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PVP2010
July 18-22, 2010, Bellevue, Washington, USA
PVP2010-2
ABSTRACT
Pressure vessels made from Cr-Mo steels are utilized for
high temperature and high pressure services including hot
hydrogen services. After long term operation, there are
several past experiences of damages and/or degradation of
materials
such
as
temper
embrittlement, creep
embrittlement,
hydrogen
attack
and
hydrogen
embrittlement.
This
paper
summarizes
typical
damages/degradation and examples of weld repairs
including special attention to development of weld repair
procedure. The subject equipments are heavy wall
petroleum pressure vessels made from Cr-Mo steel with
austenitic stainless steel overlay cladding. Cracking could
be prevented by controlling the repair welding process to
reduce the hydrogen content at the interface. After repair
welding, adequate post weld heat treatment (PWHT) has to
be executed.
Recently, repair welding has become an important
aspect as part of post construction codes for pressure
equipment to keep safe and long term continuous operation
of the process plants because many of the plants have been
operated for more than thirty years in Japan. Responding
to the needs of petroleum and chemical industries, The
Chemical Plant Welding Research Committee (CPWRC) of
The Japan Welding Engineering Society (JWES)
established the Pressure Equipment Repair Welding
Subcommittee (PERW S/C)[1]. The S/C has developed
1. Introduction
In recent 40 years, the progress of technologies for
petroleum pressure vessels, such as hydrocracker and
hydrodesulfurization reactors, can be divided into four
generations as shown in Tale1. These reactors have been
operated in high temperature, high pressure hydrogen
environment. This experience provides fundamental
database for serviceability assessment of the reactors.
Damages such as creep, temper and hydrogen
embrittlement and hydrogen attack during long time
operation were reported in the base metal, weld seam and
weld overlay cladding by in-service inspection for old
generation reactors. As a result of investigation these data
and measures to prevent the damage has been accumulated
and reported.
In the case of repair welding for petroleum pressure
vessels after long term operations, weld cold cracking
sometimes occurred at the base metal of Cr-Mo steel
/overlaying metal of austenitic stainless steels interface in
the structural materials of the pressure vessels after
welding [2,3]. It has been reported that such cracking is
caused by thermal and hydrogen embrittlement in the
3rd Generation
4th Generation
5th Generation
1965 1972
1973 1980
1981 1987
1988 1997
1998
Multi-Layer Rx
1st Generation
Year
Technology
Improvement
PZ OL
TE Sensitivity
Factor,
J-Factor
No-Spec.
CVN Impact
Toughness
Av.55/Min.45J
10oC
J=150max.
J=130max.
J=180max.
- 7oC
- 15 oC
- 20 oC - 30oC ( vTr 55 = - 40oC )
930ton
850ton (250mm)
(260mm)
Thickness
& Size-up
814ton
(251mm)
500ton Field Fab.
325ton (260mm)
2.25Cr-1Mo Rx
(211mm)
1,138ton
(328mm)
Max. 344mm
1,450ton
(273mm)
2.25Cr-1Mo-V Rx
3Cr-1Mo-V Rx
1,298ton
(262mm)
Max. 347mm
(mass.%)
Si
Mn
Cr
Mo
0.5Mo
0.251)
0.15/ 0.40
0.90
0.030
0.030
0.45/ 0.60
1Cr
0.17
0.45
0.36/ 0.69
0.030
0.030
0.74/ 1.21
0.40/ 0.65
1.25Cr
0.17
0.44/ 0.86
0.36/ 0.69
0.030
0.030
0.94/ 1.56
0.40/ 0.70
2.25Cr
0.17
0.50
0.27/ 0.63
0.030
0.030
1.88/ 2.62
0.85/ 1.15
3Cr
0.17
0.50
0.27/ 0.63
0.030
0.030
2.63/ 3.37
0.85/ 1.15
5Cr
0.15
0.55
0.27/ 0.63
0.030
0.030
3.90/ 6.10
0.40/ 0.70
Table3
S teel
0.5M o
0.5C r-0.5M o
0.75C r-0.5M o
1C r-0.5M o
1.25C r-0.5M o
2.25C r-1M o
3C r-1M o
5C r-0.5M o
9C r-1M o
Ehn.2.25C r-1M o
2.25C r-1M o-V
3C r-1M o-V
P -N o.
3-13-2
4-1
5-1
5-2
5C -1
P reheat and
interpass
tem p./deg.C
80-200
120-300
150-350
200-350
200-350
P W H T tem p
/degC
595
650-700
675
705
675
Fig.2 Creep rupture strength and ductility of various Cr-Mo HAZ(Test temp.:550)[10]
Fig.3 Hydrogen Assisted Crack Problem of Cr-Mo
Steel [14]
5
1
Repair Weld of
Gasket Groove
Thermocouple
3
Insulation
Panel Heater
Nozzle Flange
7
8
Fig.4 PWHT guideline after repair welding of the bottom of gasket groove
(a)
(b)
(c)
Type of Reactor
Type of Defects
427oC
-DP : 11.8MPaG
-2.25Cr-1Mo Steel
-Tp.309 Weld O. L.
Shell Side
-DT :
Tp. 309L
Weld Overlay
Remove of
Cracks in
1/3 Circum.
Quench Nozzle
Preheat:100oC Min.
Gouging
NDE
Preheat:200oC Min.
Cr-Mo Weld
NDE
PWHT:690oC x 8hrs.
NDE
Type of Defects
-DT :
454oC
-2.25Cr-1Mo Steel
-DP : 14.6MPaG
-Tp.309+347 Weld O. L.
Manhole Nozzle
Cutting of
Nozzle Neck
Detection of Crack in
Gasket Groove of
Bottom Nozzle
Flange
Cutting of
Damaged Flange
Panel Heater
Insulation
Cr-Mo Weld &
S.S. Weld Overlay
Local PWHT
NDE &
Partial Hydrostatic Test