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DILLINGER PRESSURE VESSEL COLLOQUIUM
DILLINGER HÜTTE GTS
16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Giacomo Fossataro(Walter Tosto SpA)
Walter Tosto SpA was founded in 1960 by Mr. Walter Tosto
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
1960 2009
First steps of company activities Nowdays, Company awarded with “INNOVATION PRIZE 2009”by The President Of the Italian Republic G. Napolitano
Walter Tosto SpA is located in the central part of Italy with shops in Chieti Scaloand in the port of Ortona
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Production range covers the most critical components of a petrochemical plant such as Reactors, HP heat exchangers and Process Columns using the most
advanced and sophisticated steels
Fabrication of heavy wall reactors made in CrMo(V) plates
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Case Study: fabrication of a CrMoV reactor
Fabrication of heavy wall reactors made in CrMo(V) plates
500 MTTOTAL WEIGHT
ASME VIII div.1/PEDDESIGN CODES
150 mmSHELL THICKNESS
4500 mmINTERNAL DIAMETER
-25,2°CMINIMUM DESIGN METAL TEMPERATURE
450°CDESIGN TEMPERATURE
92 bargINTERNAL DESIGN PRESSURE
REACTOR DATA
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Courtesy of Axens
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Adopded materials:
- Shell by plate in SA 542 D Cl 4a- Heads by plate in SA 542 D Cl 4a- Shell course with catalyst grid support ring by forging in SA 336 Gr F22V-All materials (including consumables) are procured in compliance with the most stringent market requirements, including both API 934 A and Axens Specificationfor chemistry limitation (ultra clean steel with very low level of tramp elements)
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
1042,14Actual Values
<= 15<=100Requested
X-barJ-factor
Fabrication of heavy wall reactors made in CrMo(V) plates
-22.5°C< 10°C
SAW (Tandem)Step CoolingTest
at 1/2 thk. WMV Tr 55 + 3 (V’Tr55-
VTr55)
N/mm2N/mm2
539T.S. >509
SAW (Tandem)HOT Tensile at 1/2 thk.
[At +454°C]
N/mm2N/mm2
465Y.S. >345SAW (Tandem)
HOT Tensile at 1/2 thk.[At +454°C]
N/mm2N/mm2N/mm2N/mm2
NW198÷205
HV10
< 248 HV10
NW217÷221H
V10
< 248 HV10NW
135÷170J
Min >48J
Avg >55J
NW162÷174
J
Min >48J
Avg >55J
619 ÷ 628T.S. 585
÷ 760634 ÷659
T.S. 585 ÷ 760SAW (Tandem)
at 1/2 thk.
N/mm2N/mm2N/mm2N/mm2
HAZ192÷204
HV10
< 248 HV10
HAZ188÷216H
V10
< 248 HV10HAZ
244÷250J
Min >48J
Avg >55J
HAZ139÷194
J
Min >48J
Avg >55J
497÷513Y.S. >415548÷583
Y.S. >415SAW (Tandem)
at 1/2 thk. (A.W.M.)
ObtainedRequiredObtainedRequiredObtainedRequiredObtainedRequiredObtaineRequiredObtaineRequired
Hardness Test PWHT max (710°C
x 26h)
Hardness Test PWHT min (710°C x
8h)
Impact test PWHT max (710°C x 26h)
[At -30°C]
Impact test PWHT min (710°C x 8h)
[At -30°C]
Tensile Test PWHT max
(710°C x 26h)[At +20°C]
Tensile Test PWHT min
(710°C x 8h)[At +20°C]
Welding Process
Adopted welding process with some test results
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
-27.5°C< 10°C
SMAWStep CoolingTest
at 1/2 thk. WMV Tr 55 + 3 (V’Tr55-
VTr55)
N/mm2N/mm2
523T.S. > 509SMAW
HOT Tensile at 1/2 thk.[At +454°C]
N/mm2N/mm2
442Y.S. > 345SMAWHOT Tensile at 1/2 thk.
[At +454°C]
N/mm2N/mm2N/mm2N/mm2
NW193÷199
HV10
< 248 HV10
NW200÷208H
V10
< 248 HV10
NW102÷117
J
Min >48J
Avg >55J
NW126÷149
J
Min >48J
Avg >55J
624 ÷ 639T.S. 585 ÷
760639 ÷ 660T.S. 585 ÷
760SMAWat 1/2 thk.
N/mm2N/mm2
N/mm2N/mm2
HAZ191÷200
HV10
< 248 HV10
HAZ187÷213H
V10
< 248 HV10
HAZ170÷194
J
Min >48J
Avg >55J
HAZ189÷211
J
Min >48J
Avg >55J
502÷516Y.S. > 415552÷591Y.S. > 415SMAW
at 1/2 thk. (A.W.M.)
ObtainedRequiredObtainedRequiredObtainedRequiredObtainedRequiredObtainedRequiredObtainedRequired
Hardness Test PWHT max (710°C
x 26h)
Hardness Test PWHT min (710°C x
8h)
Impact test PWHT max (710°C x 26h)
[At -30°C]
Impact test PWHT min (710°C x 8h)
[At -30°C]
Tensile Test PWHT max
(710°C x 26h)[At +20°C]
Tensile Test PWHT min
(710°C x 8h)[At +20°C]
Welding Process
Adopted welding process with some test results
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
A) Longitudinal welds
B) Nozzles and heads welds
C) Circumferential
Typical Heat Treatment Sequence
x 8h710°C (±5°)PWHT
x 6h650°CISR
x 6h350°CDHT
Summary of adopted heat treatments
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
- Hot forming of petals at 950°C
- Quenching & tempering of petalsaccording to mill recommendation
- Warm calibration of petals (at 250-300°C)
- Fit-up and SAW welding followed by ISR
- Machining of circumferential bevel
- Fit-up and welding of nozzles followed by ISR
HEADS FABRICATION
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
- Warm rolling of plates (at 350-400°C)
- Fit-up & SAW welding of longitudinal seamfollowed by ISR
- Machining of circumferential bevel
- Fit-up and welding of nozzles followed by ISR
SHELL COURSES FABRICATION
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
- Weld overlay by double heads ESW process type 347
FABRICATION OF SECTIONS (3 courser or 2 courses + head)
- Circumferential fit-up and SAW weldingfollowed by DHT
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Automatic system of pre-heat/interpass management
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
“Drying and feeding fluxsystem designed and manufactured in-house.”
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
- Assembly and circular welding of main sections, followed by DHT
REACTOR COMPLETION
- Assembly and welding of external & internal appurtenances
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Main Non Destructive Tests
PT - UTPT – UT - FERRITEOverlay
MT – TOFD - PHASED ARRAYMT – TOFD - PHASED ARRAYMT – TOFD - PHASED ARRAYNozzles welding
MT - TOFD - MANUAL U.T.MT - TOFD - MANUAL U.T.MT - TOFD - MANUAL U.T.Circumferentialwelding
MT - TOFD - MANUAL U.T.MT - TOFD - MANUAL U.T.MT - TOFD - MANUAL U.T.Longitudinal welding
AFTER HYDRO TESTAFTER PWHTBEFORE PWHT
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
– Rejected except if classified as another type of defect and passing ASME Code requirements.
1) Greater than 20% DAC -Reject
2) 10-20% DAC- Investigate and Characterize
RejectionCriteria
Primary objective is to determine if indication is planar and transverse.Look for >9 dB difference between the 70 and 60 degree scans (45 and 60 degree for depths greater than 120 mm). If > 9db (Hdmax-Hdmin) then classify as planar. Compare maximum signal obtained from transverse and parallel directions with thesame probe that produced the maximum signal (Figure 4) if the difference is >9 dB, the defect can be considered transverse.
Based on EN1713 (except no minimum amplitude and no echodynamic evaluation)
FlawCharacterization
Both directions along weldScanningDirection
Scanning for transverse flaws or “A-scan”, however this terminology is not consistent worldwide.Along ground weldScanning
Location
+ 14 dB above reference levelScanningSensitivity
Holes at multiple depths and some EDM notches are typically included.
3 mm side drilled holes (DAC set-up)
CalibrationReference
Multiple probes are used to “cover” the near and far zones:•70 degrees covers about 10-100 mm,•60 degrees covers about 50-150, and•45 degrees covers the deeper areas.
70 (primary detection angle), 60 and possibly 45 degrees
ProbeAngles
Transducer frequency should be 4 MHz for near side examination and 2 MHz for depths greater than 100 mm.
2 to 4 MHz (focused if necessary to achieve adequate resolution at
maximum depths)
ProbeFrequency
Flush GroundSurface Condition of Welded Joint
CommentsRecommendation
Manual Shear Wave Procedure for Identifying Transverse Reheat Cracks
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
POST WELD HEAT TREATMENT
The whole reactor has been treated in furnace with target 710°C +/- 5°C.
During the soaking time the temperature range was between 707°C and 714°C
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
10x11x28,5 mt.Furnace Dimension
Fabrication of heavy wall reactors made in CrMo(V) plates
FINAL ACTIVITIES
- Assembling and welding of bottom nozzles and skirt + local PWHT
- NDTs after PWHT
- Hydrotest
- NDTs after Hydrotest
- Painting, cleaning, blanketing etc.
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Conclusion
Some of the winning factors for a safe reactor fabrication
- Intensive training of all involved personnel- Special care in consumable management system- Reliable automatism in preheat/interpass continuous control- Development of appropriate welding procedures- “Locked” welding parameters in production and automatic continuous record of them- ISR furnace located inside the shop- Severity in NDTs (Specific training and qualification for the operators)- Reliable PWHT procedure, furnace & skilled personnel to guarantee precise temperature (+/-5°C)
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates
Thank you for your attention
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009