SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
Revision status Record:
Revision Date Page no. Details of Changes Reason for
No. changes
Document Approval sheet:
Prepared by Signature
Core team members M.G.Binu & Team
Reviewed by Signature
HOD A.Sudhakar
Issued& Controlled by Signature
MR C.Holiram
Approved by Signature
Station Head Jayant Sagade
Standard Maintenance Procedure Page 1 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
1.0 Purpose:
This Procedure is intended to provide guidance and instructions for carrying out the
Maintenance of P91 tube repair
2.0 Scope:
This Procedure is applicable to P91 tube repair of 4X150MW in Simhapuri Energy Ltd. located
at Boiler area of the plant.
3.0 Responsibility:
Designation Responsibility
Staff Level –I (Team Member) Primary
Staff Level-II (Section In-Charge) Secondary
HOD (Mech. Maintenance) Over all responsibility
Other department to be intimated:
(Main Plant Operation, C&I, Electrical, Safety)
4.0 Procedure:
4.1. OBJECTIVE:
The objective of standard maintenance procedures for P91 tube repair is to train and guide
maintenance personnel enable them to perform maintenance efficiently and safely in minimum
time.
4.2. SPECIFICATION:-
Boiler Tubes Specification
Material : SA213 T91
Size : 42*6.5 mm
Standard Maintenance Procedure Page 2 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
4.3. Details of Hazard Involved
4.3.1 Fire
4.3.2 Failure of lifting tools & tackles
4.3.3 Exposure to high noise
4.3.4 Welding effect
4.4 Safety Precaution Required
4.4.1 Keep the fire extinguishers ready within reachable limit for any exigency.
4.4.2 Ceramic hand gloves to be used while handling hot surface.
4.4.3 Ensure use of periodically tested proper lifting tools & tackles.
4.4.4 Use of earplug and welding helmet is mandatory along with other general PPEs.
4.4.5 Ensure good housekeeping.
4.4.6 Put barricade tapes around the equipment under maintenance.
Permit Type: Permit to work / Hot work permit
Permit Approving Authority: Shift in charge / unit in-charge
4.5 Isolation procedure
4.5.1 Drain water from boiler
4.5.2 Switch off FAN as per normal operation procedure.
4.5.3 DC supply of control panel made OFF.
4.5.4 6.6 KV breaker to be rack-out and locked.
4.5.5 Inform C & I & electrical maintenance people for instruments removal.
4.6 T & P required:-
4.6.1 Argon set
4.6.2 Cutting set
4.6.3 Grinding machine.
4.6.4 Certified rigging and welding tools.
4.6.5 Induction heater
4.6.6 Calibrated auto graph recorder
4.6.7 Thermocouples
5.0 MAINTENANCE –
5.1 Preventive Maintenance:-
Standard Maintenance Procedure Page 3 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
Daily check:-
5.1.1 Visual inspection
5.1.2 Tube thick ness at joint elevation and erosion areas
5.1.3 Fins grinding if required
5.1.4 Erection joints inspection.
5.2 Periodical maintenance:-
5.2.1 Visual inspection
5.2.2 Tube thick ness at joint elevation and erosion areas
5.2.3 Fins grinding if required
5.2.4 Erection joints inspection
Engineer is responsible to take PTW & carry out the preventive maintenance job.
5.0 WORK PROCEDURE
5.1 Replacement of Damaged Tubes
5.1.1 Drain the water from boiler.
5.1.2 Check the tube thickness near damaged tube
5.1.3 Mark the length of the damage tube for cutting
5.1.4 Cut the damaged tube with cutting wheel by using grinding machine..
5.1.5 Edge preparation of the tube to be done as per STD.
5.1.6 Issue the new tube from stores as per required MOC and size
5.1.7 Cut the new tube as per required length and edge preparation to be done
5.1.8 Place the tube in position and maintain the root gap as per WPS.
5.1.9 Pre-heating, welding, post heating & SR to be done as per WPS.
5.1.10 DP test to be done for fin welding.
5.1.11 RT test to be done for IBR joint.
5.2 Welding and welder qualification
Standard Maintenance Procedure Page 4 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
Only qualified welding procedures are to be used. Qualified as per ASME Sec IX and IBR on
P91 material shall be engaged. Welder log book to be maintained and welder’s performance to
be monitored by site welding engineer/ quality assurance engineer.
5.3 PREHEATING:
5.3.1 Prior to start of pre heating ensure that surface are clean and free from grease, oil
and dirt.
5.3.2 Pre heating temp shall be maintained at 220oC (min) by using induction heating.
5.3.3 Rate of heating/Cooling 100oC/hr.
5.3.4 The temperature shall be ensured by using a calibrated autograph recorder and two
thermo couples fixed at 0 deg and 180 deg positions on both pipes 50mm away
from the EP.
5.3.5 The thermocouple shall be welded with condenser discharge portable spot welding
machine.
5.3.6 The preheating arrangement shall be inspected and approved by welding engineer.
5.4 Welding:
5.4.1 Root welding shall be done using GTAW process five minutes after the start of
argon purging.
5.4.2 Filler wire shall be cleaned and free from rust or oil
5.4.3 Argon purging shall be continue minimum two filler passes of SMAW.
5.4.4 SMAW electrodes used must be dried in drying ovens with calibrated temperature
controller.
5.4.5 The draying temp shall be recommended by the electrode manufacturer.
5.4.6 The drying temp shall be 200-300 deg C for 2hrs if not specified by the
manufacturer
5.4.7 Portable flask shall be used by the welder for carrying electrodes to place of use.
5.4.8 Electrodes shall be kept at minimum 100 deg C in the flask.
Standard Maintenance Procedure Page 5 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
5.4.9 Welding shall be carried out with short arc and stringer bead technique only.
5.4.10 Inter pass temperature shall not exceed 350 oC. After completion of welding bring
down temp to 80-100 oC and hold it at this temperature for one hour minimum.
5.4.11 PWHT shall commence after completion of one hour soaking.
5.5 Post Weld Heat Treatment:
5.5.1 A minimum of four thermocouples shall be placed such that at least two heating
band at 180degrees apart about 50mm from the weld joint.
5.5.2 Two standby thermocouples shall also be provided on the weld in case of any
failure of the thermocouple.
5.5.3 The width of the heating circumferential band on either side of the weld must be at
least 5 times the thickness of the weld.
5.5.4 In case of fillet joint the heating band shall be six times the thickness of the weld.
5.5.5 An insulation of about 10mm thickness shall be provided b/w cable and weld joint.
5.5.6 Obtain the clearance for post weld heat treatment cycle from QAE/ Welding
engineer.
5.5.7 The PWHT temp for p91 with P91 material shall be 760 ± 10 deg C and the soaking
time shall be 2.5 minutes per mm of weld thickness, subject to a minimum of two
hours.
5.5.8 All records shall be reviewed by welding engineer prior to PWHT clearance.
5.5.9 Heating shall be done by induction heating only.
5.5.10 The rate of heating and cooling (above 350 deg C)
Thickness up to 50mm - 100deg C/hr. (max)
Thickness up to 50 to 75mm - 75deg C/hr. (max)
Thickness above 75mm - 55deg C/hr. (max)
5.6 INSULATION
Standard Maintenance Procedure Page 6 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
The width of the insulation band beyond the heating band shall be at least two times the
heating band width on either side of weldment.
The recording of time and temp shall be continuously monitored with a calibrated recorder right
from preheating. This will be ensured at every one hour by site authorized personnel.
5.7 Temperature Monitoring:
The welding and heat treatment chart given in figure shall be followed for following details.
The actual PWHT chart shall be monitored for the following.
5.7.1 Pre heat.
5.7.2 Inter pass temperature (GTWA + SMAW).
5.7.3 Controlled cooling and holding at 80-100 deg C for minimum one hour under
insulation start PWHT after minimum one hour of soaking.
5.7.4 Heating to PWHT.
5.7.5 Soaking at PWHT.
5.7.6 Cooling to 350 Deg C.
5.7.7 Cooling to room temperature (under insulation).
Standard Maintenance Procedure Page 7 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
Sl.No Operation Temp deg C Rate of cooling /
Heating
1 Preheat 220 oC 100 oC/hr.
2 Welding by 220 oC-350 oC
GTAW+SMAW
3 Cooling 80-100 oC 100 oC/hr.
4 Holding at 80-100 oC for min 1 hr. holding shall continue till the start of PWHT
5 Heating to Reach 760±10oC for P91 As per clause
PWHT 4.0.06.e
6 Soaking at 760±10oC at 2.5minutes/mm
PWHT
(Minimum 2hrs)
7 Cooling Cooling to 350oC As per clause
4.0.06.e
8 Cooling Cooling to room temperature under insulation
Standard Maintenance Procedure Page 8 of 9
SIMHAPURI ENERGY LIMITED
Document No. Issue No/Date Revision No/Date
SEL/MMD/BLR/SMP/29 01/24.04.2014 00/24.04.2014
Title Procedure for P91 tube repair
5.8 Trial / Test Procedure
5.8.1 Take Hydraulic test up to 1.5 times of the working pressure.
5.8.2 Check the joint of the replaced tubes and other areas.
5.8.3 In case of any leakage stop the pump and inform the maintenance persons.
.5.9 Checks before release of Permit
5.9.1 All T & Ps and manpower are removed.
5.9.2 Clean the maintenance area properly.
5.9.3 Ensure safety protection cover / guards are fitted in its position.
. 5.10 Re-Commissioning Procedure
5.10.1 Return PTW.
5.10.2 Normalize isolations after release of PTW.
6.0 References
6.1 OEM manual
6.2 Highly Experienced Expert / Advisor involved in preparation of SMP
7.0 Records
Preventive maintenance recorded in Checklist
Standard Maintenance Procedure Page 9 of 9
