API TR 942-B-2017 Material Fabrication and Repair Considerations for Austenitic Alloys Subject to Embrittlement and Cracking in High Temperature 565 to 760 (1050 to 1400 Refinery S_1.pdf

1、Material, Fabrication, and Repair Considerations for Austenitic Alloys Subject to Embrittlement and Cracking in High Temperature 565 C to 760 C (1050 F to 1400 F) Refinery ServicesAPI TECHNICAL REPORT 942-B FIRST EDITION, MAY 2017EFFECTIVE DATE: NOVEMBER 1, 2017Special NotesAPI publications necessar

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14、A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Technical Approach/Re

15、port Organization and Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Acronyms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Process Units. . . . . . . . .

16、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17、. . . . . 23.2 Fluid Catalytic Cracking Units (FCCUs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3 Hydrogen/Syngas Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18、. . . . . . . . . . 143.4 Catalytic Reformers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.5 Delayed Cokers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . 213.6 Hydroprocessing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Damage Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.1 Metallurgical Embrittlement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.2 Sigma Phase Embrittlement. . . . . . . . . . . . . . . . . . .

21、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.3 Carburization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464.4 Stress Relaxation Cracking (SRC). .

22、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544.5 Creep. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594.6 Therma

23、l Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674.7 Solidification Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24、. . . . . . . . . . 70Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Figures1 FCCU Simplified Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25、 . . . . . . . . . . . . . . . . . . . . . . . . 42 Replacement of Primary (Outer Ring) and Secondary (Inner Ring) Cyclones. . . . . . . . . . . . . . . . . . . . . . . 53 Example of New Hexagonal Mesh Welded Inside a Regenerator Cyclone . . . . . . . . . . . . . . . . . . . . . . . . . 84 Large Are

26、as of Internal Hexagonal Mesh and Refractory that Failed in a Brittle Manner. . . . . . . . . . . . . . 85 Example of External Refractory that Failed After a Short Time in Service. . . . . . . . . . . . . . . . . . . . . . . . . . 96 An Example of a Mitered Joint After Removal From Service . . . . .

27、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Creep Failure on a FCCU Regenerator Overhead Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 A Two Pass SAW Weld Was Found with Creep Cracking in the Outside Weld Bead . . . . . . . . . . .

28、. . . . . . 39 Interdendritic Creep Voids and Cracking in a Weld Cross Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1310 Hydrogen Reforming Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1411 Reformer Feed

29、Preheat Coil Arrangement in Units with a Preconverter . . . . . . . . . . . . . . . . . . . . . . . . . . 1512 Multiple T/C Shields Welded to an Alloy 800H Superheater Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1713 Cross Section of a Crack at the Toe of One of the TC Shiel

30、ds Showing Intergranular SRC . . . . . . . . . . 1714 Tubesheet-to-Inlet Channel Cone that Cracked in Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1815 Cracking From the OD Was Intergranular and Was Attributed to SRC. . . . . . . . . . . . . . . . . . . . . . .

31、. . . . . 1916 Catalytic Reformer Simplified Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2017 Continuous Regenerating Catalytic Reformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2018 Dela

32、yed Coker Simplified Process Flow Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2219 Stress Rupture of a Coker Heater Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2320 Carburized Tube

33、 that Cracked During Pig Decoking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2421 Carburized Tube Cross Section Showing Variations in Depth of Carburization . . . . . . . . . . . . . . . . . . . . 2522 Hydroprocessing Simplified Process Flow Diagrams for Hydr

34、otreating and Hydrocracking . . . . . . . . . 2623 Hydroprocessing Simplified Process Flow Diagram of a Hydrotreater with a Recycle Hydrogen Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2624 Fe-Cr Equilibrium

35、Phase Diagram Showing Sigma at 40 % to 50 % Cr (Top Axis) . . . . . . . . . . . . . . . . . . 3325 Isothermal Section of Fe-Cr-Ni Phase Diagram at 650 C (1202 F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3426 Precipitation of Sigma Phase in Different Grades of Austenitic Stainless

36、Steel at 700 C (1292 F) . . . 35vPagevii27 Penetrant Test Showing Sigma Phase Embrittlement Cracking in Type 308H SS Butt Weld . . . . . . . . . 3628 Cross Section View of Sigma Phase in a Type 304H SS FCCU Regenerator Plenum. . . . . . . . . . . . . . . . 3729 Cold-worked Microstructure Containing

37、Higher Amounts of Sigma Phase. . . . . . . . . . . . . . . . . . . . . . . . 3830 KOH Etch Revealing the Sigma Phase, but Not the Cold Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3931 SEM of a Type 304H SS Cyclone After 14 Years of Operation at 716 C (1321 F), 5 % Sigma Pha

38、se. . . 4032 Metallograph of Sigma Phase in a 304H SS Cyclone After 14 Years Operation at 716 C (1321 F), 5 % Sigma Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4033 Bend Test Results of Type 304H SS with 12 % Sigma 4134 Tensile

39、Test of 304H SS with (a) 12 % Sigma at 21 C (70 F) Depicting Brittle Fracture and (b) Ductile Fracture at 716 C (1320 F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4235 Impact Properties of 304 Type Stainless Steel with 2 % and 10 % Sig

40、ma 4 . . . . . . . . . . . . . . . . . . . . . . . . 4236 Charpy V-notch Impact Test Results at Room Temperature and Service Temperature . . . . . . . . . . . . . . 4337 Temperature vs. Charpy V-notch Impact Energy of Type 347 SS Weld Metal . . . . . . . . . . . . . . . . . . . . . . 4438 Temperatur

41、e vs. Charpy V-notch Impact Energy of Type 347 SS Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 4439 Relative Severity of Carburization in the Form of Metal Dusting for Type 304 Stainless Steel and Alloy 800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42、 . . . . . . . . . . . 4740 Cross Section of a Type 304H SS Regenerator Cyclone with a 3 mm (0.12 in.) Thick Carburized Layer on the ID Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4941 Microstructure at the Transition from Carburized

43、Layer (Right Side) to the Base Metal of a 304H SS Regenerator Cyclone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5042 Cross Section of a Stainless Steel Coker Heater Tube with a Brittle Crack. . . . . . . . . . . . . . . .

44、 . . . . . . . . 5043 Light Micrographs Showing Typical Carburized Structures of Nickel Alloys After Testing at 982 C (1800 F) for 55 h in 5 % H2, 5 % CO, and 5 % CH4 (Balance Argon) . . . . . . . . . . . . . . 5144 SEM View, Cr Dot Map, and Fe Dot Map of Carburized Zone Near ID of 347 SS Heater Tub

45、e . . . . . . . . . 5145 Penetrant Examination Results Showing SRC Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5746 SRC in an Alloy 800H Furnace Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46、 . . 5847 Stress Rupture Curves for Several Annealed Stainless Steels (Extrapolated Data). . . . . . . . . . . . . . . . . 6148 Creep Rate Curves for Several Annealed Stainless Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6249 Three Stages of Creep Damage . . . .

47、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6350 Neubauers Classification of Creep Damage from Observation of Replicas 70 . . . . . . . . . . . . . . . . . . . 6551 Two Types of Creep Test Samples, Tangential and Longitudinal . . .

48、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6652 DeLong Diagram for Estimating Ferrite Content in Austenitic Stainless Steels . . . . . . . . . . . . . . . . . . . . 7253 WRC Diagram Including Solidification Mode Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49、. . . . . . . 73Tables1 Process Units, Conditions, and Typical Austenitic Stainless Steel Damage Mechanisms*. . . . . . . . . . . . 32 Ferrite and Austenite Formers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Austenitic Stainless Steel Embrittlement Phases and Stress Relaxation Cracking Susceptibility. . . . . 304 Nickel Based Alloy Embrittlement Phases and Stress Relaxation Cracking Susceptibility . . . . . . . . . . 315 Typical Compositions (wt %) of Select Alloys Shown in Figure 25 .