p91 and beyond… william f. newell, jr., pe, iwe, ltd. ipeia conference 1-3 february 2006 the banff...
TRANSCRIPT
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P91 and Beyond…
William F. Newell, Jr., PE, IWE
, Ltd.
IPEIA Conference
1-3 February 2006
The Banff Centre
Banff, Alberta
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SCOPE
Where We’ve Been
Where We’re At
Where We’re Going
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P(T)91 Origin
• Developed by ORNL for Clinch River Breeder Reactor
• Early and Continued European Experience
• Domestic Acceptance Minimal until Recently
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Domestic Reluctance - Why?
Manditory: Elevated Preheat Interpass Temperature
Controls PWHT Required on
EVERYTHING! P(T)91* is NOT just another
CrMo ! (the others too !)
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Compare: B2/B3 to B9/505 Mod.
T/P 22 T/P 91
Preheat Always Always !
PWHT Sometimes Always !
N & T(after cold work) Sometimes Always !
CMTR Rarely Always !
Toughness Rarely Always !
Post Bake Rarely Always ! (except GTAW)
Cool to <100C No Yes ! (?)
Bead Sequence Rarely Always !
Purge No Always !
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WHY?
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Current P(T)91 Usage
• Dramatic Domestic Increase in Last Several Years
• Use Mainly for Cogeneration
• Utility Usage increasing for Repowering, Replacements & New Facilities
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Possibilities
• P91, P92, E911• T23, T24• P122
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Base Metal
Base Material Specifications
P91 P92 E911 T23 T24 P122
Cr 8.00-9.50 8.50-9.50 8.50-9.50 1.9-2.6 2.2-2.6 10.00-12.50
Ni <0.40 <0.40 (<0.40) - - <0.50
Cu - - - - - 0.30-1.70
Mo 0.85-1.05 0.30-0.60 0.90-1.10 0.05-0.30 0.90-1.10 0.25-0.60
W - 1.50-2.00 0.90-1.10 1.45-1.75 - 1.50-2.50
V 0.18-0.25 0.15-0.25 0.15-0.25 0.20-0.30 0.20-0.30 0.15-0.30
Nb 0.06-0.10 0.04-0.09 0.06-0.10 0.02-0.08 - 0.04-0.10
N 0.030-0.070 0.030-0.070 0.050-0.080 <0.030 <0.012 0.040-0.10
B - 10-60ppm - 5-60ppm 15-70ppm <0.005
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Major Differences
• P92 (like P91, but with .5%Mo &1.7%W)
• E911 (like P91, but with 1%W)
• T23 (like P92, but with only 2%Cr)
• T24 (like T22, but with V+Ti+B)
• P122 (like P92, but with 11%Cr + 1%Cu)
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Advanced CrMo’s
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ASME Code Cases
Trade Name
Grade
Material (seamless)
Code Case
Issue Date
NF616 P92 9Cr-2W 2179 8 August 94
HCM12A P122 12Cr-2W 2180 8 August 94
HCM2A T23 2.25Cr-1.6W-V-Cb
2199 5 June 95
E911 E911 9Cr-1M0-W-Cb 2327 2 May 00
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Welding Consumables
Welding Consumables
P91 P92 E911 T23 T24 P122
SMAW
Chromet 9B9
E9015-B9
Chromet 92
*
Chromet 91W
Chromet 10MW
Chromet 23
Chromet 23L
Special
*
GTAW
9CrMoV
ER90S-B9
9CrWV
*
?
2CrMoWV
Special
*
FCAW
Supercore F91
E91T1-B9
Supercore F92
*
Cormet 10MW
*
Supercore F23
*
N/A
SAW
Cormet M91
9CrMoV EB9
9CrWV
*
*
*
Special
*
Potential Patent Issues
* No applicable National Standards.
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Caution Areas
• Design
• Heat Treatment
• Low Bidder
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From the ‘Net…..
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Caution: (design)
Dissimilar
Welds !
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Caution: Dissimilar Welds !
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Design …
1.25Cr 1Mo VP91
PipeValve
E9018-B3 Weld
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PWHT – Req’d by Valve Mfg.
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Dissimilar Strengths…
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Design
P91
Pipe
1.25Cr 1Mo V
Valve
E9018-B3
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Caution: Dissimilar Welds
• Materials may NOT relax at operating temperature
• Watch thickness changes
• Choose Weld Metal Carefully
• Design PWHT Carefully Do not exceed A1 of base or weld metal Assure tempering
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Dissimilar Welds - Solutions
• Consider using transitions Machined transition to change
section thickness
“Pup” Pieces
• Multiple PWHT’s Where A1’s are significantly different
Nickel Base Butter
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Caution (heat ?)
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Preheat…Maintenance ?
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Low Bidder Simple: You get what you pay for….$$
$
Low Overhead usually means minimal technical expertise Susie’s Botique and … Weld Shop
“Offshore Enterprises” May have technical ability, but many
things don’t translate well ….! ASME Codes and USA Contract Documents
may be gathering dust…..
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Low Bidder ?
“…Pay Me Now, or Pay Me Later…” Fram Corp. 1971
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ASME Code Changes (proposed)
• ASME I,PW-39; ASME VIII, Div.1, Part UCS; CC 2179 [P92]; CC 2180 [P122]; CC 2192 [Cast P91] CC 2199 [T23]; CC 2327 [E911]• New Temperature Minimums
• < ½” = 1325 -14700F (720-8000C)• > ½” = 1350 -14700F (730-8000C)
• Rules if heated above 14700F (8000C)
• Why 14700F (8000C) ?
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Beyond the CrMo’s !
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Beyond the CrMo’s
Alloy Nominal Composition Developer
Haynes 230 57Ni-22Cr-14W-2Mo-La Haynes
INCO 740 50Ni-25Cr-20Co-2Ti-2Nb-V-Al
Special Metals
CCA 617 55Ni-22Cr-.3W-8Mo-11Co-Al
VDM
HR6W 43Ni-23Cr-6W-Nb-Ti-B
SumitomoSuper 304H 18Cr-8Ni-W-Nb-N
Save 12 12Cr-W-Co-V-Nb-N
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“Back to the Future…”
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Conclusions
• -B9 (P91), T23, T24, P92 & P122 Base Material & Consumables Available, proceed with caution…
• T24 & 122 Consumables Special
• Caution: Dissimilar Connections
• PWHT is Key to Success
• Beyond the CrMo’s ????
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Questions
?
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References
• Viswanathan, R., et al; “U.S. Program on Materials Technology for USC Plants”*
• Masuyama, F.; “Alloy Development and Material Issues with Increasing Steam Temperature”*
• Scarlin, Brendon, et al’ “Materials developments for ultrasupercritical steam turbines”*
• Henry, J.F.; “Advanced Supercritical Technology: Back to the Future”*
• Maile, K. et al; “Development and Qualification of New Boiler and Piping Materials for High Efficiency USC Plants”*
• Euroweld Seminar; June 2005; Columbus, Ohio*Fourth International Conference on Advances in Materials Technology for Fossil Power Plants, October 25-28, 2004, Hilton Head Island, South Carolina