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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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Presentation on theme: "P91 and Beyond… William F. Newell, Jr., PE, IWE, Ltd. IPEIA Conference 1-3 February 2006 The Banff Centre Banff, Alberta."— Presentation transcript:

1 P91 and Beyond… William F. Newell, Jr., PE, IWE, Ltd. IPEIA Conference 1-3 February 2006 The Banff Centre Banff, Alberta

2 SCOPE

3

4 P(T)91 Origin Developed by ORNL for Clinch River Breeder Reactor Early and Continued European Experience Domestic Acceptance Minimal until Recently

5 Domestic Reluctance - Why?  Manditory: Elevated Preheat Interpass Temperature Controls PWHT Required on EVERYTHING!  P(T)91* is NOT just another CrMo ! (the others too !)

6 Compare: B2/B3 to B9/505 Mod. T/P 22T/P 91 PreheatAlwaysAlways ! PWHTSometimesAlways ! N & T (after cold work) SometimesAlways ! CMTRRarelyAlways ! ToughnessRarelyAlways ! Post BakeRarelyAlways ! (except GTAW) Cool to <100CNoYes ! (?) Bead SequenceRarelyAlways ! PurgeNoAlways !

7 WHY?

8 Current P(T)91 Usage Dramatic Domestic Increase in Last Several Years Use Mainly for Cogeneration Utility Usage increasing for Repowering, Replacements & New Facilities

9 Possibilities P91, P92, E911 T23, T24 P122

10 Base Metal

11 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)

12 Advanced CrMo’s

13 ASME Code Cases Trade NameGradeMaterial (seamless)Code Case Issue Date NF616P929Cr-2W21798 August 94 HCM12AP12212Cr-2W21808 August 94 HCM2AT232.25Cr-1.6W-V-Cb21995 June 95 E911 9Cr-1M0-W-Cb23272 May 00

14 Welding Consumables

15 Caution Areas Design Heat Treatment Low Bidder

16 From the ‘Net…..

17 Caution: (design) Dissimilar Welds !

18 Caution: Dissimilar Welds !

19 Design … 1.25Cr 1Mo V P91 Pipe Valve E9018-B3 Weld

20 PWHT – Req’d by Valve Mfg.

21 Dissimilar Strengths…

22 Design P91 Pipe 1.25Cr 1Mo V Valve E9018-B3

23 Caution: Dissimilar Welds Materials may NOT relax at operating temperature Watch thickness changes Choose Weld Metal Carefully Design PWHT Carefully  Do not exceed A 1 of base or weld metal  Assure tempering

24 Dissimilar Welds - Solutions Consider using transitions  Machined transition to change section thickness  “Pup” Pieces Multiple PWHT’s  Where A 1 ’s are significantly different  Nickel Base Butter

25 Caution (heat ?)

26 Preheat…Maintenance ?

27 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…..

28 Low Bidder ? “…Pay Me Now, or Pay Me Later…” Fram Corp. 1971

29 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 -1470 0 F (720-800 0 C) > ½” = 1350 -1470 0 F (730-800 0 C) Rules if heated above 1470 0 F (800 0 C) Why 1470 0 F (800 0 C) ?

30 Beyond the CrMo’s !

31 Beyond the CrMo’s AlloyNominal CompositionDeveloper Haynes 23057Ni-22Cr-14W-2Mo-LaHaynes INCO 74050Ni-25Cr-20Co-2Ti- 2Nb-V-Al Special Metals CCA 61755Ni-22Cr-.3W-8Mo- 11Co-Al VDM HR6W43Ni-23Cr-6W-Nb-Ti-B Sumitomo Super 304H18Cr-8Ni-W-Nb-N Save 1212Cr-W-Co-V-Nb-N

32 “Back to the Future…”

33 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 ????

34 Questions ?

35 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


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