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Introduction
BOILER
Superheater 3
Lifetime
Reheater 2 Superheater 2
125k oh Convection
Radiation +
convection
200k oh
Superheater 1
250k oh convection
? Reheater 1
Convection
Temperatures: 550-600C
700C
ECO
Evaporator
Pressure: 130-200bar 365 bar Radiation +
convection
Water/steam: 540 tons/hour
Coal consumption: 80-100
tons/hour
C /C-Mn & Mo
Carbon
steels/Low
alloy
CrMo Ferritic
Martensitic
Stainless
steel
Austenitic
Super Duplex
Ni alloys
alloys
5/09/2014 4
Introduction
BOILER - MATERIALS
Steels
carbon vs. alloyed steels
ferrite, martensite, austenite
<650C steam
Examples: St35.8, 13CrMo45, 10CrMo910, 14MoV63, T/P91, T/P92, S304H
Nickel alloys
> 650C steam
Examples: A617, A740,
Costs - /kg
16Mo3: 5
T/P92: 10
S304H: 20
A617: 70
7
According to EN10216-5
8
Introduction: Steel
Metal:
grains with crystal structure
Fe-C diagram
Steel:
Fe + C
ferrite, pearlite
Alloying:
Fe + C + Mn, Si, Cr, Ni, Mo, V, Ti, Nb
increase strength, corrosion resistance, ...
ferrite, pearlite, austenite
Heat treatment:
increase strength
martensite, bainite
9
Source: Metallurgy for the non-metallurgist, Harry Chandler
Date
P22
5/09/2014 11
P22 content
Background of P22
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 12
Background grade 22
Standardized for over 50 years (ASTM: P22/T22, DIN: 10CrMo9-10, BS: 622, etc.)
Used in high-capacity power stations with excellent operating behaviour for pipes
and tubes (and bars, forgings, castings, plates, sheets)
Background of P22
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 14
10CrMo9-10 = T22 = 1.7380
Chemical composition*
Main characteristics
High-temperature strength primarily because of dispersion of fine Mo carbide precipitates
Resistance to oxidation due to higher %Cr
Used to temperatures up to 600 C, although design allows more
Ferrite bainite structure (Martensite when cooled rapidly)
*SOURCE: EN10216-2 15
T22 Chemical composition
Creep characteristics result from precipitations (nitrides and carbonitrides) which will
pin down mainly the grain boundaries.
During long term high temperture exposure precipitates will coarsen (large number of
small precipitates will be replaced by a small number of large precipitates).
Date
T22 Allowable stresses
5/09/2014 17
P22 content
Background of P22
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 18
T22 Manufacturing and fabrication
Microstructures from T22 will depend on the heat treatment, grain size and chemical
composition
After initial manufacturing further fabrication (bending, welding, forging) will alter
microstructure and properties
E.g.Casting is different from forging and extrusion
Altough design codes (e.g. ASME I) are not always clear on these subjects it is still
very important
5/09/2014 20
T22 Manufacturing and fabrication
675C
675 950C
950C 1040C
5/09/2014 22
P22 content
Background of P22
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 23
T22 Ageing
Creep characteristics result from precipitations (nitrides and carbonitrides) which will
pin down mainly the grain boundaries.
During long term high temperture exposure precipitates will coarsen (large number of
small precipitates will be replaced by a small number of large precipitates).
5/09/2014 24
Identification
Microscopic:
Micropores/voids (isolated, aligned, micro cracks, macro cracks)
Cfr.
Laborelec
report CFB1
Microstructural plastic deformation at location of leak
5/09/2014 25
Real Cases
5/09/2014 26
P22 content
Background of P22
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 28
Non GDF-Suez plant Piping T-parts
240.000 OH
Steam temp. 540 C
10CrMo9-10
Severe creep damage at
welds
Accelerated creep process
29
Damage mechanisms
High temperature corrosion
coal ash corrosion
35 LABORELEC
Phenomenon
Coal combustion: at high temperature minerals (in coal)
form volatile alkali compounds and sulphur oxides
Metal temperature: 560-730 C
The volatile components deposit on the fly ash, react at the
interface between metal/deposit and form complex alkali
sulphates (K,Na)3Fe(SO4)3 - low melting point salts: 552 C
Molten slag attacks the protective iron oxides fast
oxidation of metal reduction in wall thickness increase
in stress creep damage
36
Identification
Slag deposits on outer wall of boiler pipes
Loss of thickness of tube walls
Low alloy carbon steel pipes:
smooth areas with loss of wall thickness on the fire
side
30-45 away from the fire side: rough & corroded
surfaces
Strongly adhering sintered or slag-like deposits
Built up of 3 layers:
porous fly ash
white, water-soluble, corrosive alkali sulphates (0.8 -
6 mm thick)
glass, black iron oxides and sulphides (< 3.2 mm)
US wall thickness measurements on 30-45 away from the
fire side min. thickness
Maximum corrosion damage @ 680 - 730 C
37
Conditions
Metal temperatures:
560 - 730 C
Locations:
Superheater and reheater tubes
Also their mountings (higher surface temperatures)
38
Prevention/elimination
bituminous coal
Non-severe corrosion:
Superheater tube
SA-213 T22 Cr-Mo steel
in service for 23 years
Dr. Rama S. Koripelli, Dr. David C. Crowe, Dr. David N. French, and Jonathan Brand
The Role of Fireside Corrosion on Boiler Tube Failures, Part I, Coal Power, April 2010.
P91
Date
P91 content
Background of P91
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 43
Background information on P91
5/09/2014 44
P91 content
Background of P91
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 45
X10CrMoVNb9-1 = P/T91 = 1.4903
Application: Ansaldo and BWE-STF headers
1. Chemical composition
2. Main characteristics
First use in 1986 and today numerous applications in HRSG and coal plants for headers and tubing
Good experiences provided the complete manufacturing and fabrication specifications are respected because creep
strength is governed by chemical composition + heat treatments
Long term creep resistance is sensitive to composition changes; EN10216-2 needs to be followed + supplementary
requirements:
Cu 0.30% weldability
Si > 0.20%
Microstructure is key !
Fine grain heat affected zone has the lowest creep strength due to low carbon martensite and smaller grains. This
is a priority in lifetime follow up.
At temperatures >600C formation of large Z phase (= Cr(V, Nb)N) precipitates over time can dissolve the fine MX
carbo-nitrides resulting in a steep drop in creep properties.
Delta ferrite
Too slow cool down can result in a larger fraction of delta ferrite with lower creep strength.
Laves phase
After 10 to 20kOH Laves phase can form above 600C reducing the creep strength because of the removal of solid
solution strengthening elements W and Mo
5/09/2014 50
Hardness
Hardness translates the tensile strength of the material into a non destructive
measureble method
Used for QA-QC and lifetime calculation due to correlation
5/09/2014 51
P91 content
Background of P91
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 52
Levels of subcontracting !
5/09/2014 53
X10CrMoVNb9-1 = P/T91 = 1.4903
Bending operation shall be qualified for the relevant thickness and lot in production
This shall include all the crucial parameters (methods, temperatures, PBHT and thermocouples)
Location of mechanical specimens shall be in the zone with the maximum straining
For in production heat treatment all essential parameters shall be included in the final documentation (type
of furnace, atmosphere, t-T records, cooling method, thermocouples, calibration certificates)
Effectiveness of heat treatments shall be demonstrated per lot by micrographic examination and hardness
Welding processes TIG, SMAW and SAW are allowed but root pass is to be done with TIG
Filler metals: Mn + Ni content < 1.5% because of long term creep properties
Filler metal Ac1 transformation temperature shall be determined per lot of filler metal
Very important region: cool down shall allow complete Martensite transformation
minimum 1h below 100C
Period cannot be too long, maximum 1 week in dry conditions to avoid risk of SCC
Importance of QA-QC
Temp, C
5/09/2014
300
500
800
100
200
400
600
700
0
-
Heat min of 50mm pipe on either
side of weld to preheat temp of
200 C
Hold at 200C f or 2h bef ore commencing welding
temp
of 300 C
interpass
Weld, max
10.0
'Hot grind' and Hydrogen bake-out at 300-316 C for 4 h
20.0
56
30.0
Time, h
Repair all def ects.
Cool to below 95 C and
carryout 100% MPI + UT inspection.
40.0
http://sharedoc.electrabel.suez/projects/CC
/Internal%20Access/2013/P1310-
28%20material%20specifications%20for%
20high%20temperature%20ferritic%20mart
ensitic%20steels.docx
11/04/2011 60 60
P91 content
Background of P91
Properties
Manufacturing Fabrication
Ageing
Failure Case
5/09/2014 61
5/09/2014 62
Replication void density
5/09/2014 63
P91 Ageing: Laborelec HaVoC
methodology
To answer the need for a practical approach:
LABORELEC proposal: Combination of Hardness measurements and Replication
HaVoC method: Hardness and Void density Creep assessment
Goal: Evaluate by means of zones with intervals for next inspections / actions
Zero-reference highly recommended (Hardness and Replica)
So far only results
on Base Material
Hardness
used as
first
indication
64
P91 content
Background of P91
Properties
Manufacturing Fabrication
Ageing
5/09/2014 65
Context
66
Context
OEM project
Subcontractor piping
Supplier Lateral T
prefab
67
Context
68
Context
69
70
Further inspection results
Local repair is not an option
Design is not according to best practice: welds concentration
Hardness drops below requirement values
After taking a boat sample erroneous filler metal is noticed in
the root
Nothing found in QA documents
After further inspection: NOT a single case!
71
Corrective measures
Check and repair of all P91 welds for erroneous filler metal
Rework of lateral T (taper end) with smooth thickness
transition + Normalizing & Tempering (South Korea)
72
Conclusions
73
Heat Treatment
5/09/2014 74
Warmtebehandeling hooks and eyes
What is it?
Why?
Mechanism
Execution
Hooks and eyes (pitfalls)
What is it?
Heat Treatment
Normalizing
Tempering
Hardness
Stresses
500
As welded Residual Stresses
450 560C-24u
560C-50u
.
400 560C-500u
560C-1000u
Hardness (HV10)
350
300
250
200
BM HAZ WM HAZ BM
150
Mechanical properties/
Corrosion Behaviour (brittle
Stress Corrosion fracture, fatigue)
Tolerances
Mechanism 1
No change in microstructure
Deformation!!!
Cracks !!!
Temperature &
yield strength Decrease in
residual stresses
Regrouping of
dislocations Reheat
cracking
Stress
corrosion
Mechanisme 3
Temperature gradients
Execution 1
Temperature Efficiency
Uniform Thermal
Gradients
Heating- and Cooling rate (bv 150C/h)
Execution 2
Critical transformation
temperature ?
X20
Execution 3
How?
Uniform
Induction
MANDATORY!
Used method(s)
300
500
800
100
200
400
600
700
0
-
Heat min of 50mm pipe on either
side of weld to preheat temp of
200 C
Hold at 200C f or 2h bef ore commencing welding
Execution 6
temp
of 300 C
interpass
Weld, max
10.0
'Hot grind' and Hydrogen bake-out at 300-316 C for 4 h
20.0
30.0
Time, h
Repair all def ects.
Cool to below 95 C and
40.0
Deformations
Free
expansion? Cold
Temper beading repair
Hooks and Eye s
Controlled deposition !
Too Low
Thyssen 720-760C
4h
Hooks and eyes 5
Holding time
Too short
Too long
Wrong calculation
Grade P91
Hooks & Eyes 9
Crack formation
Reheat cracking
Sensitive microstructure: Coarse grain HAZ with strong matrix and weak grain
boundaries
Hooks & Eyes 10
100
90
.
80
70
60
Reduction of area (Z%)
50
40
30
20
10
Licht Reduction of area (%) > 20
Sterk
Extreem
Unsensitive
0
400 425 450 475 500 525 550 575 600 625 650 675 700 725 750 775 800
Temperature (C)
Hooks & Eyes 11
Intercooling
Tempering of martensite
Grade 91
Hooks & Eyes 12
Tussenkoeling temperatuur ?
T < Mf
Hooks & Eyes 13 X20/10CrMo9.10
P91/P22
P91/Super304H
Dissimilar Welds
Different possibilities:
5/09/2014 98
Hooks & Eyes 14
Etc.
Q&A
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