34, 2010
Keywords
ABSTRACT
Operators of geothermal resource production and power generation facilities face a large number of technological challenges,
not the least of which is optimizing the performance of the various
materials of construction. With regard to metallic materials, degradation mechanisms include pitting corrosion, general corrosion,
erosion, various forms of stress corrosion cracking, embrittlement,
fatigue, and potential for exposure to large strains from seismic
activity. In many cases, the welded connections represent a possible weak link in the chain of mechanical integrity. In other
cases, welding represents a form of life jacket that can cost effectively increase the service life components by either reducing
the rate of degradation or restoring the integrity of components
that are already degraded.
This paper describes the ways in which welding can inadvertently promote accelerated degradation of welded fabrications
in geothermal service and approaches toward minimizing the
susceptibility to those forms of welding-related degradation. The
approaches include optimizing the selection of weld filler metals,
careful control of welding procedure parameters including heat
input, and using beneficial surface treatments or postweld heat
treatments in selected locations.
Methods of using welding to extend the serviceability of degrading components include the use of welded cladding, including
conventional metallurgically-bonded weld overlays of corrosion
resistant alloys, and techniques originally pioneered by other
industries, including use of corrosion resistant alloy wall paper
lining and direct deposition welding.
Finally, this paper describes advances in weld cooling rate
modeling that have resulted in the development of user-friendly
software that allows staff to optimize welding procedures intended
for use on in-service, pressurized piping. The models allow users
Alloy
System
Feature
Degradation Mode
Localized corrosion
Localized corrosion
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zones[1][2]. Even though the composition of the weld heat affected zone is the same as the composition of the adjacent base
metal, the different microstructures in each area have different
resistance to corrosion. The effects of microstructural differences are difficult to eliminate, although microstructures can be
influenced by adjusting weld procedure heat inputs, interpass
temperatures and, when necessary, postweld heat treatment
(Figure 1). For steel assemblies that are stress relieved after
welding, the stress relief heat treatment can also produce some
beneficial modification of weld zone microstructures in addition
to relieving stress. Note, however, that the corrosion resistance
of many CRAs (corrosion resistant alloys), including most
austenitic stainless steels and some Ni-Cr-Mo alloys can be
significantly degraded by exposure to stress relief temperatures
typically applied to mild steel and low alloy steels. For those
alloys, postweld heat treatments designed to solution anneal
the weld zone are preferred, but are generally impractical and
uneconomical to perform in the field. Solution annealing is
sometimes performed as part of manufacturing since it not only
makes the HAZ microstructure more similar to the base metal
microstructure, but it also improves the corrosion resistance of
the weld metal by making the distribution of the alloying elements within the weld metal more homogenous.
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Even if the base metal and weld metal deposits have adequate
corrosion resistance, designers need to be aware of the effect of
welding on the susceptibility of some alloys to stress corrosion
cracking. Stress corrosion cracking relies upon the simultaneous
presence of a susceptible alloy, specific environmental conditions,
and an adequate level of tensile stress. Since the residual stress
at a weld can often approach the yield strength of the metal, the
residual stress from weld metal solidification and shrinkage, or
the stress concentration associated with welded connections can
be enough to cause stress corrosion cracking that would not occur
remote from the welds. In the absence of stress relief heat treatments it is difficult to ensure that the stresses at welds are below
the threshold to avoid cracking. Therefore, the preferred solution
is to avoid using susceptible alloys. Alternatively, ensure that the
process upset conditions or transient conditions do not produce
the environmental characteristics needed to produce cracking.
Examples include limiting chloride carryover into steam and
ensuring the absence of oxygen intrusion into neutral pH brine.
However, maintaining strict control on the environment is not
always easy or reliable. Single upsets can have long lasting effects o material performance.
Figure 2. Transverse cross section of a welded Ni-Cr-Mo alloy pipe showing intergranular cracking of the HAZ after excessive weld heat inputs
caused intergranular carbide precipitation. The weld metal deposit was
located immediately to the left of this photograph. Shown approximately
12x magnication, polished and unetched.
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Conclusions
Weld zones represent metallurgically inhomogeneous areas of
a fabrication that can be susceptible to localized degradation from
increased susceptibility to corrosion or cracking. On the other
hand, repair by welding can enable geothermal operators to extend
the serviceability of degraded fabrications exposed to aggressive
environments. In addition, for new construction of geothermal
facilities welding can cost effectively improve the corrosion or
erosion resistance of localized areas of piping, pipe components
and vessels where use of full-thickness corrosion resistant alloy
pipe or plate can be impractical or uneconomical.
References
1. Amend, B., Considerations in the Testing and Selection of Materials for
Corrosive Geothermal Environments, Geothermal Resource Council
Transactions, 2009, v.33 p 633-637
2. Smart, J. , Weld Corrosion in Lines Deserves Closer Attention, Pipe Line
& Gas Industry, June 1996
3. Thornton, C., Cooper, C, Overmatching Superalloy Consumable
Inco-weld 868CPT Broadens its Applications to Include Welding
Superaustenitic and Super Duplex Stainless Steels Stainless Steel World
2004, KCI Publishing, 2004
988
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989