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June 26–29, 2012 Marco Island Marriott Resort & Spa, Marco Island, Florida
Welding and Repair Technology for Power Plants Tenth International EPRI Conference
Announcement
Background
Previous Electric Power Research Institute (EPRI) conferences on welding and repair technology highlighted emerging repair technologies and reviewed many established methodologies for repairing power plant components, including reactor pressure vessels, steam generators, vessel nozzles, piping, headers, valves, and pumps. Favorable response from utility members and vendors prompts the continued offering of this popular event. The 2012 conference will capture emerging and advanced repair technologies for nuclear and fossil components.
Today, emerging issues such as life expectancy of repaired components; avoidance of time-consuming postweld heat treatments; repair guidelines for aging components; on-line repair options; use and application of advanced alloys; and repair procedures for critical power plant components, rotors, blades, headers, and piping are increasingly important. EPRI, utilities, original equipment manufacturers, and vendors worldwide have been carrying out related research and application activities. As a result of these issues and efforts, there exists a need to consolidate this experience and identify current limitations and future needs.
Technical Scope
The Welding and Repair Technology for Power Plants Tenth International EPRI Conference will address the repair of nuclear, fossil, heat recovery steam generator (HRSG), and steam turbine power plant components. Topics for discussion will include repair methods, performance, prior service effects, repair and welding qualifications, materials properties, advanced repair technology, corrosion, and case histories. Although repair and welding technology for the maintenance of existing power plants will be the primary focus of this conference, with the emergence of new nuclear and fossil plant construction, advanced fabrication and welding technologies for new plants will be included. The program—designed for technical exchange among participants—will highlight utility needs and current industry capabilities and experience.
Conference Topics
Nuclear•Innovative repair methods and case studies
•Stress corrosion cracking (SCC) repair and mitigation in ferritic and austenitic piping
•Repair of dissimilar metal welds (including nozzles and penetrations)
•Alloy 600/690 SCC mitigation and repair techniques
•Weldability of high-chromium nickel base filler metals
•Development of new welding alloys for nuclear applications
•Stress improvement technologies and processes
•Temperbead welding of Code components
•Welding of spent fuel casks
•Repair and maintenance of spent fuel and refueling pools
Fossil•Welding and performance of welds in advanced alloys
•Welding and heat treatment of creep strength enhanced ferritic steels: 23/24/91/92
•New repair techniques
•Case studies on the repair of boiler, turbine, and HRSG components
•Installation and repair of scrubber materials
•New welding consumables
•Dissimilar metal welds
Other•Codes and standards
•Steam turbine rotor and disk repair
•Steam turbine casing repairs
•Training and implementation
Workshops Tuesday, June 26, 1 pm
Discussion of B31.1 Chapter VII and Case Studies of Piping FailuresSession Description This workshop will discuss the bases for the B31.1 Power Piping Code Chapter VII rules for operation and maintenance of power piping. The origins of some of the requirements will also be discussed along with current industry practices for accomplishing these requirements. Case studies of selected piping failures will be presented.
Instructor
Joe Frey, Staff Consultant, Stress Engineering Services, Inc. (SES) is a licensed engineer who has worked for 24 years at Houston Lighting & Power and Reliant Energy, where he eventually was responsible for providing engineering support for the FFS program for all boilers, pressure vessels, and high energy piping. Mr. Frey also provided engineering support for several emergency repair projects at the company. Since joining SES in 2004, Joe has worked on several emergency repairs, including 13 fire assessments in the last 5 years. He currently chairs the ASME B31.1 Power Piping Code Committee.
Guidance for Temperbead WeldingSession Description
This workshop will discuss temperbead welding techniques used to avoid difficult or impossible post-weld heat treatment (PWHT) that might otherwise be required by applicable codes and standards. Included will be an overview of current and prospective applications covered by ASME Codes and Standards along with discussions on how temperbead welding can reduce or eliminate the need to perform PWHT, how ASME Section IX addresses welding qualification of temperbead welding, and recommendations for the implementation and control of temperbead welding activities.
Instructor
Philip D. Flenner, PE, retired in 2001 after 29 years from Consumers Energy Company in Michigan. After retirement, Mr. Flenner founded Flenner Engineering Services, LLC, and is still active as a Senior Welding Consultant, concentrating on welding programs and codes and standards. He has been a member of the B31 Code Committee (35 years) and the ASME Section IX Committee and is an ASME Life Fellow. Mr. Flenner has taught ASME-sponsored B31 courses for 25 years, making more than 150 presentations. He has also written several instructional guidelines and handbooks for the power industry, including a temperbead guidance document, published as EPRI report 1022879 in August 2011.
Technical InformationGreg Frederick, EPRI Welding and Repair Technology Center (WRTC) Phone: 704.595.2071 E-mail: [email protected]
John Shingledecker, EPRI Fossil Materials and Repair (P87) Phone: 704.595.2120 E-mail: [email protected]
Steve McCracken, EPRI Welding and Repair Technology Center (WRTC) Phone: 704.595.2627 E-mail: [email protected]
Dana Couch, EPRI Welding and Repair Technology Center (WRTC) Phone: 704.595.2504 E-mail: [email protected]
Eric Willis, EPRI Welding and Repair Technology Center (WRTC) Phone: 650.855.2023 E-mail: [email protected]
Artie Peterson, EPRI Welding and Repair Technology Center (WRTC) Phone: 704.595.2605 E-mail: [email protected]
John Siefert, EPRI Fossil Materials and Repair (P87) Phone: 704.595.2886 E-mail: [email protected]
Bill Carson, EPRI Heat Recovery Steam Generator (HRSG) Program (P88) Phone: 704.595.2698 E-mail: [email protected]
Jonathan Parker, EPRI Boiler Life and Availability Improvement Program (P63) Phone: 704.595.2791 E-mail: [email protected]
Meeting PlannersStacey Wells Phone: 704.595.2176 E-mail: [email protected]
Lynda Lake Phone: 704.971.7141 E-mail: [email protected]
MaryKay Havens Phone: 704.595.2681 E-mail: [email protected]
Virtual Manufacturing and Repair of Energy Components and AssembliesSession Description
ESI, the leader in simulation-based design solutions, presents a comprehensive suite of simulation solutions for the energy industry for life extension, performance improvement, and repair feasibility analysis. For over 30 years, ESI has been a pioneer in developing physics-based finite element analysis solutions for the energy industry in collaboration with major industrial and academic partners. This workshop will focus on three areas of simulation development and analysis: additive manufacturing, residual stress distribution of multipass dissimilar metal welds, and fundamentals of virtual welding simulation using Sysweld™ to predict residual stress and distortion of large welded assemblies based on material properties, multiple welding/heat treatment cycles, and various welding processes.
For more information, visit www.esi-group.com.
Instructor
Harald Porzner, MSE, is Director of Product Management of the Virtual Manufacturing line and has held qualifications in simulation engineering for more than 20 years. He is recognized as a specialist in heat treatment, welding, and welding assembly simulation.
Contacts
Target Audience
This forum will provide an opportunity for power station managers, engineers, and maintenance personnel to exchange utility experience and lessons learned. Equipment manufacturers, service vendors, consultants, researchers, and university students in the United States and abroad are encouraged to come to the conference and share current and emerging technologies for welding and other repairs of fossil and nuclear plant components. Conference proceedings will be provided to attendees.
Sponsors
EPRI Welding and Repair Technology Center (WRTC)
EPRI Fossil Materials and Repair Program (P87)
EPRI Boiler Life and Availability Improvement Program (P63)
EPRI Heat Recovery Steam Generator (HRSG) Dependability Program (P88)
Vendor Expo 2012
A vendor exhibition will complement the technical presentations. A limited number of 8- x 10-ft (2.4- x 3.1-m) exhibit booths are available for $1200 each (including one pass to the conference). Specialists in the field of welding, fabrication, and forging as well as maintenance engineers, equipment manufacturers, and service vendors are encouraged to display their equipment and/or capabilities.
Following is a list of 2010 exhibitors. Plan today to participate in Vendor Expo 2012!
2010 Vendor ParticipantsABL Co., Ltd.
Applied Technical Services, Inc.
Arc Machines, Inc.
AREVA
Bohler Welding Group USA, Inc.
Bolttech Mannings
Conforma Clad, Inc.
Euroweld, Ltd.
Haynes International, Inc.
Innov-X Systems, Inc.
Liburdi Dimetrics Corp.
Lincoln Electric Co.
MTI Power Services
Olympus NDT
Plymouth Engineered Shapes
Praxair Surface Technologies, Inc.
Proto Manufacturing, Ltd.
Seamoss, Inc.
Stress Engineering Services, Inc.
Structural Integrity Associates, Inc.
Superheat FGH, Inc.
Techalloy Welding Products
TRI Tool, Inc.
TWI, Ltd.
Weldtech Services Corp.
Westinghouse Electric Co.
Accommodations
Marco Island Marriott Resort & Spa 400 S. Collier Blvd. Marco Island, FL 34145
Phone: 239.394.2511 Fax: 239.642.2672 Reservations: 800.438.4373 Meeting rate: $165/night Web: http://www.marcoislandmarriott.com
We recently invested $187 million to make Marco Island Marriott Beach Resort a pure paradise. Nestled on three miles of pristine beach, our elegant but laid-back setting is the perfect backdrop for doing everything or nothing at all. Distinctively warm, Balinese-inspired hospitality creates a welcoming, friendly ambiance in our beautifully remodeled guest rooms and luxurious suites. And every inch of the resort is in perfect harmony with you. So kick off your shoes and relax: the most difficult decision you’ll make during your stay is choosing among a range of diversions that include our fantasy pool and water slide, golf, sailing, parasailing, shelling, kayaking, and sightseeing cruises on the Gulf of Mexico. Welcome to paradise!
International Visitors
Non-U.S. citizens should make sure that they have the proper documentation before traveling to the United States. Due to increased security, the United States has changed some entry and exit requirements that may affect you. Please allow increased time should you need to apply for a visa. All invitation letters should be requested from the EPRI meeting planner. For important information, please consult the U.S.-Visit Program at http://www.dhs.gov/dhspublic/interapp/content_multi_image/content_multi_image_0006.xml or your local U.S. Consulate.
Welding and Repair Technology for Power Plants Tenth International EPRI ConferenceJune 26–29, 2012Marco Island Marriott Resort & Spa, Marco Island, Florida
Registration Instructions
For more information and to register for this event, go to www.epri.com, and select Events at the top of the page. Select Main Calendar, and locate this conference by its date. Click on the link, and follow the registration instructions. If you have any questions, please contact Stacey Wells.
Mark Your Calendar
Conference Reservation Deadline May 25, 2012Hotel Reservation Deadline May 25, 2012
Registration Fees
(Registration fees include all breaks and lunches as well as conference proceedings.)
EPRI funding members ..................................................................................................$450
Other EPRI-member utilities and U.S. government and university personnel ..............................$645
Speakers ...................................................................................................................$450
Others .......................................................................................................................$800
8- x 10-ft (2.4- x 3.1-m) exhibit space (includes one nontransferable pass to the conference) ....................................................... $1200
Exhibit booth staff (entrance to exhibit hall only) .................................................................$200
Students .......................................................................................................................$50
Proceedings
Booklets containing all of the abstracts and author information will be distributed onsite. Conference proceedings will be available post-conference.
Wednesday, June 27, 2012General Session9:00 Greg Frederick and John
ShingledeckerEPRI Conference Intro
9:30 Tom Alley, V.P. Generation EPRI Keynote
10:00 D. Gandy, J. Shingledecker, J. Siefert, and G. Frederick
EPRI Progress on Implementation of Powder Metallurgy and Hot Isostatic Pressing (PM-HIP) for Production of Nuclear and Fossil Components in ASME Codes
10:30 Break
11:00 William F. Newell, Jr. Euroweld The Importance of Composition and Wire Processing for Automated or Orbital GTAW (GTAW-AU)
11:30 Bernd Rutzinger Fronius International
Trends in Power Generation Cladding with CMT in Carbon Fossil Power Plants
12:00 T. C. Luskin, B. T. Alexandrov, J. C. Lippold; Steve McCracken
OSU; EPRI Improvement and Validation of a Newly Designed Cast Pin Tear Test Apparatus
12:30 Lunch
Nuclear Session: Materials1:30 Steve McCracken and
Jonathan TatmanEPRI Influence of Austentitic Stainless Steel Base
Metals on Hot Cracking Susceptiblility of High-Chromium Nickel-Base Filler Metals
2:00 A. T. Hope, E. Fusner, and J. C. Lippold; Steve McCracken
OSU; EPRI Determination of Elemental Effects on Solidification Behavior in High-Chromium Nickel-Based Filler Metals
2:30 E. W. Fusner, A. T. Hope, and J. C. Lippold; Steve McCracken
OSU; EPRI Experimental Validation of Elemental Effects on Solidification Behavior in High-Chromium Nickel-Base Filler Metals
3:00 B. Alexandrov, J. Lippold, T. Luskin, A. Hope, and B. Sutton; Steve McCracken
OSU; EPRI An Update on the Weldability of High-Chromium Nickel-Base Filler Metals for Nuclear Power Applications
3:30–8:00
Vendor Expo Reception
Fossil Session: Performance of CSEF Steels1:30 Jonathan Parker EPRI Recommended Best Practice for Purchase
and Fabrication of Grade 91 Steel Components
2:00 Daniel Saltzmann, Boian T. Alexandrov, and John C. Lippold
OSU Development of Predictive Formula for the A1 Temperature in Grade 91 Weld Metal
2:30 Herbert Heuser; Russel Fuchs; Mahmud Jarrar
Bohler Welding Group Germany; Bohler Welding Group USA; V&M Germany
Experience in the Use of CSEF Steels—In Particular, T24—In Boilers for Modern Power Plants: Lessons Learned
3:00 Xiao Chai and Sindo Kou; Joe Bundy
University of Wisconsin; Hobart Brothers
Creep Life Performance of P91 Steel Welds
3:30–8:00
Vendor Expo Reception
Agenda
Thursday, June 28, 2012Nuclear Session: Applications
8:30 Kyoungsoo Lee Korea Hydro and Nuclear Power Co. Ltd.
Weld Overlay Experiences on Dissimilar Metal Welds of the Pressurizer in the Nuclear Power Plant in Korea
9:00 Dave Waskey; Lennie Daniels
Areva; Constellation
Mini ID TB Welding at Calvert Cliffs Unit 1 Pressurizer
9:30 Barry Ditzler; Alexander Gutierrez
WeldTech Services; PG&E
Innovative Repair Methods and Case Studies
10:00 Break
10:30 Bud Auvil; Jim Puzan Structural Integrity; WSI
Challenges and Alternative Solutions for the Remaining Alloy 600 Market
11:00 P. Doubell; H. P. Burger, C. Van Rooyen, and J. H. J. Rossouw
Eskom Holdings SOC Ltd.; CSIR, National Laser Centre
Leak Sealing of Austenitic Stainless Steel Vessels by Fiber Laser Weld Overlays
11:30 Marc Carnus, Charles Bonan, and Bastien Delaunay
EDF, UTO DET Noisy le Grand, France
Welding Repair During Maintenance Operations on EDF’s PWR Plants
12:00 Lunch
Nuclear Session: Process
1:30 John M. Haake; Eric Willis Titanova; EPRI Overview of Diode Laser Overlay Welding for Nuclear Systems and Components
2:00 Darren Barborak; Dick Smith; Steve McCracken
Aquilex; SIA; EPRI Temperbead Welding and International Codes
2:30 Ed Gerlach and Tommie Blankenship; Troy Blankenship
PPL; Seamoss, Inc.
Weld Filler Metal Control Improvements at the Susquehanna Power Plant
3:00 Break
3:30 X. Yu, R. Smith, D. F. Farson, and S. S. Babu; S. L. McCracken
OSU; EPRI Role of Magnetic Stirring on Grain Refinement and Nickel Alloy Weld Cracking
4:00 Lina Yu, Masato SaSa, Kenta Ohnishi, Kazuyoshi Saida, Masahito Mochizuki, and Kazutoshi Nishimoto; Masashi Kameyama; Shinro Hirano and Naoki Chigusa
Osaka University; Japan Power Engineering and Inspection Corporation; The Kansai Electric Power Co., Inc.
Neural Network-Based Hardness and Toughness Prediction in HAZ of Temperbead Welding Repair Technology for Nuclear Power Plants
4:30 Ing. Lubomír Junek Institute of Applied Mechanics Brno, Ltd.
Computational Modeling of Welding and Heat Treatment Process with Application of Elastic-Viscoplastic Material Model
5:00 Adjourn
Agenda (continued)
Thursday, June 28, 2012Fossil Session: Corrosion and Repair of Wet FGDs
8:30 Brett Tossey DNV Installation and Repair of Scrubber Materials
9:00 James R. McCadden; Thomas L. Johnson
Blome International; Ashland Performance Materials
Polymer Lining Protection for Fossil-Fueled FGD Absorber Modules Fabricated with 2205 Alloy
9:30 Lewis Shoemaker, Jim Crum, and Deba Maitra
Special Metals Corporation
An Investigation of the Accelerated Crevice Corrosion of Duplex Stainless Steel Wet Limestone FGD Absorber Vessels and Development of a Potential Repair Procedure
10:00 Break
Fossil Session: Inspection and Repair
10:30 Jeff Henry and Kim Bezzant Structural Integrity Associates
Inspection Issues Related to CSEF Materials
11:00 Gilbert Poon, Mohammed Saiedfar, and Behzad Alavi
Ontario Power Generation
Alternate Repair Strategies for Thermowells in Fossil Plants
11:30 Kim Bezzant and Jeff Henry Structural Integrity Associates
Successful Weld Repair of CSEF Steels
12:00 Lunch
Fossil Session: Cold Repair of Grade 91
1:30 Marcello Consonni and David Abson
TWI, Ltd. Investigation of Weld Repair Without Post-Weld Heat Treatment for Grade 91
2:00 K. C. Mitchell and S. J. Brett RWE npower Development of Modified 9Cr “Cold Weld” Repair Techniques
2:30 John Siefert and John Shingledecker
EPRI Temperbead Repair of T91 Using EPRI P87 Filler Metal
3:00 Break
Fossil Session: Advanced Plant Fabrication
3:30 B. A. Baker, R. D. Gollihue, and J. J. deBarbadillo
PCC Energy Fabrication and Heat Treatment of Weld Joints in Inconel Alloy 740H Superalloy Steam Header Pipe and Superheater Tubing
4:00 David C. Tung; John C. Lippold
OSU; Babcock & Wilcox
Weld Solidification Behavior of Inconel Alloy 740H
4:30 John Shingledecker EPRI Evaluation of Creep-Rupture Behavior in Inconel Alloy 740 Cold-Formed Tube Bends
5:00 Adjourn
Agenda (continued)
Friday, June 29, 2012General Session8:30 Josef Tejc; Jirí Kovarík and
Václav Zedník; Madhu Nannapuraju and Harald Porzner; Frederic Boitout and Yannick Vincent
Mecas ESI; Skoda; ESI North America; ESI Group
Using Numerical Simulation to Predict the Distortion of Large Multi-Pass Welded Assemblies
9:00 P. Doubell and R. Scheepers; L. Von Wielligh and D. Odendaal
Eskom Holdings SOC; NMMU
Novel Core Sampling Technique for HP Turbine Rotor Remaining Life Study
9:30 Break10:00 Michael Crichton AEP American Electric Power Turbine Casing
Repair Experience10:30 Steve Paterson PIKA Solutions Case Study on Turbine Shell Repair11:00 Phillip Dowson and David
DowsonElliott Group Defect Tolerant Design Concepts Applied
to Welded Rotor Resortation for Power Generation Industry
11:30 Wayne Penn Alabama Laser Laser Cladding Technology12:00 Adjourn
Agenda (continued)
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© 2012 Electric Power Research Institute (EPRI), Inc. All rights reserved. Electric Power Research Institute, EPRI, and TOGETHER...SHAPING THE FUTURE OF ELECTRICITY are registered service marks of the Electric Power Research Institute.
The Electric Power Research Institute, Inc. (EPRI, www.epri.com) conducts research and development relating to the generation, delivery and use of electricity for the benefit of the public. An independent, nonprofit organization, EPRI brings together its scientists and engineers as well as experts from academia and industry to help address challenges in electricity, including reliability, efficiency, health, safety and the environment. EPRI also provides technology, policy and economic analyses to drive long-range research and development planning, and supports research in emerging technologies. EPRI’s members represent more than 90 percent of the electricity generated and delivered in the United States, and international participation extends to 40 countries. EPRI’s principal offices and laboratories are located in Palo Alto, Calif.; Charlotte, N.C.; Knoxville, Tenn.; and Lenox, Mass.
Together...Shaping the Future of Electricity
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