S G M AT E R I ALS S E LE C T I O N

SS 316
Suitable for sodium service in excess temperatures around 650 0 C, but is limited in its use in
water side due to SCC in the presence of Chlorides or Hydroxides. High temperatures ,
residual stress due to cold forming ,tube rolling or welding etc enhances its effects.

Chloride conc. as low as 0.1ppm is sufficient to initiate SCC .

The water side of SS 316 can be coated with Nickel or Inconel to protect from SCC.
(Yevick-Page 204)
------------
Studies reveal that significant amounts of Chlorine and Sodium slip through polishing unit
even when using new fully regenerated resins. Even at low rates of condenser leakage the
chloride slip through aged resins can reach 10-60g / l .The feed water targets as per CEGB are

The main value of condensate polishing unit lies in the salt hold up time it gives in the event of
a small condenser leak . But Cl slip can occur even at low levels of condenser leakage ,
particularly when near exhaustion or with aged resins , and its important to remember that the
polishing plant doesnt guarantee low feed water impurity levels at all operation conditions.

(Selection of values of design peak heat flux to reduce the risk of waterside corrosion in Fast
reactor SG Bolt & Garnsey) V2

The sodium hydroxide can be particularly aggressive especially when SG is highly stressed and
SCC can readily occur if the material is susceptible to this mode of failure. PFR experience
suggests that SS 316 should be avoided. Both operating and residual stress contribute to this
mechanism.

Ferritic steels are not immune to Caustic SCC, but if correctly heat treated exhibit increased
protection.

Type 300 steels are rejected on environmental backgrounds and in particular due to their
susceptibility to SCC in the event of an off target water chemistry or sodium water reaction.

Alloy 800

Superior to 300 series , but not immune to SCC.

Susceptible to loss of ductility when exposed to high temperature due to ageing mechanisms.
Used in Superphenix-1 SG,750MWt.

2 Cr Mo Nb stabilised

Use of a stabilized steel in the SG will lower the Carbon content put into the circuit by design
and leave greater margins for uncertainties or faults such as the leakage of oil from secondary
sodium pumps.
FBTR -25 MWt uses 2 Cr 1Mo ,Nb , Ni stabilized steel (125Bar, 480 0C).PFR uses 2
Cr Mo Nb stabilized steel.

2 Cr unstabilised steel

2 Cr unstabilised steels stress to rupture values falls down sharply above 5000 C.

12 Cr 1 Mo
This is the strongest of the candidate ferritic steel with excellent creep properties enhanced by
addition of Vanadium or Tungsten. Its difficult to form and weld. Also since theres not much
incentive in raising temperature much above 500 0 C its felt that enhanced high temperature
properties are not required and 9Cr 1Mo can be used instead.

9 Cr 1 Mo (DFBR, EFR,)

Allowable stress for this steel is sufficiently high so that 2-3mm thin sections can be used with
15 mm bore dia. It has good water side stress corrosion resistance in the event of a Chloride or
Caustic ingress. Corrosion of this steel in low oxygen sodium will be low ,typically less than
0.1mm in 30years of service.

The modified 9Cr 1Mo steel is strengthened by addition of Vanadium and Niobium. The alloy
is used in Normalised and Tempered condition (????).

The material used in PFBR is ESR (Electro Slag Refining) and VAR (Vaccum Arc remelt)
grades for Tubes and tube sheets to ensure clean material with less porosity and inclusion.

The yield strength of standard and modified 9Cr 1Mo steel is significantly above
SS304 up to 700 0 C.

The ultimate tensile strength of standard and modified 9Cr1Mo steel is higher than that
of SS 304 for temperatures up to 550 0 C.

The modified alloy shows higher yield and ultimate tensile strength than standard alloy
over the entire temperature range.

Creep strength of Mod 9Cr 1Mo is comparable to SS 304 up to 625 0 C, though it falls
below SS304 after that range.

Thermal expansion of Mod 9Cr 1Mo is less than that of SS 304 and Thermal
conductivity of Mod 9Cr 1Mo is greater than SS 304, both these factors are expected to
contribute to better thermal fatigue performance compared to SS 304.

Allowable stress value of Mod 9Cr 1Mo is higher than other ferritic steels over entire
temperature range from 427-7000C and its allowable stress values are equal or better
than SS304 upto about 6000C.

For a given stress the modified alloy can be used 75 0C higher than other ferritic alloys
that have from 2.2 to 12% Cr.

300 series steel typically contain 18%Cr and 8% Ni and have better air and Steam oxidation
resistance. Ferritic steels contain much less Nickel and Chromium and are relatively free from
SCC. (Any relation between Cr% and SCC? Check)

Post weld heat treatment role is crucial in weldings. Lack of PWHT led to the SCC of ferritic
steel evaporators in PFR.

Other problems anticipated from operating experience around the world are Flow Induced
Vibration and wear ( PFR superheater units failure events attributed to wear subsequent to FIV
of tubes) and in PFBR Inconel 718 material has been selected as tube bundle support material
as it has better wear characteristics.

Erosion of Feedwater orifice subsequent to expansion of water jet downstream of orifice led to
the failure of tubes in Phenix. Two orifices are put in series to eliminate this problem in PFBR.

Potential failures anticipated in PFBR

Tube to Tube sheet weld

Cross flow induced Vibration

Transition Joint welding

Welding of SG nozzles to Secondary sodium piping is done by trimetallic Mod 9Cr 1Mo
Alloy 800 SS joint. Butt welding of Nozzle of Mod 9Cr 1Mo steel to Alloy 800 transition
piece without buttering by manual TIG welding process with filler wire and followed by
Shielded Metal Arc welding by coated electrodes.

Heat Treatment

All weld joints of Chrome-Moly ferritic steel shall be preheated to 200-2500C and post heating
to 2000C for 2 hours should be done. The post weld heat treatment should be done at 760
100C. Holding time 3 hours.

SODIUM WATER REACTION CONSEQUENCES

Reaction temperatures as high as 10000C were measured in the large leak experiments, but the
wastage effect is not as severe as in the case of small leak reaction .

Since the reaction front moves with Sodium which is pushed away from the reaction site by the
large amount of hydrogen generated (by a piston effect), it is understood that except in some
special configurations like dead end type vessel where reaction front is stagnant the tube failure
propagation will not occur in large leak incidents.

So in a large leak situation much of the Sodium will be swept out of the
SG and the Sodium water reaction at the leaking point will be quenched
by excess steam, temperatures fall and further tube failures are
suppressed.

To limit overheating, the sodium must be taken away from the reaction
site. For this two rupture discs at top and bottom of SG are provided and
these R/D should break during Design basis leak. This will result in
sodium moving out of the reaction zone in both the directions and thus
avoids further overheating of tubes and additional tube failures are suppressed.