Fabrication of Heavy Wall Reactors in Crmo V Plates

DILLINGER PRESSURE VESSEL COLLOQUIUM
DILLINGER HÜTTE GTS

16-17 September 2009
Fabrication of heavy wall reactors made in CrMo(V) plates

Giacomo Fossataro
(Walter Tosto SpA)
Walter Tosto SpA was founded in 1960 by Mr. Walter Tosto
1960 2009
First steps of company activities Nowdays, Company awarded with “INNOVATION PRIZE 2009”
by The President Of the Italian Republic G. Napolitano
DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Walter Tosto SpA is located in the central part of Italy with shops in Chieti Scalo
and in the port of Ortona

Production range covers the most critical components of a petrochemical plant

such as Reactors, HP heat exchangers and Process Columns using the most
advanced and sophisticated steels


Case Study: fabrication of a CrMoV reactor
REACTOR DATA
INTERNAL DESIGN PRESSURE 92 barg
DESIGN TEMPERATURE 450°C
MINIMUM DESIGN METAL TEMPERATURE -25,2°C
INTERNAL DIAMETER 4500 mm
SHELL THICKNESS 150 mm
DESIGN CODES ASME VIII div.1/PED
TOTAL WEIGHT 500 MT

Courtesy of Axens

Adopded materials:
- Shell by plate in SA 542 D Cl 4a

- Heads by plate in SA 542 D Cl 4a
- Shell course with catalyst grid support ring by forging in SA 336 Gr F22V
-All materials (including consumables) are procured in compliance with the most
stringent market requirements, including both API 934 A and Axens Specification
for chemistry limitation (ultra clean steel with very low level of tramp elements)
J-factor X-bar
Requested <=100 <= 15
Actual Values 42,14 10

Adopted welding process with some test results

Tensile Test PWHT Tensile Test PWHT
Impact test PWHT Impact test PWHT Hardness Test Hardness Test
min max
Welding Process min (710°C x 8h) max (710°C x 26h) PWHT min (710°C x PWHT max (710°C
(710°C x 8h) (710°C x 26h)
[At -30°C] [At -30°C] 8h) x 26h)
[At +20°C] [At +20°C]
Required Obtaine Required Obtaine Required Obtained Required Obtained Required Obtained Required Obtained
Y.S. > Y.S. > Min > Min >

SAW (Tandem) 415 548÷583 415 497÷513 48J HAZ 48J < 248 HAZ < 248 HAZ
at 1/2 thk. (A.W.M.) Avg > 139÷194 Avg > HAZ HV10 188÷216H HV10 192÷204
N/mm2 N/mm2 N/mm2 N/mm2 55J J 55J 244÷250J V10 HV10
T.S. 585 634 ÷ T.S. 585 Min > Min >

SAW (Tandem) ÷ 760 659 ÷ 760 619 ÷ 628 48J NW 48J < 248 NW < 248 NW
at 1/2 thk. Avg > 162÷174 Avg > NW HV10 217÷221H HV10 198÷205
N/mm2 N/mm2 N/mm2 N/mm2 55J J 55J 135÷170J V10 HV10
Y.S. >
SAW (Tandem) 465
345
HOT Tensile at 1/2 thk.
[At +454°C] N/mm2 N/mm2
T.S. >
539
509
SAW (Tandem)
[At +454°C] N/mm2 N/mm2
SAW (Tandem)
Step CoolingTest
at 1/2 thk. WM < 10°C -22.5°C
V Tr 55 + 3 (V’Tr55-
VTr55)

Adopted welding process with some test results

Tensile Test PWHT Tensile Test PWHT
Impact test PWHT Impact test PWHT Hardness Test Hardness Test
min max
Welding Process min (710°C x 8h) max (710°C x 26h) PWHT min (710°C x PWHT max (710°C
(710°C x 8h) (710°C x 26h)
[At -30°C] [At -30°C] 8h) x 26h)
[At +20°C] [At +20°C]
Required Obtained Required Obtained Required Obtained Required Obtained Required Obtained Required Obtained
Y.S. > 415 552÷591 Y.S. > 415 502÷516 Min > Min >
SMAW 48J HAZ 48J HAZ < 248 HAZ < 248 HAZ
at 1/2 thk. (A.W.M.) N/mm2 N/mm2 Avg > 189÷211 Avg > 170÷194 HV10 187÷213H HV10 191÷200
N/mm2 N/mm2 55J J 55J J V10 HV10
T.S. 585 ÷ T.S. 585 ÷ Min > Min >

SMAW 760 639 ÷ 660 760 624 ÷ 639 48J NW 48J NW < 248 NW < 248 NW
at 1/2 thk. Avg > 126÷149 Avg > 102÷117 HV10 200÷208H HV10 193÷199
N/mm2 N/mm2 N/mm2 N/mm2 55J J 55J J V10 HV10
SMAW Y.S. > 345 442

[At +454°C] N/mm2 N/mm2
T.S. > 509 523

SMAW
[At +454°C] N/mm2 N/mm2
SMAW
Step CoolingTest
at 1/2 thk. WM < 10°C -27.5°C
V Tr 55 + 3 (V’Tr55-
VTr55)

Summary of adopted heat treatments

DHT 350°C x 6h
ISR 650°C x 6h
PWHT 710°C (±5°) x 8h
Typical Heat Treatment Sequence
A) Longitudinal welds
B) Nozzles and heads welds
C) Circumferential

HEADS FABRICATION
- Hot forming of petals at 950°C
- Quenching & tempering of petals

according to mill recommendation
- Warm calibration of petals (at 250-300°C)
- Fit-up and SAW welding followed by ISR
- Machining of circumferential bevel
- Fit-up and welding of nozzles followed by ISR

SHELL COURSES FABRICATION
- Warm rolling of plates (at 350-400°C)
- Fit-up & SAW welding of longitudinal seam

followed by ISR
- Machining of circumferential bevel
- Fit-up and welding of nozzles followed by ISR

FABRICATION OF SECTIONS
(3 courser or 2 courses + head)
- Circumferential fit-up and SAW welding

followed by DHT
- Weld overlay by double heads ESW

process type 347

Automatic system of pre-heat/interpass management

“Drying and feeding flux

system designed and
manufactured in-house.”

REACTOR COMPLETION
- Assembly and circular welding of main sections, followed by DHT
- Assembly and welding of

external & internal appurtenances

Main Non Destructive Tests

BEFORE PWHT AFTER PWHT AFTER HYDRO TEST
Longitudinal welding MT - TOFD - MANUAL U.T. MT - TOFD - MANUAL U.T. MT - TOFD - MANUAL U.T.
Circumferential
MT - TOFD - MANUAL U.T. MT - TOFD - MANUAL U.T. MT - TOFD - MANUAL U.T.
welding
Nozzles welding MT – TOFD - PHASED ARRAY MT – TOFD - PHASED ARRAY MT – TOFD - PHASED ARRAY
Overlay PT – UT - FERRITE PT - UT

Manual Shear Wave Procedure for Identifying Transverse Reheat Cracks

Recommendation Comments
Surface Condition
Flush Ground
of Welded Joint
2 to 4 MHz (focused if necessary

Probe Transducer frequency should be 4 MHz for near side examination
to achieve adequate resolution at
Frequency and 2 MHz for depths greater than 100 mm.
maximum depths)
Multiple probes are used to “cover” the near and far zones:
Probe 70 (primary detection angle), 60 70 degrees covers about 10-100 mm,
•
Angles and possibly 45 degrees 60 degrees covers about 50-150, and

•
45 degrees covers the deeper areas.

•
Calibration 3 mm side drilled holes (DAC set- Holes at multiple depths and some EDM notches are typically
Reference up) included.
Scanning
+ 14 dB above reference level
Sensitivity
Scanning Scanning for transverse flaws or “A-scan”, however this

Along ground weld
Location terminology is not consistent worldwide.
Scanning
Both directions along weld
Direction
Primary objective is to determine if indication is planar and

transverse.
Look for >9 dB difference between the 70 and 60 degree scans
Based on EN1713 (except no
Flaw (45 and 60 degree for depths greater than 120 mm). If > 9db
minimum amplitude and no
Characterization (Hdmax-Hdmin) then classify as planar. Compare maximum
echodynamic evaluation)
signal obtained from transverse and parallel directions with the
same probe that produced the maximum signal (Figure 4) if the
difference is >9 dB, the defect can be considered transverse.
1) Greater than 20% DAC -

Rejection Reject – Rejected except if classified as another type of defect and
Criteria 2) 10-20% DAC passing ASME Code requirements.
- Investigate and Characterize

POST WELD HEAT TREATMENT
The whole reactor has been treated

in furnace with target 710°C +/- 5°C.
During the soaking time the temperature

range was between 707°C and 714°C
Furnace Dimension 10x11x28,5 mt.

FINAL ACTIVITIES
- Assembling and welding of bottom nozzles and skirt + local PWHT
- NDTs after PWHT
- Hydrotest
- NDTs after Hydrotest
- Painting, cleaning, blanketing etc.

Conclusion
Some of the winning factors for a safe reactor fabrication
- Intensive training of all involved personnel

- Special care in consumable management system
- Reliable automatism in preheat/interpass continuous control
- Development of appropriate welding procedures
- “Locked” welding parameters in production and automatic continuous record of them
- ISR furnace located inside the shop
- Severity in NDTs (Specific training and qualification for the operators)
- Reliable PWHT procedure, furnace & skilled personnel to guarantee precise temperature
(+/-5°C)

Thank you for your attention

Fabrication of Heavy Wall Reactors in Crmo V Plates

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DILLINGER PRESSURE VESSEL COLLOQUIUM

DILLINGER HÜTTE GTS

Fabrication of heavy wall reactors made in CrMo(V) plates

Walter Tosto SpA was founded in 1960 by Mr. Walter Tosto

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Production range covers the most critical components of a petrochemical plant

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Case Study: fabrication of a CrMoV reactor

DESIGN TEMPERATURE 450°C

MINIMUM DESIGN METAL TEMPERATURE -25,2°C

INTERNAL DIAMETER 4500 mm

SHELL THICKNESS 150 mm

DESIGN CODES ASME VIII div.1/PED

TOTAL WEIGHT 500 MT

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

- Shell by plate in SA 542 D Cl 4a

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Adopted welding process with some test results

Y.S. > Y.S. > Min > Min >

T.S. 585 634 ÷ T.S. 585 Min > Min >

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Adopted welding process with some test results

T.S. 585 ÷ T.S. 585 ÷ Min > Min >

SMAW Y.S. > 345 442

T.S. > 509 523

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Summary of adopted heat treatments

Typical Heat Treatment Sequence

B) Nozzles and heads welds

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

- Hot forming of petals at 950°C

- Quenching & tempering of petals

- Warm calibration of petals (at 250-300°C)

- Fit-up and SAW welding followed by ISR

- Machining of circumferential bevel

- Fit-up and welding of nozzles followed by ISR

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

SHELL COURSES FABRICATION

- Warm rolling of plates (at 350-400°C)

- Fit-up & SAW welding of longitudinal seam

- Machining of circumferential bevel

- Fit-up and welding of nozzles followed by ISR

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

- Circumferential fit-up and SAW welding

- Weld overlay by double heads ESW

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Automatic system of pre-heat/interpass management

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

“Drying and feeding flux

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

- Assembly and circular welding of main sections, followed by DHT

- Assembly and welding of

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Main Non Destructive Tests

DILLINGER PRESSURE VESSEL COLLOQUIUM 16-17 September 2009

Manual Shear Wave Procedure for Identifying Transverse Reheat Cracks

2 to 4 MHz (focused if necessary

Angles and possibly 45 degrees 60 degrees covers about 50-150, and

45 degrees covers the deeper areas.