P91 and Beyond

IPEIA Conference 1-3 February 2006 The Banff Centre Banff, Alberta

William F. Newell, Jr., PE, IWE

, Ltd.

SCOPE
Where Weve Been Where Were At Where Were Going

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

Domestic Reluctance - Why?

Manditory:
Elevated Preheat Interpass Temperature Controls PWHT Required on EVERYTHING!

P(T)91* is NOT just another CrMo ! (the others too !)

Compare: B2/B3 to B9/505

Mod.

T/P 22
Preheat PWHT Always Sometimes

T/P 91
Always ! Always !

N & T(after cold work)

CMTR Toughness Post Bake Cool to <100C Bead Sequence Purge

Sometimes
Rarely Rarely Rarely No Rarely No

Always !
Always ! Always ! Always ! Yes ! (?) Always ! Always !
(except GTAW)

WHY?

Current P(T)91 Usage

Dramatic Domestic Increase in Last Several Years Use Mainly for Cogeneration

Utility Usage increasing for Repowering, Replacements & New Facilities

Possibilities

P91, P92, E911 T23, T24 P122

Base Metal
Base Material Specifications P91 Cr Ni Cu Mo W V Nb N B
8.00-9.50 <0.40 0.85-1.05 0.18-0.25 0.06-0.10 0.030-0.070 -

P92
8.50-9.50 <0.40 0.30-0.60 1.50-2.00 0.15-0.25 0.04-0.09 0.030-0.070 10-60ppm

E911
8.50-9.50 (<0.40) 0.90-1.10 0.90-1.10 0.15-0.25 0.06-0.10 0.050-0.080 -

T23
1.9-2.6 0.05-0.30 1.45-1.75 0.20-0.30 0.02-0.08 <0.030 5-60ppm

T24
2.2-2.6 0.90-1.10 0.20-0.30 <0.012 15-70ppm

P122
10.0012.50 <0.50 0.30-1.70 0.25-0.60 1.50-2.50 0.15-0.30 0.04-0.10 0.040-0.10 <0.005

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)

Advanced CrMos

ASME Code Cases

Trade Name NF616 HCM12A HCM2A E911 Grade P92 P122 T23 E911 Material (seamless) 9Cr-2W 12Cr-2W 2.25Cr-1.6W-V-Cb 9Cr-1M0-W-Cb Code Case 2179 2180 2199 2327 Issue Date 8 August 94 8 August 94 5 June 95 2 May 00

Welding Consumables
Welding Consumables
P91 P92
Chromet 92 *

E911
Chromet 91W Chromet 10MW

T23
Chromet 23 Chromet 23L

T24 Special * Special * N/A

P122

SMAW

Chromet 9B9 E9015-B9

GTAW

9CrMoV ER90S-B9

9CrWV *
Supercore F92 *

2CrMoWV

Potential Patent Issues

FCAW

Supercore F91 E91T1-B9

Cormet 10MW *

Supercore F23 *

SAW

Cormet M91 9CrMoV EB9

9CrWV *

Special *

* No applicable National Standards.

Caution Areas
Design

Heat Treatment
Low Bidder

From the Net..

Caution: (design)

Dissimilar

Welds !

Caution: Dissimilar Welds !

Design
P91 1.25Cr 1Mo V

E9018-B3 Weld

Pipe

Valve

PWHT

Reqd by Valve Mfg.

Dissimilar Strengths

Design

E9018-B3 P91 Pipe 1.25Cr 1Mo V Valve

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

Dissimilar Welds - Solutions

Consider using transitions
Machined transition to change section thickness Pup Pieces

Multiple PWHTs
Where A1s are significantly different Nickel Base Butter

Caution (heat ?)

PreheatMaintenance ?

Low Bidder
Simple: You get what you pay for.$$$ Low Overhead usually means minimal technical expertise
Susies Botique and Weld Shop

Offshore Enterprises
May have technical ability, but many things dont translate well .! ASME Codes and USA Contract Documents may be gathering dust..

Low Bidder ?

Pay Me Now, or Pay Me Later Fram Corp. 1971

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
< = 1325 -14700F > = 1350 -14700F
(720-8000C) (730-8000C)

Rules if heated above 14700F

Why 14700F (8000C) ?

(8000C)

Beyond the CrMos !

Beyond the CrMos

Alloy Nominal Composition Developer

Haynes 230
INCO 740 CCA 617 HR6W Super 304H Save 12

57Ni-22Cr-14W-2Mo-La Haynes
50Ni-25Cr-20Co-2Ti2Nb-V-Al 55Ni-22Cr-.3W-8Mo11Co-Al 43Ni-23Cr-6W-Nb-Ti-B 18Cr-8Ni-W-Nb-N 12Cr-W-Co-V-Nb-N Sumitomo Special Metals VDM

Back to the Future

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 CrMos ????

Questions

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