700°C PLANT VISION OF HIGH EFFICIENCY AND CLEAN ENERGY ... C Plant... · Basic Research...

700°C PLANTVISION OF HIGH EFFICIENCY AND CLEAN ENERGY PRODUCTIONMPA - GKM EXPERTISE ON MATERIALS AND COMPONENTS

Status of Advanced Ultra Super Critical Power Plant designed for operation at700°C in Germany

•Project Information GKM HWT II, March 05, Venice

Overview

1. General introduction

2. Overview about R&D in Germany (Europe)

3. Detailed information about ongoing basic R&D

4. Detailed information about field tests

5. Conclusions


GKM – MPA Vision

• Higher efficiency by increasing• steam parameters using

new materials • CO2 capture

700°C Power Plant

GKM:Test loopsMPA:Scientific investigations on material and component qualification

30

35

40

45

50

55

1950 1960 1970 1980 1990 2000 2010 2020

Time

η [%]

Intro

duct

ion

of th

eO

nce-

Thro

ugh

Tech

nolo

g y17

5 / 5

40 /

540

1st S

uper

criti

cal U

nits

acc

ordi

ngto

the

Slid

ing

Pres

sure

Prin

cipl

e

(240

- 28

0 ba

r Eva

pora

tor P

ress

ure)

250

/ 550

/ 57

0

350

/ 700

/ 72

0

260

/ 580

/ 60

0

280

/ 600

/ 62

0

Introduction


Overview

1. General Introduction GKM – MPA





700°C Power Plant – R&D


Actual situation:

Vattenfal: Oxyfuel project realized, but stoppedRWE: IGCC plant not yet startedEON: 700°C Demo Plant postponed

Material qualification programs and field tests (test loops) shall form the basis for the possible realization of the 700°C power plant



Projects in Europe on 700°C Technologies

EU-FUNDED PROJECTS

NATIONAL FUNDED PROJECTS

700 ° FIELD TEST RIGS


Marcko / COORETEC projects

002 606px

Boiler applicationMARCK0 700 Material qualification for the 700/720 °C power plant

DE-1 Fireside corrosion and steam side oxidation behavior of materials for 700°C power plant

DE-2 Characterization of superheater materials after cold deformation

FDBR02 Qualification of pipes with longitudinal welds made of Alloy 617

DE-4 Characterization of strength and deformation of pipes and forgings made of Ni-based alloys

725HWT Investigation of the long term service behavior of tubes for the future high-efficiency power plant

Turbine applicationDT-3 Qualification of dissimilar welds between 10%Cr-steels and Ni-based

alloysDT-4 Procedures and Fracture mechanics approaches for life assessment

of components operating in high temperature regime

Turbine and pipe work applicationTD-1 Optimization of non-destructive testing methods for thick walled

components made of Ni-base alloys


Overview






Basic Research

Nickel based alloys:

▪ Experience from gas turbine and other applications (mostly thin walled structures)

▪ Different material structure (grain size, precipitation) and mechanical behavior (stress-strain relation, thermal expansion and conductivity)

▪ New alloys (Alloy 263, Alloy 740) long-term qualification (e.g. ageing, creep rupture) not sufficient


Basic Research

Nickel based alloys:▪ Susceptibility to weld cracking is higher

– Hot cracking– Reheat cracking / ductility dip cracking– Strain age / stress relief craking

• Appropriate welding processes with regard to heat input and interpass temperatures are required

• Higher efforts in terms of quality assurance are necessary


Basic Research

Weldabilityprocedures, consumables

InspectabilityNDT methods

considering aspects of costs, quality and reliability

Component qualification and testingDemonstration of Manufacturability

Good yield during processingof several product forms (rotors, discs, pipes, tubes..)

Workabilityhot workability for forging, extrusion and hot rollingcold workability – tube reducing, cold drawing, drawing to wire


Basic Research

• New scientifically proved ambitious methods for design to precisely determine safety margins

• Simulation of the component life time covering complete load history including new non-destructive test methods to demonstrate risk of failure

• Validation by means of component tests

Component qualification and testing - design


Basic Research

LCF behavior - Comparison between different grades of Ni-based alloys

2,5

1,5

2,0

1,0

0,5

0,2510 100 1000 10000 100000

Cycles to crack initiation NA

Stra

in a

mpl

itude

% Alloy 740

Alloy 263Alloy 617

Test temperature: 700°CR=-1d/dt=6%/min

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500-800

-600

-400

-200

0

200

400

600

800

Stre

ss /

MP

a

Number of cycles / -

•Cyclic softening

Alloy 740 and 263 show better LCF behavior than Alloy 617

0 500 1000 1500 2000 2500 3000 3500-600

-400

-200

0

200

400

600

Stre

ss /

MP

a

Number of cycles / -

•Cyclic hardening

0 5000 10000 15000 20000 25000

-600

-400

-200

0

200

400

600

Stre

ss /

MPa

Number of cycles/ -

•Cyclic softening


Basic Research

Material qualification in order to fulfill the requirements of PEDDesign data (focus on long term data of base material and cross

welds – creep, creep-fatigue, fatigue characteristics)Mechanical behavior including ageingPhysical propertiesFracture mechanics dataEvaluation of time and load dependent microstructural changes

and the relevant damage mechanismsCreep laws, unified material models, damage hypothesis

700°C Technology - Deliverables of COORETEC projects:


Basic Research

Demonstration of manufacturing (bending, welding..) of components

Corrosion / oxidation behavior of boiler materials

Quality assurance aspects – application of NDT

Advanced design based on inelastic Finite Element calculation (constitutive creep laws, damage hypothesis, influence of multiaxiality, fracture mechanics)

700°C Technology - Deliverables of COORETEC projects:


Overview







COMTES700

COMTES+

ENCIO HWTII

700°C Demo Plant

Component tests in a

commercial power plant

Demonstration plant (GKM)

HWTI

Component tests in a

commercial power plant

(design phase)

COORETEC MARCKO Material Qualification Lab tests

2011

2015


R&D Partner

002 606px

•Gruppe

•Schweißtechnische•Lehr- und Versuchsanstalt

•Mannheim GmbH

Research Organisation:MPA Universität Stuttgart (MPA)

Power Plant Manufacturer:Alstom Power Boiler (APB)Alstom Power Generation (APG)ABB AG Division EnergietechnikBopp und Reuther Gruppe (B&R)Essener Hochdruckrohrleitungsbau (EHR)Kraftanlagen Heidelberg (KAH)Klein, Schanzlin & Becker (KSB)Burgmann Industries GmbH & Co KG (BIG)

Inspection Authorities:TÜV SÜD Industrie Service GmbH ereich Anlagentechnik (TÜV SÜD)Schweißtechnische Lehr- und Versuchsanstalt Mannheim GmbH (SLV)

Utiliities: Grosskraftwerk Mannheim AG (GKM) EnBW Kraftwerke (EnBW)MVV Energie (MVV)VGB PowerTech

Investigation of the long term service behavior of tubes for the future high-efficiency power plant

„HWT 725“


725 HWT GKMSteam Flow Diagram

008 702px

530°C170 bar

Flue gas temperatures up to. 1200°C

Control valvesReduction of pressure 165 20 bar

Mixing piece

725 530°C725°C

Test loop SuperheaterH

eade

r in

sula

tion

Creep test loop 1630°C

Boiler wall

530°C~20 bar

Creep test loop 2725°C

630°C

From SH 4

From SH 3

~ 390°C~172 bar

To HRH-IIpipe

P PTT T IP

•T

T

Unit 6, Boiler 17

Periodical start upand shut down

Flue gas corrosionSteam oxidationMicrostructural changesWelds (similar, dissimilar)Erosion by sootblowingDesigned lifetime 200 kh

Steam oxidationMicrostructural changes and damageLife time assessment and MonitoringDesigned lifetime 50 kh notched/reduced wall thickness

DesignOperational reliabilityMonitoring and repair


GKM 725 HWTData

121 255p

Original Design Data at 100 % load

• Steam flow: 0.33 kg/s

• Steam conditions at the inlet: 166.5 bar / 530 °C

• Steam conditions at the outlet: 156.0 bar / 725 °C

• Flue gas temperature: approx.1260 °C

• Tube dimensions: 38 x 8,8 mm

• Tube length (heated): approx. 35 m


Internal superheater test loop

SH 1 - Outlet

SH 1 - Inlet

SH 2 - Inlet

SH 2 - Outlet

SH 1

SH 2


External test loops

External creep test loop

Assembly of the PRVsExternal turbine materials test loop


Overview Materials

outlet : ca. 585°C outlet : ca. 630°C outlet : ca. 680°C outlet : ca. 725°C

Superheater 1.1 Superheater 1.2 Superheater 2.1 Superheater 2.2T 92 Super 304 H SB DMV 310 N 1.1 Alloy 617 mod

VM 12 SHC Tempaloy AA1 SB HR3C Sumitomo A617

Tempaloy AA1 SB DMV 304 HCu SB HN 55 HR6W

Super 304 H SB TP 347 W (XA704) SB Sumitomo A617 HR 35

DMV 304 HCu SB Tempaloy A3 Sanicro 25 (Alloy 174) Alloy 263

HR3C NF 709 (22Cr-LC) HR6W Alloy 740

Star 304 H adv. DMV 310 N HR 35 Alloy 617 mod

SAVE 12 AD HR3C Alloy 617 mod

DMV 310 N Star 304 H adv. Alloy 263

Tempaloy A3 HR6W Alloy 740

NF 709 (22Cr-LC) Sanicro 25 (Alloy 174)

Sanicro 25 (Alloy 174) HR 35 Martensitic steels

Sumitomo A617 Austenitic steels

Alloy 617 mod Ni-Base Alloys

Internal superheater test loop


External Creep Test Loops

Reduced wall thickness circumferential notches

• Lifetime 50000 h• Measurement of longitudinal and hoop (creep)

strain• Observation of damage development• Observation of microstructural changes• Calculation of life time consumption creep

tests with specimens of the same heat

Operation based knowledge on deformation and damage behavior of key materials for 700°C PP


Creep and LCF tests – material qualification

Material (same heat) Max test time

Mod. SAVE 12 AD 23000

DMV 304HCu sp 17000

DMV 310N 17000

Sanicro 25 19400

Alloy 617 mod. 16000

HR35 9344

Alloy 263 24500

Alloy 740 (Schmelze B) 16000

Alloy 740 (GW) 22000

Loading time h

Stre

ss h

Load cycles

Stra

inam

plitu

de%

•a)

•b)

Inelastic FE simulation of external creep test loop


Data collation – Mícrostructure (as received, damaged)

Material: A617 mod Specimen: L2.1 Initial annealing sequence: Condition: Temperature: Load: --- Time:

Microstructure element: dislocations

Dislocation structure: Average Minimum Maximum

Dislocation density*inside grains

[ 109 cm-2]

6.4 1.4 17.7

Magnification of tracings: 100 000 times

Number of analysed features: 1219

Microstructure elements: precipitates ( 1 type predominant)

Particle type Inside Grains Grain Boundary

M23C6

´

M23C6

M6C

Particle size [nm]

Equivalent diameter de

Mean value

Minimum

Maximum

Number of particles

n.f.

n.f.

152 28

53

862

70

nf

Magnification: 25 k+50 k

Analysed area: 69.9 µm2

* determined by line section method

Material: A617 mod Specimen: L2.1 Initial annealing sequence: Condition: Temperature: Load: - Time:

Thinned metal foil

Grain Boundary: (TEM09_0690)

Dislocations: (TEM09_0686)

Grain Boundary: (TEM09_691)

Dislocations: (TEM09_673)

Remarks: No precipitates inside grains. Cr-Carbides on grain boundaries.

Quality assurance, damage evaluation


Deliverables Field test HWT I

• 725 HTW GKM project with several test loops serves as a test platform for materials for the future 700 °C power plant.

• Welding and bending was performed under typical conditions of usual boiler fabrication with previous optimisation for welding and bending.

• Detailed Quality Engineering strategy was developed in order to meet code requirements under detailed consideration of material behaviours

• Together with qualification, fabrication, operation and test programs in parallel, necessary experiences and material data will be generated to be used for the erection of the planned 700°C power plant in Germany

• Running successfully since October 2009 – operation time at 725°C: 12000 h


Follow up Projects

COMTES+

ENCIOGeneral: European project funded by RFCS Budget: 25.3 M€ ENEL power plant (Italy)Technical: Test of very thick walled components Examine COMTES700 repair concept Verify new production procedure

(HIP) Conditions for life time calculation

GKM HWT IIGeneral: German project funded by COORETEC Budget: 17.6 M€ GKM power plant (Germany)Technical: Cyclic test of components to examine

life time consumption (conditions for power plant flexibility)

Superposition of primary and secondary stresses

Content: Information exchange platform for ENCIO and GKM HWT IITest facilities for Nickel based alloys

Coordination: VGBParticipants: European utilities and suppliersDuration: 2011 - 2017


Follow up Projects

•Gruppe

•Schweißtechnische•Lehr‐ und Versuchsanstalt

•Mannheim GmbH

RWEEnBW

VattenfallEvonikE.ON

…

Investigation of the service and damagebehaviour of thick walled components for the

700°C Power Plant


Follow up Projects

Technical Aim:

Cyclic test of components made of Alloy 617 / Alloy 263 to examine life time consumption (conditions for power plant flexibility):

PipesPipe bendsWeldsValvesHeaders

Superposition of primary and secondary stresses effect on lifetime and thus the improvement of design procedures

Optimization of life time evaluation procedures by monitoring the time dependent damage


Follow up Projects

Flow Chart HWT II

Static load

•M•M

725°C

da = 219,1 x 50 mm

2,5 kg/s from BÜ 4

Combustion chamber 1200°C„Superheater Pipes“

•M

•M•M

Bypass

KZÜ steam

< 400 °C

PRDS

BÜ 3 steam

feedwater

530°C, 170 bar

Thick walled pipe„Cyclic Load “

feedwater

feedwater

❶Pipe + bend + weldPrim. Stresses from inner pressureSec. cycl. Stresses from hangers

❷Pipe + weldPrim. Stress from inner pressureTherm. gradient from simul. start‐up and shut‐down(injection ΔT ≈ 300 °C steam)

❹PRDS functionality

❺hangers, insulation

❸HT‐conditioning valvesDesign, reliable longtime operation

❷•Mass flow control •Set to 725°C/162 bar

❶Steam extraction530 °C

❸Bypass with PRDS


Final conclusions

HWT I and HWT II field tests has to be considered as the key for the realization of the 700°C Plant

Why?

To minimize the risk of premature failure by gathering operation experience

To have reliable safety margins by optimization of the component design

To have safe operation conditions by developing reliable monitoring concepts

Final conclusions


Final conclusions

Field tests have to demonstrate the feasibility of a 700°C power plant

Reliable data base

Optimized design

Optimized life time monitoring

FabricabilityQuality assurance

Advanced NDT

Knowledge aboutdamage mechanisms

700°CPowerPlant

Thank you for your attention

700°C PLANT VISION OF HIGH EFFICIENCY AND CLEAN ENERGY ... C Plant... · Basic Research...

Documents

Transcript of 700°C PLANT VISION OF HIGH EFFICIENCY AND CLEAN ENERGY ... C Plant... · Basic Research...