Post on 15-Mar-2020
Grosskraftwerk Mannheim AG Investigations on Material Behavior and Condition
Assessment to Address Demands in Flexible Power Generation
44th MPA-Seminar 2018
Andreas Klenk, MPA University of Stuttgart Klaus Metzger, Grosskraftwerk Mannheim AG
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 2
Future needs in Developments for Energy supply
• A continuous process to reduce emissions was started worldwide • Different situations in the countries worldwide mainly depending on a
more or less saturated demand (as in Europe) or growing energy markets (as for example in India)
• All energy options have to be used to come to an highly effective mix in energy production based on the individual situation in a country.
• Energy options are related to old and new technologies, old technologies must be optimized as far as possible with respect to emissions and efficiency
• A realistic schedule defining intermediate steps of technological developments based on realistic assumptions for the time needed to achieve completely emission-free techniques
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 3
Where we are: Development of a changing energy mix
Past - Present Intermediate Future
Expected Load Profile in the near Future
Large power plant ressources designed for different load profiles
Large power plant ressources still needed - highly flexible
Base Medium Peak load Smaller usage – no categories
<
time
Load Profile 2008
Week Week
?
Future
Renewable
Conventional
Mo Tu We Thu Fr Sat Sun
Pow
er /
GW
2018
„Zero-Emission“
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 4
Where we are: Research directions
Intermediate Future Expected Load Profile in the near Future
time
Load Profile 2008
?
Future
2018
Strategy:Efficiency CO2 capture Materials for 700°C (Creep)
Development of storage systems Improvement of infrastructure
Increasing flexibility Design for small usage and accelerated startups, shut downs and load changes Materials for Creep-Fatigue
Further development of new technologies: CSP, PV, Wind…
Past - Present
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 5
Agenda
Introduction - future needs ?
Concepts addressing demands for future plants
Where are we going to in the next 20 years? Technical efforts for qualification of materials for flexible fossil power plant operation: - Characterisation of in-service material - Assessment of creep-fatigue loading - Simulating real conditions: Test loop operation
Summary and Conclusions
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 6
Design Study PP4F (power plant for future)
• Design for 3500 hours operation per year, 360 starts per year, high efficiency ~ 50%
• A-USC Steam Generator Technology for Highest Efficiency and Highest Flexibility
• Advanced boiler material concept • Advanced heating surface arrangement concept
and temperature control concept • Partially indirect firing system • Solid fuel start-up firing system with staged ignition
(with micro-oil, micro-gas or plasma) • A-USC Steam Turbine Technology
• Advanced turbine material concept • Optimisation of thermal processes
and inclusion of intermediate storage systems (steam, water) as heat storage to easen start-ups and decrease the minimum power for operation
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 7
Boiler Sketch & Materials
ECO
RH1
RH2
SH3
SH4
RH3 SH5
SH2-grid
SH1 wall
Evaporator wall
SH5 RH3
SH1 wall outlet: 544°C
Evaporator outlet: ~500°C
Hot reheat steam: 721°C Live steam: 703°C
Steam Temperatures (BMCR) Headers
Inlet: 15NiCuMoNb5-6-4 (WB36)Outlet: 15NiCuMoNb5-6-4 (WB36)
Inlet: 13CrMo4-5Outlet: X10CrMoVNb9-1 (P91)
Inlet: X10CrMoVNb9-1 (P91)Outlet: HR6W
Inlet: HR6WOutlet: NiCr23Co12Mo (A617mod)
Inlet: NiCr23Co12Mo (A617mod)Outlet: NiCr23Co12Mo (A617mod)
Inlet: SH5 HR6WRH3 NiCr23Co12Mo (A617mod)
Outlet: SH5 NiCr23Co12Mo (A617mod)RH3 Alloy740
Inlet: X10CrWMoVNb9-2(P92)Outlet: HR6W
HR6W7CrMoVTiB10-10 (T24)13CrMo4-5
Walls
ECO 13CrMo4-5
10CrMo9-10RH1 X10CrMoVNb 9-1
X10CrNiCuNb18-9-3 (S304H)
X10CrNiCuNb18-9-3 (S304H)RH2 X6CrNiNbN25-20 (HR3C)
HR6W
X6CrNiNbN25-20 (HR3C)SH3 Sanicro25
NiCr23Co12Mo (A617mod)
NiCr23Co12Mo (A617mod)SH4 Alloy 740
RH3 SH5
SH2-grid Sanicro25
SH5Alloy 740
RH3NiCr23Co12Mo
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 8
Improvement of dynamic behavior
Hot Start
Load Change 100%-25%-100%
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 9
PP4F reduction of emissions concept for flue gas treatment
NH4OH Pressurized air
Air, calcium hydroxide..
Preheating of feedwater
steam
Chalk, limestone, oxidated air, process water
Fly ash
gypsum Waste water
[1] [2]
[3]
[4]
[5]
[6]
Pressurized air]
[8]
[9]
fuel
7,4MWth T1 °C T2 °C
Rauchgas 49 64
Wasser 130 97
NOx : 10 mg/m³ dust: 2 mg/m³ SOx : 10 mg/m³ Hg : 1 µg/m³
Challenges and solutions:
DeNox (Selective catalytic (SCR) Dedusting Desulfurization (2 loop) Mercury
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 10
PP4F Outcome
• This design study delivered a concept for a both high efficient and most flexible fossil power plant:
• Optimised process with increased start-up and load change rates – process and component design to avoid thermal stresses
• Inclusion of internal heat storage systems
• Improved control and monitoring systems
• Material concepts for boiler and turbine design
• Although designed for 700°C the main results of the study can be transferred to other (lower) temperature ranges
• Means to optimise the the conflict of the targets “efficiency” and “flexibility” have been identified
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 11
Agenda
Introduction - future needs ?
Concepts addressing demands for future plants
Where are we going to in the next 20 years? Technical efforts for qualification of materials for flexible fossil power plant operation:
- Characterisation of in-service material - Assessment of creep-fatigue loading - Simulating real conditions: Test loop operation
Summary and Conclusions
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018
Creep Rupture and Fatigue initiation of ex service material
Research project on residual life of material near or over end of lifetime
Stra
in A
mpl
itude
%
Cycles to crack initiation NA
Ex service Simllar melt initial state
Bend from Mannheim power plant Unit 7 Comm. 09/1981, Replaced
09/2013 Service hours > 239 000 h Starts: 585 245 bar 530 °C
Crack initiated running
IfW Darmstadt
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018
Creep Rupture and Fatigue initiation of ex service material
18 19 20 21 22 23 2410
100
1000
Laufend
Betriebsbeanspruchter Rohrbogen 530 °C 550 °C 575 °C 600 °C
Quasi-Ausgangszustand 530 °C
DIN EN 10302 DIN EN 10302 +20% DIN EN 10302 -20%
C = 22X20CrMoV12-1
Ze
itsta
ndfe
stig
keit
Ru
in M
Pa
Larson-Miller Parameter PLM
Cre
ep R
uptu
re S
treng
th
MP
a
Ex service bend
Regenerated initial state
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 14
Overview - Design and Life Assessment
Codes and Standards Numerical Methods / CDM
Dat
a
Creep Rupture Life Data Extrapolation/Scatter Remaining life
Creep Damage Development Damage Parameters Metallurgical findings
Fatigue Damage Crack Initiation Curves
Life
Ass
essm
ent
Met
hods
Effects to be considered Loading Environment Multiaxial effects Relaxation and stress redistribution Inhomogeneous Material Behavior Welds Operational Data
Rules based on Time Fraction Ductility Exhaustion
Bas
e
Damage accumulation
Rainflow analysis Stress level categories Simplified methods
Applicability ? Derivation of representative loading schemes
Calculation of Stresses and Strains – Deformation Models Inclusion of Damage models
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 15
Subproject 1
Inelastic stress calculation
Improved and easy to use calculation
procedures for components
Subproject 2
Subproject 3
Evaluation of welded joints
Thermal Fatigue Evaluation
Creep Fatigue Interaction
Component Tests for Validation Standzeit
Creep Fatigue Evaluation concept
Boundary conditions Calculation concept Experimental validation
Testing
Determine Para-meters Heat transfer Calculation procedure
Establishing calculation procedures incl. stress redistribution Guidelines for welded joints
Fatigue Design curves
Bilfinger Piping Techn.
TÜV Nord Bilfinger Piping Technologies
Behavior of welds (exp. and num.)
Standard Solutions Experi-mental Validation
Stress and strain evaluation Calculation procedure
Research Project: VGB Calculation Procedures
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 16
Qualification of new materials
Development and qualification of new manufacturing methods
Development and qualification of new design and life assessment methods
Development and qualification of new monitoring methods
PLANT
Basic R & D
Transfer to Plant: • Validation • Optimization • Experience real practice conditions: Components with loading conditions Manufacturing defects…
Test Loop – Field Test
Test Loops Working platform (Reallabor)
Test loop: platform for the synergetic combination of scientific and industrial skills and direct transfer of results/knowledge to partners involved
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 17
Background - Previous work
The HWT II – Test Loop is a unique platform for Testing and Approval of thickwalled components with regard to manufacturing and service issues under real plant conditions
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 18
Background: Operational Experience from HWT II
- Parallel to plant service - 9.900 h service @ ϑ > 700°C - 2638 thermal cycles - Significant Damage in Key Components
Determination – Comparison - Validation
Successful Test loop operation
4400 4600 4800 5000 5200 5400
400
500
600
700
Tem
pera
ture
°C
Time s
Steam temperature Inner wall temperature
450s Haltezeit @ 520°C
Inner wall temperature 550°C
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 19
Test loop (Focus on existing plants)
620°C
Steam injection
Water injection
Investigate effects of flexible operation of USC-plants on components made from existing martensitic steels and new materials
Cyclic operation ≈ 620-380-620°C
• Improvement of standardized design and life assessment procedures
• Remaining life assessment of existing plants – development of operational strategies
• Material qualification for high efficiency with operational experience under cylic loading
• Creep Fatigue behavior of components
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 20
HWT III Basic Ideas
• Installation of new materials into the existing HWT II – test rig
• Basic Lab Tests on new materials under static and cyclic conditions
• Investigations on deformation and damage of components in the loop
• Implementation of new materials (HR6W) for valve manufacturing
• Implementation of new austinitic materials in the new superheater
• Investigations on oxidation resistance and thermal barrier coatings
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 21
Materials and Operation
Materials: – HWTII: A617B, A263 – HWTIII: P92, HR6W, A617B, A263,
A625, Coatings Temperature: 725 °C Temperature Cycles:
– HWTII: 720 °C – 400 °C – 720 °C – HWTIII: 620 °C – 380 °C – 620 °C
Operational Targets:
– HWTII: 14 cycles per day / 10 000 hours operation @>700°C
– HWTIII: 3-4 cycles per day with increased holding time / Operation: 2,5 years
3-4 Zyklen pro Tag
HWTIII
620°C 520°C 620°C
620°C 380°C 620°C
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 22
Key Components and Damage Assessment
Application and modification of standardized life assessment procedures, Constitutive Equations for Deformation and Damage
Constitutive and creep equations to describe the material behaviour Validated life assessment models
𝐷𝐷𝑓𝑓 =𝑅𝑅𝑉𝑉
Ω 1 − 𝐷𝐷 𝛼𝛼1
∆𝑝𝑝2
𝛾𝛾+1
𝛾𝛾 + 1d𝑁𝑁 �̇�𝐷𝑐𝑐
=𝑅𝑅𝑉𝑉
1 − 𝐷𝐷 𝛼𝛼2
𝜎𝜎𝑣𝑣,𝑀𝑀
𝜆𝜆𝑟𝑟𝐻𝐻 𝜀𝜀𝐼𝐼tot
ASME RCC-MR R5 Lemaitre DIN EN
Damage envelope
material-
Depen-dent
material- dependent
material- indepen
dent
Material-indepen-
dent
material indepen
dent
Simulation inelastic inelastic inelastic inelastic elastic
Alloy 617 m
r = 3 mm
Na / - 23 197 384 318 1885
Alloy 263 r = 3 mm
Na / - 106 536 1703 770 5336
Alloy 263 r = 10 mm
Na / - 1003 1768 2758 2224 7406
Applicability of life assessment procedures
Damage models (Lematire)
Results:
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 24
Cyclic Range (380°C-620°C) Materials: HR6W and P92 - Dissimilar welds
Pipe Dimensions OD219x50mm
A617B
P92 Oxidation protection coating (Vallourec)
6
HR6W
380°C = f (ps + ΔTSicherheit)
Header (P92) – bore holes and connection tubes
P92-Component with reduced wall thickness
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 25
100 1000 10000 100000
50
75
100
125
150
175200225250275300
WSF=0.65
4
4
4
4
laufender Versuch
1
1
Bruchlage:1: GW3: SG4: WEZ
(4 + SL)
(4 + SL)
(SL)
SV VM12/Alloy 617, Probe (dickwandig) SV VM12/Alloy 617, Probe (Kesslerohr) SV VM12/Alloy 617, Bauteil (dickwandig) SV VM12 artgleich, Probe (UP dickwandig) E911, Mittewert (ECCC,2005) +/-20% Mittelwert E911 VM12, GW, Schmelze 1 VM12, GW, Schmelze 2 VM12, GW, Schmelze 3
VM12, T=625°C
RutT (MPa)
t (h)
Dissimilar welds VM12 – Alloy 617 Similar welds VM12 Base material (E911) Base metal tests
Fracture in fusion line Type 4 + fusion line crack
COST 536
• Creep strength of dissimilar weld is smaller compared to similar joints • Different damage mechanisms, interaction of damage mechanisms • There is no distinct dependence from stress level • Fusion line cracking was also observed under cyclic loading conditions • Local stress and strain distribution must be optimised to avoid failures
Investigations on mechanisms and causes are necessary
Dissimilar welds
Grund-werkstoff, 2%Cr-Stahl
Fusionline
HA
Z, 2%C
r Weld material Alloy 617
Base material , 2%Cr-steel
Iinner surface
Outer surface
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 26
Benefits and expected results • Modification of an existing testing platform cost reduction by using
existing infrastructure and continued use of parts (test continuation) • In the static part this enables the investigation of microstructural
changes and thereby induced changes in the material behavior This findings can also be used for other application temperatures Application, test and approval of PP4F results • Use of the unique possibility of to perform cyclic „tests“ and approval
under plant service conditions (Acceleration in time is possible) Both parts are useful for different purposes and interest groups • Static part delivers information at low costs for Longterm behavior, new materials, coatings Benefit for OEMs
• Cyclic part delivers important results for life assessment issues under flexible operating conditions
• Benefit for utilities, manufacturers Maintaining a testing platform for future application and inclusion of other energy sources and storage systems for future actions supporting the energy change.
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 27
Summary and Conclusions • Global demand on energy is growing – further development of all existing
technologies is necessary What we have • Data base, knowledge and experience on materials for A-USC plants from various
programs including test loops • Specific experience on components under plant conditions Assessment methods,
knowledge of damage behavior, validated for specific • Design study taking into account flexible operation We need • New ideas on operation, concepts and design of highly flexible plants to fulfill the
demands of next 20 year´s needs of energy supply • Further investigations on behavior of materials and components under flexible
operation (specificly creep-fatigue behavior, dissimilar welds) • Improvement of design and life assessment methods and standards with respect to
increased cyclic damage • Validation of further developments and numerical assessments under real conditions Efforts for further development of A-USC power plant technology are necessary to reduce CO2-emissions in the intermediate future
A. Klenk, K.Metzger 44th MPA-Seminar, Stuttgart October 17-18, 2018 28
Thank you for your attention!
HWT2 was funded by the Federal Ministry of Economy (BMWi) under grant No 03ET2017 and an industrial consortium of material and plant manufacturers and utilities. PP4F was funded by BMWi under grant No 03ET7044
The contributions of PP4F partners are especially acknowledged: R. Dobrowolski, A. Helmrich, T. Steck, GE Power F. Stahl, Bilfinger Piping Technology J. Lerche, Steinmüller Babcock Environment O. Reismann, G.Keck, ABB H.C. Schröder, TÜV Süd
ACKNOWLEDGEMENTS