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I used a lot of keyways where alignment was not critical, the loads were low, and failure didn't destroy the device. Otherwise it was splines.

Yes, this is a real calculus problem. It will start very fast, and slow as the you reach the endpoint. For much of the process it will limited by sonic velocity, steam can expand faster than that.

as to your second question, if you are building this up then it is still a 3 pass weld. All of the rules about interpass temperatures and inspection will still apply.

While oxygen is the biggest concern for corrosion of boiler tubes there are also problems associated with CO2 (lower pH) and nitrogen in the system. So even in plats running OT there still may be a need for some DA during certain phases of operation.

CSCC cannot start unless there is active corrosion. But once corrosion starts the actual conditions dictate which will be faster, SCC or pitting.

But even with 100% condensate return it is likely that there are air leaks in the condenser and you still need to DA. I have yet to see a condenser with prefect sealing and perfect non-condensable removal.

What does the equipment builder say? What about asking your LVL III? It isn't can you do it, but can you calibrate and get a good S:N so that you have a useful test.

Sounds like you are closer to the conditions in a wind tunnel than a typical drying oven.

And how much testing have you done?

I have seen blowdown water that would eat 304 or 316 in short order. Talk to your water chemistry guys. And always assume that they will run higher concentration (more cycles) than they tell you.

Size, flow, temp, above/below ground, and water chemistry are a place to start. I have seen these systems range from no big deal to a real chemistry lesson. One good thing about GRP is that you have a choice of resins depending on service.

Because it depends on the pipe spec. Autogenous welded pipe has a different set of test requirements than pipe welded with filler. When you use filler there are a lot more variables involved. In the ASME world autogenous welded pipe and tube is material, those are not fabrication welds.

Don't go from 1yr to 5yrs in one step. If there is a slight change in conditions or if long term effects start kicking in you could be in a lot of hurt. Why do you want to extend this? You are shutting down for other reasons aren't you? How frequent are your major shutdowns?

H2S is chemically reducing, hence no oxygen. However the absence of oxygen will eliminate the ability for SS to re-passivate and pitting is virtually assured. Just remember that if this system is above ground and there is any leak you will get CSCC. If water can leak out then oxygen is getting...

Please clarify, the documentation shows that there should be zero water, but in actually you have various small amounts of water in the process. Is this correct?

the current ASM handbook is two volumes newer than yours. There also is an ASM specialty handbook on Al alloys that might help.

What density are you reaching? Is there any hydrogen in the process?

316 Aus SS is not an official designation for anything. I will presume that you mean S31600 which is commonly called 316 in its wrought form. A351 CR3M is a cast grade designation and the chemistries will be slightly different. Since you didn't refer to a specification for the wrought material...

bolt manufacturer identification markings Put this into your search engine and you can identify the manufacture.

Any of the major suppliers list this on their web sites.