In refineries and oil and gas plants, air-cooled heat exchangers, so-called fin fan coolers, are fabricated from 22% Cr duplex stainless steels where type 300 series stainless steels would have problems with chloride pitting and chloride stress corrosion cracking (CSCC). Depending on application, limits are often specified for ferrite content and hardness (typically 35-65% for ferrite content and 320 HV maximum) during welding procedure qualification. Recent several cases of failures in hydroprocessing reactor effluent air cooler (REAC) system in refineries are now attracting worldwide attention to ferrite content and hardness in 22% Cr duplex stainless steel welds. In this study, welding trials were performed on 22% Cr duplex stainless steel UNS S32205 corner joints with different wall thickness similar to the top plate and tubesheet plate joint configuration used in a fin fan cooler header box. The effects of material thickness (15 mm, 25 mm, and 35 mm), weld heat input, and joint restraint during welding fabrication on ferrite content and hardness of the welds were evaluated. The results seem to suggest a need for careful re-evaluation of the upper limits of ferrite content and hardness for thick-wall 22% duplex stainless steel joint which are currently used.
Key words: Conference papers, 2017 conference papers, 22% Cr duplex stainless steel, welding, ferrite content, hardness, thick-wall