CR Mo by Gross PDF

Essentials in welding
of CrMo reactors
Application Technology, Volker Gross

Bhler Schweisstechnik Deutschland GmbH / Hamm, Germany
Content
basics, metallurgical features

application
weld metal properties
strong recommendations
Process schema for petrochemicals

Natural resources
Crude Oil
CrMo(V)
Refinery
why?
Resistance to creep / Hydrogen
+
stainless overlay why?
Coal
Natural Gas
~454 C
Resistance to H2S etc
~220 bar
Gasification, Liquifaction
Typical equipment (~1000t)

11/4Cr0,5Mo
CrMoV
21/4Cr1Mo
21/4Cr1Mo
Behaviour of C in
ferritic micro structure
- thermal expan.
- thermal conductiv.
- diffusion coeff.
Tendency to carbide formation
- solubility for C
- carbide formation
effect of stable carbides

less risk of CH4-formation > petrochemical hydrotreating reactors
Applcation in the creep range > power plant equipment
TTT diagram for SA weld metal
Bainitic/ Martensitic pwht essentials

Feature of bainitic/ martensitic structure requires
Post weld heat treatments
DHT: dehydrogenation treatment (~350C )

removes Hydrogen!
ISR: intermediate stress relieving (~620-650C)*
for highly stressed joints (nozzles, manholes etc)
SR: stress relieving <min pwht> (620-705C)*
desired structure achieved (final heat treatment)
Step Cooling / max pwht
Simulation of refinery conditions
*epending on the grade
Old materials with limited strength
CrMo- grades
PWHT
[C]
YS
[MPa]
TS
[MPa]
0,5
660
275
485 - 660
B2
2,3
690
310
515 - 690
B3
2,30
705
415
585 - 760
Type
Cr
Mo
11
0,15
1,3
22
0,12
22 V
0,10
0,3
Nb
0,05
AWS filler
metal
B3 mod.
Code Case
2098
Service conditions and demand for bigger reactors increased
Consequence of increased service conditions:

increase in wall thickness
increase in weight of the equipment
(limitations in transport to be considered)
358mm F22
PC:
454 C
215 bar
CrMo- grades
PWHT
[C]
YS
[MPa]
TS
[MPa]
0,5
660
275
485 - 660
B2
2,3
690
310
515 - 690
B3
2,30
705
415
585 - 760
Type
Cr
Mo
11
0,15
1,3
22
0,12
22 V
0,10
0,3
Nb
0,05
AWS filler
metal
B3 mod.
Code Case
2098
Benefit of CrMo(V) materials for hydroprocessing reactors

high (creep) strength conditions due to stable carbides
higher resistance against hydrogen, disbonding
high toughness level
Wall thickness acc. to ASME code criteria

service conditions:
454C, 215 bar
ASME VIII
Ed.
F22
F22V
2006
358mm
317mm
2007
267mm
allowable stress MPa
ALLOWABLE STRESS
economical advantages:
save in thickness
save in weight
BUT:
250
21/4Cr1MoV has to be welded
225
200
175
150
125
ATB
100
350
378
406
434
462
490
temperature C
Conventional 2Cr1Mo -ASME 2006
Conventional 2Cr1Mo -ASME 2007
2Cr1Mo V modified -ASME 2006
2Cr1Mo V modified -ASME 2007
Welding Essentials
to be considered:
initial grain size (influence of heat input, welding process,
nucleation)
increased tendency to carbide precipitations
strength in as welded condition (restrained condition of heavy
wall thickness, nozzle welds, influence of Hydrogen)
YS (MPa)
TS (MPa)
A (%)
CVN (J)
CrMoV
880
1070
19
20
conv. CrMo
800
950
19
50
internal strength increases with wall thickness

strength (after pwht, ISR)
toughness (pwht)
ISR of restrained joints, 22V SA welds

Tests on tandem DC/AC all weld metal,2x4mm
550/550 A, 29/ 32 V, 80 cm/min
Preheat.: 180 C, interpass: max 230 C
Strength,rt
ISR As welded
620C/ 4h
650C/ 4h
680C/ 4h
710C/ 4h
Rp0.2, MPa
880
859
778
650
591
Rm, MPa
1070
956
858
735
682
A5, %
18,9
16,2
15,7
19,2
19,4
Z, %
51,2
60,4
62,9
69,9
70
17 19 20
8 14 11
17 26 40
127 123 132
152 153 156
345
333
295
252
232
CVN (J) at RT
Hardness HV10
Secondary hardening
Check up of welding conditions
welding generator
mass
cables
amperage, voltage to verified at welding
head
wire face distance=electrode dia
Welder !!!
heat treatment equipment
Preheating arrangement
toughness issue in 22V SA welds

fracture surface of impact specimens
from same lots, but different coupons (fabricators)
fracture along grain bounderies

21J
ductile surface
190J
small sized coupon for PQ

Reason for overheating:
Interpass temp. (recom. max 230C) was measured on top s ide.
loss in temp. from actual weld location to top side not considered
measured 230C
actual
Temp. gradient!
~400
C
Not an issue for reactor welds (except nozzle welds) due to

massive qty., but to maintain the min preheating temp.
becomes essential!
Temp. range of pwht equipment

record by thermocouple in the furnace: 705C
actual: 740 -760C
!!!! thermocouple to be attached to the coupon !!!!
770
765
Kanal 1
Kanal 2
Kanal 3
Kanal 4
Kanal 5
Kanal 6
760
Kanal 7
Temperatur in C
Kanal 8
755
Kanal 11
Kanal 12
Kanal 13
750
-far cheaper than repeat test
Kanal 14
Kanal 15
Kanal 16
Kanal 17
Kanal 18
745
Kanal 19
Kanal 20
Kanal 21
Kanal 22
740
Kanal 23
Kanal 24
Kanal 25
Kanal 27
735
730
14,0
-low cost for equipment
Kanal 9
Kanal 10
14,2
14,4
14,6
14,8
15,0
15,2
Zeit in Stunden
15,4
15,6
15,8
16,0
-online control on PC possible

LESS RISKS
Ferrite precipitations in S(M)A welds, 2Cr1Mo

low toughness
Precipitation of ferrite / 148 HV1
Matrix / 185 HV1
100 mm
9
8
7
192
77
194
6
5
4
3
2
1
162
199
73
144
29
29
CVN [J]
10 mm
Narrow gap welds
325mm
Flat thin beads mandatory

Sufficient refinement by
subsequent beads !!!!
Electrode weld build-up

Different bead formation in SMA welds;
Phoenix SH Chromo 2 KS, 4,0 mm, 3G up
low
thick beads
toughness
high
thin, weaved beads
Reasons: part of refined areas increased, smaller grain size, less

precipitations
HYDROGEN issue
Kind attention to the rebaking of SAW flux

~60C
300C
~300C
Colds Cracks in build up welds (support rings) caused

by Hydrogen
recommendations for smooth CrMo welds

fine grain to be maintained by
flat beads (see API 934B too)
weaved beads for SMAW, max 2,5mm
Saw: aim ~max 3mm
controlled heat input
controlled preheating, intepass temp.,
welding-, process/ parameters to be controled
Quality of the equipment to be controled
Welders to be trained!!!!!!!!!!!!!!!!!!
consequence: strict limitations in welding
Schematic range of parameters

(e.g. amperage, preheating, interpass temp., pwht)
2Cr1Mo + V
martensitic
martensitic
X20 / P91 / P92
bainitic
bainitic
CrMo steel / Ni-steel
Low alloy steel
C-steel
optimum
parameters
Perlite
Perlite
summary
Essentials to be considered for satisfactory welds
21/4Cr1Mo(V) material is considered to be different
totally from conventional ferritic steels in terms of
properties. It responds to any kind of heat influence
by welding and/or heat treatment much more
significantly than the conventional grade!
Therefore 21/4Cr1(V requires (a must!) the
application of specific:
procedures
equipment
control mechanism/QA system
= understanding this material!

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Essentials in welding

Application Technology, Volker Gross

basics, metallurgical features

Process schema for petrochemicals

Resistance to creep / Hydrogen

Resistance to H2S etc

Typical equipment (~1000t)

Tendency to carbide formation

effect of stable carbides

TTT diagram for SA weld metal

Bainitic/ Martensitic pwht essentials

DHT: dehydrogenation treatment (~350C )

Old materials with limited strength

Service conditions and demand for bigger reactors increased

Consequence of increased service conditions:

Benefit of CrMo(V) materials for hydroprocessing reactors

Wall thickness acc. to ASME code criteria

allowable stress MPa

21/4Cr1MoV has to be welded

Conventional 2Cr1Mo -ASME 2007

2Cr1Mo V modified -ASME 2006

2Cr1Mo V modified -ASME 2007

internal strength increases with wall thickness

ISR of restrained joints, 22V SA welds

127 123 132

152 153 156

Check up of welding conditions

toughness issue in 22V SA welds

fracture along grain bounderies

small sized coupon for PQ

Not an issue for reactor welds (except nozzle welds) due to

Temp. range of pwht equipment

-far cheaper than repeat test

-low cost for equipment

-online control on PC possible

Ferrite precipitations in S(M)A welds, 2Cr1Mo

Matrix / 185 HV1

Narrow gap welds

Flat thin beads mandatory

Electrode weld build-up

thin, weaved beads

Reasons: part of refined areas increased, smaller grain size, less

Colds Cracks in build up welds (support rings) caused

recommendations for smooth CrMo welds

consequence: strict limitations in welding

Schematic range of parameters

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