Materials, Fabrication, and Repair Considerations for Hydrogen Reformer Furnace Outlet Pigtails and Manifolds
API1ECHNICAL REPORT 942-A FIRST EDITION , JUNE 2014
........
energy ~~
A M ER I CAN PET RO LE UM I NST IT UT E
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3 3 .1 3.2 3 .3 3.4 3 .5 3.6
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11.'''''.01 Ir>d ... try Su""'y .... ... .... ... .... ... ..... .. ..... .. ..... .. ..... .. ..... .. ..... .. . 1& Ge~" 1& De.igne,. 01 1I.lorm . ....... ... .... ... .... ... ..... .. ..... ... .... ... .... .. ....... ... .... ... 19 loc.tion 01 Outlet ManJloId and P ig .. ils 1I.laIi"" to f ir.box ... ... .... ... ..... .. ..... .. ...... ... 19 Distribution 01 1I.lonne,. .. ..... .. ..... .. ..... .. ..... .. ..... .. ..... .. ....... .. ..... .. . 20 O!>eraling COftdrtiOfl. : Temj>Or• •", •. Pr• •• ur• •• rod Cyclic Operation ..... .. ..... .. ..... .. .... .. . 20 Manifuld Syst.m ""Ioys .... ... ..... .. ..... .. ..... .. ..... ... .... ... .... .. .. . .... ... .... ... 21 .nd Problem •. ... ..... .. ..... .. ..... ... .... ... .... ... .... ... ...... ... .... ... 22 Pigtail "'.pecboo pr_om • ... ..... .. ..... .. ..... ... .... ... .... ... .... ... .... .... ..... .. ..... .. . 2J lI.pai ... Modilication •• or Upgrode • . ... .... ... ..... .. ..... ... .... ... .... ... ...... ... .... .. . 2J Str . . .... up... r. Behovior 01 ... ,Ioy. ... d W.Id •... .. ..... .. ..... .. ..... .. ..... .. ..... ... .... ... 2J
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Co• • l: CreepCr.>elde.- Weld •..... .. ..... .. ..... .. ..... .. ..... . ..... ... C••• 2: Creep Fa ihlre olOutiet H•• rIer . .. ..... .. ..... .. ..... .. ...... . ..... .. ..... ... .... .. . C••• 3: Pig .. il llupt"' •• . .... ... .... ... .... ... .... ... .... ... .... ... ..... ... ..... .. ..... .. . C••• 4: Str • •• 1I.lax.tion Crac ~in g 01 ""Ioy 800HT Pigtail S. c'iOfI ... ..... .. ..... .. .... ... .... .. C••• 5: W.ldability I. . .... with Caot20Cr-32Hi_rI> . ..... .. ..... .. ..... .. ..... .. .... .. ..... .. . Co• • 6: lI.pair ... d MitigatiOfl 01 Co st 2 0Cr-32Hi.., b Toe • .. ..... .. ..... .. ..... .. ..... .. ..... .. . C••• 1: Cracking.t Weld Betw..en on "'loy IIOOHT FOfl/Od f itting and ...... lIoy 800HT Oude. Tr... . I. r l ine .. ..... .. ..... .. ..... .. ..... .. ..... .. ..... .. ..... .. ..... . . .. ..... .. ..... .. .
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"'nnex ... r.,""""'tiY.)""o ly.i. 01 Stre • • _ruptur. Do .. U.ing l . .. oo _fohller Para met.r .. ... .... ... .... .. 4 5 Bibliography .... .. ..... ... .... ... .... ... .... ... .... ... .... ... .... ... . . ..... .. ..... .. .... ... . oW Figur • • 1 Example 01 HA..lliqualiOfI Cr.>eld T.mpera tur. lI.nl/O' IOf St.om ..... tII .... 1I.' orming ... .... ... .... .. ..... .. 6 Typica l De.ign. 01 Outlet M.... ilold System • .. .. ..... .. ..... .. ..... ... .... .. ..... .. ....... .. . 1 Typica l De.ign. 01 Outlet Pigtail Syst.m •.... ... .... ... .... ... .... ... .... ... ..... .... .... .. . • Oistribu'ion 01 R. lonner De.ign.,. in 5 ....... y ... .... ... .... ... ..... .. ..... .. ..... .. ....... .. . Distribution 01 1I.lonne,. in Surv. y ..... .. ..... ... .... ... .... ... .... .. ..... .. . .. .... .. . 9
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Materials, Fabrication, and Repair Considerations for Hydrogen Reformer Furnace Outlet Pi~ils and Manifolds 1 Scope The AmeOean P1>troieum ""tiMe (API) Committee 00 Rell>er)o Equipmenl, SutH:ommittee on COIT_ a nd Mal_Is urwlen_ • proiecl 10 develop _ ledloi . Hq, reIOabdir; 01 outlet pigtails and manlokl e~"""to , ..,ch he ader> , tee., and fmi'l ll', is important 10 the .""u..IuI~ _ lem1 <>peralion 01 hydrogen and .y~ • • reIormer /u",. eeo. The..., compooento 1ypitiolly oubjeot
a.
In recent ye~ a number 01 relolm.,.. """"ce operalOB ha"" en\i _ clle e ..... 01 pig"" and manilold e ra a in<) problem. and i'>d ~e <1 e,peOence g.ained from ~ """"It)' _ regO
out"',
1iII,.,
The objeetive 01 the proieet was to develop a n oode<>tan h . "" not had ..,ch problem.
2 Teoc hn ica l Appro.1ch The proiect object"'" '01" a cfliell1>d by reviewing _""'" II"l>Iohed literal"", and indY.tr)' expe_u and the<> do<<>mentin\l tI1e "'""~ 0 1 th. t review in "". """" The II"bIioI1ed ledloig IotK d.tab8seo
E nlli'><~ ~e
CSA
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2 l'tlttp JIwww.emiroeeringvi!lace2 .orgll,
Rese arch D_..., ... ith METADH (M!p:""""", .00' com!\,
REF IH"COR S.D dotab ... e (M!pJIwww.!!ICC.omIl
t>a..,.
were . ""lIabie throg Inoltufoe (TW I), while the IoOOh ooe ..... o v _ 1hr~ NACE in_ . Iio.,..1. The S~ " .., ... e re alOmber of relev_ foechni<:aI papeB . The.., oympooj. proceedinQ> are II"bbhed searellable CD., whi:l'
...,,,,,,1Ied
a.
IndOJ.tr)' ........... <"/ed by ooeodin<j • QUestionnaire ., key P<. 5oeond , ~ ...as "",t to individYai. in eompMie. !hat <>perale relolmer tuma ce. in oIher indY"""". or in infoemotional refnin<) «>rrpanie. no! . 1IJi,ated wth API. 5 0 ' - 6 of this repobIished Iitera""e th. t is c;ted herein The """"es of indYouy eommemo ha"" been kepi anonymou.; eoeh re.pondont is _ ply identifted by a e _ . The inkllmatioo . nd
, d ... ", . t . ,,,. obtained from the _ow", ond irMIYOIry ..... eys ore """ma
" pre"""",","
1'Indngo
,.porI: (1) materiolo ..,lection, <00....., _ _ lion, (3 1...eld~ 000 "par lIfo etiees, (4 ) me cl\arjeal des9>, and (51 eo ... studies. 000'\' equipment"'' ' i.
3 Results 01 LiterOllure Survey 3.1 Geoerol Thio _lion o! Ihe re""" """""'" !he res"" of !he loeralUre ........ ...,. The IoIIowing subsection. eorreopond '" !he trle major t.
3.2 3.2 .1
Ma! .... ials Selection Gene .. t
._.Iion,
Qualitieo rOQal I.tigue s,,""')Ih, and = e p-rupt e"'4H'f8ture equipmem o re thelma! de~ad . t ioo , ""
stress
3.2.2
relax._
er.Wr>g_
T.... rm.1 [)egra d.bOfl
Thermal de9r. d~ . moot "",.bIy creep. io the prim ..... damage me cho .. "", lor hqI~empe<""'" """';ee TIler< are hiotoricol e -temperoture . .. e•• _ru!'""" 1.iIOre. in Type 304 .teel piping. _<1>.00""", . _ <_empMe<1 wiII1 one m_ 01 the HU olio)' be""u •• of the impro.ed _,.,/ of ~ 600. wtoieh in IUm wn . ttrib<Jted to ito lowe< roV1>d dug <entrillgaly ent pipe m_ 1rom HT modi1led...,.,. (2OCr_35Ni) material be""u.., 01 ito h9t _able ove the rupture or ereep .tren<)th 01 Type 310 ",rough, .. _ . . .teet . BI>ckbdord ..... ,....... '""' olio)'
..,_01
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The . . aIoyo. ineludi'>g ~ 600 •• f io <....-en1I\' s:>eei1led • ...., mentioned here 001)' from the hiotoricol . iupoir" aod "'" 00 Iooger uoed in OOIIe, mandold ..,. .. .".,. . POOr 10 the introdu<_ 01 ~ 600H in 1973 and ~ 800KT in 1989. the ~ 800 material often .. tide"; 600H • •• ~ io <..-ren1iy oper>
.-
rtie.
CUrfffilly, AIIo~ &OOHlHT and its delivat""'s, ""'~ eost 2OC , -32Ni-l'lb , "'" ... ed e ,"nsivel\' in h9htemper.Me ..,rvice, and _ _ and perIorm"""e are of coo.idenoble inte,e." The Special ~. Corpora_ "" .,.teo !hat AIIo~ 6001 .nd AI< rel="nofollow">'; 600HT .on""," !>ave highef creep and rupture .trength than AI<>'; 600 . A. summarized in T _ I, AI<>'; Il00, 6OOH , and 600HT 'Of)' only wit> respect to earoon, . Uminum, and titani<>m cooten" and minimum gorain oi.ze . The , ~01 _ _ carbon '; BOO 1<> AI<>'; &OOH '" AJm <J the cherniUy requirements o f AJ'; 600H , and ""Y 101 o f m."'rial . ati.1yinanieal than the ~ at room ",""-.IUre, _ AI<>'; 800H and fd10y 8()(ltjT h o ve """""'" and flJ!I!"'" ' "-''' ...men opero~ ot hiIIh temperature kif e,tended period. of time
alum......,
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Table I _ Chemica l Compo.rtion a nd Gra in Size Re quiremen ts for the Va ,ia nts o f Allo ~ 100
1' 1 Poor .. ' . 13_
' ''' ' , '''~
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_
~00
_ _ _ , . . _ . _. Thu>.
, . _ .. ~803_~ ...... OHH .............. ~"""or~so:tIT .. ............... _
"'" S3O " ~ h •• """ ... t 01 .V~ and minimum (
,
,,_;.,,0
.... "'plure e ........ that apply to both Alloy
0001 1 ..... Aloy I)ODt ' T, The •• "'" .... ""d "" a n ...... '" ."" • ...."...'" d a t ........ the l ....,.,. ~ p.,.am"'e<"~, The do .. and procedure. used to
= "', An"",
. ... ~ and minim"", tensile yield nCfl\lth lor Alloy 600 and both AI<>'; &OOH ""d Alloy 600HT • • 0 ","c_ o f t. q>eflIture . ~ . too h ... equation. kif the hiIIl>-tempero"". fa t""" nCfl\lth 01 AJ'; BOOH and Aloy 800 HT !>ave _ , beho vior, wtlich .. ",pre_ted by """ .... 01 cu"",. in b,II', API S30 " " and "'" S1!1- IJASM E FF S_l I,,",
.,,,,os.-rupt,,,,,
"""o--rupIUre
Exampies 01 n streos-ruplure pe'; 600HT are used kif their 0 ", reported to ho ve \IOOd o xidation and o:ort>OOzation resi"",nee ,,~
h9h~.q>eflIture .trength .nd
""tit
F ioIte<"~ than the wrought Alloy 600 . He determined "'at =~1Iy "" .. 2OC ,--32N~Nb m.terial (the east "equivalent" of AI<>'; 800 ) _ be uoed • • • 9",e \IOOd weldabMy .ne, PfOIonIIe-Nb alloy ..... induoUy exper;ence ... ith the streu-rupl'''' perbmton&e of this alloy ore pre.ented.nd dOscuosed loter n • . 10. With reg.rd to 2OCr_ 31N~Nb eo01 _I", Shibj
_.Iiv..
P. tb and Sehillmoler " n _ that Alloy 600H had • low t _ e - ; ",,..rds . mbrit&ement but noted thot the 2OC1 _ 32N ~ Hb ""ot alloy Ito. ltjghe<' c,.,.,p . nd ruP"". otr.~tIt than AJ the 2OC ,--32N~Nb ea ot material; they _oted that n _ - m e \11'....... _ be
•
<_
KoIIman "~ evaIua1ed the 09inII 01 2OCr_32N>-Nb <&S~ • .tIe< 21 mootho 01"""';« a t B52 · C (1565 "F) and Ioood _ M" C, and rn em>e " ~< N ~ i _ pre
-.
<_
H<>IIm.., and Go pi"'~ 001 evoluated ...",pie> of . :/OC , -32Ni-l'lb ""'" oo&e1 m. " _ !hal I>ad de~ ! .liguoe jde «>ale><ence. The
_1\I1>d
obo.,.,..,d a lli'>\l.q.iliOIoh "'pacr = . tal1« , .t1eU-rupIfeoglh and w eldabili!y of !he mot eli.al . The earbOe. and silicide. Wefe -.oonized I»' ~ io n """"*'11 ., lD9]'C (2000 "F). _ ' ' ' ' ' '. <~Io t e ooIutionilin<) 0 1 "'eroidiz. _ of !he prim"'Y """,ired • miniroom -..;on of 1149'C (2100 "f ). Ben .. SIreDrupture proped I»' ~ion.......,aIing " 12()o1'C (2200 Of ) "'an by - . . ..... .t 1093 'C Of 1149'C (2000 of Of 2100 ' FI_ The 10 and mainlainin<J . "'",_iii< NbIC ratio of 1.1.
<._.
.......,.Iing tern.,.,..""""
_ g
An _~ ...... made 10 1lrwI1i'ne-"""\H'~~ t .... _... n.lDfTM_ (TTT)
pre""''''''
3.2 .3
MetalO ... ting
Metal du" ing is 0 ~h _lemper""", eorrooion me <:llonenta ... hO«> the coroon o ct ... ty e «""do one . nd the metal tempeefOture r""9", '" metal dm1il>J io not 0 major ioooe for "'e ou&et m,,,,,101do and pigta i10 _ressed n the mm<>nIy encountered in . yog .. plan" .nd ..,me ,.. .. Ie he . t boiler> . Snce metal dm1il>J io not • oigndieant coo<em for "'e O
..,.""ptibIe
w"'" _
&harg.~ "" ""med oot "'., "'e ..,lection of "",' eli.ol h.. . oignhont irrpa<1 00 the re.istance 01 • eomponefll 10 m etal dusting, bYt no .1Ioy is comple1e1y re.istant '" metal m n _ c .tainless, ..... e nitic .tainleu, and nd e , ""sed oI1oyo nereooeo re.istance 10 "'e pIle"""",noo . A. "'" amount of iron n ere . ..... !he ",Ie of metal dusting inerea ..,. in both lenib< and • . , . _ ..... Ie.. .. eel Nic kel n ere . .... resistance '" metaldmtng n ",ck_sed alloys, but decre .... . !he reoj","""" of • . , . _ c oteelo . The _ - . oI.iIi
"'Of
.tainIes. _1"_
The M_rioIo Te-Nb . 1Ioy . The «>n"CIOOiIioo 0 1 "'" AIoy 600 m.,erial ",. t the"; e vokl. ted satisfied the c~_ reQ
o.
"'I'" ' , .. '
~ p ~;~I. ~§~~~~~
Il i ~ ~ .. l ,I;!
~ '"
1"
Ie,!••l',
!i s ~~~ ~
. 'I
~ ~: ~8 "': :,.
hi h; ,~
" • ... Ji,11 ...
x~ll j.. ~'
t!i"l U ; ~~ f , ~:" ; ~ :l ~ .e~H s·d"li
-
~,§
'ii!!!!: ljn ! L!n "ji 1~ ! ~ I !j!llisl ; !h !
H ~ ~~
'hl :hl·181
l!~ .q is' ~' 1: H
I'! " 'II
'~ !i
I~~~,\ljl~ :{"'j'
" 1' .
""l-I!
;;
1 Ii' ~ ~"
· "j'S
'1 ~ l~i
!
'" I '"i l !l , .~ iIiI! "
e:;"
i .j;
~:§! ~ 'U ~H
i Hl
! .
...
f
p ,Ii
ell
'"
.
till ;
.,
.,
C;;g,.. ~ "",,/O
~
~
..
~
-I" ~
I
><
i ~ ~
, i
~. ~ ~
'
..
u
~ ~I
I " "
'~
<'
I
II! ",
:H 1l: 1 hi
!!oj; ~ ~
:i; i i
~ b.!!'2~
.,
Iii
~ E!'S' ,~
., "· .Ii !(
~
!!o ~
i ,5 ,I:'
JI ~ •
•
~
E
i ~Hit ~
,~ ';; "!
~ '8~llt
;; :~ ; !! ~
X
lil;l • •• • IlL !1"1' l : I. • 1 • ·" II i I j!l·: jll tIl., II. i ~ >- q •' .~~.8 • "I
.g'l l ••
~
.
iI
~
<0
~ ; ~ b i
'
E
11
8.
1l
0
c
lII ~,"" Z '.i
' .. '
.. i';'.. .,
J
il Id ~ "H l ~. '~fl". J! ~ = ~ i' ;
~ ~ C. 1l
..
~
~£ ill' ! l! ' l -C'! ~!! ic;,~ f
~
ph.
n" i
f I .!l!~llI
If
_l!
• ·i -
~ !!o~ 8
.
,Il '
_
lil
;;
.
l; -
~i!f! t!1:':~ c.Ku ,.",~
"~ - i!
Ii
~~i!8:~
HH ~ if; ~
Hi!!1 ..
"
o
~ H~ ~ -;;tg~sf = ' ~ ~Eii I § I i 11'! ! i~i§ ! ; ! ·1 I j
~
~
:i
. ~"
t::~ " U ,8 '~ ~ '2!i ~ ~ ~E~~ lH ; . ! ! ql ~ I
• "".,...,.,<1
Thr~h papeB and Pfe_ toIioo. , ir> identified kif fedI>
he.,
3.2 04.2
he.,
lim it .0.1 * Ti Content.o le •• than 0.1 % in 'he 6 ... Mel.I ....
_er
A. shown in Tobie 1, "'" fan<Je' of AI . Ti of Alloy 800H but _ !hose of AIoy
-, l.2 .4.3
Re quire S .. b~'u bo n Heat Tr • • tment 01 6 . . . " .t. 1
A . -. tion he .' treatment at OO2'C ( 1800 "F I !of J oo..n _ be peOOrmed on 800H "" ... matefiol. __ "*>\I , lormin<), Of _ manulo'; ",.ctng >rih _ lIordenng e lements .ud1 •• Ti, AI, ..d Nb . Tfle , e _ is ", . t .t o.,...atin<) tem.,....... "' , " SO of the ... e lements "'" . . oOabIe kif the Iormotion of _ e _. _ the
<._
he.,
"'' 'in
11"1'"
he.,
grain. '"
"'_ g
Cold delofm'- ing tIIio el'!ec~ In the " ."';zed eoodition, ., " • ., f 5 "" <) "" _ _, Bale< " " points 00' thai a .taI>iIizing . "",,01 is teeommeOOed oler u p to 15 "" Id"- _ _ ...... ..... "'uystalizolion _ mus' be kept in mind to . void exeeu."le ...-in """"'" g the annealing lIfOC"os
in,,,,"_
!em.,...•....,"",
3.2 .4.4
Weld w ith Ma tching Fill« Met.1
ws
FOf many prodYet _ , I<Jch . . ~ilud in . ...__ and flttR}I , and kif man)' fabrieated items, ",eh . . piping . . , . - and vO$Oel., e"""nt typieal mtstry ",.<1i<e is '" """" .....,.,. IIOOH Of .....,.,. SOOtH wtt. an ",',,,-moU:hing , N>-baoed filer metal, oud1 •• ENiCtf'e_3 (Im:o nel 1821 Of ENiCiCoMo- I (Ineonel 6 171; ..,., Table 2. WIlde the.., Mer "",t.1s m9'>1 be .ecep*ty 10 stress relax.t"'" -baoed rue, meta .. in tIIio lower ra_
=
!em.,...•....,
WI1en Alloy &OOtt ~en ts are t>e;ng fabriea ted "" intended ...,.,.;« a t S38 ' C to 704'C ( 101lO "f to 13110 'FI, ~ is ",cOfmTlOnded that the tiler metal chemistry m . tch the m ajor elements 01 the bue metal chern is~ . The.., elements ore pr'rmorjy the ", c ~ eI .nd romum value" bYt the Mer metals • typic .... m., the <>!he, elemefl1S . . wel _ ChemisO",lor lOme typi<0I e " c"ode. and.re. "'" shown in Table 2 . U_ otety, 1IIe Ameri..., Welding Society (AWSI does not hove a cIa ... ~cation kif a liter metal w ith .....,.,. &OOtt ehemioUy yet, so _ d 'l< ehemisO"ieo Of brand n.ame flier me .... need to be _cilled_
...-"riI
G . ....... g oten are w eldil>g (GT"'Wl o nd .... .,kIed-met .. arc (SMAl wekling ore 1IIe welding proc ...... wth a vailable ma" hing Mer "",tals and the moot proven e>:perienee to d.o1oe . Gas-metol Of' w elding (GMAW I also h. . been used . Sub-metl/Od Of' w eldin<) (SAWI ~ beir><) e ....... ated in ,."",.lOry but h. . no! )'et been applied in the 1IeId
.tudie.,
3 .2.4 .5
PW HT . t • Minimum 0 1 900 "C (1651 Ofl fOf 1.5 Hours
PW HT of the '*'I 800 va"""," is co_fed the best pr •• ~ againol .. · ..,Moe .1re .... ,.,Ia .. tion e ra " 0 .!14 hrutirm1 ( ' _ -I of Ihi< ag.-eed "pro I»' "'" prKeha""r and 10_ 0'" SoUtion ~ in &<<_ , <>-tubesheet and e.poosD> _ . attachment weld. is
Code"". _
""cI
<11'_.
<11''''"'''
I_.tt)' pro <1ioe is not to .ppIy PWHT to _ _ on AIIo~ IIOOt1 Of 800HT .... !let pigtails 1><"",""" they at temperature. wei 0l>o\I1> th" "Il\/" _ . stres.o--fela
3.3 Welding COflsumable Selection T"" primary uiterio !Of cIl of hiQI>er ni<~ ~ eontent lor !1iogII_temperarur-e a pplig produ-Hb alloy. Tempera ""'" lor IIPpkotOoo of the"" motenol. "'" indicated .. T _ 2 baoed on the reoommend. tOoo. of Shorg. y . t aI . "'". Ineo-Weid A a nd Incooel 82 hav. oer <<0"''' 01 tor>g_term . mbfi!tlement isooe> . Howe"",. most reIormef ope"""" choose IO use AJIoo; 6'7 !Of IIighef creep strength at ,emperature. a bove 843 "C ( ' 550 "Fl. Ineooel ' 17 and AJIoo; 617 or. typ; bted in Table 2 ha"" comprloitioo • .milar to those of the AJIoo; 800 varian" and the . Umiting eompoob>n value. a,., avaloble lor the ni< ~ _oed m.,erioIs, a. indig from 750 "C to 1050 "C (1352 "F '0 '922 "f l that "'" applicable IO the 21 33 Mn and 21/J3 So
,.,._Is.
.,.,
ma"''''
Roach and Va n E cho ~' . '" _ that tho weklmento t!...-,. tested had low", otreso-fUp!Ure uer>gtl1 thOfi the eompMOble ba.., me~ •. ' n-WeOd A wekIm""". ,.,Iorm", oper.,,,,, .. ~ ha"" e. _ o e d ae<elenlted ereep e _ n t. and " " res with Ineooel '82 weld me~ . Failure . have been attributed to a lou of "'pi"", oIrerl\lth c&Uoed I»' " " , _ e n t Inoonet '52 is now known to e . - t a lou of rupl"", neogth and d"
5<>....,,,,,
dom_ .
C""""""'Y u oed material. lor joining AJIoo; 800 or. the 'nco-Weld A eIe",,_ and In«>r>el 82 fIIIr>el 62 lor '*'I 800 ...eld> . R<>och and V.... Echo . ' . '" indie.t. that In«>r>el 82 weklmen .. ha"" highef otreu--rupl>K. oIrer>
_til
• &l>ba ..... i .t aI ..., feCO"" ,.. nded the US< of • "9'>-"'.~~ alloy metal (IneI 82 ) !of w~ 2OCf_31N~Nb m"",I• . Kobm ~. 0 _ superiof ",..,Ito usin<) Inconel 62, Mot 625 flier metal, and !noonel 1 12 in place of Inconel 162 . Ooch and VanE,ho "'. '" ai><> _ Ihot Inconel 1 12 h&d ouperiof creep ",,,,'am ,,, compared .... i1h lllat "' Inco-Weld A, I n~ 162 , and !ncoo," 62 we_ to_Van won .. " " "",0<1 Ihot .. of the ",,,,,,d weNlments 01 Alloy 600H and Alloy SOOt H were ''''''''plilllo '" ...... rela .. _ eroUir>g In the os-w elded <000-' and !hat Alloy 611 1iIIef ...... !he moo! ."soeplible . FOf oppliealiooo !hot "'QUft!he hi?,_t . ... ~ and corrosion ",..mance, I n~ 117 eleelrode and fdIoy 6 17 lIIe< metal "'" fewmmeOOed I ' !of """ '" tempe
_'"
In<.....,.
p"".
( 1450 "f )
3.4 Welding and Repair Pract ices ThrOlJ9' rel="nofollow">oe<e ...",,,, • • _Iion and INure 01 an AlIo~ 600 luma<e lUbe ",,<,,Ved dur'\I !he fnI moo!I1 of operation. GriMing and abram. b!aotiog '01'" . void l<J
_.ted '"
_ .>ed
Ah/ubeh ... repoIled m _~ .uItra ooni< to .nsure qu. 1ity "'pan. AnoIh ... ..... ceoolu! "' pot method, as dls.ussed by Thielseh . nd Cooe OQ, involY .. \IA'> _ . 0 0 _ to mnimiz. oIIOOI<.aQe . utilzinQ lneone! 162 Mer ..... tal lhat 01 ""'~ due!ili"', ovoid . ... e 01 weld gmdin<J , minimizin<J .. orto ood "<>pO, using needle gun. ood ..... bNshe. !of slag "' '''''val, UMlg _ stOOge< bead ieellnique, ood ....ilOlmly preh.atng ro in the ran<J. of 212 ' C to :loI3 "C (.5O "F to 650 " F). The oIlOOeomin<) of_,.pair me1hod Is Ih.t Ineone! 18 2 w eld> have ~ high_ t ~ t ure
.
_ , rel="nofollow">ed"""ide, _ "'''"4><''''''''''
Kiser O ~ . . . . ..... the m portance 01 sOOoce are. eleaning u ling ~ , maohin~ , .....,. ~a.ling , Of pickling priOf 10 fepajr weld~ . Wife _~ wos eomig . A eoo..--d_opeeg to spall ood 111 • • leetrod. to \10 out 01 eontroi. H. _100 ..... oed !hat weill sIa<j mu", be eomplete!y re"",ved from the finished joi'It b.
ood LippoId ~" pe the _ m ductMl' , er. Uing oce!.Q. The fOSIJ h 01 the Gleeble _cated Ihat liqu.otioo erack.ing , ood 001 duetJil)' dip er. Uing, is _ . _ ! o r era Uing that oec
>IUdy
siroo.".....
Kiso .t 01. "" . •• in"".ligated the . . ....., of ."" k ~ in Ihe weld> 01 _ vy_n<1ion AIoy IKlOt H pipi'lg dur'ong I. lineation . AIoy 617 filer metal _ nd AIoy 117 electrodes w ,"", used 10 faOOe. te the _ . The
Ie.,
input, interp .... temper. ture. " u 1hon 135"C (275 " F). ood liquid pe""""nt n . pe<1ion before and .fter PW KT W eft rel="nofollow"> uoed 10 . void lu rthe<
1o<m._
indu<""
Ky11.., metal. The 00. "~ .,voIYeo i'I9'>-I
_ot""
lobley el • . ' " _ that rt W 8S r>e<e""""l to bo<e m o_ ond ~ioo . ...... . 2OCr-32Ni-Nb Ulot he ader prior to repair wel!Ixn dill not report !he mechaniom 01 embo it""men!. The oolJtioo ooneaIiI>g was ""lund '" ..,cond.,.,. ... _ predpi!oteo
britt"
dis..,..,..,
_ ood IIrw>o '"" reviewed w~ tooue. 1II. t -.-e encoun_ g !he ~ 01 • new eooe piece '" an exiolin<) tee (0<Jed mote depooiled revea led bo1h KAZ Iquolion erackin<) . nd r_at \I poirO: -...e pre4IiIate. tIIot had Iormed \I where . . "", reheat eroUin<) ..... '" hove beef> .... oed I»' • _ _ 0Ii0n 01 mism. tched mechonieal prop<"'" . nd i'I9'> n w oion eonIent. They b.
..,rvi<e.
beIiev""
Pens<> ood Meo d " " re_ ero el.ing 1II . t W 8S _ on e xiOlin\l 2OC r-32Ni-l'lb OIotjeally east "'" ,"",ce • ..men new eerllJi!u<}olly cast 2OC r-32Ni-l'lb reducer <00< . .... ere welded 10 1hem . The Iocalioo o! 1IIis er o ~ .. .. .... " , . ~ .... . , . tt .. n ..... '" ., '"' ~ _ _ "'" ... to • •"""., ...... ...... t • ............ "'" • • " '" .""'''' (0<Jed ) m. te!tefir.g layer 10'0' lin! . ppIied usin<) low omper_. Dye penetrOnl (P T ) inopeg ogo" wi1ll o tower he . t inpY!. The joints were lin! ta< ~ _ • .00 then • root po .. ..... applied OP inspeclion was per10rmed 1oIowin<j e""f)''''eond fill po .. and . !ler blend grinding the cap pus
J.eI.'" reported cra
0
2 1133 weld between • tee .00 • • u _ _ ., • "",t 2OCr_ 32N~Nb outlet
moni1oId .Iter 1. years of '<Mee at oppro
oIee"".
designed . nd welded over !he erael."" weld . nd _
3.5
Moch~ni C81
Ior"'- in !he outlet m. nilold.
Design
10<._
The details of me chanical desiQn depend on operatRj preo""", and 1e cs: (1) om~ (NH,). (2 ) hydr"""", (H, ). and (3) methoool (CH,oH). The range 01 operating press"'" decreueo and the '""I/< o! operating lempera...., increa ..,. a . !he re10rmer type chanll".1rom ammooio to ~ydro<,j
. Table 2_ Speeificationo ofTYI>",o l Weld ing Con ...m.blu l or Hydroll""
Relon..." Outler M... ~okls .... d P;g,.il.
,0,5.1 1, EOCrf'1>.3 · '
h
AS. l 1, EliCIM>-3 '"
(W Xl "F) when tigler ~.~ .. .-led. S/"'*l "'" be LlSed lor
_593_700 (1100
h
16_1. , ERNCrI.t>-3 · )
-,-
-=
.-led. S/"'*l "'" be LlOed lor
.. ' .... _~593_700·C
(1100 _ 1..a!"F) because" ",11>_, ___._ ...... _ .
~
of...,..,., ""'"
~6 1 1lor
hf,Iler ~
~ . ~_7&l-C
,
ERtiCtC<JM>-1 · )
BS EN
uon "
BS EN
uon "
~1T '"
(W Xl "F) ConbeLlSed_
UTPA213JM>
.... _...- ....
..
(O) ........ ..,w _ _ .. WS) " .......
{c i Lt<S
.poc" _
(d 1"""'· S _ \01Ill<
""",611
_""'"
Table l -Chemica l Compo.ibOfi . 01 Wekl Me"" . U ..,d ..
H ~ df <>9"n
Relo""", OUlIe, Ma nilold. a nd P ig,.i ..
(0) """" 182 1") ........ 112
~ ~
_ _
_ _
' ""'" " . "'"" boc.o . . . . . .. """''''''''' ............ ' ""'" " "","" boc.o . . . . .
u _"""""'"
b o _ , . , -C and . . , ' C (I 100 . , .... '""" 'F ) (.I .. .. _ ""' Co .. . .O " .0 (d ) N ; on~
(· I Nb ......
Figu re 1_ E.""",1e ol llAZ liqu.abon Cfl ck" g .. AlI"d 2OC. -32N;_Nb Cn b ng. lTom AndeB "" and Bruno ...
"
.' •
-250 ~m
-,
•
•
\
F;gure 2--Ex"",p.Ie or Rehe.t Crackiflg in Aged 20Cr-31Ni-ll b C•• ling. from An
Figure 3-locabon 0' ('&eking in Ag o
f igure 4---Example 01 Cracko.g "' S u bl>e_r 10 T"" Weld: 0 "'" A,. 2OCr_J2N i~lb C. .li
•
,•
I !
, , H, CH30 H
"'" T"""'.....,'C f i_e !i- Typical Pruou re and Temperatllfe R... ge . 10< Steom Metl>aoe Relorming. lTom K _ .. enl . ...
. A. rel'iewed I»' Kawai '" 81 .. and "." aled in f ig"'" 6 , . ...... rebmle, fI.
three types 01 outlet heOe<e the ottacl>ed dife<",. to the marlilokl by me ..... of MfinQ> and the 001 Ija"'" exil !rom the m . .. bld "" riser tubeo, (2), ",/ro"""Y-«>ed f _ . the cata lyst tuI>eo ore direclly .... ched '" the outlet he adef . . .d (3), hoI.<>bheadef 1II'it> . e<>ta of Type 3 maoiIoIdo we<e •• eluded . K.... ai '" aI_ '" also ",viewed typeal oo&e1 piQloi design., • • AI . ... ted in f iQ
<.,.....'
B~hllinll .t 01_ ... observed tha1 the m ploment.tion of the cold "ude, manilold Sys1em !or prim"'Y ",lofme", drastically redYeed the numbe< of ctili preuore. Ru,ioko aod WorIe<j'" OOIed the beoeftts of ..,1e,tinQ .... . ".mally _ heO "'1Oew_ Read.", rne<e>ted in design aod repajr of relnKlOfy .~.tem. in reio. mer eoId_w'" oo!Ie1 mani_ should coo""" the pope< 01 CoIw .. and ~ • •
"""",ed ,.te.
&harg.~ "" .. die. ted ", . t the _ of ness relaan_ .. cros .... e<1ionoI ""' • . Kobrin"" _ 9".,ed th. t in'4>rov,,,,.. nto .. me fe<eiviflll mermol cy\l o! long \lef$UI shon IIi
fI.
row.
a.
Cromany '~ re oper' lin<) ~ oode< the same "'r'~"'tu'" lIfoflle. He oIso noted th. t a ~ ey de ...... 1e.lIKe is the preoence 01 inlet and outlet piQt. io to each c.talyst tUbe. wtlI<" _ .... f<>r one operatof to ~ one pOQto . . """ - . . . one c. talySt tube _ ._ .... oth"", online . C.taIyst tube e.p.an.ion is . «<>mmOdMed by eounterwe
3.6 C a .., Studies 3.'.1
Gener.1
Cu e " _ feIa1ed to ootlet headers, 1hio _ _ of the report. 3.6.2
pin<~
of
1Ii
othe< refomler
c~nen to
are d io< .... ed ..
Outlet Hearle rs
Rumk. and WOOe-; . " _"""",ted e xperiee'W deoi9n. A """,be< 01 plan" e' perion&ed Of """.rer line> and lined piping Of equipm""'. The &.IIU..,. 01 the era ckin<j """" iden1ified to be thermal """ • .., • • t the weld> c&USed by d i ~ eremial e xpamion between metab, la,' 01 ductility 01 the cast HK--40 aIoy «>mp<>nefII. and IIi!>inII movements eau_ by thermal e.p.an-' impo .... g bendir.g " re .. e . 00 the system . lite r>e'W deoi9n !or the """ ...ion system employed a _ h I alloy tIIroughout the zone !o< m 00 AIio"; IIOOH or fdIoy 600HT _",~aIysio of the pipir>g.rId pn poinlo.
pie'''' _/oar
_eaI
.tres.
Il) HoI CoIo<' ..
(l l Cold CoUO
Il) Hot S~_IocIo' ..... Cold T.....,.' II.. FOg...., &-Typical Oeoigno 01 Ou!le, lI .n~okl Systems . from Kaw ai et aI . ...,
.
-
,
Figure 1- TYI'''''' o.s igno 01 Out'" ?iglail System •• from Kawai et .1 ..... Rumk. and WOfIey ." also described
""'Of
. AA UPS'" n !he
.teom system pelmilled liquid ...", ... 10 e.' ..... ttube. UlUOi->g ~ enn" Iho< ~ !hal '!>IiI "'" tube . Sixty percent of "'" ~e_ join" •• pe ,. ,,,. grOlKld out and repoaired willi In~ '82 w eld metal. Aft e , Ihree """""". leal< ..... detected n On< of"'" "'pared jointo , aod n ... _ month !he er . c ~ had opened ""ou!!i1Iy to require .ruJ\d"""". 1M> ...... of !he .. eId> .... re <1>_""0<1 and 40 "" 01 them Ihowed
pet''''''
Kobrin·~ . 0"" bun weld failed ... . "''''''' of . !fe. . - . use 01 !he inadvertent uso of Type 310 . .. _ .. . _ 10< "'. w eld material. The _rod b<m w eld hliIure ...... ottribu1ed to the lie< ...... , !he original w eld, Inconet 182 , whieh Mo """ otreu-< Ihir
Ineooel 625 ideal\'
_!or
Of
In
metal
Dejae<Jer '" aI. "" discussed « 0 <1<. n an....". 600H outlet _ m"""fa ctored ~ .......ea led AIoy 800H PMe m. _
"MIg .
. In _ panic .... , ease, !he headef w... l lIIot w• • cold _ into . cylirwler ood
then ~ilud in ally w elded .,;th Ni-b"", _ _ No heat treat ment ..... a PP'ed __ the manuf. ctlKin<J proceo.o After two years, • lea~ ..... !rom f. brieation ( ",Id _~lding l or "' "" ~ from , yet< eade< by • he .t tre.tmefl1 at !l5O'C ( 11. 2 "f 1 peOOrmed bel"", w ~_ After w eldin<), ' ""cood he. t tre. tmefl1 at 65O'C ( f 5&2 "f l ...as per!om>ed , de,,,,asin<J "",Id residual _ .... . This method ... « e .. fully
11'<>«'''''_
",..,.Iion
,,,,,,,ole
r•.,..,erne'"
_ .Iion
Ie.. th.., the r.eommeOOed ...... 01 982 "C (1600 "F), ..... the PWHT wn ..... lhan the recommeOOed .atue of 900 "C (1652 " F). Thes. r .eommen~. were re'o'iewed prel'iouoly in 3 .2 .•
Brongen and Ju.I .'" " - e d an fdIoy IIOOtj oollet m . ndoId ", . t h&d _ . m_ using w eldoin<j Ele<1rOde 112. It w... remoV1>d from _ . _ normal opemterenlial but! _ • . Creep"'plure test. were per1o<med a t stre .. Ie.... co~ '" the .....,;« and _rature • • bove the
.tres.
3.6.3
P inchin g 01 Pig tails
fdIoy IIOOtj and fdIoy 600HT oudet IIi&ve . re"",,tty reviewed by St.ven. ~", nipping is "'. proce .. of _ z ng the IIit wth • dampin<J tool to cut o ~ !he g ... !low "'rough the pigtail . Th. procedure is done in eonjooction wiIh nipping the inlet pigtu '" iod.t. a hided c a talyst tube without ohut1iog down "'. r.kIrm .... 01 «>1.00, this proces. <>nil' a pplie. to r.kIrm.,. inlet and outlet pigtails. St •• en. on mut •• that • nipping procedure w• • fin! developed in 19&1 . 001>&. been rel'ised m..,.,. tim .. sin<e. Cra a ng may <>cc,.. ~ "'. tempeg, Of ~ the d . mping »01 is wom Of in"Vopeg "'. nipping process St.ven. "'1 indioate. that !he .. mper., .... 01 !he ootlet pigta~ is I)'piealy maintaned . t 100 "C (1292 " F) Of higher '" . void the potential lor
St.ven . "" presen1ed a de.-d ease h<S1ory 01 ~ flipping lor a In-tube ammonio reklrmer "'a t h .. been in.....,;« .... "" the 19&00. C.taIyst tube> are re.,-a c ed only"""'" dom_ i. detected by n .pection Of _ _ , ......., Og were updated
out'"
dam.,.
" '.1'/
Slu.rg.ay et aI . .... nli'"t."'.. "'. ou!Ioet pigtail is pinched 1irsI;!hen!he inlet IIied . They n dieate !hat pin.hing is typi<:oI1y per1om>ed _ the proce .. lem"... . .... is 9re .... than 31 6"C (1500 "FI, but ", . t the lem"....,.... is diI1ieuk to maintain on"" acces. to "'e pigtail is _ d . FOf thi. re. son, "fIIing ondIOf in. uIation m a y be used to help keep the tube metal temped 10 be the highest. Aft ... the iniIiai Y'I'"'" of ... rvice , the duet*!y n ere. "". 00 that the fiN 01 g tube pinching gre.tly de"", . "" •. How ..... , .""n in thi. eo"". a prehe., of . t least 6. 9 "C (1200 "FI ..., is recommeooed.
a.
tn 1915, J . W . Coombs" re;>OOed .... ineident th.t resuked in an unplanned ohut_n 01 . hyg the inlet pigtail , but then lOOk • lunch bre'" belore pinehin<j the ootlet IIi&ve . u!!ielent ooc1ilty ., &49"C (1200 "f ). At ~ture . gre" ", than 188 "C (1.50 "F), the m . terial had . u!!ieient ooc!*ty . ~ ..... oonekrded that the IIied
_t
out'"
.
,." T.""'......., ..",,,,.,,.,.
In 1994, P J. ~"'"".., poi'lted out",", ..,me eom~. <10 .... prakI .......... ., . fire is ""'grea' TNo is . isc",,!hat each opende 1t8 ~ n g piQ!M~_ 3.604
OtlierCompo .... nto
_.t
&harg.~ "" p' .... nted • eo ... of ness feIa-<><>1Ie. _ welds_ The .;gmo_pha ... embrit1!ement, which is em_men< of iror>-ehromLom ~ , ea..- by pre< ~ tion ., g rai'l _ a ries of !he oq"a ph_ wtlen e xposed ID "9'> 'emperotlJre. f'lf e I1eU feIa 10 haw m-''' "' ......... es, . ¥<>ding . /.." " chaf>geo in e.
>!e" __
_WI< 11"1"'
c_. ·~ presented an ...mple «>n<eming hydorogen rebrm ... eorwection ..,ction oopell>ea1 ... eoiIlaiIure>
., poot_o aod rep.air .des . The hMkK •• ... "'" otuibYted '" """.0 feIa
he.,
teq rel="nofollow">ef8' ure .eMee. R.mediation inclOOed r .~ . rId repa;mg _
4 Results 01 Industry Su rvey
4.1 General An indY"'", ...-vey _"""""
wn developed and _
10 "'Plio< d i_ _ 10 it. members. The
woo .." .......,......,. ' ,"""."u.. 'e.... '" """ ...'..,. ,,.' .. e ,""
or"",,""' _
... , ~ , ..... " •• • ''' L ....... ~L ~1 " PI and 10 indi-.... in ~ a '- th., 0pe<81. feIorJfe B """"'" of the relinin<) induoI", . '" """' of 2. reopomeo '" the ...-vey we<e re<eM>d. Moot of the re. """..,. related '" e.per.enee with • ope
""",be< 01 feIormeB
loIIo~
Fifteen ( 15) "",,_"'PI membe< eomponie. appro_ely 15 r.lomlero. Two (2) rellnin<) indYotJy. Ten (1 0 1 """"""'. indYotry. Three (3 1_ " and methanol industry
location of oudet mooilolil arid pi<jloil. relative 1 0 _ .
A.l/O dis1libution of r."""'... Opero tin<j <<>nef8lure, preo ........ , ood
"""" 00
gr.. . . b<eak-" of
Inspection program. Re",," , modilieatioM , or _ _ •. Stre .... ruplure behavior of a lloyo and _ The .. " !<>pi< . .. re .._ruplUre _ _ of . 1Ioyo and _ . .......... e.pIi<:iIf\' requested on "'e . wvey dowment. H""",,,,,,, • • pM 01 the ourvey, d ato.""" .. _ e obtained on _ .... rup...." 0Iren<j1h of ~ . nd ... eld> from voriouo ""p~ . Oato Irom 1hose ..,.... . re reviewed . nd «>n"4Ia<ed _ oro ", . t may . ~ e<1 neuruplure neogth ore . Iso reviewed.
_.1In>
4.2 Designers of Reformers The ....... ey response. ioeluded do .. on 22 re - . from 12 "'1Iefent
!
"
! , , c
I
0
, , ,
,
0
_
,
•
'" ReIormeB
f ",y", S-Di.tributioo of Re ~rmer
De."'......
•
in Sy"",y
4.3 location of Outlet Manifold a nd Pigtails Relative to Firebox
..
Th<ee
....
p~ to ilo ( ~ pre .. nt)
_ e '" the _
. were identi1led
The ""'"" m. ndold w... inside and ., the bottom of the fireb", in 3 ",Iormen; these "'fDmle<> OO!Iet 1Ii
"'~
h ad ooU., manifold and
~ ad
00
IIi
4.4 Age Distribution 01 Rel~5 The _ distriOOtion of the , .fDmleniform . . . is _ They ""I/< from rno<e than year. 0lil to " .. than ye. rs 0lil
.0
,
'0
in f iQure 9
I, I
Figu ", !\-Age Di.tr iOOtion 0 1 Re lonnero in Su,"",y
4.5 Opero! ing Condi!ions: Tempe....!...-e. Pressure. and Cyclic Operalion
,empe,.,....
Figur. 10 and f igure 11 show the ""'geo 0 1 opeee
' """'y.
_to
R.ported .totI ... p/"""'down oycle rel="nofollow"> lor the , .Iorme<Jmber of <"Ide. per ye' f . The median ......... ber o! 0Iar1_ "","""'down <"101<0 is only 1 per year. How ...... the nLlmbe< of operoling ups." ...... oI;~ n the opposile difec_. and the median number of operating upseto 2.7S pe< ye ..
w""
' 600 < 1 - 1700 ' 600< 1 _ ' 600 , 500< 1 _ ' 600
,
! •
I
, &lO<1 _ ' 5&I 1<00< 1 - ' &lO ' 0100< 1 _ " 00 ' 300< 1 _ ' 0100 ' J
•
0
Figu", I II-Range.
oj
•
OperMing TeOlj>
4.6 Monffold System Alloys F.,... ddle<efl1 alloys WOfe reponed to be ",ed in the 00j outlel manifold . ystems . . follow • .
C a" 2DCr_32Ni--Nb oQoy: 13 "'fDmle<>
Wn>UQII1 Type 316
_os
steet 1 re10mler
Thus, !he maj<>rily 01 the relomle<s 1>a"" eosT 2OCr_32Ni--Nb *'I OO! outle, manifold . yste .... , but ma ny employ "' r<).~ht AkY/8ooH or AkY/800HT. The Type 316 stainless . ystem io in an old _ and io "'" ",presen""'e oj mate!\al used in <....."" . ystem desig ..
.le"
= . p · ooo
~·P · ~50
~50·p ' 500
!
I; I
_.P . ~5O
",,, < ~ • """
:lOO. p . 350
250'P ' 300
2OO'P ' 250
0
,
•
• """""• _oIR
"
f igure " _ !lang ... 01 Ope,,' ing Pr••• ure 10< R.lorm.,. in S""'.Y
4.1
Pigtail Alloys and Problems
T .... nty....... (21 ) 01 the twenty.Jour (2 ~ ) reformers in the ........ ..,. hO"; 6OOHT . Thirteen (' J) 01 the . . twenty ....... (2' ) r.formers ""re repo
"""lily
None: 8 relormen
M ajor: 2 reformers.
out'"
A. indieate
Creep damOQ
ref""""".
_.red
Thus, moot of !he reported pigtaif proble .... in. _ 10 hov< been "",u.ed by creep Of by them\of . ssoc:ia1ed wilh welded joints. Some 01 !he < r .c~ ~ lot .. "", buI deta iled hMkIr< anofyoeo were "'" reponed In one <. . e , . .. <.. relu .tion <Ja ckin<) was identified • • Ihe domoQe me chanism
4.8
Inspection Programs
The andIOf oo!let pigtails. The", we« _ _ (19) r e s _ '" Ihis Q....tion. E 9ht (5) eomp.anie. indi
deIoon._,
_am
The ~ ......,eyed we« 001;«1 l!hey 1 rel="nofollow">0"" • ~ in ~ lor ou1Ie1 he"""'" and pi9toilo. TWffi'Y_1WO (22) eomponie. indi0"" "'9_ proQramo, _ three (3) ~ indued !hot .....,.,. do "'" 1>0"" ~ . I"OQramo. The .de'" of .otieo inn"4'"1lY "'por1ed inOldrloJ on ~ IIOOt1 ou&e1 m _ , r_ l h . . , • 2OC,_32Ni-Nb ~ mor.-, I m . _
"-
beie_
4.9
Repai, s , Modfficalions, or UpgoOOes
Fourteen (1 . ) re. poodemo indiea1ed th. t the0 • • made major repaO, modiIit (6 ) reoporwlerns .Il>1ed !hal lhey hove done 00 ouch """'" Moo' of !he ",poned repon h • • e been oodeftlo ~ en ...,'" 1990. AI but one of Ihe reoponden1s _eoted Ih. t 1hey Iftre pleased wtf> !he re ... ~ . 01 !he r.p.airs. The respondent th. t ..... "'" oa1isfied with Ihe ",.ub of 1heif "'P"n • ..,ed, "The re is an o~ pr.-rn a nd oi9ni1Ieont " a a in<) can be •• pe<1ed . boot e v"'Y lhfee yearo ."
Pubbhed -Nb -.,. l arson_Mile< pOOl. andIOf . ..... V.B LlO lime to rup1Ufe plots (.."hoot ""'t d . t. points ) ""re _ in technil:a l IilefOtur. from fot Ioondr'oeo . T. bIe . 1isI. 1he chemiol re' '''''' , !he sour",. "", identikd .. FOI.fO"idoed .pe< i ~ eotion IOn.., _ .... FoondOe. C and o only 9OV. """, ...1 eompositioo •. The me.....-.,d
00'
00 _ .
The l. ~-M_ po.-ometef (U~P ) "~ " _ '" p'eoent 1he . ... u.--rup1"'" data io defioed as _ . : LMp · (T . 273) (C . log ',)
'"
Where T io 'em"",a ture In "C , C is Ihe l""",,-Mllet -fIJpWre Ii!e in ho<.n 0 .... we«> "".n 1rom!he plots in 1he foundry 1iI..-o""" 000 used to <0001"," neu • time 10 ruplUfe eur.<e • • t 616 "C, 671 "C, and 927"C (1500 "F, 1600 "F, and 1700 "F ), as >hown In F9ufe 12 . The l ..-.on-Miller parame1..- • ..-suo . treu plots eould nol be n. tont we« repol1ed in some eo.eo . There is . ... - . - in Ihe a""fO~ elK'leo Ifom Ihe _ , but Ihe trend. wtt. tem"",. w", 000 _ time '0 rup<"'" are simiIa, !Of ... fo
..-.u.
Table 4-- TWic. ' Chemic. 1 Com _ ition. of 1he 20Cr-32Ni-N b Alloy ond Chemic. 1 C~itionof . M od~ie d HT Alloy
•
-
,.
----- - -,- - --- - --- -- ---- - ---- , - ---- ---- - --- -- -
-
0 -
,'-' --
'- ' ---"' -- '- ' ~ -
,
!
1 '"
I
'"' ,
""
'" ,..".
1
........... '" ,
f igure 12_ Streu _"'I . . in design 0< fe~ life useosment Some 0pe<0lOB indieote that !he """.. _ture .trength of material 1100 been foood ., be signdiconlly ~ . Ihan !hot repor1ed by !he """",lac""",, wt !hey did nO! provide ... y _cill< d . .. . f o< thio ", ason , O<>me u """, ...""", ~ O "" 10 50 "" IowOf . _... rupl"'" O!ren<jth than fepor1eme pureh. """,
""*
"0"'"
Ie...,.
is...,
One operator fepor1eI'i1h premature ..... >-ruplU'" faiklre. of many Alloy 800H OO!Iet pigtails on ... am""""a reformer. An imesti<)O!ion ",vealed that .. of !he Ioled piQtoi tubeo hod 9"" .ize. finer "'"'
ASHI Numbef 5, ... fli< h w... !he .",,"'fIed _ ..... \/fain oO.,. . The problem ",..,Ied from mtJllicient solution aor>eahng .ft ... fabrie. _ , • _~
0<_
A. mentioned .. !he Mora...., _ , tho Sti ....... ptufO beha'iior '" AIoy 600, 600H, and IIOOHT flo. been wei cI\oractortzed lor u..., .. Ihe ""1i9n '" IRd heatln, oud1 • • hydro<,jen "''''''''''''' . API 530 on 110. mini'num and e ......... T _ F.30 '" 51!1- 1JASME fFS- l"" flo. oqu. tiooo !of
'''''ro<JO ""'...""""'"
equa_
Ro. and V.n Eeho " " '" .... \I four "'lIefen! weld r_ "",lOis InWeId A
In
wer.
g cross __
.podm.,... The
t• . oominol
_ 01 oOtion ol 2OC r-32Hi ... ith no Hb _tioo and . ",,,bon those !of ba"" metal .... pected '" indic. t."'" reIoti'ie creep . ... r.gIh of !he _ klmen" to "'" base metal
g"""
The _ and Van Ed>o · " '" tteso.-Np<we --Mkr constafIt, lor ead> type ",...-... . The best __ laBon--MiIIer _ _ """" """ . - '" <:reep-rupture .....". !of eoch moteriol.t S16 '<: , 87 1 "C , and 927'<: ( ISW'F, 1600 '1' , and I roo'F)
_to .__
PO'"""'''''.
""'''_1QUafO>
f igure 13, f ig"'" 1. , and FiQg !h. l~ _ MiIer par. mete<. CUf'ie' ore shown !of AIoy SOON , rather tI>on AIoy 1I00HT, be""u..., AIoy SOON """ "'e""'" m."" used in tho ROKh . nd V... E eho ~" ·o work . AIoy SOO HT ... _.pe016 17 flier metal Figu", 13, Figu", 1. , . nd Figure 15 ore Iog-log plots, so the ~
Jl ,. I
'
!Ill Jll! I' "l> f ' ·!.: . llill ~l· !lh I!li ';! ii h ,. H
'I~
~i
iUi !;i
.
~
I
!!~~
~~.~ ~
~~I~
~_
. ~~ ,, ~
~uu
~
J=g~
N~~
; ~2! ~ I~~~
LIJ
II
:~~~~j ~i !
~NI~j:;f
~ _ .
10
~~~ 'i~j 6~ §
liili'
~I~~ I!j$~ ~j~l i!~:~ i
8
~~iJ~i ~ ~t
~F!
~8~1 ~ ~~~ I:i~ii-I ~~E~~ ~~~ , ~~§~i~ ~
I~il ~ ~~~ -, "-
~~~p ~: ~ u
~
= ~
l i ! 'j:; ' =1 i
u~;
I"· r
= ~ i S~
i ;~
'P l'ii! I *~, i !ll' !" Ii lill
I. · .
_
!
I
:i!'i 11~1 I' (',!e !'If - . ! ' l' ~~ ~ ~~ ~~1~i: ii
""~ ~ E II
;
~~~:~E~ i i!I"ljj~ ll 1i
~ · iih
,,. "Ii'· ~
e
_
11"
~
i"1'1'· i~jj
~
I!
J
E ;" ."f
Q"'
E
~ult ~~Ilg ~]'9 §~~ §5 i 1Ii~i~ i -8 ic· ~~~. i~ -ci'~ ll< I~~. ,~~ =: 'i~~c~ le1i iii, ~ , l L1I 'e , ~:~I I~tj~ I!: ~ I~II!~ IK ,'/'i:iiI Ii . l!ll l~=~~;., ., l~ ,-j! :II'I! 'I ~~ Pi = i ~~i J ~~e j~~U '~ j~ ~ I"'~si 1,1", I ~!~I:' ~~f:~ j!!1 gjglr! ~~ lH11 I !il:1 111:1 -Ii! Illlj! III lilld i g < , ,• I ~I ~I l ; ~I ~~~~ ~ _ ~~ ; ~ ~ ~ §h~;~ j 1 I 11!~1 li;ii lill ;!I:II III \ I I t! - " '" • • • I I>' '-I' 'I ·PI , • I~ !; 11 •. 1 l.ll li.I.! III ;: • III
___ >OC<_"_
-- 1. -- _
~- _0" H1 _ _
--v-- _ . _
--11.-- - . , .... -
----B-_ ~
_ - )( -
_
..... _
- - l' - -
-",-
_'02 _
;
I '" "
•
'. f igure
1 3--C~rison
01 Streoo-ruptur. 6 "'n ior 01 H ot -ma n~okl .... Ioys and Weldmento . , , , 6 'C II 500 Of )
Inel l lll1a. on.'\' aboo150 % Ni, buI ito .pe.ilieatiooo . al l<>< 9 % to 15 '" CO, " wei • • 2 1 % t
resist""".," f igure 16 show>....,.,oo, ""'u.-nJII!"'" da .. lor two • ....,ehinq",.,. weld ..... _
Ihal ore often used 10 weld !he AIio)' IlOO variants and !he 2OC r-32Ni-l'lb --,. . The weld meta" are 2133 Mn a nd 21/33 So, and the d . .. ..., «>n"4Ia<ed w illi !he vendor d . .. !Of the 2OC ,-32N ~ Nb . Ioy. IIoIh lie< meta," were represented I»'!he .. me ..... o-11.., m_ • • , 927 · C (1 100 ' f ). compan~
<0""4'0'1-'.
~
of the
_
_.Iion
e. ted that
~
~
m ay
~eI)'
.110"
Ihe .feep'-.... ~ and is belieV1>d Iha1 u"" of virgin motedeor able imptrtie • . Ano!hef eompany indieated ."., cootrok>g the 9 _ . ize of.tali<: <. SIing ... important and thot ""I)' IoIIi<.ted ~ . t the most important micro"""ctural parometeflo eootroi in prod<J<><10<)' """ OPO
used ., ou&e1 maniltlid system. and pi:jtUo.
~
-. ----_..~ ~
-,,'
- -x --
-- 1. --
- - 6 --
--v--
--,.--
_.-....-
""""''''''''""""'''' """""t> _
i
i "
f Og",. 14---Comparioon 01 Str.n _n .... "'" Beh. vi<>< 01 H"'-M ... ~"'d Alloy. and W.ldme"," . t 1 11 "C 11600 Of )
5 Industry C;Jse Studies
5.1
General
The IoIowi">g ..,ven ca.., _ .
.xperience
5.2
C o.., 1: Creep C r acking
f""'"
fe'I "'" !he details c!
typjc.Iol problem. idenlifled n !he ...-vey of n ooou.,.
of Bull Tee 10 Heode.- Welds
17 oIlow.!he • dra~ of ~ . eentrof portion of . ~ r e _ oo!Ie1 monilokf wtt. • _ lee eoonected 10 two h. _ eytnden and one eone I»' bum ....,1IIs_ .... of !he.., «>n"4>OOg ...... _ . t .. three b<Jtt _ Id • • • ohown in f ;g"'" 18. The tee op. uted at opproxmatety 87 1 'C 11 600 ' F) and on int.mol pr . ...... of 16&2 kP. 1270 1'SiII) . The .... Id. wer. " ' - uMl<) . n In'''If>el82.- p.... Ineonel 82 nef 182 for !he """oindef of!he ~ . Th"', !he mojofify 01 the ... ekf !iller metal n !he joinIs .... . Inoonel 182 . Weld rep.r. hod been m_, usin<) !he originol "'bricotion proeedg
.,pMder
_"""""'t,
twi,.
~
---e--&-
--
.
~
-- -.
_."
--'1--
- -0 - . - -T- -
..,.--
-,-., .... -., .....
-'"'-
~ --~ - ~ ~~.~~ ~-' ~ "- -~ ~.'-
"~
'~~
:
-
i
I ~ . ~,
~ .
"
,-
'"
"
r ... ., .... ,...... ..
f igDfe 1 r.-CompOfison of SIr.n _m",...,
Beh~viof
01 Hot-m .... ifukl .... Ioys
a M We_nlS .. 927 ' C (1700 ' F) f nil .... lement
n" .. analysis .....
per\oImed to
~
m ..1i<}a1e !he g. Ro w l.. 01
_-demeo' . ""lysis (f EA ) .rowed!hal pres""" .... dYeed .Ire.. vol.le> (see F" "" 19 1 at Io<. !iono oear !he w eld jointo 11>01 11._ er.ding l INn llighlly " .. !han !he _ _ -Hb motorial, buI ~ llinll S l r e u _ be minimized tIlrough _ operation and maintenance 10 avoid potefllial dam_ 10 "'" m and(lId
wa_
w... eoncIuded 1he IrKOOel 162""'" metal ...... _ w.a~ !of the >eo'ice literature _ rid _ _ indu .. ", " 'peOen<e, "'" new tee ...... "",kled ""o 111" manifold using m ..-ove and IneoneI6 17 !kf metal
Based 00 the a bove In
A
~
",~!he
_1iY.
faiure analysis also ..... pe re....oved him !he old ,.., . The chemi (see Fig .... :IIl 1 10'= pro . ..,,, in Iho ho.t . _ted zone (KA.ZI and w old metal, but 001 in Iho buo motal_ ln1er9ranWor ~ crack. ( _ Fig...., 191 "'" """" _ in Iho HAZ om weld metal. The m~ 0I1ho buo "",tal _ _ fino carbide predpilate. and 10'' ' jOOged 10 be typieoI 01 ""'t e xpected "" iooQ_1Om1 operation '" torn"",,,,,,,,,. noar 671'C (1 600 "F I_ The ... ro..,ls ..,ppotted Iho ~ of Iho ..-. .. ooa/ysio and Iho ... Iocted weldin<) material om proeedure_ ~ eaI
~.
• ' ............. c."'o
--
'.
.
--
'''', ... _ " '" so _
- -8--
" " ... _,,,,,, .. _ . , , , '0
--A--
" " ... _
"'" .. _
...14·C .. ." '0
i
I
.
,
• f igure
.. ....." ..........
.'
l&-C ~rison
01 Str<>oo-rupture 6 "'a.ior 01 21 J3 M n and 21/3J So Weklo with Th o, '" 21Cr _ 32Ni -N ~ Alk>y B.se Metal
..
~
. . -I' .•••.•• • • • • • • • • • ••• • - j••• f igure 11_ 0fOwing or Centrol p Oftjoo of Outlet Manifold Show ng Con tral Portion 01 He_f, Bull Tee, a nd Iocr ..... CO""
Btl"
Figure Il----l'hOl<>g'aph 01 Tee ShO'Wiflg Ar . . . Where C,acking o f Weld. W•• Ob.."nd lC. II"'.... r.I., to otIIe, flgur • • ifI repan from ,.hich photograph w •• tok... : fig", •• are not included in the pre..,nt r.port.)
"'00.
F"",re
I!1-Re . u~
'" Finrt • ..,I0"",nl Str . . . "'n.r~ ... 01 O",lot Manifold lor InterMI Pmsure loadiflg ",f 11162 k P. (270 ".ig)
"
"..
,,
'
.. •",
•
,
"
C . . .p
crnch
f Og .... 2G-P hotomic'ograph of C'.'I> C •• d;ifIg a nd Vo ids Obo ..... ed .. e.. 11 T"" Wok!
5.3
ea"" 2: Creep Fail...-" ofOutle! Header
The Irf
mic~
tempera""" ......
~•
• two headen in the .... !Iet maniltlid .ystem. The
m _ .... """·C (14"" . ~ ) . "" '210 , P O (320psig ), ""pe< feIormer oriIIinal'\' had ...,.,. H K-oIO eataly., tube> and an AIIo)' IIOOH outIe1 m_.,,;u., Inconel 621162 weld • . The relorme< WlI . revamped in 2000 to _ fade the
p<e' rel="nofollow">S'J'" b
.... """'"
HI' ma1eria1 and "'. OO!Iet manilold t" 1h<
2OC ,-32N~Nb . """
..mil 11><00<1 611 welds
In 2007, one 01 the r>eW outIe1 heOperaled _
the ,,!her " " _ l>ad rIO oq,s 01 ef "'an the typi~ v..... irwIieated abo••. The tailed heO
One _
A ""'..IIurgi1f)' the damage mech_m kif the <:Ung F9Je 21 show • • ~ _ _ that wn ",~ .n from the ~._ where d creep ..-. r>ear the ooter .., ~ . <e th", we<e found on the >ide 01 !he ling _lion the u a cled the P" " "I>
he_ •.
_'Ie
"'is
Ropoaifs a nd h e _ replacement WefO IUC"" ..1uIy impiemefl1ed, but !he", ... 8S a Ion<) lead lime !of 2DC,_ 32N~Nb
obtainin\I a new
"""'e1din9
Figure 21_ Phgraph or Cr.ch>g 0"""","" in Ring Sect"", from Outre! He. dor
,-
""
" "
""
"\ ,
•
"
Figure 22_ Ph<>1
,. ., , •, I •
. -- .. '.
,
!'•
,.''..
•, • "
• • •
,...',
•
•
!
.'
'.
: .-< •
f igure 13----Photomierograj>h 01 Aligned C"",p Vo"," He ... OtIto, Surf""", '"' S .... Opposite eroding of He.de, Ring Sectioo Shown in Fig.n 21 aoo Figure 22 I... . -poli.hedl
,< y<
,
/ • Figure 24---l'hOlornicrogr.pIJ 01 C.... p Cracking on Surl."" 01 H._, •• s..en on M.... ,i<>g,.phic R."bc.
5.4 C...... 3: Pigta il Ruptures This h)'er wa. m emal Pf"SWI" 01 2010 ~ P . ( 300 pojq) The ootlol pigtUs ... «>mtru<",d o125_. _mm (1_;,q ejam.tef pipi'lg ood .... eIded 10 2 5 .• -mm (1';".) fi tting' "'"' . '" in ....,. ..... Ided to 1I>e eatalysl wbe outlet . nd 1te outle! header . The pigtail. "'" sOOJIion ...".,. Ied . t 112 1 ' C 10 11. 9 'C (2050 ' f 10 2100 ' f ) . Iter I>er>ding 10 !het final ~ t ion . The ~h ood ! t1ing. "'" we lded ~ In ,, ," \el 62 ood lneoW.kI A RIef metal> During 1I>e .orvi<e He 01 the , .forme<, m""l' piQton flo • • rupl..-ed . Crack. ""'''' _ in !he weld be""'en 1I>e ooupiin<J and !he <_ Iyst tube_ They 1\a"" . 1s< be." found in !he e<>nne<1ion between the «>upIirI<J ood 1I>e outlet header . The"", ""'''' ground out . nd ,...,.u-ed foIIowin<J !he ope< . ..... .. _ g procedure
_.rd
"OJ"'"
Two eau..,. 01 cr. eking I\a"" bee<> identified_ One w.. found ., be th"""aI faliQu e _ Aoo!hef eauoe support shoe. _ \/<Jde., wtlid1 put me chanical stre . . on the _ • . The operator . ..... tho! _<1 """"aI inopeclioo. 01 the piQtaiIs ood 1I>e .... eIds_ The inspection. indOOe dye penet,ant t.S1irI<j , • • wei ... uftnroonie she ..._w."" ood wall ___ kne .. ' ''''''''_
w... d . termined to be «>rroded
5.5 C...... 4: Stress Relaxa!ioo Cracking of Alloy 800HT Pigtail Secti"" ....". SOOtH _ Type 304H .toinIe.. . tee! (see Fie 2 '!e remaindef 0I11>e pigtai w• • mode 01 Type 3114 _ .. steef . The ope<. tRj tempee ....". 800HT foiled by "" OU<Jf>-woll <e , the fMK. mechanism w• • identified . . . ..... rNxafion UlI
<01><"""" __
""""oing
K w.. indi<.ned thot SIre • • reliel'ing O! 1185 · C (1 625 ' F) or -.oon W<>UId ,educe 1I>e ine 2 ' 1<<: 1_1I0I0 .tee! weklolet. Possiblo . _ t e d ookJtioos w"", ,."'. cernen1 with fir>e-qroned ....". IlOO " , " _, or highe< chromium alloys thot W<>UId be """" ,. _ '" . ..... rNxafion
5.6 C...... 5: WeldabiH!y Issues with Cas! lOCr _32Ni-Nb A new re/ro<1O<)'-«>ed traMIe< line w• • to be in ...1Ied in the """'" manifold system of • h)'dorogen , .forme<""_ 1 his in ..... tio" """,ired !he w elg 01.- east :IOCI-.lLNi-l'lb -Nb lee. _ The tee> _ <>IiI
.Item.,..
Initial . t ~ resuftee <>IiI nd down . nd dye pe""". nt "'''in<) ...... pefformed. l neor ood traMv""e e,. eking ...as _ in !he HAZ, • • had bee<> oboef\l1>d in1he .ttempted _ _
•
--. ., ~
f igure 25-PhOlograp/l of Alloy aoo lll ..... ,
'0
I.
>0
"
"
"
"
..
"
Pig'.~
and An.ehmen. f itting
,'''
f ig .... Z&-Photograph 01 C f 'C ~ "g <>1 Alk>y 1I00 HT Inle' Pigt.il Shown .. Figu re 25
f igure 21_ Photom",rogrOj>/l 0 1 Cra c l. in Alloy 800HT Inlet Pigt.il Showing E.Klence 01 Str.... Relanbon Cracking Me!aIkr'llieal .... tyo.;o wa s perlomled on ho weld...,. test..."pIe to determine the eou"", 01 the « .ctin<) """ help de",,1o!> • ~ 10 the
be ...,""" me range .pe
shown .,
The m",rosIruee or .. _ preeipita_ in dendrite cores """ rIenurIe' eon.tit""" .. in the miero"",,"ure . Iron and nie ~ ~ Wm earb;d". from !he or'qinoI eas~ proce ••. Secondary precipilate. W
_c_
p.,. shown in f ig..-e 29, there w os e l'irle<>ee oIliqu~ """" lourld to be . 0000000ted ";111 the er.ctin<). There "' • • 0100 .~ar,o
p.,. shown ., F" ure :10, some erack.ing wo • ...., 100 11<1 beyoodthe HAZ The"", 0Il1 the rIeodfile core. """ the .,terrleOOritie regoion • . In reg ..... YI'he<e ineu - .. per!orated dendrite _ _ ' , there . ppeared 10 be .. _ "",oed .. _ of rehe. t ua<_ing K w... lourld th. t the aged 2OCr_32W_Nb m . t«iol ~ od 10 be ~ . 000_ befo<e welding eouId be completed ";Ihout 1iQua_ Of re he. t er' ''''ing . Thu', tile old e xiOling tee . W
Figu,e 28----l'hotomK:'ogrOl'll of SII
f iguro 29---PhotomK:'ogrOj>lJ Showing E"_ce of liquotion Cracking in Woklol>< lit)o To .. Sa mple o f "'lI"d 2OC,_J 2N i-flb Cono Motorial
f ig"" l6-Pho tom ",rogrOj>/l Showillg E. idenco of R...... t Crackillg ill W. klobilit)' Tes t Sample of Aged l OCr-31Ni-ll b Co,," Moter iol
5.7 C...... 6:
Rep~ir
000 Mitigation of C~st 20Cr -J 2Ni-tlb Tees
n .. eo .. 01$0 re.iews erocking problems tha t w ere eneo< the outlet ma nilold we", 67 1 'C (1roO ' f l a nd 23110 kP a (345 p~l , re ' pecti"",.,. Figu", 31 ohowo the p<>SiIioM of OIl old "'" and a ""'" reducor in the outlet manifold Figure 32 ohow. the rOQion whore crack. were bJnd aile< welding, _ Figure 33 ....,..,. the _ of the cra ct.in<) , .. revealed b~ "om"'lin<) at . .",ice tempera"..e •. K "'00 eon<e ""'kIin<J was required to ming at< this type 01 cro<~
w..
Both old tee. were cut "'" of the monilold and ~ion annealed at 1149 "C (21 00 "f l to re"'", me to a'o'Oid proPO<Jalin<) crock> . .... surIoee. a osointo were "-009hIY before~ ..... w~ ..... to be peII
cIe._
He.t input n
low . . possible: . 9 'C (1 20 ' f l prehea t and , . 9 'C (300 ' f l m a.on",,,, iII_o.
t empe
We~ ",,0/1 cup size 01 12.7 mm ('12 in.) or large< Torch _ """ail! pedic"' ... to piece
be at center of weld and _
•
Figure J' _ PhOlogroph of Sltowing l ocatio... of Old T"" and He", Reduce, Cone in 20Cr _32Ni-Ub Outlet Manilold
f iQure 32- PI>o1011<3"" 01 ShowOlg location or Cracking TIla, Occurr<1l W,,"n u.,,,, Centrifug.lly Cut
2OC. -32t1i _tlb Re
f igure J 3-Pho tog,a pll Showing C,,,,,,king That WH f """d in Ba • • Moot., 01 Old 1 0C,-31Ni-flb Statica lly Cn t Tee . n., W. lding
n w... noted !h. 1 ~ is ",,-,"nt to maintain _inII 9" boo ....., ~ is dd!'oc'" to ..........1 tho met .. ~ . n oxide
gu_ """'.
isI. nd lorm. ao . "' ..... 01 .. "" 0I1I"OekIir>g 1>< weld boo
bo .lghtly colwe< (oot o""cave)
The w eldin<) 01 tho _ . a nd "'OO<eB '01'" .... oce. oMy compieted by "sin\! tho in. pe<1ion leQIJ"""e
~
weldin<) and
Apply a btJU ... to)'efof Alloy 617_ .... taI . usin\!low _ _ Inope'; 617 w eld metal
Center boo
~
<ent ... bead <,"
f.,..,., zone or
('It. in.)
lIIind oot """ ro--weld. m al
IU'" that boo
HAZ liqualioo era"" inII: , _ zone or Iiqu~ erao Ianj ... than 1_6mm and eon"'",o,,,, is loond, lowe, h eat input""" ro--appIy btmef loy ... "" old _ _ • using
otmge< boad._ Hammer pe
0,.., """" .. ont teOi e ach loy ...
~
r>eeded_
_lim toyer wiIh >ame _
Tock weld. Visual'\' ".pect !of
Che"" kif coo ... tent root opening ROO! p .... is ""f'I im""""",. Root opening 0II001d b<> 32 mm '" 4 .0 mm ('II in. '" ' "" in .1 a round entire _"",fe,e",:".
-.
Dye peoetnrnt test O'Iel)' ...,oond pus,
f .... cap p... _
~
.. me .. spection pro<:e
,... \1<1 beyond the previouo pa ... Blend grQI and dye peoee. " t test lnoI p....
5.8 Ca"" 1: Cracking at Weld Between on Alloy 800HT FOfged Fitting and on Alloy 800HT Outlet Tmnsler line This 0_ describe. the
5<_
Sever" failu", . of thO. type """" been reported .. e QIJ .... Ie"t Ioeatioo. in _ tuma< ... The failure <>«:<.
a.
(Ala! 600HTI
The M in<) ...as . tt. ched to the transfer line by • G • • Toogsten AJo WekIing (GT AWl proee .. usin<) Ala! 611 IiiIer metol . The ootIet tronster _ was de.igned kif • m u im"", pr......-e of 124 kPa (1 6 1)Siper. tin<) P"'''''''' and te""4H'fllture were 103 kP. (1 5 psiool and 636 · C (1 5.11 ' f l, ",specli'lely.
It 10'' ' c o o _ th. t the 1.*,,,, <><wrred by a combination 01 c' eep . nd thermal fatigue orack 9~!rom < re!>e . t cra~ <>em .. try, the 'liII~ .trenQ1h of the Ala! 6 17 - . metal, and the h9'II\' ",oeained weld joint eIp redu<e the . treu Tf>< "",Id. failed by ereep-!.riII"" interaction be<"".., 01 additional ~erm" .tre.... ~ ~q~ _ "",t.te. m.
",10,,_ ,.
<000""""_.
<0""4"'''''''''
Figu re :W-Cr"",king .t tile Weld Joint BeIW..,n on Alk>y 1I00 11T FOfIl"U Fitting (on nghtl onU.., AI Io ~ aoOtH Out ... l ron.fer l ...., 10ft
''''1)
6
Conclusions
From "' .. r"""'w, ~ w ... _ thot iml..,,.e-ruplUfe propertie. o! !he 2OCr_32W_Nb . Ioy is ~ . This should i n _ &<>loftr
--
<""'"
The M.tel. and weld., and d.t. "" mote
I~
inspee_ technique. aro noedod 10< 1>0111 hoadoB and F'i """-"d be
hiQhIy _ _ . UIlra""",<, edd'\' «.
.....-oId>
Modem .Ire.. ... ..,.... 10010 _ be utiOzed 10 <esign _ 01 .... and F'i<Jill miligalo m a".,. of !he prob!omo of high .tress "","'" be."",.., of poor design "", • • in ro!ormer OU1!e1 . yo1em •. I ~ _irlII ~. 0II001d be doveloped !of both now and .emeo-e_d "",' 0Ii01o . ~ is poniwlarty mp
A 'yo1omo1ic o valuation 01 "'" lot.-Nb a loy opWn<>m h igh_1empe
'irlII'
witt>
7 Acknowledgements Tho . u1horo O<~ 1110 ouppon of "'" Amor>: .... P,,1roIo um I",tituto'. Commimeo 00 Rofir>er)' E Q<Jipm",,~ Subcommittee of Corrosion and In p a rtic<>l.ar, !he e001rib
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