the

Conduit
The new generation materials were steels with ostensibly 9% or 12% Chromium with other elements such as tungsten, molybdenum, columbium, vanadium and copper nickel added to achieve optimal microstructure and properties. The microstructures of these steels were martensitic as compared to the more typical bainitic structures for the P11/T11 or P22/T22 low alloy steels. The martensitic microstructure is developed by precise heat treatment to develop both superior high temperature creep resistance and tensile strength. The development of the Grade 91 (P91/T91) family of steels has moved steadily forward since the mid-1970s with increasing use in new power plants and some older plant retrofit applications. The Grade 91 type

A quarterly publication from M&M Engineering Associates, Inc.

Vol. 10, No. 3 In this Issue

EPRI Publication Available ................. 3 The M&M Engineering Laboratory .. 4 Events and News ................................. 6 materials are well-suited for the new higher temperature boilers and Heat Recovery Steam Generators (HRSG) being constructed. Because the Grade 91 steels have higher strength -to-weight ratios the component thickness (and therefore, thermal mass) can be considerably less than with the Cr-Mo steels. With the pressure components thinner and less massive the units can be started and shut down more quickly with less thermal fatigue damage. This characteristic is well suited for the dual-cycle combustion turbine HRSG plants being constructed today. So if Grade 91 is so good why not use it more extensively? There are several reasons. Grade 91 alloy is inherently more difficult to heat treat and is less tolerant to overtemperature abuse in service than its P11/T11 or P22/T22 ancestors. Lets discuss some issues. Mechanical Fabrication Because the strength of the P91 is dependent upon proper microstructure any mechanical fabrication of the steel must respect and preserve the structure. For example, hot bending of tube or pipe will remove the martensitic microstructure and result in poor as -formed properties. Cold-bending is difficult and also results in the formation of detrimental residual stresses. P91 must be re-normalized and tempered after bending operations.
(Continued on page 2)

P91 Steel - No Good Deed Goes Unpunished

By Ronald E. Munson, P.E. Corporate Engineer The energy crisis of the mid-1970s led indirectly to the accelerated development of a class of Grade 91 ferritic/ martensitic alloy steels. These steels were developed to replace the chromium-molybdenum alloy steels such as P22/T22 (2 Cr1 Mo) or P11/T11 (1 Cr- Mo) used extensively for high temperature service in power plants. The new generation of Grade 91 steels would be suitable in advanced generation power plants with higher steam temperatures and pressures . The ultimate goal was higher thermal efficiency. Higher thermal efficiency also translates into environmental benefits as less fuel is burned to produce equivalent amounts of thermal energy.

Figure 1. T91/T22 tube stub showing a crack adjacent to the P91 weld fusion line (arrow).

Welding The welding of P91/T91 is particularly troublesome if one does not understand or follow a rigorous procedure. First of all, the welding consumables must be closely monitored and chosen. Current practice is to require a certified materials test report (CMTR) for each batch of welding wire. The composition must be kept within specific limits that are much more rigid than the current AWS or ASME guidelines. For example, if the sum of the nickel and manganese in the weld consumable is too high the post weld heat treatment cycles can actually exceed the lower critical temperature for the alloy. If that

happens then the component microstructure is completely compromised. Welding Group 91 and the other Creep Strength Enhanced Ferritics (CSEF) require more care and control than T22/P22 alloys. They all require a high pre-heat, a minimum cooling hold point and a post weld tempering heat treatment. If low hydrogen consumable and welding procedures are not meticulously followed the welding may also require a post weld hydrogen bake (immediately after welding). These requirements are independent of thickness. Even a simple field repair on a tube will

require a full post weld temper heat treatment at 1400F. Figure 1 and Figure 2 show what can happen when welding procedures are not followed precisely. In this case, safe-ends were fabricated to join a new P91 header to existing T22 tubes. Safe ends are made by welding short sections of T22 tubing to T91 tubing using a low alloy steel weld. After welding, there was a considerable delay before post weld heat treatment resulting in an eventual field failure. The strong but brittle post weld microstructure allowed environmental cracking to occur in the welds high residual stress area before the toughening of the post weld tempering was done. The Grade 91 alloys also offer an inservice challenge. Because these alloys loss their strength if exposed to temperatures of more that 1400 F they are less tolerant to boiler upsets such as dry-firing or low water conditions. While components manufactured of P22 or P11 have been shown to be very tolerant to short duration exposures during these events, P91 alloys have no tolerance for these conditions. Even short exposures to these conditions will require replacement. Normal fabrication practices, such as local torch heating during fit-up can significantly damage P91/T91 parts. In summary, as the saying goes no good deed goes unpunished. The P91 family of alloys has a vast improvement in their properties, but at the cost of being more demanding to fabricate and weld. They are less forgiving than their T22/P22 or P11/ T11 ancestors. As technology advances, the knowledge of how to properly utilize the technology must increase. Be sure your fabricators and contractors respect the demands of this new technology.

Figure 2. Metallographic section showing environmentallyassisted cracking in a T22/P91 tube safe end weld.

Feedwater Heater Tube Failure Manual

By Andi Cragen, Mechanical Engineer In July of 2010, The Feedwater Heater Tube Failure Manual (Report 1017622) was made available for purchase and download by the Electric Research Institute (EPRI). M&M Engineering Associates Inc. conducted the primary research and documentation for this manual. The report will allow plant engineers, metallurgists, chemists, and laboratory failure analysis personnel to identify failure mechanisms in feedwater heaters to provide a basis for root cause analysis and guidance on corrective action. This guide is a valuable tool for understanding failure mechanisms observed in both old and new feedwater heaters

and assists in developing corrective actions to mitigate or eliminate damage. The manual includes comprehensive information and guidance on the materials of construction, an advanced understanding of damage mechanisms, and the technical criteria for mitigation or elimination of damage in feedwater heaters. The primary tube failure mechanisms discussed in the manual include: the following:

Wet Steam Impingement Erosion Tube Vibration Flow Accelerated Corrosion (FAC) General Corrosion Stress Corrosion Cracking (SCC) Cavitation-Type Erosion To find more information regarding the manual visit www.epri.com.

Failures in Steam/Power Generation Staying Out of Trouble!!!

M&M Engineering Associates, Inc. will be hosting a Two-Day Conference that will focus on the issues most common in steam generation systems. The Conference is scheduled for March 9-10, 2011, in Austin, Texas. Check our website and the Winter issue of the Conduit for a list of topics that will be covered. Contact the Authors

Ron Munson, P.E., 512-407-3762 ron_munson@mmengineering.com Andi Cragen, 512-407-3760 andi_cragen@mmengineering.com Spencer Rex, 512-407-3755 spencer_rex@mmengineering.com

The M&M Engineering Associates, Inc. Laboratory

By Spencer Rex, Metallurgical Engineer
A consulting engineering firm that has a laboratory in-house has many advantages in the marketplace. The ability to observe and direct the laboratory process directly is invaluable to the lead engineer. M&M Engineering Associates, Inc. has a world class metallurgical laboratory where laboratory analyses are performed according to ASTM, ASM, NACE and other industry standards. All testing equipment in the laboratory is calibrated and maintained to ensure that all measurements and documentation meet the highest industry standards for traceability and accuracy. All laboratory personnel have been thoroughly trained in the testing that they perform while a trained Laboratory Safety Officer ensures that safety is the top priority. The following is a brief description of some of the capabilities of the M&M Engineering Associates, Inc. Laboratory in Austin, Texas. The first step in any investigation is a thorough visual examination and documentation of the sample as it is received. Often, a trained eye knows what to look for and will see features normally overlooked. Photography is done in our Photography Room (Figure 1) using a variety of different digital cameras and lighting options. Also available is a Stereomicroscope (Figure 2) which is used to examine and document surface features at magnifications up to 60X. Non destructive testing (NDT) capabilities include magnetic particle and dye penetrant testing for detection of cracks, defects and flaws, and ultrasonic testing for thickness measurements. NDT is helpful in a laboratory setting to locate otherwise invisible features that will help guide the investigation. The location of cracks and flaws typically dictates where a submitted sample will be sectioned. For weld inspection, M&M Engineering has a Certified Welding Inspector on staff. The M&M Engineering Laboratory has a wide array of equipment used for sectioning (Figure 3). Our precision cutting is done on a diamond saw with a blade kerf of less than .035-inches. Our largest cuts are made using a HEM saw which has a throat depth of 18.5 -inches and height of 28-inches. The various saws may be fitted with different blades allowing sectioning of a wide variety of materials. To move and lift heavy samples onto the saws, the M&M Engineering Laboratory has an array of cranes and forklifts, the largest of which is rated to handle 5,000 lbs. Metallography is the technique most commonly used when studying the microstructural features of a material. Microstructural features indicate manufacturing, as well as in service conditions of the item being evaluated. This process begins by deciding how the sample should be mounted and in what media. The M&M Engineering Laboratory has both hot and cold mounting capabilities and can mount in a variety of conductive, nonconductive, hard or soft media depending on the material and the examination to be

Figure 1. Photography Room

Figure 2. Stereomicroscope Room

Figure 3. Machine Shop

4

performed. Mounts are then ground, polished and etched, a process that varies depending on the material. Mounted samples can then be viewed on a metallograph with up to 1,000X magnification. The metallograph is equipped with a digital camera for documentation of the observed microstructures, cracks, flaws, etc. (Figure 4). In cases where very small surface features are important to an investigation, M&M Engineering possesses an AMRAY 1830 scanning electron microscope (SEM) which can magnify an image up to 50,000X (Figure 5). The magnification and depth of field capabilities of the SEM are important when examining and documenting fracture features. The image output from the SEM can be viewed in the SEM Room on a 46-inch color monitor, where seating is available for up to ten observers. The SEM is fitted with an EDAX energy dispersive X-ray spectrometer (EDS), which is controlled by an advanced 4pi imaging system. The EDS system identifies and quantifies elements present at a specific location. This imaging system is able to colorize the location of various elements, providing a map of their locations. This is especially useful in investigations involving unknown corrosive agents. The M&M Engineering Laboratory has various hardness testing capabilities. Hardness testing is important when the properties of a material are suspected in causing or contributing to a failure. Bulk hardness is done with a Wilson Hardness Tester where measurements can be taken

in Rockwell A, B or C, superficial hardness, and Vickers hardness scales. Microhardness measurements are done using a Struers Duramin A300, Automated Microhardness Tester that outputs the hardness data into a statistical program where it can be analyzed and presented in a variety of different ways (Figure 6). Metallography, NDT, ultrasonic thickness testing and hardness testing can all be done in the field during Figure 4. Metallography Room plant outages or on equipment too large to ship to our Laboratory. All equipment is easily packed in fly-away kits for fast response. The ability to provide quick and accurate failure analysis, diagnostic and usable life analysis while minimizing customer downtime is the core of the M&M Engineering Associates, Inc. business model. The team of mechanical, metallurgical and materials engineers and scientists interpreting the laboratory data has a combined 502 years of experience. The unique combination of a metallurgical laboratory inhouse and extensive experience allows M&M Engineering to quickly and efficiently interpret and apply laboratory results to find applicable solutions and recommendations for our clients. Editorial Note: After graduating from the University of Utah in Metallurgical Engineering in June of 2009, the author worked in the M&M Engineering Associates, Inc. Laboratory before joining our Engineering Staff earlier this year.

Figure 5. SEM Room

Figure 6. Micro Hardness Machine

5

Upcoming Events Seminars and Workshops

Mark Tanner will be attending the Wind Turbine Conference to be held October 26-27, 2010, at the Renaissance Austin Hotel in Austin, Texas. Dave Daniels will be attending the Nalco Conference Power Plant Chemistry Seminar to be held October 12-13, 2010, at the Northern Illinois University Conference Center in Naperville, Illinois. Ron Munson will be presenting at the Gas Turbine Users Symposium to be held October 4-7, 2010, at the George R. Brown Convention Center in Houston, Texas. His presentation is entitled Failure Investigation Principles for Combustion TurbinesCombining Science and Art . Dave Daniels will be presenting at the International Water Conference to be held October 24-28, 2010, at the Crowne Plaza Hotel Riverwalk in San Antonio, Texas. His presentation is entitled HRSG and High Pressure Boiler Water Treatment and Operation.

2010 International Water Conference: October 24-28, 2010, The Crowne Plaza Hotel Riverwalk, San Antonio, Texas

Dave Daniels will be attending the Second International Conference Instrumentation for Power Plant Chemistry to be held November 15-18, 2010, at the Movenpick Hotel Stuttgart Airport in Stuttgart, Germany. Further information can be found at http://www.ppchem.net/news/Instrumentation% 202010.pdf The conference will consist of both invited and contributed technical papers and the official language will be English. There will be a special vendor exhibition at the Conference. Spencer Rex will be attending the Battery Power 2010 Conference and Expo to be held October 19-20, 2010, at the Gaylord Texan Resort and Convention Center in Grapevine, Texas. This international conference and expo will be highlighting the latest developments and technologies in the battery industry with more than thirty presentations on portable, stationary and automotive battery technology.

Spencer Rex joined the M&M Engineering Associates, Inc. Staff in May of 2009 as an entry-level engineer. Before joining M&M Engineering, Spencer graduated with a degree in Metallurgical Engineering from the University of Utah in May of 2009. On Thursday, September 2, 2010, Spencer gave a presentation about Failure Analysis at M&M Engineering to the Metallurgical Engineering undergraduate students at the University of Utah, giving the students an idea of the transition from college to the working world.
6

the Conduit is distributed free of charge by M&M Engineering Associates, Inc.. We welcome your comments, questions, and suggestions, and we encourage you to submit articles for publication. We grant limited permission to photocopy all or part of this publication for nonprofit use and distribution. For technical information, please contact:
David Daniels (512) 407-3761
david_daniels@mmengineering.com

__ Please add my name to your mailing list. __ Please delete my name from your mailing list. __ Please correct my information as listed below. I prefer to receive this newsletter by ____ Email _____ Mail

Name: ________________________________________ Title: _________________________________________ Company: _____________________________________ Address: ______________________________________

Ron Munson (512) 407-3762

ron_munson@mmengineering.com

City: ________________ State: _______ Zip: _______ Phone: _______________ Fax: ___________________ Email: ________________________________________ Comments on this issue: __________________________ _____________________________________________ _____________________________________________ _____________________________________________

Karen Fuentes (512) 407-3778

karen_fuentes@mmengineering.com

Texas Illinois Oklahoma

Please send or fax this form to : M&M Engineering Associates, Inc. 4616 W. Howard Lane Building 2, Suite 500 Austin, TX 78728-6302 Fax: (512) 407-3766

www.mmengineering.com

the Conduit M&M Engineering Associates, Inc. 4616 W. Howard Lane, Bldg. 2, # 500 Austin, TX 78728-6302