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Bethlehem Lukens Plate

PLATE A516 & A387


PRESSURE VESSEL STEELS

A Technical Overview

of Plate Steels for

Petroleum and

Petrochemical Processing

Introduction
Bethlehem Lukens Plate

Production Practices

(BLP) is the major producer

Most of BLPs PVQ steels are manufactured to stringent metallurgical practices in two

of carbon, alloy and roll-

steelmaking shops at Burns Harbor, Ind., and Coatesville, Pa. Our Coatesville electric

bonded clad plate for the

arc furnace facility is described here, and is the basis for all the information herein.

petroleum, petrochemical

Figure 1: Steelmaking Process at Coatesville Operations

and chemical processing

Continuous
Caster-Slabs

industries in the United


States. We operate three
production facilities in
Pennsylvania and Indiana.
Many of our 400 plus

Electric Arc
Furnace

Ladle Refining

grades of carbon and alloy

Ladle
Degasser
Bottom Poured Ingots

plate steels are pressure


vessel quality (PVQ) grades
used in the design and
fabrication of process
vessels. In addition, we

These steels are melted in an electric arc furnace from scrap that is carefully
selected to meet specification requirements.
The molten steel is then refined in a ladle metallurgy station, which includes a ladle

offer the thickest, widest

furnace. A ladle degasser is available for removing undesirable gases when required.

and heaviest plates available

High cleanliness levels are available. When specified, levels to 0.001% maximum

in North America. For a


comprehensive list of PVQ
grades and size availability,
refer to the Bethlehem
Lukens Plate Steel Specification
Guide, available on request.

sulfur, 0.005% maximum phosphorus and 0.002% maximum oxygen can be


achieved for certain grades. The lowest sulfur levels are achieved through Fineline
processing, which includes calcium treatment for inclusion shape control.
Improved accuracy and precision of chemical composition is achieved, making
it possible to offer the stringent carbon equivalent (CE) controls required by
our customers.
Microalloying elements (B, Ti, Cb, V) are not intentionally added to PVQ steels,
unless required by customer specification. This practice addresses industry concerns

Two pressure vessel plate


steel specifications are,
by far, the most popular
for ambient and high
temperature process vessel
applications. ASME SA516
or A516 carbon steeland
ASME SA387or A387
alloy steelare technically
detailed based on BLPs
experience in this brochure.

about the unpredictable response of hard heat affected zones from welds containing
these elements during post weld heat treatment (PWHT) of fabricated process vessels.
However, when specifically approved by our customer, microalloying additions will
be considered to achieve special properties.
These steels are bottom poured into ingots or continuously cast into slabs,
depending on plate size and weight.
Based on final product dimensions, PVQ steels are rolled on our 40-, 110-, 140-,
or 206-inch wide rolling mills.
Depending on specification requirements, PVQ steels can be heat treated in one
of many car-bottom or continuous furnaces. If the steel is intended for hot forming
applications, BLP will perform a capability test on laboratory heat treated samples
from the as-rolled plates.

A516 Carbon Steels


BLP produces the full
range of A516 plate steels
in grades 55, 60, 65 and
70. Plate thicknesses to
15 inches, widths to
195 inches, lengths to
1525 inches and pattern
weights up to 50 tons can
be produced, depending
on a combination of
specification and size
requirements. Our advanced
facilities make possible the
production of A516 to a
variety of customer and
industry specifications,
including the most rigorous
hydrogen induced cracking
(HIC) testing requirements.
There are no heat lot
ordering requirements for
any of the quality levels of
A516 produced by BLP.

Carbon Equivalent Controls


Due to the concern for weldability, BLP will produce A516 steels to restricted carbon and CE
levels when requested. The maximum levels will vary by grade, thickness and post weld heat
treatment requirements.
As shown by the data in Figure 2, the carbon and other elements that comprise the most
commonly-used CE formula are important for providing strength. Figure 3 shows, by plate
thickness, the CE levels that can be achieved
for the various grades of A516, while still

Figure 2: A516
Normalized Thickness

maintaining the required strength levels.


Both carbon and CE can be controlled by
employing special melting practices.
Figure 4 demonstrates the improvements
that can be achieved with special melting.
Furthermore, if even more aggressive
requirements are desired, quench and
temper (Q&T) heat treatment will allow
even lower carbon and CE levels. It also
improves toughness and resistance to
post weld heat treatment (PWHT).

Thickness Over 1.5" to 3" Inclusive

Figure 3: A516 Maximum Carbon Equivalent Levels

Figure 4: A516 Grade 70 Max. Carbon and CE Levels

Grades 60, 65, 70 and Effect of PWHT

Normalized or Q&T Applications with PWHT

The improvement in CVN toughness realized by Q&T is demonstrated in Figure 5.


In general, a PWHT cycle of 1150 degrees F for eight hours will create the need for an
additional three points of CE to achieve the same strength as in a plate of the same
thickness without PWHT. The effect of PWHT on lowering strength levels is shown in
Figure 6.* Figures 7 and 8 further summarize the results of testing on a 1-inch thick A516
Grade 70 plate and show the degradation of toughness as PWHT severity increases.

Figure 5: Effect of Heat Treatment on


Transverse CVN Toughness

Figure 6: Effect of PWHT on A516 Strength

1" Thick A516 Grade 70 Plate, Code L

1" Thick Plate


* Bethlehem uses the Larson-Miller time-temperature parameter
to assist in identifying the effects of PWHT on properties.

We will consider multiple certification of A516 to Grades 60, 65 and 70 on normalized


plates from 3/8- to 3-inches thick. The necessary chemistry controls can be achieved in
our ladle metallurgy facilities.

Figure 7: Effect of PWHT on A516 Toughness

Figure 8: Effect of PWHT on A516 Toughness

1" Thick Plate

1" Thick Plate

Hydrogen Induced Cracking Testing


As shown schematically in Figure 9, hydrogen ions generated by the reaction of steel with
a sour process environment attempt to pass through the steel shell containment boundary
and, in the absence of inclusions in the steel, can do so harmlessly. However, if inclusions
are present, the ions nucleate at these voids and form hydrogen gas pockets, appearing
as blisters on the steels surface. High internal pressure can eventually cause the inclusions
to be initiation sites for further hydrogen induced cracking (HIC) in the steel.

Figure 9: The Process of Hydrogen Induced Cracking (HIC)

Figure 10: Steels for Refinery Application

Clad
(H+)

Aqueous, Acidic, H2S Containing Environments


BLP has produced HIC-Tested A516 plate steels since 1990 for use in a variety of process
vessels where there is a concern for HIC in aqueous hydrogen sulfide service or other
hydrogen charging environments.
To meet HIC-testing requirements, it is imperative to have very clean steels with low
inclusion contents. All HIC-Tested A516 steels are produced to our exclusive Fineline
process, which reduces sulfur levels to 0.002% max. or less and employs calcium
treatment for inclusion shape control. Maximum levels of phosphorus and oxygen
may also be accepted.
Next to cleanliness, we have found heat treating to be very important in attaining
satisfactory results in HIC-testing. Both normalizing and Q&T heat treatments are
available to help meet other properties as well.
The use of HIC-tested steels is one approach to deal with potential HIC applications.
Other approaches, including stainless steels, or stainless clad steels, may be considered
as indicated in Figure 10. A more detailed review of this subject is contained in NACE
Publication 8X194, Materials and Fabrication Practices for New Pressure Vessels Used in
Wet H2S Refinery Service.
BLPs HIC-tested A516 can be produced in plate thicknesses from 3/8 through 6 inches and
plate weights to 55,000 pounds. Other thicknesses and weights will be considered on an
individual basis. HIC-testing of these steels is performed as outlined in BLPs Specification
LSC-HIC-01, the important aspects of which follow:
HIC testing is performed according to NACE TM0284-96, modified
by BLP for plate thicknesses greater than 1.18 inches (30 mm).
Figure 11 depicts the orientation and size of three test specimens to be cut
from one plate of each thickness rolled from each heat of steel. The formulae
used to determine various HIC-test parameters are also shown.
Figure 12 demonstrates the two acceptable HIC-testing calculation methods.
Note that a minimum value per cross-section is not an acceptable criteria.
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The Testing Solution A of NACE TM0284-96 (the low pH solution, 2.75 0.1 pH)
is used for the test. Testing Solution B of TM0284-96 (high pH) is also available.
Test reports for all HIC-tested A516 steels include values for CLR, CTR and CSR,
and other information specified by the purchaser.
Either of two classes of chemistry control and HIC-test guarantee levels may be specified
for crack length ratio (CLR), crack thickness ratio (CTR) and crack sensitivity ratio (CSR)
as shown on the bottom of this page.
The influence of sulfur on CLR, the most commonly specified HIC test parameter, is shown
in Figure 13. Recent studies have shown however that quality of inclusion shape control is
more important.
BLP HIC-tested A516 steels are also available from select service centers nationwide.

Available HIC-Tested Maximums, TM-01-77 Solution

Class

Heat Analysis
Maximum %
S

Overall
Average %

Individual
Sample Average %

CLR

CTR

CSR

CLR

CTR

CSR

.001

.008

.002

5.0

1.5

0.5

10.0

3.0

1.0

.002

.010

.003

15.0

5.0

5.0

Figure 11: Determining Hydrogen


Induced Cracking Resistance

Figure 12: Calculation of CLR, CTR or CSR Values

NACE Specification TM 0284-96

Sample Average Versus Overall Average

Figure 13: HIC Tested A516 Steels

Influence of Sulfur Level

Other Available Testing


A variety of additional property controls for A516 steels are available from BLP.
Some of these require more restrictive chemistry control and/or heat treatment.
Ultrasonic internal quality requirements, such as ASTM A578/ASME SA578 Level III,
may be specified. Depending on plate size, this specification requires a minimum of
BLPs Fineline with 0.005% max. sulfur processing, or if modified for 1/2 -inch diameter,
requires Fineline with 0.002% max. sulfur. More restrictive requirements will be
considered on request.
The most aggressive CVN impact properties for A516 steels can be met using a variety
of sulfur controls and heat treatments. Please inquire your specific requirements.
Through-thickness tensile properties may be specified per A770 for plates up to 6-inches
thick, including reduction of area (RA) up to 50%, when purchased to Fineline with
0.002% max. sulfur. 40% RA and 25% RA are available with Fineline with 0.005% max.
sulfur or Fineline 0.010% max. sulfur, respectively. For plate thicknesses over 6 inches,
please inquire.
The weldability of A516 is primarily addressed through the control of carbon and
carbon equivalent levels, which may permit the use of lower preheat levels. A516 steels,
whether HIC-Tested or otherwise, can be welded with conventional welding techniques.
High temperature tensile properties are rarely specified for A516 steels. However,
for reference purposes, Figure 14 shows BLP test results for three plates of
various thicknesses.

Figure 14: Elevated Temperature Tensile Strength of A516 -70

Results for Three Normalized Plates

A387 Alloy Steels


BLP is the major supplier
of A387 PVQ alloy steels in
North America. The company
produces a full range of
A387 grades, including
Grades 11, 12, 22, 22L, 5
and 9. We are also prepared
to produce Grades 21, 21L,
7 and 91, if required in
sufficient quantity. These
grades are offered in Class 1
or Class 2. Exceptions are
Grades 21L and 22L, only
available as Class 1 and
Grade 91, only available
as Class 2.
Grades 11, 12 and 22 are
most commonly used in
process vessels and are the
primary focus of this review.
Plates up to 12-inches thick,
186-inches wide and 600inches long, with weights up
to 100,000 pounds can be
produced, depending on the
combination of specification
and size required.

Chemistry
In applications where improved toughness and temper embrittlement resistance are needed,
restricted levels of impurity elements may be specified. These restrictions can normally be
obtained by taking special care in scrap selection and subsequent treating of the molten steel
at our ladle metallurgy facility. The following controlled impurity levels are available for fine
grain A387 steels.

Heat Analysis, Guaranteed Maximum Levels (When Specified)*


Grades 11 & 12

Grade 22

Sulfur

0.002%

0.005%

Phosphorus

0.005%

0.008%

Tin

0.010%

0.010%

Antimony

0.0025%

0.0025%

Arsenic

0.010%

0.010%

*Inquire if more restrictive levels are required.

Concern about temper embrittlement, discussed in more detail later, is normally addressed

by specifying limits on one of two factors, J and X defined by the following equations:

J = (% Si + % Mn)(% P + % Sn) x 10 4

X =(10 P + 5Sb + 4Sn + As)


{elements in ppm}
100

X is most often specified for welding consumables not base plate. The maximum levels,
by grade, that are available from BLP are:

Grade

J Factor

X Factor

12

110

12

11

150 180

12

22

90

14

The range of J Factors for Grade 11 are to allow for higher Mn levels required to meet
strength levels in thicker plates and/or when extensive PWHT is required. The distribution

of J and X data for Grade 22 heats produced by BLP are shown in Figures 15 and 16. More

restrictive levels of individual impurity elements, or J and X factors, will be considered on a


case-by-case basis.

Figure 15: Distribution of J Factor for A387 Grade 22

Factor for A387 Grade 22


Figure 16: Distribution of X

J Factor, J=(%Si + %Mn)(%P + %Sn) x 104

10

X Factor, X=(10 P + 5Sb + 4Sn + As)


100

{elements in ppm}

Charpy V-Notch Toughness


Improved Charpy V-Notch (CVN) toughness properties can be met for A387 steels with
BLP Fineline processing, including vacuum degassing and calcium treatment for inclusion
shape control. When thick plates are specified with high CVN toughness requirements, a
quench and temper heat treatment may be required. Multiple austenizations may also be
utilized to meet increased toughness requirements. The general effects of Fineline processing
and heat treatment on toughness are shown in Figure 17. PWHT also has a significant effect
on CVN toughness; this phenomena will be discussed later. In all cases, it is strongly
recommended you contact us for specific CVN guarantees.
Impurity elements may cause degradation of CVN toughness over time in vessels with
long-term service, a phenomenon known as temper embrittlement. The effect is shown
schematically in Figure 18. As previously discussed, certain impurity elements, but
particularly phosphorus and tin, are restricted to minimize the temper embrittlement
susceptibility of A387 steels.

Figure 17: Influence of Processing on


the Toughness of A387 Steels

Figure 18: Effect of Temper


Embrittlement on Toughness

Shift in 40 ft-lb Transition Temperature (TT40)


Some specifications additionally stipulate that a laboratory step cooling simulation
be performed to determine the steels susceptibility to the phenomena.
BLP will perform step cooling treatment and meet commonly specified shifts in the 40 ft-lb
CVN transition temperature (TT40). Test results for A387 Grade 22 steels shown in Figures 17
to 19 demonstrate these capabilities for transverse orientation testing. In particular, the excellent
toughness, prior to step cooling, is shown in Figure 19 and the low susceptibility to temper
embrittlement, after step cooling, is demonstrated by the data in Figures 20 and 21 shown
on the next page.

Figure 19: Q&T A387 Grade 22 CVN Toughness

Eight 7.6" Thick Plates


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Figure 20: Q&T A387 Grade 22 CVN Toughness

Figure 21: Q&T A387 Grade 22 CVN Toughness

Shift of 40TT after Step Cooling

Shift of 40TT after Step Cooling

Post Weld Heat Treatment (Stress Relief)


End users and fabricators typically impose various stress relief requirements when specifying
A387 steels. The temperatures and hold times at temperature stabilize and soften the
microstructure of the heat affected zones after fabrication and account for possible weld
repairs during the life of the vessel.
However, as stress relief temperatures and hold times are increased, the capability of the
chemistry of each grade to achieve the tensile strength requirements of the specification,
using normalize and temper heat treatment, is limited.
Extensive stress relief treatments also have been found to have a deleterious influence on
CVN toughness in all A387 steels. This is demonstrated in Figure 22, which summarizes the
influence of increasing PWHT
cycles on longitudinal CVN

Figure 22: Effect of Stress Relief on A387


Grade 22 CVN Toughness

toughness of a 2-inch thick


A387 Grade 22 plate by
showing the resultant shift
in the transition curve. The
shift is due to the coarsening
of carbides at the grain
boundaries as shown in the
photomicrograph below
(Figure 23).

N&T Heat Treatment; 2" Plate

Figure 23: Effect of Stress Relief on A387 Microstructure


Increasing Size of Grain Boundary Carbides
As N&T

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N&T + PWHT (1325F 20 hrs.)

Figure 24: Effect of Stress Relief on


A387 Grade 11 Toughness

Figure 25: Effect of Stress Relief on


A387 Grade 11 Toughness

N&T Heat Treatment; 2" Plate

N&T and Q&T Properties; 2" Plate

Figure 24 further demonstrates the combined effect of PWHT time and temperature
on toughness.
As toughness requirements become more restrictive, the PWHT cycle often mandates the
A387 base plates be quenched and tempered to maintain toughness. Figure 25 shows the
improvement in toughness that occurs, in this case for 2-inch thick A387 Grade 11 plate,
as a result of the quench and temper heat treatment.

Figure 26: A387 Grade 11 CVN Toughness at -20F*

*Average based on number of plates tested (xxx) shown

Various Thickness and PWHT

Due to the increasing demand for improved resistance to creep embrittlement, higher PWHT
temperatures are being specified, especially for Grade 11. To further improve performance,
Class 1 strength levels are also being specified. This allows lower carbon and CE levels to
be achieved, particularly when quench and tempered heat treatment is specified. To date,
production results have been very encouraging and indicate there is less degradation in
CVN toughness with extensive PWHT. Figure 26 presents a summary of our experience.

Ultrasonic Quality
A387 plates to 6-inches thick and over 50,000 pounds can be ordered to meet the
requirements of A578 Level III, when the steel is produced with BLP Fineline processing.
For plates thicker than 6 inches, please inquire.

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Additional Information
For more information and specific guarantees for a particular application of A516 or A387
steels, please call our Specification Metallurgy Department at 610-383-2589.

Literature to supplement the


contents of this brochure is available
A516 Steels
A. LSC-HIC, Lukens Specification for Hydrogen Induced Cracking Testing of A516 Steels
B. Hydrogen Induced Cracking (HIC) Resistance of A516 Grade 70 Plate Steel,
Emil G. Hamburg and Alexander D. Wilson, AIME-TMS Conference
Metallurgy of Vacuum Degassed Steel Products, October 1989
C. HIC Testing of A516 Grade 70 Steels, E. G. Hamburg and A. D. Wilson,
NACE Corrosion 93, March 1993

A387 Steels
D. Improvements of the Mechanical Properties of 1 Cr - 1/2 Mo Steel, R. A. Swift,
ASME Petroleum Mechanical Engineers Conference, Mexico City, Mexico, 1976
E. High Toughness 2 1/4 Cr - 1 Mo Steel for Hydrocarbon Process Pressure Vessels,
K. J. Benusa and R. A. Swift, API Mid-Year Meeting, May 1981
F. Evaluation of A387-22 Steel Modified for Improved Toughness, R. A. Swift and
J. A. Gulya, MPC-ASME Symposium Advanced Materials for Pressure Vessel Service
with Hydrogen at High Temperatures and Pressures, June 1982
G. The Effect of Inclusions on the Fracture Properties of A387-22 Steel Plate, A. D. Wilson,
MPC-ASME Symposium Advanced Materials for Pressure Vessel Service with Hydrogen
at High Temperatures and Pressures, June 1982
H. Effects of Composition and Heat Treatment on the Mechanical Properties of
300 mm Gauge 2 1/4 Cr -1 Mo Steel Plate, R. A. Swift, ASTM STP 755, 1982
I. Fineline A387-11 Data, J. A. Gulya, Lukens Steel Company Report RPR 86 -1,
February 1986
J. Properties and Behavior of Modern A387 Cr-Mo Steels, A. D. Wilson,
C. R. Roper, K. E. Orie and F. B. Fletcher, ASME PVP Vol. 239, 1992
K. Tougher Steels Improve Pressure Vessel Performance, A. D. Wilson,
Advanced Materials & Processes, Vol. 143, April 1993

Other Bethlehem Lukens Plate Literature


A. Bethlehem Lukens Plate Steel Specification Guide, updated annually
B. Fineline Steels, April 1996
C. Roll-Bonded Clad Steels, October 1998
D. Hardwear, A Premium Line of Abrasion Resistant Steels, February 1996
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IMPORTANT: The information provided herein is based on testing or Bethlehem Lukens Plates
experience and is accurate and realistic to the best of our knowledge at the time of publication.
However, characteristics described or implied may not apply in all situations. Bethlehem Lukens
Plate reserves the right to make changes in practices that may render some information outdated
or obsolete. In cases where specific plate properties are desired, Bethlehem should be consulted
for current information and/or capabilities.

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Mill Locations

Headquarters

Burns Harbor, IN

Bethlehem Lukens Plate

Coatesville, PA

Administrative Resources Center

Conshohocken, PA

Modena Road

P.O. Box 3001

Coatesville, PA 19320-0911
800- 441-3320
www.bethsteel.com

Bethlehem Lukens Plate


10/983M