DESC:FORM 2
THE PATENTS ACT 1970
39 of 1970
&
The Patent Rules 2003
COMPLETE SPECIFICATION
(See sections 10 & rule 13)

DEVICE, SYSTEM AND METHOD FOR EXECUTION PHILOSOPHY
OF TITANIUM WELDING IN FGD ABSORBER
1. APPLICANTS (S)
(a) NAME (b) NATIONALITY (c) ADDRESS(d)
MITSUBISHI POWER INDIA PRIVATE LIMITED INDIAN GROUND & 5TH FLOOR, PRIDE HULKUL, 116, LALBAGH ROAD, BANGALORE, KARNATAKA, 560027, INDIA.

2. PREAMBLE TO THE DESCRIPTION
COMPLETESPECIFICATION
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF INVENTION:

[0001] The present invention generally relates to the field of execution philosophy of Titanium welding in FGD Absorber. More particularly, this invention relates to Exotic material application & welding in Outlet ductwork and stacks of the FGD (Flue-Gas Desulfurization) absorbers for exotic material welding with faster, better, cheaper & safer approach in welding/execution.

BACKGROUND OF THE INVENTION

[0002] Welding systems isa core part of Manufacturing Technology and modern industrial age. From massive assembly operations to controlled manufacturing environments for reactive & exotic material welding, these systems facilitate joining in ever more complicated manufacturing operations. Conventional welding system includes dedicated welding chamber & controlled environment welding in dedicated fabrication shop wherein sophisticated controllers enable individual welders to operate within relevant portions of the process& in In-situ conditions and/or in fabrication shops.
[0003] Titanium Grade 2 has a lower density making it very desirable wherein weight can be a concern. Titanium’s commercial pure (Grade 2) grades corrosion resistance comes from a strongly adherent, stable, protective oxide ?lm, which forms in the presence of oxygen. This ?lm makes the commercially pure titanium grades resistant to most oxidizing, neutral and inhibited reducing, as well as mildly reducing environments. Grade 2 o?ers excellent resistance to attack from moist chlorides, metallic chlorides, chlorite and hypochlorite solutions, nitric and chromic acids, organic acids as well as many gaseous industrial applications.
[0004] Titanium Gr. 2 has a lower density 4506 Kg/m3than C276 which has 8900 Kg/m3. Outlet duct with Titanium Gr. 2 cladding having cost 2-3 times approximate lesser than with C276 material cladding. Hence Titanium Gr. 2 cladded outlet duct material selected for FGD absorber.
[0005] Outlet ductwork and stacks of the FGD system is highly aggressive and quite corrosive. Titanium has demonstrated its exceptional corrosion resistance and most effective life cycle cost in the circumstances. Though the flue gases that flow into the outlet duct have been scrubbed to remove sulfur dioxide and processed through a demister system to remove moisture, they are still wet and have some acidic character. Moisture condenses on the cold walls of the duct. Evaporation resulting from the high flow concentrates the acidic condensate resulting in corrosive conditions. Thus, alloys for the floor and lower portions of the wall may need to be more resistant than those on the ceiling and the tops of the wall.
[0006] Titanium Grade 2, have strong affinity for oxygen. Titanium is a highly reactive material & hence difficult to welding at vendors works, work in-situ condition & also due to intricate shape and dimensions of outlet duct.
[0007] From the aforementioned standpoint there has been a need for awelding device and/or a method, which may be executed with accuracy, aesthetics & quality and may be much better than conventional method. Therefore, there is a genuine need to overcome all the above problems by developing an improved system and method, which is accurate, efficient, dynamic, and simple.

OBJECTS OF THE INVENTION

[0008] It is an object of the present invention to provide economical material selection than conventional methodology.
[0009] It is an object of the present invention to provide faster welding speed than conventional welding method.
[00010] It is an object of the present invention to provide Fabrication, Welding, Erection In-situ at ground level as well as In-site at the height of >25 Meters Outlet Ducts for FGD erections.
[00011] It is an object of the present invention to provide Applicability of Titanium Grade 2 in FGD Fabrication Erection work.
[00012] It is an object of the present invention to provide Joint design/ Batten Strap joint design- shielding and protection.
[00013] It is an object of the present invention to provide a unique Joint design/ Corner joint design- shielding and protection.
[00014] It is an object of the present invention to provide system/set-up for welding of Exotic material Titanium Gr. 2 for FGD absorber In-Situ condition than conventional method which is dedicated chambers at fabrication workshop.
[00015] It is an object of the present invention to provide a system and method which is accurate, efficient, dynamic and simple.
[00016] It is an object of the present invention to provide system/setup for welding of exotic material Titanium Gr. 2 for FGD absorber In-situ condition 100 % than conventional method which is dedicated chamber at fabrication workshop (80%) & In-situ (20%).
[00017] It is object of the invention to provide In-situ condition welding & avoid transportation difficulties of ODC panels (>3 meter).
[00018] It is an object of the present invention to provide a system and method which is faster, better, economical& safer approach in welding/execution.
[00019] It is object of the present invention to provide a system & method which improve quality, productivity, repeatability, efficiency& aesthetics in welding/execution.

SUMMARY OF THE INVENTION

[00020] The present invention generally relates to the field of execution philosophy of Titanium welding in FGD Absorber. More particularly, this invention relates to Exotic material application &welding in Outlet ductwork and stacks of the FGD (Flue-Gas Desulfurization) absorbers for exotic material welding with faster, better, cheaper & safer approach in welding/execution.
[00021] Although the present disclosure is explained with respect to systems and methods for Titanium Welding in Outlet ductwork and stacks of the FGD, it would be appreciated that this application is used for illustration purposes, but it is not a limitation.The various embodiments of the invention illustrateTitanium Welding in Outlet ductwork and stacks of the FGD. More particularly, this invention relates to Exotic material welding FGD absorbers with faster, better, cheaper & safer approach in welding/execution.
[00022] The various embodiments of the invention provideApplicability of Titanium Grade 2 in FGD Fabrication Erection work and also provides unique Joint design/ Corner joint design- shielding and protection. Another embodiment of the invention provides Fabrication, Welding and Erection In-situ at ground level as well as In-site at the height of >25 Mts- Outlet Ducts for FGD erections.
[00023] The present invention provides system/set-up for welding of Exotic material Titanium Gr. 2 for FGD absorber In-Situ condition than conventional method which is dedicated chambers at fabrication workshop.
[00024] In Fluidized Gas Desulphurization Plants (FGD), there are Absorber vessels, tall and Cylindrical Tank where Chemical reaction takes place. These are designed with clad metals. The Flue Gas Desulfurization process for SO2 removal, using Limestone or lime as an absorbent and producing gypsum as a byproduct.Based on Initial notification from Central Electricity Authority, dated 11.12.2017, all the exiting Power Plants were advised to install FGD (Flue Gas Desulphurization Units in existing Coal based Power Plants. This was to reduce So2 emissions to direct atmosphere.
[00025] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[00026] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which.
[00027] Fig 1 is a block diagram illustrating a device, system & method for Titanium Welding in FGD absorber with various embodiments of the invention.
[00028] Fig 2 is a block diagram illustrating aWelding execution philosophy for Titanium Welding in FGD absorber with various embodiments of the invention
[00029] Although specific features of the present invention are shown in some drawings and not in others, this is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.

DETAILED DESCRIPTION

[00030] Embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying figures and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[00031] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[00032] Embodiments of the present invention may include various steps, which will be described below. Steps may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose with the instructions to perform the steps. Alternatively, steps may be performed by a combination of hardware, software, and/or by human operators.
[00033] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that component or feature is not required to be included or have the characteristic.
[00034] Some of Abbreviations used in this disclosure:
FGD: Flue-Gas Desulfurization
C276/N10276: UNS No. N10276
CS: Carbon Steel.
Titanium Gr. 2: B265 G.2 UNS R50400 or equivalent.
Ti: Symbol of element Titanium & atomic number 22
WPS: Welding Procedure Specifications
PQR: Procedure Qualification Record.
NDT: Non-Destructive Testing.
RH: Relative Humidity.
A/C: Air Conditioning.
HF: High Frequency.
GTAW: Gas Tungsten Arc Welding
ODC: Over-dimensioned consignment.
[00035] The foregoing illustrated and described embodiments of the invention are susceptible to various modifications and alternative forms, and it should be understood that the invention generally, as well as the specific embodiments described herein, are not limited to the particular forms or embodiments disclosed, but cover all modifications, equivalents and alternatives falling within the scope of the appended claims. By way of non- limiting example, it will be appreciated by those skilled in the art that particular features or characteristics in one embodiment may be combined as suitable with features or characteristics described in another embodiment.
[00036] The present invention generally relates to the field of execution philosophy of Titanium welding in FGD (Flue-Gas Desulfurization) Absorber. This invention relates to exotic material application & welding in Outlet ductwork and stacks of the FGD (Flue-Gas Desulfurization) absorbers for exotic material welding with faster, better, cheaper & safer approach in welding/execution.
[00037] Although the present disclosure is explained with respect to systems and methods for pulse diagnosis of human being, it would be appreciated that this application is used for illustration purposes, but it is not a limitation.
[00038] In an embodiment, In Fluidized Gas Desulphurization Plants (FGD), there are Absorber vessels, tall and Cylindrical Tank where Chemical reaction takes place. These are designed with clad metals. The Flue Gas Desulfurization process for SO2 removal, using Limestone or lime as an absorbent and producing gypsum as a byproduct.
[00039] Figure 1 is a block diagram illustrating device, system & method for Titanium Welding in FGD (Flue-Gas Desulfurization) absorber (100) with one or more embodiments of the invention. According to Figure 1, illustrating device system & method comprises a selection of CS (Carbon Steel) +Titanium Grade 2 clad material selection than CS (Carbon Steel) + C276at (102); and selection of Typical Welding Geometry at(104);inserting a plate of typical aluminum gradeat (106); welding in sequential methodology at(108); and comprises Titanium welding at Ground level & at height greater than 25 meter In-situ condition (110) with various embodiments of the invention.
[00040] In an embodiment of Figure 1, the typical welding geometry (104) further comprises CS + Titanium Grade 2 Clad Plate (102); welding groove on CS side and completion of CS welding and drilling of 3 mm diameter hole at 2-meter interval for purging during GTAW Titanium Grade 2 welding (102b); Placement of Insert plate 26mm x 2mm [Aluminum AL 1002/Equivalent] (102c); and placement of batten strip [Ti 50mm x 2mm] and welding by GTAW Process (102d).
[00041] In an embodiment of Figure 1, Welding Methodology-Sequentially (108) further comprises of De-Cladding CS+Ti Cladded Plate; Edge Preparation CS-Side; Completion of CS –Welding & Applicable NDT; Purge Hole Drilling (Dia 3 mm per 2-meter Interval); Batten Strap- Welding (Methodology Figure 2) and NDTwith various embodiments of the invention.
[00042] Figure 2 is a block diagram illustrating Welding Execution Philosophy for Titanium Welding in FGD (Flue-Gas Desulfurization) absorber (200) with various embodiments of the invention. According to Figure 2 , illustrating execution philosophy comprises welding & curtains side & top of frames during welding to avoid air draft(202); Dehumidifier for humidity control (204);a Portable Air Conditioner A/C at (206) to control humidity less than 50RH & temperature less than 250C respectively in-situ conditions; comprises cleaning of Filler Metal & weld joint with lint free cloth & acetone before welding(208); comprises use of Primary , secondary & trailing Ultra High Purity(99.999%) Argon Gas(210) during welding & with GTAW Welding Machine having Inverter Base with inbuilt HF(High Frequency), Pre-Gas & Post Gas Functions at (212); comprise measuring tools viz. Oxygen analyzers, Rotameter , Temperature & Humidity meter(214) to measure performance; comprises special stainless steel gridding Aids/Tools Tackles(216) to ensure contamination; and comprises Safety Helmet(218) with hood outside for breathing protection & for comfortable working condition for welding at Ground & In-situ Titanium Welding in FGD (Flue-Gas Desulfurization)Absorber with various embodiments of the invention.
[00043] The present invention generally relates to the field of Titanium Welding in Outlet ductwork and stacks of the FGD(Flue-Gas Desulfurization). More particularly, this invention relates to Exotic material welding FGD (Flue-Gas Desulfurization) absorbers with faster, better, cheaper & safer approach in welding/execution.
[00044] In an embodiment, Titanium Grade 2 has a lower density making it very desirable where weight can be a concern. Titanium’s commercial pure (Grade 2) grades corrosion resistance comes from a strongly adherent, stable, protective oxide ?lm, which forms in the presence of oxygen. This ?lm makes the commercially pure titanium grades resistant to most oxidizing, neutral and inhibited reducing, as well as mildly reducing environments. Grade 2 o?ers excellent resistance to attack from moist chlorides and metallic chlorides, chlorite and hypochlorite solutions, nitric and chromic acids, organic acids as well as many gaseous industrial applications.
[00045] In another embodiment, Outlet ductwork and stacks of the FGD(Flue-Gas Desulfurization) system is highly aggressive and quite corrosive. Titanium has demonstrated its exceptional corrosion resistance and most effective life cycle cost in the circumstances. Though the flue gases that flow into the outlet duct have been scrubbed to remove sulfur dioxide and processed through a demister system to remove moisture, they are still wet and have some acidic character. Moisture condenses on the cold walls of the duct. Evaporation resulting from the high flow concentrates the acidic condensate resulting in corrosive conditions. Thus, alloys for the floor and lower portions of the wall may need to be more resistant than those on the ceiling and the tops of the wall.
[00046] In an embodiment, Titanium Grade 2, have strong affinity for oxygen. Titanium is highly reactive material & hence difficult to welding at vendors works, work in-situ condition & also due to intricate shape and dimensions of outlet duct.
[00047] In an embodiment, the present disclosure is explained with respect to systems and methods for Titanium Welding in Outlet ductwork and stacks of the FGD(Flue-Gas Desulfurization), it would be appreciated that this application is used for illustration purposes, but it is not a limitation. The various embodiments of the invention illustrate Titanium Welding in Outlet ductwork and stacks of the FGD(Flue-Gas Desulfurization). More particularly, this invention relates to Exotic material welding FGD (Flue-Gas Desulfurization)absorbers with faster, better, cheaper & safer approach in welding/execution.
[00048] The various embodiments of the invention provide Applicability of Ti Grade 2 in FGD (Flue-Gas Desulfurization)Fabrication Erection work and alsoprovides unique Joint design/ Corner joint design- shielding and protection. Another embodiment of the invention provides Fabrication, Welding and Erection In-situ at ground level as well as In-site at the height of >25 Mts- Outlet Ducts for FGD (Flue-Gas Desulfurization)erections.
[00049] In an embodiment, it used to be Welding Process earlier where maximum welding (80-90%) fabrication to be done at dedicated fabrication shop partial 10-20 % at site with convention method.
[00050] In an embodiment, Titanium Cladded plate welding arguably the most complex manufacturing processes and especially skill set requirement & dedicated environment required for welding was question while decision on new method.
[00051] In an embodiment, also, maximize productivity & control of Arc processes crucial for Absorber Titanium Clad Plate Welding as most of welding will be done at remote site location.
[00052] This approach, Research & Technology development are assets to us& has proven significant cost savings with the proposed technology in comparison with conventional vendor deputation approach.
[00053] The present invention provides system/set-up for welding of Exotic material Titanium Grade 2 for FGD (Flue-Gas Desulfurization)absorber In-Situ condition than conventional method which is dedicated chambers at fabrication workshop.
[00054] The products can be manufactured with significant saving in welding time, material movement & with high level of consistency, safety & quality under Supervision. Material handling will be far better compared to sending material to vendor end as well as Setup time is less & very flexible & hence can be transfer to other FGD (Flue-Gas Desulfurization)Projects.
[00055] The present invention provides easy usage mechanism. The mechanism provided is easy to work on thereby making the device very user friendly and easy.
[00056] While embodiments of the present invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claim.
[00057] The various embodiments of the invention illustrate specific studies and validations with WPS/PQR qualification &production test Analysis like specific parameters & meets specification/customer requirements.
[00058] The present invention successfully demonstrated at Construction Project and have exhibited the intended results in field of Fabrication, welding leading to overall efficiency in Absorber tank Fabrication and erection.
[00059] While embodiments of the present invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claim.

ADVANTAGES OF THE INVENTION:

[00060] The present invention provides Fabrication, Welding, Erection In-situ at ground level as well as In-situ at the height of >25 Meters Outlet Ducts for FGD(Flue-Gas Desulfurization) erections.
[00061] The present invention provides Applicability of Titanium Grade 2 in FGD (Flue-Gas Desulfurization)Fabrication Erection work. Titanium Grade 2 has a lower density 4506 Kg/m3than C276 which has 8900 Kg/m3. Outlet duct with Titanium Grade 2 cladding having cost 2-3 times approximate lesser than with C276 material cladding. Hence Titanium Grade 2 cladded outlet duct material selected for FGD(Flue-Gas Desulfurization) absorber.
[00062] The present invention provides Joint design/ Batten Strap joint design- shielding and protection.
[00063] The present invention providessystem/set-up for welding of Exotic material Titanium Grade 2 for FGD (Flue-Gas Desulfurization)absorber In-Situ condition than conventional method which is dedicated chambers at fabrication workshop.
[00064] The present invention provides a system and method which is accurate, efficient, dynamic, and simple.
[00065] The present invention provides a system and method which is faster, better, economical & safer approach in welding/execution.
[00066] The present invention provides a system & method which improve quality, productivity, repeatability, efficiency & aesthetics in welding/execution.
[00067] The present invention provides a system where Conventional vendor cost much greater than present Invention. Research & Technology development assets to company & significant cost saving with proposed proposal in comparison with conventional vendor deputation approach
,CLAIMS:I/We Claim:

1. A method for Titanium Welding in FGD (Flue-Gas Desulfurization) absorber (100) comprising:
selecting welding geometry (104); and
inserting welding methodology-sequentially (108), wherein FGD (Flue-Gas Desulfurization)are absorber vessels, tall, and cylindrical tanks where Chemical reaction takes place and the FGD (Flue-Gas Desulfurization) absorber (200) are in outlet ductwork and stacks of the FGD(Flue-Gas Desulfurization);
wherein the cylindrical tanks are designed with clad metals.

2. The method in FGD (Flue-Gas Desulfurization)absorber (100) as claimed in claim 1, wherein CS (Carbon Steel)+Titanium Grade 2 clad material is selected and CS (Carbon Steel) +C276 (102) is provided.

3. The method for Titanium welding in FGD(Flue-Gas Desulfurization) absorber (100) as claimed in claim 1, wherein welding geometry (102) and Insert plate (106) is provided with unique joint design and or system/set-up for welding of exotic material Titanium Grade 2 material in-situ condition.

4. The method for Titanium welding in FGD (Flue-Gas Desulfurization)absorber (100) as claimed in claim 1, wherein titanium welding at ground and/or at height>25 meter and/or in-Situ condition (110) at construction site in the FGD(Flue-Gas Desulfurization)absorber.

5. The method for Titanium welding in FGD (Flue-Gas Desulfurization)absorber (100) as claimed in claim 1, wherein Welding Execution Philosophy for Titanium Welding in the FGD(Flue-Gas Desulfurization)Absorber(200) for titanium welding at ground and/or at height>25 meter and or in-situ condition(110) at construction site in FGD(Flue-Gas Desulfurization) absorber.

6. A system for Titanium Welding in FGD (Flue-Gas Desulfurization)absorber (100) comprising:
select a welding geometry (104); and
insert the sequentially welding methodology (108), wherein the FGD (Flue-Gas Desulfurization)are absorber vessels, tall, and cylindrical tanks where Chemical reaction takes place and the FGD(Flue-Gas Desulfurization) absorber (200) are in outlet ductwork and stacks of the FGD(Flue-Gas Desulfurization);
wherein the cylindrical tanks are designed with clad metals.

7. A device for Titanium Welding in FGD (Flue-Gas Desulfurization) absorber (100) comprising:
select a welding geometry (104); and
insert the sequentially welding methodology (108), wherein FGD are absorber vessels, tall, and cylindrical tanks where Chemical reaction takes place and the FGD (Flue-Gas Desulfurization) absorber (200) are in outlet ductwork and stacks of the FGD(Flue-Gas Desulfurization);
wherein the cylindrical tanks are designed with clad metals.

Dated this13thof November 2022

Nalini Kant Pandey
Bizrights IP Partners LLP
(IN/PA 2187)
Agent for applicant(s)