Final Superheater Header

Gruppo #1
Diego Raffa
Gabriele Barboni Aula Magna – Rettorato
Luca Nemboli Mercoledì 27 maggio 2015
Corso ‘Materiali per
SUPER HEATER HEADER
PRODUCTION PROCESS
 PRODUCTION
PROCESS
MANDERL MILL
PROCESS
IN THE MANDREL MILL PROCESS, A SOLID ROUND (BILLET) IS USED.
THE MAIN PASSAGES ARE :

- PRE-HEATING
- PIERCING (MANNESMANN PROCESS),TO CREATE THE HOLE
- ROLLING BY A MANDREL MILL,TO REDUCE THICKNESS AND DIAMETER
- HEAT TREATMENT TO PREVENT INTERNAL STRESSES
- STRETCH REDUCING,TO REACH SPECIFIED DIMENSIONS
- COOLING DOWN
- CUTTING
 WELDING PROCESS

TIG-GTWA

SMAW
 P92

CHEMICAL CMPOSITION

P92 IS A FERRITIC (9% CHROMIUM,1.75% TUNGSTEN,0.5% MOLYBDENUM)

STEEL MICRO-ALLOYED WITH VANADIUM AND NIOBIUM AND WITH
CONTROLLED BORON AND NITROGEN CONTENTS.
 MAIN APPLICATIONS

1. BOILER E SUPER HEATER AND REHEATER TUBES OF ADVANCED POWER

PLANTS

1. HEADER E STEAM PIPING FOR EXTREMELY SEVERE STEAM CONDITIONS

(EXCEEDING 600°C,250 bar)
ADVANTAGES

1. INCREASED HIGH-TEMPERATURE STRENGTH AND CREEP BEHAVIOUR

COMPARED
TO OTHER FERRITIC ALLOY STEELS

2. CORROSION/OXIDATION RESISTANCE EQUAL TO OTHER 9% CR FERRITIC

STEELS

3. REDUCED WEIGHT THANKS TO HIGH CREEP VALUES.

4. RESISTANCE TO THERMAL FATIGUE SUPERIOR TO AUSTENITIC STAINLESS

STEELS.

5. THE HEAT TRANSFER AND EXPANSION COEFFICIENTS OF THESE

MATIRIALS ARE
MUCH MORE FAVOURABLE THAN THOSE OF AUSTENITIC STAINLESS
CCT CURVE
 HEAT TREATMENTS
.
DONE TO FIND A COMPROMISE BETWEEN :
HIGH CREEP RUPURE STRENGH - LIMITED HARDNESS

- NORMALIZING PROVIDES FOR DISSOLUTION OF MOST CARBIDES

WITHOUT
SIGNIFICANT GRAIN GROWTH

- TEMPERING ALLOWES CARBIDES TO PRECIPITATE HOMOGENEHOUSLY

WITHIN THE
MARTENSITIC STRUCTURE,THUS IMPROVING THE MATIRIAL CREEP
BEHAVIOUR
 TYPICAL MICROSTRUCTURE OF P92

THE SPECIFIED HEAT TREATMETS

CONDITION LEADS TO A STRUCTURE OF
TEMPERED MARTENSITE WITH
PRECIPITATION OF :
- M23C6(M=Fe,Cr,Mo) CARBIDES
- VANADIUM/NIMOBIUM CARBONITRIDES OF
TYPE MX(M=V,Nb X=C,N).

THE PRESENSCE OF THIS PRECIPITATES

IMPROVES :
- CREEP ROPTURE STRENGTH BY
PRECIPITATION
HARDENING

IN ADDITION MO AND W CONTRIBUTE TO

SOLUTION HARDENING.
 POST WELDING HEAT TREATMENT

THE POST WELDING HEAT

TREATMENT PROVIDES FOR :

- TEMPERING MARTINSITE

- REDUCING HARDNESS

- IMPROVE TENATICITY

- REPRECIPITATION OF
CARBIDES
 MICROSTRUCTURE EVOLUTION BY AGING

MAIN DEGRADATION MECHANISMS

- THE COARSENING OF CARBIDES

- THE NUCLEATION AND GROWING OF LEAVES PHASE

- THE DECREASE OF MOLIBDENUM CONTENT INTO THE MATRIX DUE TO

LAVES PHASE PRECIPITATION
 LAVES EVOLUTION

W-BASED PHASE IS MORE STABLE AGAINST GROWTH THEN MO-BASED

LAVES PHASE
(P92 HAS MORE W CONTENTS COMPARED TO P91)

LAVES PHASE COARSENING RATE IS DIFFERENT AMONG THE 9% STEELS

 CAVITATI
ON
CAVITATION DURING LOW STRESS
CREEP TESTS IS OBSERVED ALONG
LARGE LAVES PARTICLES

HIGH CREEP RESISTANCE BEHAVIOUR

EXPLANATION
HIGHER CREEP RESISTANCE OF GRADE 92 WITH RESPECT TO GRADE91 IS
EXPLAINED BY THE LOWER COARSENING RATE OF LAVES PHASE(W-
BASED LAVES PHASE).
YIELD AND TENSILE STRENGTH AT HIGH
TEMPERATURES
 SAVE12AD
SAVE12AD IS A FERRITIC (9% CHROMIUM,3% TUNGSTEN) STEEL MICRO-
ALLOYED WITH VANADIUM AND NIOBIUM AND WITH CONTROLLED BORON
AND NITROGEN CONTENTS.
AFTER NORMALIZING AND TEMPERING IT SHOWS A MARTENSITIC
STRUCTURE.
COMPARISON P92-SAVE12AD CREEP
RESISTANCE
- DEGRADATION IS SUPPRESSED COMPARED TO GR.92.

- CREEP RUPTURE STRENGTH OF SAVE12AD IS ABOUT 40% STRONGER

THAN THAT OF
GR.92 AT 600℃& 650℃.
 USD-TONN
(USD/(ton*Amm)-T (P92)
250.000

200.000
USD/(ton*MPa)

150.000

100.000

50.000

0.000
0 100 200 300 400 500 600 700
T(°C)

USD/(ton*Amm)-T (SAVE12AD)
300.000

250.000
USD/(ton*MPa)

200.000

150.000

100.000

50.000

0.000
0.000 100.000 200.000 300.000 400.000 500.000 600.000 700.000
T(°C)
 NORMATIVE REFERENCES

➢UNI EN 12952-3_2012
• Allowable stress values
• Tube thickness

➢UNI EN 12952-4_2011
• In service damage tests

➢EN 10216-2_2013
• Materials’ composition
• Creep rupture strength
values
• Thickness tolerances
 CALCULATION OF ALLOWABLE STRESS
300 VALUES
ALLOWABLE-T(P92)

250
ALLOWABLE (MPa)

200

150

100

50

0
0 100 200 300 400 500 600 700
T(°C)

ALLOWABLE – T (SAVE12AD)
200
180
160
ALLOWABLE (MPa)

140
120
100
80
60
40
20
0
0 100 200 300 400 500 600 700
T (°C)
 CALCULATION OF THICKNESS AT PROJECT
CONDITION
dos(mm) Ps(bar) T2(°C) Fs(MPa) v Ecs(mm)
P92 457,200 275,000 630,000 43,330 0,800 122,870

SAVE12AD 457,200 275,000 630,000 72,000 0,800 84,838

Ecs/dos SPESSORE EFFETTIVO

0,269 141,300
0,186 97,564

THERMAL FATIGUE TEST AT PROJECT CONDITION

N°Cicli RampRate(K/min) usage factor(n/Nrottura)

P92 2000 2,1 1

SAVE12AD 2000 3,72 1

CALCULATION OF LARSON-MILLER’S
COEFFICIENTS 3
y = -7,8226x + 40,243x - 75,18x + 86,552 2
KLM-P92 R² = 1
40

35

30

25

20

15

10

0
1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2.3 2.4
LOG(σ)(Mpa)

y = -13,576x2 + 49,479x - 12,69

KLM-SAVE12 AD R² = 1
32.5
32
31.5
31
30.5
30
29.5
29
28.5
1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2.3 2.4
LOG(σ)(Mpa)
 CREEP TEST
C P(Mpa) dos(mm) t(mm) din(mm) v F(Mpa) T(°C)
P92 35 26,5 457,2 141,3 174,6 0,8 33,7158 620

SAVE12AD 30 26,5 457,2 97,564 262,072 0,8 57,394 620

 Beta 0 Beta 1 Beta 2 Beta 3 KLM

86,552 -75,18 40,243 -7,8226 37,729

0 -107,17 156,51 -48,038 32,342

Time rupture(h) Time(h) Time/Time rupture % of Time

17786168 200000 0,0112 1,124

1651151,6 200000 0,121 12,11

 THERMAL FATIGUE TEST
N°Cycles RampRate(K/min) RampRate(K/s) Usage factor(n/N) Status
P92 1500 12 0,2 31 Negative
SAVE12AD 1500 12 0,2 6,32 Negative

N°Cycles RampRate(K/min) Opening Usage factor(n/N) Status

P92 1500 2,4 Small 1 Positive

P92 1500 2,8 Big 1 Positive

SAVE12AD 1500 4,41 Small 1 Positive

SAVE12AD 1500 4,86 Big 1 Positive

 CREEP AND THERMAL FATIGUE
N°Cycles
INTERATION
RAMP RATE(K/Min)
SUM OF USAGE FACTOR &
STATUS
TIME/TIMERUPTURE
P92 1500 12 31,011 NEGATIVE

SAVE12AD 1500 12 6,44 NEGATIVE

IDEAL ALLOWABLE RAMP RATE

MAXIMUM RAMP RATE
P92 2,34
SAVE12AD 4,07
CREEP-FATIGUE INTERATION
1
0.9
0.8
TIME/TIMERUPTURE

0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.2 0.4 0.6 0.8 1
USAGE FACTOR
 MAXIMUM ALLOWABLE RAMP RATE

N°Cycles RampRate(K/min) usage factor(n/N)

P92 1500 1,8 0,5

SAVE12AD 1500 0,4 0,12

 FINAL THICKNESS
RATIO THICKNESS STARTING
mmm*10^-3 TIME LOSS(mm) THICKNESS FINAL THICKNESS
P 92 80 200000 16 141,3000352 125,300
SAVE 12 AD 20 200000 4 97,56376518 93,564

MAXIMUM ALLOWABLE STRENGTH

dos(mm) Ps(bar) T2(°C) Fs(MPa) v THICKNESS

P92 425,200 275,000 630,000 37,700 0,800 125,300

SAEV12AD 449,200 275,000 630,000 61,892 0,800 93,564

 P92
STRESS-TIME
45.000

43.500

42.000
STRESS (MPa)

40.500

39.000

37.500

36.000

34.500
100000 110000 120000 130000 140000 150000 160000 170000 180000 190000 200000
TIME (h)

SAVE12AD
STRESS-TIME
73.500
72.000
70.500
STRESS (MPa)

69.000
67.500
66.000
64.500
63.000
61.500
60.000
100000 110000 120000 130000 140000 150000 160000 170000 180000 190000 200000
TIME (h)
 CONCLUSION

- FROM USD/TONN CURVES WE DEDUCE THAT THE COSTS AT 620°C

ARE SIMILAR

- BY THE CALCULATION OF PROJECT DIAMETERS IT’S CLEAR THAT

SAVE12AD HAS AN ADVANTAGE (LOWER THICKNESS)

- BOTH MATERIALS HAVE A HIGH CREEP RESISTANCE

- BY CONSIDERING THERMAL FATIGUE PROBLEM, SAVE12AD

ALLOWS HIGHER RAMP RATES

- DISPITE CALCULATION,NOT EHOUGH DATA ARE GIVEN FOR

SAVE12AD TO RIGHTLY EVALUATE CREEP PLUS FATIGUE
CONDITION