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Global Unit Generation
From the 600/620°C to the 700/720°C-USC-PP History and Status Dr M. Bader
Global Unit Generation
The Motivation
Global Basic Conditions for the Energy Industry
Environmental Impact Climate protection and new technologies
Economics Competition in the European Market
Security of Supply Resources, mix of power
production and political framework
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 2
Global Unit Generation
The Road Of The Development
30%
35%
40%
45%
50%
55%
1950 1970 1990 2010 2030
Net
effi
cien
cy
Nickel Base Alloys (365 bar, 705°C)
Austenites (290 bar, 600°C)
Ferrites and Martensite (260 bar, 545°C)
Possible Step
Materials for SH and RH
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 3
Global Unit Generation
700/720°C Boiler (Demo- 500MW)
88m
Ni base alloys: - Material data - Design by analysis - Manufacturing - Welding
[Hitachi Power Europe GmbH Duisburg]
High pressure part Steam rating 334kg/s; 1024t/h Allowable operating pressure (gauge) 390 bar SH-Outlet temperature 705 °C Reheater Steam rating 285 kg/s Allowable operating pressure (gauge) 81 bar RH-Outlet temperature 720 °C
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 4
Global Unit Generation
R&D from 2007 - 2012
Steam generator
Piping
Turbine
NDT
Valve cast
Simulation
Housing cast
NDT
Material Characterisation
Rotor
Creep
Corrosion
improved UT
Weld HAZ
Membrane walls Concept of
Reparation
Super heater Bending
Welding
Forging pieces
Embrittlement
Main steam piping
HR - piping
Valves, Forgings Pieces
Cold Working
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 5
Global Unit Generation
700°C Boiler - Material Concept
13CrMo4.5
WB36
WB36 13CrMo4.5
Alloy 617m
10CrMo9.10 T91 S304
Inlet
Outlet
HR3C Alloy 617m
HR3C Alloy 617m
Alloy 617m
Alloy 617m
Alloy 617m
Alloy 617m
Alloy 617m Alloy 740
Alloy 617m
Alloy 263
Alloy 174
P92
Alloy 617m headers
13CrMo4.5 T24 T92 Alloy617m
[NRWPP700, Variant A]
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 6
Global Unit Generation
700°C Boiler - Material Concept
[NRWPP700, Variant B]
13CrMo4.5 T24 Alloy 617m
WB36
WB36 P91 Inlet
Outlet
P92
Alloy 617m
Alloy 617m
Alloy 617m
P91
P91
WB36
P91 headers
16Mo3 S304
HR3C Alloy 617m
Alloy 617m
S304 HR3C
HR3C Alloy 617m
P92
P92
Alloy 617m P92
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 7
Global Unit Generation
Damage SRC…?
Crack initiation In the welding area: 1. Shrinking stresses (σres)
2. In the HAZ (heat affected zone) 3. At the outer surface
(stresses caused by bending) Crack propagation Mainly in the base material: 1. Steered by the stress
(no different between HAZ and Parent Mat) 2. Intergranular crack (IC)
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 8
Global Unit Generation
Relaxation Cracking At A617-Welds
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 9
Global Unit Generation
R&D Road Regarding The SRC-Behaviour
Properties
Tensile tests: CSR 10-5/s CSR 10-6/s
Bending tests: 3 point bending 4 point bending
Characteristic value
microstructure
Optical microscope
TEM
Description of Influence
Alloy and Heat treatment
Simulation
980°C / 3h
Homogenizing
Solution annealing
Composition
Investigation Scope of variation
Time scale
SEM
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 10
Global Unit Generation
Welding: Influence of PWHT on Alloy617
• Welding = Casting = Shrinkage Stresses
• Heavy-walled a Stress Relief Annealing is necessary
• Normal Hardening of Nickel Base Alloy at 700°C (no plastic relaxation over
dislocation gliding) and stress induced gamma prime formation in HAZ
Operating area Stress relief annealing
VDM-Werkstoffdatenblatt Nr. 4119 (Januar 2005)
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 11
Global Unit Generation
Welding: Influence of PWHT on Alloy617 – Influence of Working Temp.
Working area
[Kirchhöfer, H. et al: Precipitation Behaviour of Hastealloy X and A617 (1984)] M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 12
Global Unit Generation
Status Of The Welding Technology For A617
Virgin material: As-delivered condition: solution annealed After welding: stress relief heat treatment (SRHT) 980°C/3h
For repair: Before welding:
Variant I: 980°C/3h (removal of γ’-phase) – necessary Variant II: 1160°C/1h (additional -removal of carbide-precipitations at grain boundaries ≅ reset the material structure in the initial status) – better weldability (however a challenging heat treatment)
After welding: stress relief heat treatment (SRHT) 980°C/3h
Remark: ongoing, tests of the repair methods in test rig “Enzio” and additional investigation programs
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 13
Global Unit Generation
Résumé
The classic process is technologically limited.
The main increase in efficiency is only possible with higher steam
temperature and afterwards with the steam pressure.
80% of R+D for the 700°C-PP is done.
No all solutions for the special technical questions are sophisticated.
History New technical levels brought also unexpected issues and failure.
M. Bader, From the 600/620°C to the 700/720°C-USC-PP (History and Status) 2013-03 14