materials technology to enable high-efficiency advanced

J. Shingledecker, R. Purgert, V. Cedro EPRI, EIO, NETL

“Advanced Technologies & Best Practices for Supercritical Thermal Power Plants.” Partnership to Advance Clean Energy – Deployment

(PACE-D) Technical Assistance Program (U.S. AID) November 21-22, 2013: New Delhi, India

Materials Technology to Enable High-Efficiency Advanced Ultrasupercritical (A-USC) Steam

Power Plants

2 © 2013 Electric Power Research Institute, Inc. All rights reserved.

U.S. Department of Energy (US DOE) / Ohio Coal Development Office (OCDO) A-USC Steam Boiler and Turbine Consortia

Castings

Fabrication

Field Test Forging

Welding

New Materials

Fede

ral –

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te –

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iona

l Lab

orat

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Non

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fit –

For

Pro

fit

Cos

t Sha

ring

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sort

ium


Increasing Steam Temperature and Pressure Increases Thermal Efficiency and Decreases Emissions

Note: HHV Basis

“Least Regret” Strategy for CO2 Reduction


40

60

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550 600 650 700 750 800

1100 1200 1300 1400

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Stre

ss (M

Pa)

Average Temperature for Rupture in 100,000 hours (oC)

9-12Cr Creep-Strength Enhanced Ferritic Steels (Gr. 91, 92, 122)

Nickel-BasedAlloys

Std. 617CCA617

Inconel 740

Haynes 230

Advanced Austenitic Alloys (Super 304H, 347HFG, NF709, etc.)

Haynes 282

Average Temperature for Rupture in 100,000 hours (oF)

Stre

ss (k

si)

Materials Limit the Current Technology

°

Steels = USC 620°C (1150°F)

Solid Soln’ = A-USC ~700°C (1300°F)

Age Hardenable = A-USC 760°C (1400°F)

Minimum Desired

Strength at Application

Temperature


Primary Technical Goals of US A-USC Materials Programs

• Materials Technology Evaluation • Focus on nickel-based alloys • Development of fabrication and joining technology for new alloys

•Unique Conditions for US Program Considerations • Higher-temperatures than Other International Programs (760°C versus 700°C) means additional alloys are being evaluated

• Corrosion resistance for US coals • Data for ASME code acceptance of new materials • Phase II Boiler work includes Oxycombustion


Comparison between two leading candidates: 740H & 617

Higher Allowable Stress for Inconel 740H = Thinner Pipe Walls


Higher-strength alloys provide an avenue for cost savings

704/704°C 732/760°C

704/704°C 732/760°C

If you have to pay for nickel, make the most of it!

Main steam and reheat piping comparison for 740H and 617 at

704/704°C


U.S. DOE/OCDO: A-USC Steam Boiler Consortium

2: Material Properties

3: Steamside Oxidation

4: Fireside Corrosion

5: Welding

6: Fabricability

7: Coatings

8: Design Data & Rules (including Code interface)

1: Conceptual Design

Develop the materials technology to fabricate and operate an A-USC steam boiler with

steam parameters up to 1400°F (760°C)

http://www.fwc.com/�

http://www.alstom.com/�

http://www.netl.doe.gov/main.html�


Most of the fundamental materials & fabrication work is complete for boiler materials

Basic Design

Welding Technology

Lab testing In-Plant Testing

Demonstrations for Fabrication

10 100 1000 10000 100000 100000010

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1000000 Grain Size < 100µm Grain Size > 100µm

Pre

dict

ed R

uptu

re L

ife (h

rs) -

eq.

1

Rupture Life (hrs)

Slope = 0.93

+/- factor of 2

Open Symbols = Ongoing Test

Long-term creep data & analysis

2µmMicrostructural Development


Extensive databases for long-term material behavior

20000 24000 28000

10074,000hrs (700oC)

617 Average 617 Stress -20% CC617

Stre

ss (M

Pa)

LMP C=20

617 + CCA617

64,000hrs (650oC)

Long-term creep strength of CCA617

10 100 1000 10000 100000 100000010

100

1000

10000

100000

1000000 Grain Size < 100µm Grain Size > 100µm

Pre

dict

ed R

uptu

re L

ife (h

rs) -

eq.

1

Rupture Life (hrs)

Slope = 0.93

+/- factor of 2

Open Symbols = Ongoing Test

Post-assessment test for long-term creep in 740/740H

Creep-rupture failure map for

HR6W Haynes 230 Welds

10,000 hr steam oxidation data Super 304H


In-Plant Testing: 760°C (1400°F) Operating Steam Corrosion Test Loop

• Phase 1 – Extensive laboratory testing – Air-cooled probes in boiler – Steam-cooled loop (high S coal)

• 2nd Steam Loop now installed and operating (8,000hrs+). – Planned duration extended until 2014 – World’s first steam loop operating at

760°C (1400°F) – Initial evaluations = little to no wastage

Prior to Welding Being Welded After Assembly

Fabrication in Alstom Chattanooga TN shop

Materials include:

740H, CCA617, HR6W, Super 304H, Coating, Overlays, and Others


Highlights: World’s First Inconel®740H Pipe Extrusion

• Special Metals (Huntington, WV) & Wyman-Gordon (Houston, TX) Project

not consortium funded • 15-inch (381mm) O.D. X 8-

inch (203mm) I.D. X 34-1/2 feet (10.4m) long

• Larger forging window for Inconel 740H compared to CCA617 (same size pipe extrusion was shorter, 8.9m) Inconel®740H Pipe after

Extrusion at Wyman-Gordon


Major Step: Code Case 2702 (Inconel®740H) now Approved (2011) for Use in Section I and B31.1

• Maximum Use Temperature: 800°C (1472°F) • Rules for:

– Chemistry – Heat-treatment – Welding – Post-weld heat-

treatment – Cold-forming – Weld strength reduction

factors Additional Research Continues to

Extend the Maximum Use Temperature


Welding Advancements for Nickel-based Alloys

B.A. Baker, et al. Welding and Repair Technology for Power Plants, Tenth International EPRI Conference. June 26-29, 2012 Marco Island, FL USA.

76mm (3”) wall thickness full circumferential pipe weld in Inconel 740H

~50mm (2”) SAW & SMAW

Welds in CCA617

Process Optimization, Dissimilar Metal Welds (DMWs),

Repeatable Qualifications, Repair


DOE/OCDO A-USC Steam Turbine Consortium Phase II

• Selected Materials from Phase I • Rotor/Disc Testing (full-size forgings, environmental interaction) • Blade Alloy Testing (and erosion resistant coatings) • Cast Casing Scale-Up Alloy Testing • Casing Welding and Repair

1400°F (760°C) Steam Turbine Conceptual Design (HP) – Bolted Construction

http://www.netl.doe.gov/main.html�


A-USC Turbine Highlight Haynes 282 Rotor Scale-Up

World’s First Haynes 282 Triple Melt Ingot

Two ingots now produced:

1. Chemical homogeneity / grain size / defects evaluation

2. Disc forging in 2014


Casting scale-up and turbine casing welding is progressing

Haynes 282 centrifugal

casting: 635kg (1,400lbs)

300mm3

Simulated casting weld defect repair

~2700kg (6,000lb) Valve Body Planned for late 2013

Haynes 282 and Alloy 263 Step Castings 135-450kg sizes (300 to 1,000 lbs)

740H Pipe to 282 Casting Weld Ongoing

Long-term creep of

weldments & microstructural

assessment


Next Steps: ComTest 1400 U.S. Utility Perspective

• Evaluation of advanced materials and components under coal fired, A-USC conditions.

• Minimize risk for a utility desiring to build an A-USC Plant. – Demonstrate turbine operation – Demonstrate reliability and safety – thick-section piping – Understand manufacturing and cost

• Evaluation of the constraints in the supply chain

• Validation of fabrication techniques, and the ability to construct, install and repair ComTest with on-site labor.


Specific Goals

• Boiler: Design, install, start-up, operate and cycle high temperature nickel components (740H & others)

• Large diameter piping • Header and tubes (gas fired heater) • Superheater materials exposure (at pressure)

• Turbine: Design, install, start-up, operate and cycle full size Steam Valves & COMTEST steam turbine for 760°C (1400°F). – Periodic testing of steam valves at high temperature – Materials & coatings – Turbine architecture – Oxidation, deposits, SPE – NDE/NDT

• Fabrication methods & supply chain for super-alloys Proposed ComTest 1400 Turbine


ComTest 1400 Schematic

HOT REHEAT

L.P. TURBINEI.P. TURBINEH.P. TURBINE

COLD REHEAT

BOILER FEED PUMP

GENERATORFEEDWATER TO BOILER

MAIN STEAM

FEEDWATERHEATERS

CO

MTE

ST

SU

PE

RH

EA

TER

BYPASS

1400F, 2400-3500 PSIA100,000 LB/HR

SV CV

HP, HT VALVE TEST

PRESSURE LET-DOWN SYSTEM WITH

DESUPERHEAT

AUXILLIARYREHEATER

NATURALGAS

EXHAUST

1400F, 700 PSIA

BYPASS

DE

SU

PE

RH

EA

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BFW

GEN

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COMTEST TURBINE

SV CV

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BFW

1300F, 2400-3500 PSIA100,000 LB/HR

Unique feature compared to other component tests:

•Higher-Temperature operation 760°C (1400°F)

•Turbine Demonstration

•Aux. Heaters for cycling / control independent from boiler


ComTest 1400

MAIN STEAM

COMTEST SUPERHEATER

GAS FIRED SUPERHEATER TURBINE

VALVE TEST

GAS FIRED REHEATER

TO EXISTING AQCS


ComTest 1400 - Schedule

Task 1 is underway and has proven to be challenging


Alternative Power Cycles Need Advanced (A-USC) Materials Technology NET Power Cycle 25MW Demo (2014-15) Gas-Fired 100% Carbon Capture Modified

CO2 Brayton Cycle is planning to use Inconel 740H for High-Temperature CO2 piping

Scale-up to 250MW will require large diameter nickel-based alloy

piping

Partners: NET Power, CB&I, Toshiba, Excelon

Partners: NREL, Echogen, Dresser Rand, Abengoa Solar, Sandia, Unv. of Wisc.,

EPRI, Barber-Nichols

DOE Sun-Shot Solar Powered CO2 Brayton Cycle – Pilot plant needs materials for

700°C+ piping and valves


Summary

• Consideration of higher-strength alloys provides an economic benefit for any A-USC Plant

• U.S. Program continues to make progress on the materials technology for A-USC – In plant testing for corrosion – Welding technology – Rotor scale-up and testing – Casing scale-up

• Planning work for a 760°C (1400°F) test facility is ongoing • Alternative power cycles can (and will) benefit from this

technology


Together…Shaping the Future of Electricity

materials technology to enable high-efficiency advanced

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