P91 and Beyond…

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

2. SCOPE

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.

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. 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 ASME Code Cases

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 E9018-B3 Weld Pipe Valve

20. PWHT – Req’d by Valve Mfg.

21. Dissimilar Strengths…

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

23. 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

24. 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

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 -14700F (720-8000C) • > ½” = 1350 -14700F (730-8000C) • Rules if heated above 14700F(8000C) • Why 14700F (8000C) ?

30. Beyond the CrMo’s !

31. Beyond the CrMo’s

32. “Back to the Future…”

33. Conclusions • -B9 (P91), T23, T24, P92 & P122Base 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