BALTICA VII. Life Management and Maintenance for Power Plants. Vol 1

261 Pages·2007·14.2 MB·English

ESPOO 2007 VTT SYMPOSIUM 246
BALTICA VII. International Conference on Life Management and Main
tenance for Power Plants, Helsinki–Stockholm–Helsinki, June 12–14, 2007.
This is one of the two volumes of the proceedings of the BALTICA VII
Conference. The Conference aims to review recent experience, new
technology and views on future developments for supporting successful,
safe and productive operation of power plants.
The BALTICA events:
BALTICA I. Materials Aspects in Life Extension of Power Plants, Helsinki–
Stockholm–Helsinki, September 19–22, 1988.
BALTICA II. International Conference on Plant Life Management &
Extension, Helsinki–Stockholm–Helsinki, October 5–6, together with the
International Symposium on Life and Performance of High Temperature
Materials and Structures, Tallinn, Estonia, October 7–8, 1992.
BALTICA III. International Conference on Plant Condition & Life
Management, Helsinki–Stockholm–Helsinki, June 6–8, 1995.
BALTICA IV. Plant Maintenance for Managing Life & Performance,
Helsinki–Stockholm–Helsinki, September 7–9, 1998.
BALTICA VII
BALTICA V. International Conference on Condition and Life Management
for Power Plants, Porvoo, Finland, June 6–8, 2001.
Life Management and Maintenance
BALTICA VI. International Conference on Life Management and Main for Power Plants
tenance for Power Plants, Helsinki–Stockholm–Helsinki, June 8–10, 2004.
Vol. 1
BALTICA VII. International Conference on Life Management and Main
tenance for Power Plants, Helsinki–Stockholm–Helsinki, June 12–14, 2007.
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ISSN 0357 9387 (soft back ed.) ISSN 1455 0873 (URL: http://www.vtt.fi/publications/index.jsp)

VTT SYMPOSIUM 246 Keywords:
power plant, maintenance, boilers,
machinery, equipment, inspection,
monitoring, condition, life, performance,
risk, reliability
BALTICA VII
Life Management and Maintenance
for Power Plants
Vol. 1
Helsinki(cid:150)Stockholm(cid:150)Helsinki
12(cid:150)14 June, 2007
Edited by
Juha Veivo & Pertti Auerkari
Organised by
VTT
ISBN 978-951-38-6315-9 (soft back ed.)
ISSN 0357-9387 (soft back ed.)
ISBN 978-951-38-6316-6 (URL: http://www.vtt.fi/publications/index.jsp)
ISSN 1455-0873 (URL: http://www.vtt.fi/publications/index.jsp)
Copyright ' VTT Technical Research Centre of Finland 2007

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Edita Prima Oy, Helsinki 2007
Preface

The drivers in power technology, production and business are again shifting, this
time towards zero carbon and other new solutions that aim to simultaneously
answer the age-old questions on cost, availability and acceptability of different
fuels and conversion processes. Only a part of the answer implies completely
new technology, and much of the rest is likely to mean evolutionary development
of existing principles. Even then, the common awareness on global warming is
unprecedented and will have large scale consequences in decisions on
investment. Tightly on the heels of new investment must follow the effort
required for life management and maintenance, which need to take into account
the peculiarities of new technology that may be very specific and suffer from
lacking prior experience. However, the changes will also affect existing plant that
may face new fuels, operational modes, and upgrading in some aspects at least.

The dash for biomass and other renewable fuels will not easily cover all power
consumption any time soon, and also the base load plants will be affected by the
change. It remains to be seen to what extent this implies e.g. ultrasupercritical
efficiency, carbon sequestration, coal gasification, and/or new nuclear concepts.
However, no single technology will cover all needs, and we probably have to live
with an array of solutions that all need to be served and maintained for best
performance. The BALTICA VII Conference aims to provide an updated and
state-of-the-art experience on the essentials for life management and maintenance
of power plants, and the conference papers of these proceedings will offer an
excellent review on the current issues and solutions.

The editors wish to express their sincere gratitude to the authors, referees,
organisers and the Board of the Conference for their invaluable contribution in
preparing for the event and the proceedings. Financial and other contributions by
the supporting and sponsoring organisations are also gratefully acknowledged.

Espoo, June 2007

Juha Veivo Pertti Auerkari

Editors
3
Contents

Contents of Volume 1

Preface 3

Session 1. New technology for competitive plant

Maintenance of industrial plants as a part of corporate social responsibility 7
A. Jovanovic, D. Brukmajster
ZIRN (cid:150) University of Stuttgart, Germany

Life management of creep strengthened ferritic steels in boilers and 20
piping
J. Parker
Structural Integrity Associates, Inc., Canada

Interrelationship between toughness parameters determined from 37
the Charpy-V impact test
K. Wallin
Academy of Finland, Helsinki, Finland

Session 2. Developments and experience (cid:150) boilers and steam systems

UK experience with modified 9Cr (grade 91) steel 48
S. J. Brett
RWE npower, UK

Life extension of hot steam piping after 200 000 h of service 61
J. Rantala, J. Salonen, P. Auerkari, S. Holmstr(cid:246)m, O. Lehtinen*,
M. Pitk(cid:228)nen**, R. Nikkarila***
VTT Technical Research Centre of Finland, Espoo, Finland
*Fortum Power and Heat, Naantali, Finland
**Fortum Power and Heat, Espoo, Finland
***Inspecta, Espoo, Finland

Predicting lifetimes of components in power station engineering plant 70
A. Morris, A. Puri*, C. Maharaj*, M. Kourmpetis*,
M. Sj(cid:246)dahl **, J.P. Dear*
E.ON UK
*Imperial College, London, UK
**Lule(cid:229) University of Technology, Sweden
4
Structural analysis and lifetime assessment of outlet headers 83
K. Calonius, O. Cronvall, P. Junninen
VTT Technical Research Centre of Finland, Espoo, Finland

Remaining life assessment of steam turbine boilers 106
V. Mentl, V. Liska
SKODA Research Ltd., Pilsen, Czech republic

Typical failures of reheater coils 113
E. Zbroińska-Szczechura, J. Dobosiewicz, F. Klepacki
Pro Novum, Katowice, Poland

Reheat cracking susceptibility of new generation 2%CrMo(W)V P23
steel multipass welds made using matching and mis-matching filler metals 128
P. Nevasmaa, J. Salonen, S. Holmstr(cid:246)m
VTT Technical Research Centre of Finland, Espoo, Finland

Long-term creep testing and microstructure evaluation
of P91 steel weld joints 143
D. JandovÆ, J. Kasl, V. Kanta
(cid:138)KODA V(cid:221)ZKUM s.r.o., Plzeň, Czech Republic

A hardness-based creep rupture model for new and service aged P91 steel 156
D.J. Allen, S.T. Fenton
E.ON UK plc, UK

Impurity effects on heat-to-heat variation in creep life for some heat 171
resistant steels
F. Abe, H. Tanaka, M. Murata
National Institute for Materials Science
Tsukuba, Japan

Predicting creep strain response from rupture data and a robust
creep curve model 185
S. Holmstr(cid:246)m, P. Auerkari, S. Holdsworth*
VTT Technical Research Centre of Finland, Espoo, Finland
*EMPA, D(cid:252)bendorf, Switzerland

A new methodology for long term creep data generation for power
plant components 196
B. Wilshire, P.J. Scharning, R. Hurst*
University of Wales Swansea, UK
*EC JRC Petten, The Netherlands
5
Session 5. Conceptual and materials aspects for novel base load plant

VTT technology strategy in novel base load concepts 208
P. Aaltonen, L. Heikinheimo, T. Vanttola, J. H(cid:228)m(cid:228)l(cid:228)inen
VTT Technical Research Centre of Finland, Espoo, Finland

Generation IV material issues 212
L. Heikinheimo, P. Aaltonen, A. Toivonen
VTT Technical Research Centre of Finland, Espoo, Finland

Oxyfuel concept development 224
T. Pikkarainen, A. Tourunen, J. H(cid:228)m(cid:228)l(cid:228)inen
VTT Technical Research Centre of Finland, Jyv(cid:228)skyl(cid:228), Finland

Modelling of supercritical conditions in the safety analysis codes 235
T. Vanttola, M. H(cid:228)nninen, A. Daavittila
VTT Technical Research Centre of Finland, Espoo, Finland

NULIFE (cid:150) Network of excellence for harmonised nuclear plant 236
life management methods
R. Rintamaa, I. Aho-Mantila, N. Taylor*
VTT Technical Research Centre of Finland, Espoo, Finland
*JRC Petten, The Netherlands
High temperature oxidation and corrosion of boiler materials 244
S. Tuurna, S. Yli-Olli, S. Holmstr(cid:246)m, L. Heikinheimo
VTT Technical Research Centre of Finland, Espoo, Finland

6
Maintenance of industrial plants as a part of corporate
social responsibility

A. Jovanovic and D. Brukmajster

ZIRN (cid:150) Interdisciplinary Research Unit on Risk Governance and Sustainable
Technology Development, University of Stuttgart, Germany

Abstract
The paper deals with the change of role of maintenance of industrial plant along
the corresponding change of priorities in the operation of plants. It looks at the
role of maintenance in the actual concepts of operation in which the highest
priority is often not any more at the technical and engineering aspects ((cid:147)the plant
must run and produce(cid:133)(cid:148)), or the economic aspects ((cid:147)(cid:133) yes, but at an affordable
price and costs(cid:148)), but at the (cid:147)socially responsible production(cid:148). Taking the
currently accepted (cid:147)measures(cid:148) like KPI(cid:146)s and indices like GRI or those proposed
in the EU project like NEEDS as the basis for the analysis, the paper shows how,
where and how much maintenance can contribute to better performance of a plant
according to the above (cid:147)measures(cid:148). In particular, the paper highlights those
KPI(cid:146)s and indices which can be of a particular interest for the maintenance of the
fossil fuel power plants.

1. Introduction (cid:150) CSR, KPI, Integrated Risk Management

1.1 Corporate Social Responsibility (CSR)

Corporate Social Responsibility (CSR) continues to steadily grow in importance.
Especially in the EU sustainable development and responsible business behavior
and ethics are high on the policy agenda. Through the debate initiated by the
Commission Green Paper «Promoting a European Framework for Corporate
Social Responsibility» of July 2001 and the subsequent Communication «Corporate
Social Responsibility A Business Contribution to Sustainable Development» of July
2002, the interest for and understanding of CSR and all its multiple facets has
increased rapidly.

In 2002 The Commission introduced a European Multistakeholder Forum on
Corporate Social Responsibility as a part of its strategy for promoting innovation,
transparency and convergence of CSR practices and instruments. Recent years
have witnessed a proliferation of CSR instruments: codes, reporting standards
and guidelines, labeling schemes, management systems, screening methodologies
for socially responsible investment. Not all these tools are comparable in scope,
7
intent, origin, implementation or applicability to particular businesses or sectors.
As expectations on CSR become more defined, there is a strong case for greater
transparency, credibility and coherence between standards, practices and
measurement of performance.

1.2 Measuring CSR (cid:150) Key Performance Indicators (KPIs)

As concern about the broad impacts of business on society has increased, there
has been an explosion in the development of instruments to measure, evaluate,
improve and communicate corporate performance in relation to social,
environmental and ethical criteria. While there is little available data to put an
exact figure on the number of companies that have taken on these instruments it
is clear that they are becoming a significant part of the business environment.

The above concern is usually expressed in practice through the key performance
indicators (KPI) as financial and non-financial metrics used to quantify
objectives to reflect strategic performance of an organization. KPIs are frequently
used to (cid:147)value(cid:148) difficult to measure activities such as the benefits of leadership
development, engagement, service, and satisfaction. KPIs are, thus, tools for
measuring and monitoring of the goals set up by the organization in the particular
area of the company(cid:146)s activities, or at the level of the company as whole.

The KPIs differ depending on the nature of the organization and the
organization(cid:146)s strategy. They help an organization to measure progress towards
their organizational goals, especially toward those difficult to quantify. KPIs
should be a part of a measurable objective. As such they can well fit the need to
(cid:147)measure CSR(cid:148). On the other hand, in the promotion of CSR one must have clear
understanding of CSR instruments, their use, merits and limits.

1.3 CSR, industrial safety and KPIs

Industrial plants appear as the source of the industrial risk on all steps of their life
cycle (Fig. 1). For large plants (e.g. power plants, refineries, process plants, etc.)
with the design life of often more than several decades and with their age
advancing towards and beyond the design limits, proper, i.e. (cid:147)responsible(cid:148),
inspection and maintenance may become key factors of safety of these plants, i.e.
of the risks related to them. One can therefore say, that (cid:147)the risk management is a
major measure of the corporate responsibility of a plant owner(cid:148) and that,
especially for the plants in advanced age (cid:147)inspection and maintenance are the
major factors of risk(cid:148). The two premises yield the conclusion that the (cid:147)inspection
and maintenance, for a given class of plants, may become the main measure of
the CSR of the company(cid:148). Practical aspects of this assertion are discussed below.
8