VGB Workshop

Material and Quality Assurance

May 13 - 15, 2009 in Copenhagen

Esbjerg Unit 3 - Investigation of Advanced Materials at Steam Temperatures up to 720 C

Dr. Qiurong Chen, Andreas Helmrich, Dr. Georg-N. Stamatelopoulos Alstom Power Systems GmbH, Stuttgart, Germany

Agenda

Introduction Material Selection and Design Aspects Welding and Manufacturing Operational Results Conclusion

Agenda

Introduction Material Selection and Design Aspects Welding and Manufacturing Operational Results Conclusion

Esbjerg 720 C
Development of the Power Plant Efficiency
50 Skrbk Skrbk DK DK Nordjylland Nordjylland DK DK 413 MW 413 MW (Double (Double RH) RH) Avedre Avedre DK DK 475 475 MW MW (Single (Single RH) RH)

AD700/COMTES700

Net
(NCV) 45

Shidongkou Shidongkou Hemweg Hemweg 8 8 Meri Pori Meri Pori Staudinger/Rostock Staudinger/Rostock Amer Amer 9 9 Esbjerg Esbjerg Mai Mai Liao Liao Schwarze Schwarze Pumpe Pumpe Niederaussem Niederaussem Lippendorf Lippendorf

PRC PRC 600 600 NL 680 NL 680 FIN 590 FIN 590 D 550 D 550 NL 650 NL 650 DK 417 DK 417 TW 600 TW 600 D 800 D 800 D 1,000 D 1,000 D 930 D 930

MW MW MW MW MW MW MW MW MW MW MW MW MW MW MW MW MW MW MW MW

40

35 1970 1980 1990 Year 2000 2010

001 758pz

700 C Power Plant Advanced Boiler Materials

Membrane Wall Tube Materials z High creep rupture strength values (at 550 - 600 C design temperature) z Resistance against steam oxidation Materials for SH and RH Tubes z High creep rupture strength values (up to 750 C design temperature) z Resistance against high temperature corrosion z Resistance against steam oxidation and formation of a stable oxide layer Materials for SH Headers and Piping z High creep rupture strength values (up to 720 C design temperature) z Resistance against steam oxidation z Creep rupture behaviour of weld joints and dissimilar welds
121 239px

700 C Boiler Design

Comparison of Material Selection (550 MW, Single-Reheat)

250 bar / 540 C / 560 C

280 bar / 600 C / 620 C

360 bar / 700 C / 720 C

Ferritic 100 %

Ferritic 80 %

Ferritic 55 % Austenitic 20 %

Austenitic 20 %

Ni-base 25 %

001 1245p

Esbjerg Power Plant Boiler Unit 3 400 MW

Live Steam 275 bar (design pressure) 560 C 300 kg/s (1,080 t/h) Reheater Steam 560 C Fuel Bituminous coal

011 301pz

IT-superheater

Esbjerg Unit 3 SH Materials Test Loops

Test loop
Outlet header IT-superheater Inlet header HT-superheater Inlet header HT-superheater

HT-superheater

Boiler right wall

Outlet header HT-superheater

Outlet header HT-superheater

Test superheater 1 2 3

LB A 24
008 366pz

LB A 23 LB A 21 LB A 22

Esbjerg Unit 3 Test Superheaters

before dismantling

after dismantling

021 188pz

Esbjerg 720 C Data Recorded During Operation

Parameter Flue gas mass flow Flue gas Flue gas temperatures Flue gas compositions Steam mass flow Steam pressure Steam and feedwater Steam temperatures Steam quality Feedwater quality Surface temperature Material Analysis of the ash deposit at the surface Coal analysis Ash analysis Operating time Operation Start-up and shut-down processes Load changes
140 172pz

Components

Measuring or Analysis Interval 2 h average value 2 h average value

O2, NO2, CO2, SO2, ect.

2 h average value 2 h average value 2 h average value 2 h average value

Conductivity, SiO2, Fe, Cu ect. Conductivity, SiO2, Fe, Cu, pH value ect.

once a week once a week 2 h average value

K2O, Na2O, CaO, MgO ect.

after the removal of a test superheater

Coal and ash

Calorific value, H2O and ash content, S, HCl ect. average weekly value K2O, Na2O, CaO, MgO ect. monthly average value

Esbjerg Unit 3 Time Schedule Test Loops

Installation

Esbjerg 620 C
Dismantling 1. Loop Dismantling 2. Loop Installation Dismantling 3. Loop

Esbjerg 635 C
Inspection Dismantling Reinstallation

Installation

Esbjerg 700 C
Repair Dismantling Installation Reinstallation

Esbjerg 720 C
Repair 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Dismantling 2008 2009 2010

021 217pz

Esbjerg 720 C Distribution of the Works

Task Project management Design and engineering of the test loop Manufacturing Erection and commissioning Operation of the test loop Examination of material samples

Parties involved VGB Power Tech e.V. and Dong Energy ALSTOM Power Systems ALSTOM Power Systems Dong Energy and ALSTOM Power Systems Dong Energy Hitachi Power Europe

140 171pz

Agenda

Introduction Material Selection and Design Aspects Welding and Manufacturing Operational Results Conclusion

Esbjerg Unit 3 Materials Tested in Former Test Loops

Material Ferritic steels T23, T24

Steam Temperature [C] 500 - 525 500 - 580 510 - 690 635 - 700

Martensitic steels X 20, T91, T92, HCM12, HCM12A, NF 12 Austenitic steels Ni-based alloys 1.4988, TP 347HFG, SUPER 304H, SUPER 304H (SB), NF 709, NF 709 R, Tempaloy A 3, Tempaloy AA 1 (SB), SAVE 25, DMV 310 N, HR3C Alloy 617, Alloy 740

121 247p

Esbjerg 720 C Material Selection

Material Austenitic steels Ni-based alloys TP 347HFG, (DMV304 H Cu), (DMV 310 N), HR3C, Sanicro 25, HR6W Alloy 617 mod., Alloy 740

Steam Temperature [C] 565 - 650 650 - 720

( ) replaced by other materials during repair in 2006

121 248p

Esbjerg 720 C Chemical Composition of Test Materials

Steel TP 347 HFG HR 3 C Sanicro 25 HR 6 W Alloy 617 mod. Alloy 740

Cr 17.0 - 20.0 24.0 - 26.0 22.5 21.0 - 25.0 20.0 - 23.0 25.0

Ni 9.0 - 13.0 17.0 - 23.0 25.0 35.0 - 45.0 Rem. Rem.

Mo 0.02 8.0 - 10.0 0.5

Nb max. 1.0 0.20 - 0.60 0.48 < 0.40 2.0

Ti < 0.20 0.20 - 0.50 1.8 N

Others

Cu = 3.0 N, Al, W, Co W = 4.8 - 8.0 Co = 10.0 - 13.0 Al = 0.80 - 1.30, B Co = 20.0 Al = 0.9

121 249p

Esbjerg 720 C 100,000 h Creep Rupture Strenght

TP347HFG: HR3C: Sanicro 25:
400

VdTV MS 547 VdTV MS 546 VdTV MS 555

HR6W: VdTV MS 549 Alloy 740: Special Metals Alloy 617 mod.: PMA TV 01.2004

Alloy 740
350 100,000 h - Creep Rupture Values [N/mm 2] 300

Alloy 617 mod.

250 200 150 100 50

Sanicro Sanicro 25 25 HR3C

HR6W TP347HFG

0 575 600 625 650 675 700 725 750 775 800
121 246p

Temperature [C]

Esbjerg 720 C Design of the Test Superheater

121 200p

Esbjerg 720 C Temperature Profile

800 750 700 Outlet 650 600 550 500 450 0 10000 20000 30000 40000 50000
003 403pz

Temperature in C

CT 005 CT 003 Steam Temperature Design Temperature Thermocouple

CT 001

Length in mm

Agenda

Introduction Material Selection and Design Aspects Welding and Manufacturing Operational Results Conclusion

Esbjerg 720 C Fabrication of Test Superheater

Component Material Dimension [mm] Superheater TP347HFG, OD 38.8 x 8.8 (6.3) HR3C, (DMV 304HCu SB), (DMV 310N), Sanicro 25, HR6W, Alloy 617 mod., Alloy 740 Alloy 617 mod. OD 136 x 36 OD 108 x 30 OD 100 x 20 OD 80 x 21 OD 38.8 x 8.8 Program of Work Workshop Site

Machining, Welding of butt welds Bending, on return bends and Welding, to external piping Heat treatment of bends, Mechanical testing of bends of Alloy 617 mod.

Mixing Piece and T-Piece External Piping

Machining, Welding of butt welds and stubs

Welding of butt welds to external piping

Alloy 617 mod.

Machining, Welding of butt welds Bending, Heat treatment of bends, Mechanical testing of bends of Alloy 617 mod.

General at workshop and at site: NDT and Pressure Test ( ) removed during repair in 2006
075 358p

Esbjerg 720 C Pressure Part Welds

Component Similar Dissimilar Dimension [mm] Superheater TP347HFG, HR3C, (DMV 304HCu SB), (DMV 310N), HR6W, Sanicro 25, Alloy 617 mod., Alloy 740 Sanicro 25 - HR6W, OD 38.8 x 8.8 Alloy 617 - Alloy 740, (6.3) HR3C - Sanicro 25, HR3C - TP347HFG, HR6W - Sanicro 25, HR6W - Alloy 617, HR6W - HR3C, HR6W - TP347HFG, (HR6W - DMV 304HCu SB), (DMV 304HCu SB - DMV 310N), (DMV 310N - HR3C), (TP347HFG - DMV 304HCu SB) Alloy 617 mod. 10CrMo9-10 TP347HFG Alloy 617 mod. OD 136 x 36 OD 108 x 30 OD 100 x 20 OD 80 x 21 OD 38.8 x 8.8 OD 38.8 x 8.8 No. of Welds Workshop Site

63

Mixing Piece T-Piece

Alloy 617 mod. Alloy 617 mod.

4 1 4

10

External Piping Alloy 617 mod. ( ) removed during repair in 2006

075 328p

Esbjerg 720 C Welding Procedure Specifications

Component Base material Dimension Welding process Filler metal Weld position Type of joint Weld preparation Backing gas Heat treatment

Pipe Alloy 617 mod. OD 400 x 50 mm GTAW/SMAW Alloy 617 mod. Tube axis horizontal fixed Butt weld U-groove on V-root Yes No

Tube TP347 HFG, HR3C, (DMV 310N), (DMV 304HCu SB), Sanicro 25, HR6W, Alloy 617 mod., Alloy 740 OD 38 x 8.8 (6.3) mm GTAW Alloy 617 mod. Tube axis horizontal and vertical fixed Butt weld V-groove Yes No, except Alloy 740 at 800 C / 4h

( ) removed during repair in 2006

075 360p

Esbjerg 720 C Mechanical Tests and Micro/Macro Section

Component Base material

Tube, Butt weld TP347 HFG, HR3C, (DMV 304HCu SB), (DMV 310N), Sanicro 25, HR6W, Alloy 617 mod., Alloy 740 Dimension OD 400 x 50 mm OD 38 x 8.8 (6.3) mm Tensile test at RT 2 x cross to the weld 2 x cross to the weld Tensile test at elevated temperature 2 x cross to the weld 2 x cross to the weld Bend test 2 x root pass at extrados 2 x root pass at extrados 2 x cover pass at 2 x cover pass at extrados extrados Impact test at RT 1 set of weld 1 set of weld 1 set of HAZ 1 set of HAZ Micro/macro section Weld and HAZ Weld and HAZ ( ) removed by repair in 2006

Pipe, Butt weld Alloy 617 mod.

075 361p

Esbjerg 720 C Microsections - Sanicro 25 / Alloy 740

Sanicro 25

Alloy 740

M 200 : 1

M 200 : 1

075 359p

Esbjerg 720 C Macrosections - Butt Weld Alloy 617 mod.

Pipe OD 400 x 50 mm Butt Weld GTAW/SMAW Tube OD 38 x 6.3 mm Butt Weld GTAW

075 329pz

Esbjerg 720 C Manufacturing of Test Superheater

Welding in fixed position Dissimilar weld Alloy 740 - Alloy 617 mod.

Alloy 740 heat treatment

075 312pz

Esbjerg 720 C Bending of Test Superheater

Alloy 617 mod. heat treatment Alloy 617 mod. cold bended Alloy 174 cold bended
075 314py

Esbjerg 720 C Overview of Test Superheater Parts

075 286pz

Esbjerg 720 C Thickwalled Component - Mixing Piece

021 219pz

Agenda

Introduction Material Selection and Design Aspects Welding and Manufacturing Operational Results Conclusion

Esbjerg 720 C Test Rig Operation

Commissioning of the test rig: September 2004 Begin of the operation: October 2004 Break of the operation: April July 2006 Operating hours (May 2009): approx. 31000 h (approx. 50 % time above 700 C at outlet) Maximum steam outlet temperature: 728 C

Esbjerg 720 C Temperature Distribution

Esbjerg 720 C Investigations after Dismantling

Microstructure investigation Steam oxidation rate Outside corrosion rate Base metals / Welds / Bends / Thickwalled components

SEM/EDX Analysis Steel HR3C, after 23,000 Hours Operation

Parent Material

(SEM - Analysis)

Cr

Fe

Ni

121 098pz

Scale Constants for Austenitic Materials

0 -0,5 -1 log KD (KD in m /h)
2

s = KD t
TP 347 H after 7,720 h TP 347 H after 23,000 h TP 347 HFG after 7,720 h TP 347 HFG after 23,000 h NF 709 after 7,720 h

-1,5 -2 -2,5 -3 -3,5 -4 -4,5 1,06

NF 709 after 23,000 h 1.4988 after 7,720 h 1.4988 after 23,000 h Super 304 H after 30,000 h HR3C after 7,720 h HR3C after 23,000 h ALSTOM Forecast Elsam Forecast

1,11

1,16

1,21

1,26

1,31 1000/T (K-1)

650

600

550

500 (C)

121 251p

Agenda

Introduction Material Selection and Design Aspects Welding and Manufacturing Operational Results Conclusion

Esbjerg 720 C Conclusions

The Esbjerg Test Rig enables: to gain extensive experiences for the material processing, manufacturing and erection, to have long-term operational experiences of advanced materials, to make investigations on material behaviour up to 720 C steam temperature (755 C wall temperature).

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