Materials for Ultra-Supercritical and Advanced Ultra-Supercritical Power Plants

903 Pages·2016·32.57 MB·English

by  Augusto Di Gianfrancesco

Materials for Ultra-Supercritical and Advanced
Ultra-Supercritical Power Plants
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Woodhead Publishing Series in Energy:
Number 104
Materials for
Ultra-Supercritical
and Advanced
Ultra-Supercritical
Power Plants
Edited by
Augusto Di Gianfrancesco
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Contents
List of contributors xiii
Woodhead Publishing Series in Energy xv
Preface xxi
1 The fossil fuel power plants technology 1
A. Di Gianfrancesco
1.1 Types of thermal power station 1
1.2 The coal-fired power generation plants 6
1.3 The power generation trend: realizing decarbonization through
efficiency gains 10
1.4 Fossil fuels classification 17
1.5 Power plant overview and main components 19
References 47
Part One Ultra-supercritical power plant materials 51
2 Low-alloyed steel grades for boilers in ultra-supercritical
power plants 53
F. Masuyama
2.1 Introduction 53
2.2 Historical development of low-alloyed steels 53
2.3 Properties and metallurgy 57
2.4 Welding and forming 63
2.5 Service degradation 70
2.6 Conclusions 74
References 75
3 High-alloyed martensitic steel grades for boilers in ultra-supercritical
power plants 77
J. Hald
3.1 Introduction 77
3.2 History of the high-alloyed martensitic steels 77
3.3 Basic properties and fabrication 79
3.4 Service experiences 84
3.5 Basic metallurgy and long-term microstructure stability 85
vi Contents
3.6 Microstructure instability: Z-phase 89
3.7 Future perspectives 92
References 95
4 Austenitic steel grades for boilers in ultra-supercritical power plants 99
P. Barnard
4.1 Introduction 99
4.2 Overview of austenitic steels 99
4.3 Thermal fatigue 102
4.4 Sensitization 103
4.5 Strain-induced precipitation hardening 105
4.6 Sigma-phase precipitation 108
4.7 Stress corrosion cracking 109
4.8 Stress relief cracking 111
4.9 Secondary hardening 112
4.10 Dissimilar metal welds 113
4.11 Conclusions 116
Acknowledgments 117
References 117
5 Martensitic steels for cast components in ultra-supercritical
power plants 121
S. Roberts
5.1 Material requirements for ultra-supercritical application 121
5.2 Why cast components are utilized for steam turbine applications 121
5.3 Casting materials for ultra-supercritical applications 126
5.4 Manufacturing challenges associated with production of
heavy-wall martensitic 9%Cr steel castings 128
5.5 Bigger, hotter, higher pressure 132
5.6 Latest alloy developments and state-of-the-art technology 132
5.7 What is next after ultra-supercritical? Cast materials for advanced
ultra-supercritical applications? 134
5.8 Summary 139
References 140
6 Martensitic steels for rotors in ultra-supercritical power plants 143
G. Zeiler
6.1 Introduction 143
6.2 Common rotor material requirements 144
6.3 Development of martensitic 9–12% Cr rotor steels for USC
application 147
6.4 Common materials for steam turbine rotors in Europe: fabrication
and basic properties 155
6.5 Present material development for application temperatures
above 620°C 168
6.6 Summary and conclusions 170
References 171
Contents vii
7 Steels and alloys for turbine blades in ultra-supercritical power plants 175
G. Lucacci
7.1 Introduction 175
7.2 Commercial alloys 178
7.3 Trends in USC steam turbine blading 189
7.4 Coatings 193
7.5 Conclusions 195
References 195
8 Technologies for chemical analyses, microstructural and
inspection investigations 197
A. Di Gianfrancesco
8.1 Introduction 197
8.2 Modeling tools 224
8.3 Nondestructive testing 232
References 243
9 Welding technologies for ultra-supercritical power plant
materials 247
S. Sorrentino
9.1 Introduction: welded fabrication of USC components 247
9.2 Welding metallurgy of USC materials 252
9.3 Weldments design, codes and standards, approvals 285
9.4 Arc welding technology and consumables for USC materials 287
9.5 Welding procedures, NDT, quality assurance, weldments testing 299
9.6 Future trends 313
List of acronyms 315
Acknowledgments 315
References 316
Part Two Advanced ultra-supercritical power plant
materials 321
10 New martensitic steels 323
F. Abe
10.1 Introduction 323
10.2 Development history and utilization of 9 to 12Cr martensitic
steels in coal power plants 324
10.3 Basic methods of strengthening martensitic 9 to 12Cr steels
in creep at elevated temperature 326
10.4 Degradation in creep strength at long times 331
10.5 Fundamental aspects of tempered martensitic microstructure
and creep deformation 337
10.6 New martensitic 9Cr steel 338
10.7 Summary 368
References 368
viii Contents
11 New austenitic steels for the advanced USC power plants 375
M. Spiegel and P. Schraven
11.1 Introduction 375
11.2 Future trends 376
11.3 Sigma phase strengthened concept
(Power Austenite) 377
11.4 Summary 388
References 390
12 Sanicro 25: an advanced high-strength, heat-resistant austenitic
stainless steel 391
G. Chai and U. Forsberg
12.1 Introduction 391
12.2 Development of new high-strength austenitic material for
high-efficiency coal-fired power plant 392
12.3 Microstructure 394
12.4 Creep and rupture behaviors 397
12.5 Low-cycle fatigue properties 405
12.6 High-temperature corrosion and steam
oxidation behavior 407
12.7 Weldability 410
12.8 Fabricability 413
12.9 Field experiences: testing in boilers 416
12.10 Future trends 417
12.11 Conclusions 418
Acknowledgments 419
References 419
13 New Japanese materials for A-USC power plants 423
A. Di Gianfrancesco
13.1 Introduction 423
13.2 Development of boiler tubes and pipes for advanced USC
power plants: HR6W, HR35 424
13.3 Superalloys development in MHPS 443
13.4 TOS1X 460
References 466
14 INCONEL alloy 740H 469
J.J. deBarbadillo
14.1 Background/introduction 469
14.2 Composition 470
14.3 Microstructure and phase stability 470
14.4 Mechanical properties 474