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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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SCOPE

Where Weve Been

Where Were At

Where Were Going

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P(T)91 Origin

Developed by ORNL for Clinch

River Breeder Reactor Early and Continued EuropeanExperience

Domestic Acceptance Minimaluntil Recently

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Domestic Reluctance - Why?

Manditory:

Elevated Preheat

Interpass TemperatureControls

PWHT Required on

EVERYTHING!P(T)91* is NOTjust another

CrMo ! (the others too !)

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Compare: B2/B3 to B9/505Mod.

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

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WHY?

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Current P(T)91 Usage

Dramatic Domestic Increase in

Last Several Years

Use Mainly for Cogeneration

Utility Usage increasing forRepowering, Replacements &New Facilities

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Possibilities

P91, P92, E911

T23, T24

P122

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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-

12.50Ni

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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)

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Advanced CrMos

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ASME Code Cases

Trade Name Grade Material (seamless) CodeCase 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

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Welding Consumables

Welding Consumables

P91 P92 E911 T23 T24 P122

SMAW Chromet 9B9E9015-B9Chromet 92

*Chromet 91W

Chromet

10MW

Chromet 23Chromet 23L

Special*

GTAW9CrMoV

ER90S-B99CrWV

*

? 2CrMoWV Special

*

FCAWSupercore F91

E91T1-B9

Supercore F92

*

Cormet 10MW

*

Supercore F23

*N/A

SAWCormet M91

9CrMoV

EB9

9CrWV

*

* * Special

*

Potential

Patent

Issues

* No applicable National Standards.

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Caution Areas

Design

Heat Treatment

Low Bidder

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From the Net..

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Caution: (design)

Dissimilar

Welds !

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Caution: Dissimilar Welds !

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Design

1.25Cr 1Mo VP91

PipeValve

E9018-B3Weld

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PWHT Reqd by Valve Mfg.

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Dissimilar Strengths

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Design

P91

Pipe

1.25Cr 1Mo V

Valve

E9018-B3

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Caution: Dissimilar Welds

Materials may NOT relax atoperating temperature

Watch thickness changes

Choose Weld Metal Carefully

Design PWHT Carefully

Do not exceed A1 of base or weld metal

Assure tempering

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Dissimilar Welds - Solutions

Consider using transitions

Machined transition to changesection thickness

Pup Pieces

Multiple PWHTs

Where A1s are significantly different Nickel Base Butter

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Caution (heat ?)

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PreheatMaintenance ?

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Low Bidder

Simple: You get what you payfor.$$$

Low Overhead usually meansminimal technical expertise

Susies Botique and Weld Shop

Offshore Enterprises

May have technical ability, but manythings dont translate well .!

ASME Codes and USA ContractDocuments may be gathering dust..

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Low Bidder ?

Pay Me Now, or Pay Me Later Fram Co rp. 1971

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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 (720-8000C)

> = 1350 -14700F (730-8000C)

Rules if heated above 14700F(8000C)

Why 14700F (8000C) ?

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Beyond the CrMos !

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Beyond the CrMos

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

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Back to the Future

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Conclusions

-B9 (P91), T23, T24, P92 & P122Base Material & ConsumablesAvailable, proceed with caution

T24 & 122 Consumables Special

Caution: Dissimilar Connections

PWHT is Key to Success

Beyond the CrMos ????

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Questions

?

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References

Viswanathan, R., et al; U.S. Program on MaterialsTechnology for USC Plants*

Masuyama, F.; Alloy Development and MaterialIssues with Increasing Steam Temperature*

Scarlin, Brendon, et al Materials developments forultrasupercritical steam turbines*

Henry, J.F.; Advanced Supercritical Technology: Backto the Future*

Maile, K. et al; Development and Qualification of New

Boiler and Piping Materials for High Efficiency USCPlants*

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