P91 and Beyond…

William F. Newell, Jr., PE, IWE

, Ltd.

IPEIA Conference

1-3 February 2006

The Banff Centre

Banff, Alberta

SCOPE

Where We’ve Been

Where We’re At

Where We’re 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 T/P 91

Preheat Always Always !

PWHT Sometimes Always !

N & T(after cold work) Sometimes Always !

CMTR Rarely Always !

Toughness Rarely Always !

Post Bake Rarely Always ! (except GTAW)

Cool to <100C No Yes ! (?)

Bead Sequence Rarely Always !

Purge No Always !

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 P92 E911 T23 T24 P122

Cr 8.00-9.50 8.50-9.50 8.50-9.50 1.9-2.6 2.2-2.6 10.00-12.50

Ni <0.40 <0.40 (<0.40) - - <0.50

Cu - - - - - 0.30-1.70

Mo 0.85-1.05 0.30-0.60 0.90-1.10 0.05-0.30 0.90-1.10 0.25-0.60

W - 1.50-2.00 0.90-1.10 1.45-1.75 - 1.50-2.50

V 0.18-0.25 0.15-0.25 0.15-0.25 0.20-0.30 0.20-0.30 0.15-0.30

Nb 0.06-0.10 0.04-0.09 0.06-0.10 0.02-0.08 - 0.04-0.10

N 0.030-0.070 0.030-0.070 0.050-0.080 <0.030 <0.012 0.040-0.10

B - 10-60ppm - 5-60ppm 15-70ppm <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 CrMo’s

ASME Code Cases

Trade Name

Grade

Material (seamless)

Code Case

Issue Date

NF616 P92 9Cr-2W 2179 8 August 94

HCM12A P122 12Cr-2W 2180 8 August 94

HCM2A T23 2.25Cr-1.6W-V-Cb

2199 5 June 95

E911 E911 9Cr-1M0-W-Cb 2327 2 May 00

Welding Consumables

Welding Consumables

P91 P92 E911 T23 T24 P122

SMAW

Chromet 9B9

E9015-B9

Chromet 92

*

Chromet 91W

Chromet 10MW

Chromet 23

Chromet 23L

Special

*

GTAW

9CrMoV

ER90S-B9

9CrWV

*

?

2CrMoWV

Special

*

FCAW

Supercore F91

E91T1-B9

Supercore F92

*

Cormet 10MW

*

Supercore F23

*

N/A

SAW

Cormet M91

9CrMoV EB9

9CrWV

*

*

*

Special

*

Potential Patent Issues

* No applicable National Standards.

Caution Areas

• Design

• Heat Treatment

• Low Bidder

From the ‘Net…..

Caution: (design)

Dissimilar

Welds !

Caution: Dissimilar Welds !

Design …

1.25Cr 1Mo VP91

PipeValve

E9018-B3 Weld

PWHT – Req’d by Valve Mfg.

Dissimilar Strengths…

Design

P91

Pipe

1.25Cr 1Mo V

Valve

E9018-B3

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 PWHT’s Where A1’s are significantly different

Nickel Base Butter

Caution (heat ?)

Preheat…Maintenance ?

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…..

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

• < ½” = 1325 -14700F (720-8000C)• > ½” = 1350 -14700F (730-8000C)

• Rules if heated above 14700F (8000C)

• Why 14700F (8000C) ?

Beyond the CrMo’s !

Beyond the CrMo’s

Alloy Nominal Composition Developer

Haynes 230 57Ni-22Cr-14W-2Mo-La Haynes

INCO 740 50Ni-25Cr-20Co-2Ti-2Nb-V-Al

Special Metals

CCA 617 55Ni-22Cr-.3W-8Mo-11Co-Al

VDM

HR6W 43Ni-23Cr-6W-Nb-Ti-B

SumitomoSuper 304H 18Cr-8Ni-W-Nb-N

Save 12 12Cr-W-Co-V-Nb-N

“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 CrMo’s ????

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