A modified 9-Cr alloy was developed by Oak Ridge National Laboratory, in early 1980s, to increase high temperature capabilities of ferritic steels for superheater tubing. The material improved high temperature creep properties by controlling alloying elements and microstructure. The material was added to ASME BPVC in 1983 (thru Code Case 1943) as Grade 91. Higher yield and tensile strength, in comparison to other low-Cr alloy steels (like Grade 22), allowed for fabrication of thinner component wall thickness. This in-turn reduced susceptibility to through-wall thermal stresses during transient events. Directionally this also reduced material costs.

Consequently, petrochemical industries have utilized Grade 91 in applications at Heat Recovery Steam Generation units (HRSG), Steam Methane Reformers (SMR), CO2 Boilers and as convection coils in Ethane conversion units.

Grade 91 material has complex microstructure and requires careful control of welding parameters to assure crack free welds that provide adequate creep ductility and retain creep strength at high temperatures. The current guidelines documented in API 582 and Technical Report 938 provide limited insights on success factors for weldability.

Grade 91 material use has been growing in the recent past Petrochemicals Complex and in offshore applications, at once-throw steam generators (OTSG). The aim of this paper is to share experience on welding parameters. Guidance needs be adjusted to specific projects and repair activities.

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