Explain the importance of ferritic stainless steel, Austenitic stainless steel,

Martensitic stainless steel and Ni based alloys (Ni and Cr alloys) and its specific

properties in the ultra-super critical boilers.

Explain the metallurgical properties of low, medium and high carbon steel with Iron

carbon equilibrium diagram and its applications in boiler industries.

Explain the importance of Ni based alloy used in fabricating machineries in power

plant industries.

Session 2: Testing and weldability of stainless steel, handled by Mr.N.Parameswaran

Fig.3. Testing and weldability of stainless steel, handled by Mr.N.Parameswaran

The following concepts are delivered to students,

Significance of welding defects such as Hydrogen embrittlement, oxidation of the

various alloy materials and its testing.

Differentiate the steel from stainless steel with respect to Chromium presents in the

ferrous material.

How carbon, Mo and chromium play vital role in steel and its applications in Boilers

and its accessories.

Explain the Heat affected Zone phenomenon in welding stainless steel.

Explain the selection of filler materials for welding stainless steel.

Importance of Post weld heat treatment and pre weld heat treatment in welding

materials to suppress the cracks ( Hot and Cold Cracks)

Explain various welding defects in welding modern materials and how to face the

challenges in welding by adopting techniques.

Selection of appropriate welding process in joining modern materials.

Session 3: Processing of 9Cr – 1Mo Steel and Welding Defects, Handled by

Mr.N.Rajasekaran.

Fig.4. Processing of 9Cr – 1Mo Steel and Welding Defects, Handled by Mr.N.Rajasekaran

The following concepts are delivered to students,

To refine the microstructure and enhance the mechanical properties, thermo

mechanical treatment (TMT) was performed on modified 9Cr-1Mo steel and the creep

deformation behavior of TMT processed steel.

Creep properties of 9Cr-1Mo steel.

Explained the significance features of Cr-1Mo steels and it possessed lower thermal

expansion, higher thermal conductivity, and improved oxidation resistance, compared

to traditional power plant steels.

Explained that Modified 9Cr-1Mo was certified in the 1980s as ASTM A213 Grade

T91 for tubing and ASTM A/Sa 335 Grade P91 for headers and piping.

Explained that in power plants, the structural materials used define the upper

temperature limit of the thermal power cycle and, hence, the efficiency of the power

plant. In nuclear power plants, apart from elevated temperature thermal and

mechanical properties, compatibility with coolant and corrosion behaviour, the

irradiation properties are also taken into consideration for selection of suitable

structural materials.

Modified 9Cr-1Mo steel has a martensitic microstructure at room temperature and

transforms to austenite over the temperature range of 1103–1143K.

Causes of welding defects and its remedies

Explained Welding defects such as Weld Crack, Undercut, Spatter, Porosity, Overlap,

Crater, Slag Inclusion, and Incomplete Fusion.

Explained the various welding design.

The vote thanks proposed by Mr.N.Thiruvisagan, III Year Mechanical B. The workshop

ended with National anthem.

Fig.5. Group Photo Session