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Repair procedure for lens ring sealing faces of nozzles

1.

General

After years of operation severe corrosion can occur on sealing faces of lens-ring
gaskets. To ensure a leak free connection in the future, repair of the lens-ring sealing
face might be necessary face. This can be done by overlay welding followed by remachining of the complete surface.
Since re-machining is difficult or even not possible on site the best way will be to cut
the flange part and perform all operations in a machine shop. Machining of the flange
face needs to be done at an angle of 20 with a surface finish of 0,4 - 0,8 Ra.

2.

Cutting and re-welding of flange part

Generally the flange is buttwelded to the nozzle on HP equipment. This nozzle is

fabricated by overlay welding a thick walled carbon steel nozzle (see sketch annex 1).
When cutting the flange care must be taken not to grind too close to the carbon steel
part.

2.1

Repair procedure

1. Before cutting the flange, the length of the nozzle needs to be determined.
2. Cut the flange at the centre of the butt weld.
3. Make a new weld preparation on the nozzle part with a bevel of 30; the root tip of
the weld preparation should be at certain distance from the carbon steel shell,
related to the fabricating drawings (in this specific case 251 mm, see specific
case in sketch annex 1). In this way all old weld metal will be removed.
4. Remove all corrosion on the bore side of the nozzle part over a distance of
approx. 15 mm by grinding until white metal.
5. Perform a DP-check of all ground surfaces.
6. After repairing the sealing face, position the flange on the nozzle using a rootopening of 2-4 mm.
7. All welding to be performed using GTAW with filler metal type 25.22.2LMn.
8. Boreside of weld with slight overthickness only to avoid turbulences behind the
weld during operations.
9. Apply backing gas (N2 or Ar) on bore side and maintain until a weld thickness of
minimal 10 mm is obtained.
10. All welding in stringer beads; weaving is not allowed. Maintain interpass
temperature of 200 C max.
11. Perform DP-check of ground area and adjacent base material.
12. Perform DP-check on internal and external part of repair including adjacent base
metal.
13. Perform radiographic examination using single wall technique.

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3.

Repair of sealing face on flange part

To obtain an optimal seating of the lensring, the complete sealing face has to be
overlay welded.
The weld preparation will be made by machining the old sealing face under 20 till
10 mm next to the end of the sealing area (see sketch).
The remaining corroded part of the sealing face towards the bore side needs also to
be removed entirely to sound metal.
Before machining document all essential measurements of the sealing face. Use
non-corroded external parts of the flange to align flange during machining.

3.1

Repair procedure

1. Take all essential measurements of flange.

2. Remove all corrosion on the bore side by machining over 5-10 mm next to the
weld preparation.
3. Build up the machined stern face next to the bore until in line with the
20 preparation.
4. Overlay weld the future sealing surface from bore side till end of 20 preparation
in minimal 3 layers by GTAW with filler metal 25.22.2LMn; minimal overlay
thickness 4 mm.
5. All welding in stringer beads in circumferential direction and maintain an interpass
temperature of 200 C max.
6. Machine the sealing face under 20 with the stern face of the flange till the
original dimensions according to item 1 are obtained.
7. Machine the welding on the bore side until in level with the internal bore diameter.
8. Machine the over-thickness of the weld on the stern face of the flange till an even
surface has been obtained.
9. Grind/polish the sealing area to obtain a surface finish of 0,4 0,8 m Ra.

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Repair of lens ring sealing face

outside flange screw thread

flange side

20

10
Weld preparation for
overlay welding of
sealing face
according to dashed
line

0,4-0,8

Sealingface after stripper

machining and
overlay weld.
Finish to 0,4-0,8 um
Ra
bore side

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