Typically you explosive bond, then you SR the steel (not the alloy), and then you fabricate.
Usually with Ni alloy overlay the SR temp for steel will not stress relieve the alloy.
If they did the weld and extracted a coupon of the 625 for testing the SR of the steel is irrelevant.
So you have a...
Are these HT after forging?
If they are then just HT a piece of the original bar stock along with them and use that for testing.
Either way it sounds like sub-sized bars.
I stopped reading after the materials list, thermal expansion is a big deal.
From RT to 390C, let's assume an 8m long unit. the expansion would be:
Shell - 39mm
overlay - 56mm
Tubes - 46mm
As for construction I would recommend against using captive bolts is corrosive service.
You might be able to pick some up in the home canning department of your local hardware or farm supply store.
I would start with 10% citric at 120F.
Give it 15-20 min and see if it is loosening up.
You may need to go longer, you may also need to go hotter (up to 150F).
1. HT the coupons in the same production furnace is nuts. This what calibrated lab furnaces are for.
2. The stress argument is nuts. You anneal and machine, then age. The aging treatment is an an effective stress relief.
Of course using H900 or 925, or even 950 is very risky. The tensile...
phosphoric, citric or straight nitric acids will not attack the SS but should attack some of the products of corrosion.
After all you just need enough attack to allow you to get it apart.
Then you can really clean things.
I (like LI) think that this is likely a piping layout issue.
Do you know your flow rate?
Do you have pump curves corrected for density and viscosity?
Are you actually near BEP?
As a guess (it depends on the system curve) two pumps would be running about 36Hz.
OK, test pieces in with parts will see longer times at temp, but the temps are the same.
Or you can strap the samples to an actual piece so that they heat more slowly.
Times are not super critical.
We used to do both.
HT some samples in the lab and some with the parts.
Served to verify both the material and the HT.
And nitrogen is not an inert atmosphere.
The alloy will absorb some at the annealing temp and it mess with the phase balance.
Some harmonic noise actually causing higher temp, but I would wager that part of this is noise on the temp sensors.
What is the measured temp 10sec after you turn the VFD off?
If your goal is to condense inside the tubes then you need larger diameter tubing, usually over 1.5" for this use and sometimes as large as 3".
You do this because you need to make sure that you can never get slug formation.
I can't find the paper now but in the old days Avesta published data on...