1、Technical Report on the Materials and Fabrication Issues of 11/4Cr-1/2Mo and 1Cr-1/2Mo Steel Pressure VesselsAPI TECHNICAL REPORT 934-D FIRST EDITION, SEPTEMBER 2010Technical Report on the Materials and Fabrication Issues of 11/4Cr-1/2Mo and 1Cr-1/2Mo Steel Pressure VesselsDownstream SegmentAPI TECH
2、NICAL REPORT 934-D FIRST EDITION, SEPTEMBER 2010Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither API nor any of APIs employees, subcontractors, consultan
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14、ertained from the API Standards Department, telephone (202) 682-8000. 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, Washing
15、ton, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Terms, Definitions, and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . .
17、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Background . . . . .
18、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 11/4/1Cr-1/2Mo Refinery Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19、34.2 Past In-Service Cracking and Toughness Problems with 11/4/1Cr-1/2Mo Steels . . . . . . . . . . . . . . . . . . . . . 45 General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.1 11/4/1Cr-1/2M
20、o Product Specifications and Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.2 Allowable Design Stresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.3 Steel Makin
21、g Practices and Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.4 Hardenability Limitations that Affect Mid-Wall Tensile Properties and Notch Toughness106 Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . .
22、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.1 The Effect of Heat Treatment, Including Post-weld Heat Treatment (PWHT) on Tensile Strength and Yield Strength of 1Cr-1/2Mo and 11/4Cr-1/2Mo Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23、 . . . . . . . . 106.2 The Effect of Thickness on Tensile Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.3 The Effect of Chemical Composition on Tensile Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
24、6.4 Notch Toughness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136.5 Forgings for 11/4/1Cr-1/2Mo Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25、. . . . . . . . 167 Embrittlement and Cracking Issues In 11/4/1Cr-1/2Mo Base Metals and Welded Joints . . . . . . . . . . . . . . 187.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26、. . 187.2 Temper Embrittlement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187.3 Stress Relief Embrittlement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27、. . . . . . . . . . . . . 197.4 Creep Embrittlement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Guidelines On Chemical Composition, Heat Treatment and Mechanical Testing of 11/4/1Cr-1/2Mo Vessels. . . .
28、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218.1 Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218.2 Heat
29、 Treatment for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Testing of Plates and Forgings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
30、49.1 Test Specimen Location to Simulate the Cooling Rates in Plates and Forgings . . . . . . . . . . . . . . . . . . . 249.2 Test Coupons to Simulate Vessel Fabrication Heat Treatments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259.3 Test Specimen Location to Simulate the Cool
31、ing Rates in Plates and Forgings . . . . . . . . . . . . . . . . . . . 259.4 Hot Tension Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2510 Fabrication/Metal Forming . . . . . . . . . . . . . . . .
32、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2610.1 Forged Shell Rings vs. Shell Rings Made of Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2610.2 Forming. . . . . . . . . . . . . . . . . . . . . . .
33、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2710.3 Cold Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2710.4 Warm Form
34、ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.5 Hot Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35、 . . . . . . . . . . . 2911 Fabrication/Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29vContentsPage11.1 Welding Processes for 11/4Cr-1/2Mo and 1Cr-1/2Mo Welding . . . . . . . . . . . . . . . . . . .
36、 . . . . . . . . . . . . . . . . . 2911.2 Preheat and DHT to Avoid Cracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2911.3 ISR vs. DHT for 11/4Cr-1/2Mo and 1Cr-1/2Mo Materials . . . . . . . . . . . . . . . . . . . . . . . . . .
37、. . . . . . . . . . . . . . . 3212 Austenitic Stainless Steel Cladding and Weld Overlay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3312.1 Weld Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38、 . . . . . . . . . . . . . . . . . . . 3312.2 Weld Overlay Procedure Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3412.3 Preheat and Heat Treatments During Weld Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39、 . . . . . . . . . . . . . . . 3412.4 Production Testing of Weld Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3512.5 Weld Overlay Disbonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40、 . . . . . . . . . . . . . . . . . . . . . . 35Annex A (informative) API 934-D Questionnaire on 1Cr-1/2Mo and 11/4Cr-1/2Mo Issues. . . . . . . . . . . . . . . . . . . 37Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41、. . . . . . . . . . . . . . . . . . . . . 55Figures1 The Effect of Cooling Rate on Tensile Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 The Effect of Post-weld Heat Treating Temperature on Tensile Properties of Nt is the time at temperature
42、 in hr;C is the constant (typically 20 for low alloy steels).The total LMP is a combination of the time during tempering of the material, as well as the PWHT cycles, including all intermediate heat treatments above 900 F (482 C).3.1.5 minimum PWHTSpecified heat treatment of test specimens used to si
43、mulate the minimum heat treatments (austenitizing, tempering, and one PWHT cycle). To determine the equivalent time at one temperature (within the PWHT range), the Larson-Miller Parameter may be used.3.1.6 maximum PWHTSpecified heat treatment of test specimens used to simulate all fabrication heat t
44、reatments (austenitizing, tempering, the final PWHT, a PWHT cycle for possible shop repairs, and a minimum of one extra PWHT cycle for future use by the owner). NOTE For minimum and maximum PWHT cycles: to determine the equivalent time at one temperature (within the PWHT range), the Larson-Miller Pa
45、rameter may be used. The results are to be agreed upon by the purchaser and the manufacturer.1ASME International, 3 Park Avenue, New York, New York 10016-5990, www.asme.org.Technical Report on the Materials and Fabrication Issues of 11/4Cr-1/2Mo and 1Cr-1/2Mo Steel Pressure Vessels 33.1.7 J-factorFo
46、rmula for evaluating susceptibility to temper embrittlement (typically used for base metal).J-factor = (Si + Mn)(P + Sn) 1043.1.8 X-barFormula for evaluating susceptibility to temper embrittlement (typically used for welding materials).X-bar = (10P + 5Sb + 4Sn + As)/100, ppm3.1.9 fine grain practice
47、A steelmaking practice that is intended to produce a killed steel that is capable of meeting the requirements specified for fine austenitic grain size.3.2 AcronymsFor the purposes of this document, the following acronyms apply.CMTR certified material test reportCVN Charpy V-notch energyFCC fluid cat
48、alytic crackingDHT dehydrogenation heat treatmentFN ferrite numberHAZ heat-affected zoneHBW Brinell hardness with tungsten carbide indenterHV Vickers hardnessKv alternative expression for Charpy V-notch energyMDMT minimum design metal temperatureMT magnetic particle testingNDE nondestructive examina
49、tionPT liquid penetrant testingPWHT post-weld heat treatmentRT radiographic examinationUT ultrasonic examination4 Background4.1 11/4/1Cr-1/2Mo Refinery Equipment Several refinery processes use 11/4/1Cr-1/2Mo steel pressure vessels and equipment. Some are listed in Table 1. Attention will be given to two major types of equipment: reformer reactors and hydrotreater reactors. Both operate with significant hydrogen partial pressures. However, there are significant distinctions between these two types of reactors in terms of operating temperatures, pressures, and wall thickness. Hydrotrea
