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AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Advanced Materials forAD700 Steam Turbines
R.W. Vanstone (ALSTOM Power)
AD700 Turbine Group leader
AD700 – Advanced 700C PF Power PlantA Clean Coal European Technology
October 27th 2005, Milan
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Steam turbine material development
Objectives
Identify suitable alloys
Demonstrate prototype manufacturing/welding
Define properties which determine allowable stresses
Investigate failure mechanisms
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
AD700-1
AD700-2
COMTES 700 Turbine Valve
Identification of 1st generationcandidate alloys
Screening tests
Selection of 2nd generationcandidate alloys
Prototype manufacture
Long term test programme
Turbine valve manufacture
Turbine valve operation
Turbine valve examination
Steam turbine materials:selection, demonstration and characterisation
October 2005
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Participants in steamturbine material
development
AD700-1 AD700-2 COMTES 700 Turbine Valve
Turbine makersAlstom PowerAnsaldo EnergiaSiemens
FoundriesDoncaster FVCGoodwin Steel CastingsHowmetSantasaloVoest-Alpine
ForgemastersAubert & DuvalBoehlerSaarschmiedeSdF TerniWyman Gordon
Research InstitutesAnsaldo RicercheCESICSMENEAJRCVGB
GeneratorsEDFElectrabelElsamEnergi E2EnBWEONPublic Power Corp ContractorRWEVattenfall Sub-contractor
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Existing alloys in new applications
Alloys used for Aerospace andland based gas turbines
New operating regime (stress, temperature, environment)
New product forms(heavier, larger sections)
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Materials requirements
Creep
Steam oxidationFlue gas corrosion
Minimum Cr content
Thermo-mechanicalcycling
2nd phase hardening: Ti, Al, Nb
Solid solution hardening:Mo, W, Co
Minimum cost: Fe
ManufactureWeldability
Economic feasibility
?
?
?
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
1st generation candidate materialsProduct form
AlloyStatic
castingCentrispun
casting Powdermet Forging155230263617625706
706M718
718M901
901Mwaspaloy
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Screening tests on 1st generationcandidate materials
• tensile• creep• low cycle fatigue• toughness• as-received and long term aged conditions• evaluation of ultrasonic inspectability and
weldability
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Kinetics of long term ageing in alloy 617
0
200
400
600
800
1000
0 500 1000 1500 2000 2500 3000 3500
Time at ageing temperature
Stre
ss (M
Pa)
Rp0.2 (650C ageing)Rp0.2 700C ageing)Rm (650C ageing)Rm 700C ageing)
0.0
10.0
20.0
30.0
40.0
50.0
0 1000 2000 3000 4000
Time at ageing temperatureSt
ress
(MPa
)
Cv (650C ageing)
Cv (700C ageing)
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Forgings
Forgings: Minimum measured proof strength after ageing at 650 or 700°C
0
200
400
600
800
1000
1200
0 500 1000 1500 2000 2500 3000
Time (hours)
Stre
ss (M
Pa)
Forgings: Minimum measured proof strength
0
200
400
600
800
1000
1200
0 200 400 600 800
Temperature
Stre
ss (M
Pa)
718
706M
706
Waspaloy
901M
901
263
625
617
718: 13JWaspaloy: 25J
617: 10J
901M: 4J901: 8J
263: 13J625: 24J
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Castings/PM
Castings and PM: Minimum measured proof strength
0
50
100
150
200
250
300
350
400
450
500
0 200 400 600 800
Temperature
Stre
ss (M
Pa)
625PM
263
625
155
230
617
Castings and PM: Minimum measured proof strength after ageing at 650 or 700°C
0
100
200
300
400
500
600
700
800
0 500 1000 1500 2000 2500 3000
Time (hours)
Stre
ss (M
Pa)
625PM: 24J
155: 8J
230: 13J
263: 13J
617: 18J625: 7J
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Fracture toughness v impact strength
0
50
100
150
200
250
0 5 10 15 20 25 30 35
Impact strength (J)
Frac
ture
toug
hnes
s M
Pam
0.5
617
263
617
263
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Castings LCF, 700C
0.10%
1.00%
10.00%
10 100 1000 10000
Cycles
Tota
l Str
ain
%
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Welding trialsTHERMIE / Alloy C-263 / ASSESSMENT OF WELDABILITY
HARDNESS ACROSS THE WELD
100
150
200
250
300
350
400
450
-10 -5 0 5 10 15
DISTANCE (mm)
HA
RD
NES
S H
V2
ALLOY 263 CAST "G" /SAW
ALLOY 263 CAST "G"/ MMA
ALLOY 263 FORGED "KN" / SAWBASE METAL
WELD METAL
THERMIE / Alloy IN 617 / ASSESSMENT OF WELDABILITYHARDNESS ACROSS THE WELD
100
150
200
250
300
350
400
450
-10 -5 0 5 10 15
DISTANCE (mm)
HA
RD
NES
S H
V2IN617 FORGED "M" / SAWIN617 CENTRISP. "U" /SAWIN617 CENTRISP. "U" / MMA
BASE METAL
WELD METAL
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Ultrasonic detectability
0
0.5
1
1.5
2
2.5
3
625PM(1) 625F(13) 718F(6) 718F(12) 718F(9) 263F(8) 263F(11) 617F(10) WASP(7) 901F(15)
DET
ECTA
BIL
ITY
LIM
IT (m
m)*
S1/trans.I
S2/long.
S3/trans.II
* Limit = mm FBH (flat bottom hole)
0
2
4
6
8
10
12
14
16
18
20
625C
(3)VIC
RO625(2
2
617C
(4)VIC
RO617(1
9
230C
(5)VIC
RO230(2
126
3C(16
)VIC
RO263(2
015
5C(14
)
DET
ECTA
BIL
ITY
LIM
IT (m
m)*
S1/trans.I
S3/trans.II
* Limit = mm FBH (flat bottom hole)
Forgings <2.5mm
Castings>10mm
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
• Solutions were identified for alloy and product formselection which met all the constraints of:– steam turbine design,– mechanical and physical property requirements,– and of component manufacture, fabrication and inspection.
• Forgings - 617, 625 (263, 718)• Castings - 617, 625• Bar products – waspaloy, 105
2nd generation candidate materials
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
Prototype rotor forgingsSaarschmiede:
•HP (700mm dia) forgings in617 and 625
•IP (1000mm) forging in 617
Boehler:
•IP (980mm) forging in 625
SdF Terni:
•HP (700mm dia) forging in718
Fortech
•HP (600mm dia) forging in263
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
• 617/625 : 10%Cr steel• TIG• Ni weld metal• PWHT defined by
10%Cr HAZ• Inspection by UT and
radiography
Rotor welding procedure
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
LIQUID WEIGHT = 6.035 kg ROUGH WEIGHT = 3.245 kg
625 valve chest cast byVoest-Alpine, April 2005
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
• As received condition:– tensile– fracture toughness– creep– fatigue crack growth– creep-crack initiation and growth– low cycle fatigue– creep-fatigue– steam oxidation
Prototype characterisation: parent• After 650C, 1000 hours:
– tensile– fracture toughness
– fatigue crack growth
– low cycle fatigue– creep-fatigue
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
– tensile cross-weld– fracture toughness HAZ WM– creep cross-weld– fatigue crack growth HAZ WM– creep-crack initiation and growth HAZ WM– low cycle fatigue cross-weld WM– creep-fatigue WM– steam oxidation WM
Prototype characterisation: weldments
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
• Alloys and product forms available• Near-net shape manufacturing v machining
from bar
• Wear resistance• Solid particle erosion resistance
Blading, bolt, valve components
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
• HP and IP rotor forging prototypes : manufactured and testprogramme in progress (>35,000 hours)
• Rotor weldments: procedure defined and demonstrated, long termtesting launched in 2005
• Model and prototype castings: manufactured and test programme inprogress (>35,000 hours): service operation in progress
• Casting weldments: manufactured and test programme in progress(15,000 hours)
• Blading: alloy/manufacturing procedure identified. SPE testingcomplete. Long term testing in progress (>10,000h).
• Bolting: alloys identified, relaxation testing in progress (>30,000h)• Valve components: wear testing complete: service operation in
progress
Component demonstration andcharacterisation: status October 2005
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
AD700-1
AD700-2
COMTES 700 Turbine Valve
Identification of 1st generationcandidate alloys
Screening tests
Selection of 2nd generationcandidate alloys
Prototype manufacture
Long term test programme
Turbine valve manufacture
Turbine valve operation
Turbine valve examination
Steam turbine materials:selection, demonstration and characterisation
October 2005
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
• Alloys for 700-720C steam turbines identified• Prototype components manufactured• Comprehensive materials test programme in
progress
• Underpinning technology for mitigation ofcarbon emissions
• Facilitate transition to zero-emissiontechnologies
Conclusions
AD700AD700 AdvancedAdvanced 700°C PF Power Plant 700°C PF Power Plant
• Partners in AD700 and COMTES700 Turbine Valve projects
• AD700 funding bodies– European Commission– UK govt– Swiss govt
Acknowledgement
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