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Guide to the Selection and Use of High Performance Stainless Steels

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Guide to the Selection and Use of High Performance Stainless Steels Soon to be published .. NiDI Nickel Development Institute GUIDE TO THE SELECTION AND USE OF HIGH PERFORMANCE STAINLESS STEELS Metallurgy - Properties - Corrosion Performance - Fabrication A Nickel Development Institute Reference Book Series No. XX XXXX Page 1 9/3/99 TABLE OF CONTENTS INTRODUCTION ........................................ 3 CLASSIFICATION OF GRADES ........................................ 5 AUSTENITIC HIGH PERFORMANCE STAINLESS STEELS ...................................... 5 FERRmC HIGH PERFORMANCE STAINLESS STEELS ................................................ 9 DUPLEX HIGH PERFORMANCE STAINLESS STEELS ............................................... 10 PHYSICAL METALLURGY ............................................... 13 PHASE RELATIONS IN THE IRON-CHROMIUM-NICKEL SYSTEM ............................................ 13 SECONDARY PHASES ............................................... 17 KINETICS OF PHASE PRECIPITATION REACTIONS ............................................... 21 AUSTENITIC STAINLESS STEELS ............................................... 22 FERRmC STAINLESS STEELS ............................................... 24 DUPLEX STAINLESS STEELS ............................................... 26 MECHANICAL PROPERTIES ............................................... 28 AUSTENmC STAINLESS STEELS ............................................... 29 FERRITIC STAINLESS STEELS ............................................... 31 DUPLEX STAINLESS STEELS ............................................... 33 PHYSICAL PROPERTIES ............................................... 34 CORROSION RESISTANCE ............................................... 36 RESISTANCE TO INORGANIC ACIDS .37 RESISTANCE TO ORGANIC ACIDS .43 RESISTANCE TO ALKALIES AND ALKALINE SALTS .46 CHLORIDE- AND OTHER HALIDE-CONTAINING AQUEOUS ENVIRONMENTS .48 NEAR NEUTRAL ENVIRONMENTS - NATURAL WATERS AND BRINES .53 INFLUENCE OF MICROBIAL ACnVITY .57 OXIDIZING HALIDE ENVIRONMENTS - CHLORINATED COOLING WATERS AND BLEACH SOLUTIONS .58 ACIDIC ENVIRONMENTS CONTAINING HALIDES- FLUE GAS CONDENSATES .61 STRESS CORROSION CRACKING ............................ 65 WATER AND BRINE ENVIRONMENTS ................................ 66 SOUR OIL AND GAS ENVIRONMENTS ................................ 70 HYDROGEN ENVIRONMENTS ................................ 73 CORROSION ACCEPTANCE TESTS ............................ 74 FABRICATION ................................ 78 HOT WORKING ................................ 79 COLD WORKING ................................ 81 ANNEALING ................................ 83 MACHINING ................................ 86 WELDING ................................ 87 AUSTENmC STAINLESS STEEL GRADES ................................ 89 FERRITIC STAINLESS STEEL GRADES ................................ 92 DUPLEX STAINLESS STEEL GRADES ................................ 93 SURFACE CONDITION ................................ 97 APPLICATIONS ............................................ 98 Page 2 9/3/99 Materials Workshop for Nuclear Power Plants Stainless Steel and Nickel-Base Alloys Presented by Mr. Curtis W. Kovach Dr. Nicole Paulus-Kinsman of the Nickel Development Institute (NiDI) Workshop Schedule 8:15 am Welcome and Introduction 8:30 am Basics of Stainless Steel and Nickel-Base Alloys 9:30 am Corrosion Basics 10:30 am Welding Stainless Steel 11:30 am Lunch 1:00 pm High Strength Stainless Steels (Discussion) 2:00 pm Advanced Stainless Steels 3:00 pm Microbiologically Influenced Corrosion 3:45 pm Conclusion The format for this workshop is flexible and open. Questions may be asked at any time and examples from the floor can be discussed during the session or one-on-one afterwards. September 9, 1999 NIDI NUCLEAR POWER PLANT WORKSHOP Conpany US Nuclear Regulatory Commission Location: Rodville. Maryland Date: SeptLeSt9 High ATTENDEE INFORMATION N0CE Perfromance Mailing List Stainless Steel Book Name: Phone: Title: Address: Name: Phone: Title: Address: Name: _ Phone Title: Address: Name. Phone: Title: Address: Name: Phone_ Title: Address: Name: Phone: Title: Address - - Curtis Kovach RUJEDI Consultant NICKEL DEVELOPMENT INSTITUTE Technical Iarketing Resources, Inc. 3209 McKnight East Drive Head Office Pitsburgh, PA 15237-6423 U.S.A. 214 King Street West, Suite 5 10 Toronto, ON Canada M5H 3S6 Telephone 412-369-0377 Telephone 416-5917999 Fax 412-367-2353 Fax 416-591-7987 ckotuch8trnr-inc.cosn Dr. Nicole Paulus K, I7~~I~bDIPo"D I Consultant NICKEL DEVELOPMENT INSTITUTE Technical Marketing Resources, Inc. 3209 McKnight East Drive 1Iead Office Pittsburgh, PA 15237.6423 214 King Street West, Suite 510 U.S.A. Toronto, ON Canada Mll 3S6 Telephone 412-369-0377 Telephone 416-591-7999 Fax 412-367-2353 Fax 416-591.7987 npaulus6tmrinc.com "1 1 "1- J L L NiDI NUCLEAR SERVICE WATER PIPING CASE STUDY No 15002 Table I 1994 OSKARSHAMN NUCLEAR System Description POWER PLANT, FIGEHOLV1, SWEDEN DESCRIPTION UNIT 1 UNIT 2 UNIT 3 Start Up 1972 1974 1985 Coastal nuclear power plants, which use brackish and System Testing 1970 1972 1983 often polluted water in their service water systems, face Power Output (MWc) 460 620 1.210 one of the most demanding service environments in the Regular System 700 1,000 1,700 Flow Rate (kg/s) industry. The Swedish utility OKG AKTIEBOLAG has Emergency System 25 400 700 this operating environment at their Oskarshamn Nuclear Flow Rate (kg/s) Power Plant in Figeholm, Sweden. The brackish, Main Condenser 20,000 26.000 45,000 polluted Baltic Sea water used in the service water system Flow Rate (kg/s) caused extensive corrosion of the original system materials. Material replacement, testing, and evaluation emergency service water system in all three plants is nor- have been on-going since 1978 giving OKG some of the mally only operated during shut-down periods. A most extensive operating experience with 6 Mo austenitic constant low flow rate is maintained through the system stainless steels, titanium and other high performance when it is not in operation to prevent water stagnation. replacement materials of any nuclear power plant in the The emergency systems in all three units were designed world. This case study reviews the problems experienced so that, even if the pumps stopped, the operating system with original system materials; replacement material eval- would never be empty. The return pipes go to the highest uation programs; and actual performance of the alloys in point in the system. service; therefore, providing valuable insight for utilities with equally severe operating environments. The open sections of the service water systems use brack- ish, polluted water from the Baltic Sea. The water enters the plant through culverts and is pumped through a short THE SYSTEM section of underground piping before entering the units. The closed portions of the service water system use demineralized water. Units I and 2 have open, once- The Oskarshamn Nuclear Power Plant has three operating through service water systems in all but the reactor units. The start-up dates for these units and other basic building, which has a closed system. The majority of the operating data for the service water system can be found piping and over 100 heat exchangers in these units are in in Table 1. The units all have open emergency service the open portion of the service water system. These are the water systems and have both closed and open once- older units with start-up dates in 1972 and 1974, through portions of their regular service water system. respectively. Corrosion problems became evident in both The condensers in all three units are fed by the open units within two to three years after commencement of portion of the service water system. commercial operation. The first problems arose in the Both the standard and emergency service water system main condensers. These were followed by problems with piping was originally rubber-lined carbon steel. The the heat exchangers, and then, with the piping. Unit 3, which began operation in 1985, has both closed and open any portion of the system. It is possible that the low water temper- sections in its service water system with eleven titanium plate heat ature during much of the year has prevented a MIC problem. The exchangers made by Alpha Laval as the interface between them. water source and description have not changed since initial testing Since this unit is fairly new and since titanium was initially installed of the system. in both the heat exchangers and the condenser, there have been no significant corrosion problems to date. Corrosion problems with the During July and August, crustaceans can accumulate in the system. pipe are anticipated when the rubber lining begins to crack or wear. At one time, a trial study was done in which hypochlorite was added to the service water system to prevent crustacean growth. Although this worked well, the use of hypochlorite additions was not adopted THE WATER by the plant because of environmental concerns. No additional chlo- rine or other chemicals are currently added to the water except The brackish, polluted water used in the open, once-through por- during system shut-down. A cathodic protection system is used to tions of the service water systems is drawn from the Baltic Sea. All prevent deterioration of the condenser tubesheets and waterboxes. three units were tested two to three years before the unit start-up date Table 2 MATERIAL EVALUATION Water Description AND REPLACEMENT Source Baltic Sea Oskarshamn selects materials by reviewing technical literature, lab- Type brackish, polluted
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