Heat Treatment of SS
Heat Treatment of SS
Heat Treatment of SS
Contents Strengthen your team with a materials professional Reliable and safe a stainless alternative Sizes and tolerances Standards From melting to finished product Research and development, Environment, Ethics, Quality, Production facilities Sandvik around the world Grade selection Typical application areas Effect of alloying elements Life cycle cost considerations PRE formula Chemical compositions Cost saving by using duplex stainless steels Mechanical properties Electropolished stainless steel Welding U-bent tubes for heat exchangers Seamless titanium and zirconium alloy tubing Steel grades standard manufacturing programme 3 4 5 6 7
8 10
11
12 14 16 20
Sandvik, Sanicro, SAF 2304, SAF 2205, SAF 2507, SAF 2906 are trademarks owned by Sandvik AB. 254 SMO is a trademark owned by Outokumpu Oy.
Recommendations are for guidance only, and the suitability of a material for a specific application can be confirmed only when we know the actual service conditions. Continuous development may necessitate changes in technical data without notice.
consistent material properties products with consistent and reliable quality in every delivery the result of full quality assurance and control throughout the whole manufacturing process. flexibility and easy access for you to reach our materials experts a worldwide, local network of Sales Units.
Complementary products
The Sandvik heat exchanger tubes supply package includes standard stainless steel and special grade complementary products welded tubes, sheet and plate, tube fittings for butt welding and socket welding, threaded joints and flanges.
Weight
mm
kg/m
34 16 BWG 34 14 BWG
0,66
b,d b
b,d b,d d d c d
0,87 1,04 1,88 1 16 BWG 1 14 BWG 0,79 0,97 b,d b,d b,d b,d
a) Calculated with min. wall. b) Stock standard = min. wall. c) Stock standard in lengths of 6 metres.
Tolerances
Outside diameter mm Tolerances Wall thickness
+20 / -0% (min. wall) +20 / -0% (min. wall) 10%, min. 0.20mm (T3) 10% 10%
Sandvik 3R12, 3R60, 5R75 and 6R35 in metric sizes EN ISO 1127 Sandvik SAF 2205 and SAF 2507 acc. to ASTM A789 Sandvik Sanicro 28 acc. to ASTM B668 / B829, ave. wall
Sandvik 6R35 and 5R75 Sandvik Sanicro 28 Sandvik SAF 2205 and SAF 2507
Further information:
www.smt.sandvik.com/fittings www.smt.sandvik.com/heatexchangers
5
Environment
Production facilities
Environmental awareness is an integral part of our business and is at the forefront of all activities within our operation. Sandvik strives for high efficiency in the use of energy and natural resources and holds approval to ISO 14001:1996. Stainless steel can be 100% recycled, and our steel plant in Sandviken operates a full materials recovery process.
Sandvik Materials Technologys tube manufacturing facilities are located strategically around the world. Our combined resources, connected through a worldwide electronic network of information and planning systems enables us to offer a reliable supply of high quality products no matter where in the world our customers are located.
Ethics
Our core values include promoting equality in all respects and operating in a highly ethical manner in relation to employees, customers, suppliers and all other industry contacts.
Within Sandvik Materials Technologys global operation, all disciplines work together sales representatives, engineers, researchers and production, in order to satisfy customer demands.
Quality
Our fully integrated steel mill ensures close control of the entire production process, from melting of the steel to the finished product. Sandvik Materials Technology has quality systems accepted by internationally recognized bodies and holds an ASME Quality System Certificate as a Materials Organisation. Approval to ISO 9001 is also held, as well as product approvals from LRQA, JIS, RW-TV, Det Norske Veritas and other organisations. Quality, both in products and services, is a major objective for us and this is expressed in the companys Quality Policy. All employees are involved and committed to continuous improvement.
Seawater coolers Oil refining Petrochemicals Chemicals Power generation Gas processing Flue gas cleaning/desulphurisation Hydrometallurgy Recuperators Pulp and paper production Fertilizers Desalination / salt evaporation
Seawater coolers
Grades selected for seawater coolers need to have high resistance to chloride solutions. One such grade is Sandvik SAF 2507.
Oil refining
Refinery process streams involve many corrosive elements, which can shorten the lifetime of low alloyed steels. Stainless steels, and, in particular, duplex grades Sandvik SAF 2205 and SAF 2507, can overcome such problems.
Petrochemicals
Corrosion in petrochemical plants can lead to contamination of manufactured products. Sandviks high quality, corrosion resistant stainless steels include a full range of standard austenitic grades up to the super duplex grade Sandvik SAF 2507.
Fertilizers
The urea process requires specific materials with low impurity levels for a long and safe service life. Sandvik 2RE69 has been developed primarily to cope with the severely corrosive conditions existing in the industry. Sandvik 2RE10 has been developed for oxidizing environments and is widely used to replace corroding 304L in nitric acid plants.
Chemicals
Sandviks special grades are used in heat exchangers in many demanding chemical processes, including the production of inorganic acids and caustics. Sandvik seamless tubes offer the necessary high reliability in these often critical applications.
Hydrometallurgy
Slurry processing under high pressures and temperatures may give rise to severely corrosive conditions. Duplex stainless steels such as Sandvik SAF 2304 and SAF 2906, with their combination of corrosion resistance, high strength and erosion resistance, are particularly suited to this type of service.
Power generation
Sandvik heat exchanger tubes can be found in condensers, feedwater heaters and wastewater handling equipment. Sandvik steel grades fulfil the high quality standards for use in both conventional fossil fuelled power plants as well as nuclear power stations.
Recuperators
Sandvik high temperature grades are used in recuperators and air heaters serving the glass, carbon black and steel industries, and in the direct reduction of iron ore (Midrex process), chemical waste incineration and sewage sludge waste incineration.
Gas processing
Reliable operation is essential in gas processing equipment. For offshore equipment, duplex stainless steels have been shown to give weight saving benefits due to the wall thickness reductions possible from these high strength materials.
Low initial cost Increased inspection cost More frequent maintenance required Greater risk of production stoppages Replacement cost
Higher initial cost Less maintenance required More reliable operation Lower life cycle cost
ASTM G48, practice A (6% FeCl3 ) is one of the toughest pitting corrosion tests for stainless steels. It gives the same ranking order for the steels as in slightly chlorinated seawater. In Sandviks laboratory, a modified version of G48 is used, with a step by step raising of the temperature. This allows the determination of the critical pitting temperature. The results from such a test are shown to the right.
Formula: PRE=%Cr+3.3%Mo+16%N
Chemical compositions
Grade Sandvik Austenitic 3R65 (316L) 2RK65 (904L) 254 SMO Duplex SAF 2304 SAF 2205 SAF 2507 SAF 2906 Ni-Alloy Sanicro 28 Sanicro 41 S32304 S32205/ S31803 S32750 S32906 N08028 N08825 0.030 0.030 0.030 0.030 0.020 0.030 23 22 25 29 27 20 4.5 5 7 7 31 38.5 3.2 4 2.3 3.5 2.6 0.1 0.2 0.3 0.3 25 >35 >42.5 41 39 29 UNS S31603 N08904 S31254 C max 0.030 0.020 0.020 Cr 17 20 20 Ni 11.5 25 18 Mo 2.1 4.5 6.1 N 0.2 PRE 24 35 43
10
Sandvik 3R60
Mechanical properties
Grade Sandvik Proof strength Rp0.2 MPa, min. Tensile strength Rm MPa Elongation A% Min.
Austenitic 3R60 (316L) 2RK65 (904L) 254 SMO Duplex SAF 2304 SAF 2205 SAF 2507 SAF 2906 Ni-Alloy Sanicro 28 Sanicro 41
45 35 35 25 25 25 25 40 30
and specialises in electropolishing, cleaning and surface treatment of stainless steel in the following areas:
l l l
Electropolished and high purity tubular products Subcontract electropolishing of components and vessels Electrolytes for electropolishing
Continuous development of the electropolishing process ensures that Sandvik Calamo is able to meet the latest and most demanding requirements. The different parameters during the electropolishing and cleaning processes are strictly measured, controlled and recorded. A unique passivation method guarantees a chromium enriched layer of the highest quality.
Further information: www.smt.sandvik.com/calamo S-191-ENG High purity steel
As one of the worlds first manufacturers of electropolished tubes, Sandvik Calamo has more than 35 years experience in the market for clean and high purity materials
11
Welding
Sandvik SAF 2205, 2304 and 2507
Sandvik SAF 2205, 2304 and 2507 duplex grades offer good weldability. Suitable welding methods include manual metal-arc welding (MMA/SMAW) with covered electrodes, submerged-arc welding (SAW), gas metal-arc welding (MIG/GMAW) and gas tungsten-arc welding (TIG/GTAW). For Sandvik SAF 2304 and 2205, welding should be performed with a heat input of 0.52.5 kJ/mm (1065 kJ/inch) and for SAF 2507 0.21.5 kJ/mm (540 kJ/inch). The interpass temperature should be kept below 250C (400F) for Sandvik SAF 2304 and 2205 and below 150C (300F) for Sandvik SAF 2507. Preheating or post-weld heat treatment are normally not necessary or recommended. If there is a risk of condensed moisture on the joint surfaces, a preheat of 5070C (90150F) can be introduced to avoid porosity. Preheating with an open flame should be avoided. Careful cleaning of the joint, before and after welding, is important for optimum corrosion resistance. Local deformation due to welding stresses will not be as pronounced as for austenitic stainless steels, but a proper welding plan is still recommended. Welding without filler metal is not recommended. Recommended welding consumables are listed in the table.
12
Further information: S-236-ENG. Stainless welding S-91-57-ENG. Welding practice Sandvik duplex stainless steels. www.smt.sandvik.com/welding
13
U-bent tubes
for heat exchangers
Sandvik Materials Technology is one of the worlds leading suppliers of U-bent tubes. U-bends are manufactured from Sandvik precision straight tubes and are produced by the cold-pilgering method with a bright annealed surface. Production is strictly controlled, step-by-step, in order to fulfill all the technical demands from our customers.
Technical parameters
OD 12.7-38 mm, see the size range table Bending radii from 1.5xOD up to 1250 mm. Minimum bending radii for ODs over 28 mm after agreement. Leg length min. 1000 mm Leg length max. 12000 mm Heat treatment for radii up to 1000 mm
U-bend definitions
Description of U-bend: a.. of legs . . . . . . . difference in length Acc. to Sandvik steel spec. 7-2-1179 c. . .. . of tangency . . . . distance between points a . . . . . . . nominal outside diameter of tube d Permissible ovality e. . .. . . . . . distance between legs how to define ovality: outside diameter measured on d a max - d a min f. . . . . . . . . distance between legs Rmax = 200 x (%) l. . . . . . . . . leg length d a max + d a min
U-bend tolerances
l g. . . . . . . .developed length rm .......nominal bend radius s. . . . . . . . . nominal wall thickness s min ....minimum wall thickness at the back of the bend t.........deviation from plane of the bend so. . . . . . . minimum wall thickness defined by specification
Rmax 12% Rmax 10% Rmax 5% smin = 0.75 x s smin = 0.80 x s smin = 0.90 x s
t 1.5 mm
14
No yield losses from separate bending operation Guaranteed quality Lower transport costs from one location Heat treatment of U-bent tubes
O.D.
(mm) 0.9
12.70 14.00 15.00 15.88 16.00 18.00 19.00 20.00 25.00 25.40 28.00 30.00 32.00 33.40 33.70 35.00 38.00
Size range
U-tubes can be produced within the size range specified in the table above. The sizes marked in light blue can be produced by special agreement.
Hydrotesting
l l l
Packing
l
Heat treatment
If specified, we are equipped to carry out heat treatment of bends plus min. 150 mm of leg. l Furnace is computer controlled and all data is recorded. l We use an argon protective atmosphere inside the tubes. l We can provide all types of annealing: Solution Stress relieving Stabilisation
After heat treatment all U-tubes are hydrotested. Minimum holding time at the required pressure is 5 seconds. All tubes are dried and carefully cleaned after hydrotesting.
l l l l l
U-bends are measured exactly in accordance with relevant standards, or to customers specification. All tubes are cut to the specified leg lengths, ends are deburred and the tubes are finally internally cleaned with air. Before packing, both ends of U-bends are capped with plastic caps.
boxes depending on destination - max. 8000 kg. Ends of tubes protected by plastic caps. Vertical separators for each radius. Chloride free plastic separators between each row, every 2 metres. Each bundle is covered with plastic. Customers can provide a packing drawing or Sandvik can prepare a packing plan. Packing lists, covered with plastic, are placed on each wooden box for easy identification of order details including exact list of radii and lengths inside.
15
The manufacture of seamless titanium and zirconium heat exchanger tubes at Sandvik Materials Technology in Sandviken, Sweden, is carried out through a completely integrated process. It starts with melting of raw materials in high vacuum furnaces and ends with the finished seamless tubes. The manufacturing process is specially designed to work with non-fer-
rous metals like titanium and zirconium. The Sandvik group has been the worlds largest independent manufacturer of seamless zirconium and titanium tubing for over 35 years, supplying to a wide range of industries including chemical, petrochemical, aerospace and nuclear.
Titanium
Titanium has a unique set of properties that makes it suitable for a variety of applications. It has a high environmental resistance, relying primarily on a very thin, tenacious and highly protective surface oxide film. Titanium is highly resistant to wet chlorine chemicals, practically all salt solutions, seawater, a range of acids, organic and inorganic chemicals and gases. The same oxide film provides a high resistance to erosion in high velocity process streams. The corrosion and erosion resistance makes titanium a preferred heat transfer material for shell/tube heat exchangers, since it permits the use of thin heat transfer walls and high fluid flow rates. In addition, titanium has only half the weight of steel, is non-magnetic, has a high melting point, high strength-to-weight ratio and a low modulus of elasticity.
Grade 9
Grade 11 Unalloyed titanium plus 0.12% to 0.25% palladium, low oxygen, low strength Grade 12 Titanium alloy (0.3% molybdenum, 0.8% nickel), high strength Grade 16 Unalloyed titanium plus 0.04% to 0.08% palladium, standard oxygen, medium strength Grade 17 Unalloyed titanium plus 0.04% to 0.08% palladium, low oxygen, low strength Grade 26 Unalloyed titanium plus 0.08% to 0.14% ruthenium, standard oxygen, medium strength Grade 28 Titanium alloy (3% aluminium, 2.5% vanadium) plus 0.08% to 0.14% ruthenium
l l l l
Excellent resistance to general corrosion in seawater applications High resistance to stress corrosion cracking in chloride and sour gas environments Excellent resistance to pitting, crevice and erosion corrosion High heat transfer efficiency Good formability and weldability Very low thermal expansion High strength-to-weight ratio
The elimination or reduction of: l Fatigue l Stress corrosion cracking l Fretting fatigue l Corrosion fatigue l Fretting l Cavitation erosion l Galling l Porosity l Spalling l Wear
16
Zirconium
l
l l
The range of dimensions is outside diameters from 8 mm up to 40 mm in tube lengths up to 28 meters for titanium and 16 meters for zirconium with certain OD/L and OD/Wt limitations. All tubing can be supplied as straight lengths or as U-tubes. Non-destructive testing facilities include ultrasonic testing, Eddy Current testing and hydropressure testing. Tubes are normally supplied as cold pilgered, vacuum annealed and cleaned with the OD in the as polished condition.
Zirconium is highly resistant to a wide range of acids and bases, both organic and inorganic, which makes it an interesting and exceptional long life alternative to other materials in highly demanding
applications. The seamless tube zirconium grade, produced for heat exchanger applications, is Sandvik Zirconium 702*, which offers the process industry a high quality and competitive product concept.
l l l l
High heat transfer efficiency Very low thermal expansion Immunity to stress corrosion cracking High resistance to localized (pitting and crevice) forms of corrosion Very good corrosion resistance in most organic acids Exceptional corrosion resistance in mineral acids Good corrosion resistance in strong alkalis Interchangeability between acid and alkali conditions
Acetic acid Urea Formic acid Sulphuric acid Nitric acid Citric acid Methyl methacrylate
17
Steel grades
Standard manufacturing programme
Designation Sandvik Chemical composition (nominal), % C Cr Ni Mo Others Standards* UNS ASTM TP
Austenitic stainless steels 3R12 3R60 3R65 6R35 5R75 3R19 5R60 3R64 8R40 Duplex stainless steels SAF 2304 SAF 2205 SAF 2507 3RE60
0.030 0.030 0.030 0.05 0.05 0.030 0.04 0.030 0.06 0.030 0.030 0.030 0.030
2.6 2.1 2.1 2.6 3.1 3.2 4 2.6 4.5 3.5 2.1 6.1 2.6
S30403 S31603 S31603 S32100/S32109 (S31635)** S30453 S31600/S31609 S31703 S34700/S34709 S32304 S31803/S32205 S32750 S31500 N08904 N08028 S31002 S31050 S31254 N08800 N08825 S44600 S31008/S31009 S30815 S35315 N08811/N08810 N06600
304/304L 316/316L 316/316L 321/321H (316Ti)** 304LN 316/316H 317L 347/347H Alloy 800 Alloy 825 4461 310S, 310H Alloy 600
High-alloy austenitic stainless steels and nickel alloys 2RK65 0.020 20 Sanicro 28 0.020 27 2RE10 0.015 24.5 2RE69 0.020 25 254 SMO 0.020 20 Sanicro 30 0.030 20 Sanicro 41 0.030 20 High temperature grades 4C54 7RE10 253 MA 353 MA Sanicro 31HT Sanicro 70
1) 2)
1.4465 can be certified. Pressure Equipment Directive 97/23/EC Also Code Case exist
Typical applications
Austenitic stainless steels Duplex stainless steels
These steels have many applications in heat exchangers, piping, hydraulic systems and other equipment for the chemical, petrochemical, pulp and paper and food processing industries. The Mo-alloyed grades have higher resistance to general corrosion in nonoxidising acids and to pitting and crevice corrosion. Ti- and Nb-alloyed grades have good strength at high temperature.
Considerably higher strength and lower thermal expansion compared with austenitic grades. Very high corrosion resistance in chloride-containing solutions and weak organic acids. Sandvik SAF 2507 has superior corrosion resistance in seawater. Used for heat exchangers and also offshore oil and gas exploration. Duplex steels have a maximum service temperature of 250-300 C.
Sandvik 2RK65 Phosphoric and sulphuric acid, seawater, refineries and petrochemical plants. Sandvik Sanicro 28 Very good resistance to all types of corrosion. Wide range of applications including refinery industry. Excellent performance in phosphoric acid. Sandvik 2RE10 Extremely low carbon and impurity content, excellent resistance to corrosion in strongly oxidising acids. Widely used as coolers/condensers and intail gas preheating in nitric acid plants.
18
EN Steel number
W.-Nr.
AFNOR
Pressure purpose PED4) ASME prEN 10216-5 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X5) X X X5) X X X X5) X5) X
Mechanical properties Proof Tensile strength strength Rp0.2 Rm MPa min. MPa 210 220 220 210 220 275 220 220 220 400 485 550 450 230 220 210 270 310 205 240 275 220 310 270 170 245 515680 515690 515690 515690 510710 550750 515690 515690 515690 600820 680880 8001000 700800 520720 550750 500670 580780 655850 520690 590750 500700 515750 650850 650750 500700 >560
Elongation A %, min. 45 45 45 35 35 40 40 35 35 25 25 25 30 35 40 35 30 35 30 30 20 35 40 40 35 35
1.4306/1.4301 1.4435 1.4404 1.4541/1.4940 1.4571 1.4311 1.4436 1.4438 1.4550/1.4912 1.4362 1.4462 1.4410 1.4424 1.4539 1.4563 1.4335 1.4466 (1.4547)* 1.4558 1.4749** 1.4845** 1.4835** 1.4854** 1.4959
* **
1.4306/1.4301 1.4435/1.4436 1.4404/1.4401 1.4541/1.4878 1) 1.4571 1.4311 1.4436 (1.4438)* 1.4550 1.4362 1.4462 1.4417 1.4539 1.4563 1.4335 1.4466 3) (1.4529)* 1.4558 2.4858 1.4749 1.4845 (1.4893) 1.49591)1.48761)2) 2.4816
Z2CN18-10 Z2CND17-13 Z2CND17-12 Z6CNT18-10 Z6CNDT17-12 Z2NC18-10AZ* Z6CND17-12 Z6CNNb18-10 Z2NC23-04AZ Z2CND22-05-03 Z2CND18-05-03 Z1NCDU25-20-04 Z1NCDU31-27-03 Z1CND25-22AZ Z1CNDU20-18-06AZ Z12CN25-20
In brackets, nearest equivalent steel grade. Not applicable for tube and pipe. Only for information.
Sandvik 2RE69 Fertilizer industry, urea strippers. Superior to 3R60 U.G. Sandvik 254 SMO Higher strength, very good resistance to pitting corrosion in seawater and brackish water. Sandvik Sanicro 30 Nuclear PWR steam generators. Sandvik Sanicro 41 Superheater tubes, very good resistance to stress corrosion cracking in acidic media such as sulphuric and phoshoric.
Sandvik 4C54 Sulphurous gases, recuperators, thermocouple protection tubes. Ferritic. Up to 1100oC in air. Sandvik 7RE10 Good oxidation resistance. Up to 1100oC in air. Sandvik 253 MA Very versatile; furnace tubes, recuperators, heat treatment furnaces. Up to 1150oC in air. Sandvik 353 MA Ethylene and petrochemical furnace tubes, recuperator tubes. Up to 1175oC in air.
Sandvik Sanicro 31HT Furnace tubes, pigtails and headers for synthesis gas production, fluidised bed combustion. Up to 1100o C in air. Sandvik Sanicro 70 Vinyl chloride plants, furnaces. Up to 1175oC in air.
19
Sandvik Mater ials Technology SE-811 81 Sandviken, Sweden, Phone +46 26 26 39 00, Fax +46 26 26 02 20 www.smt.sandvik.com
S-154-ENG. Mar 2004. For makom. Photogrofer : Ibr a Ibr ahimovic , Jr gen Svendsen, Mats Jonholt, Jan Car lsson, Jer nkontoret, Ekstrom & son. Pr inted in Sweden by Sandvikens Tr ycker i AB .