Structural Alloys for Power Plants: Operational Challenges and High-Temperature Materials

519 Pages·2014·16.42 MB·English

by  A. Shirzadi

Structural Alloys for Power Plants
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Woodhead Publishing Series in Energy: Number 45
Structural Alloys for
Power Plants
Operational Challenges and
High-temperature Materials
Edited by
Amir Shirzadi and Susan Jackson
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Contents
Contributor contact details xi
Woodhead Publishing Series in Energy xv
Preface xxi
Part I Operational challenges and structural alloy
requirements 1
1 Gas turbines: operating conditions, components and
material requirements 3
A. W. James and S. RaJagopalan, Siemens Energy Inc., USA
1.1 Introduction 3
1.2 Overview of materials systems and their role in gas
turbines 6
1.3 Operating conditions and materials selection 10
1.4 Critical degradation mechanisms, aging and monitoring 13
1.5 Materials performance assessment and life management 16
1.6 Materials limitations, challenges and future directions 17
1.7 Acknowledgements 20
1.8 Sources of further information and advices 20
1.9 References 20
2 Steam turbines: operating conditions, components
and material requirements 22
S. osgeRby, Alstom Power, UK
2.1 Introduction 22
2.2 High temperature cylinder components 23
2.3 Factors affecting the service life of high temperature
components 27
2.4 Low temperature cylinder components 28
2.5 Factors affecting the service life of low temperature
components 31
vi Contents
2.6 Conclusion 34
2.7 References 35
3 High temperature materials issues in the design and
operation of coal-fired steam turbines and plant 36
F. staRR, Consultant, UK
3.1 Introduction 36
3.2 Recent power plant history and its lessons 38
3.3 Challenges of advanced plants 40
3.4 Thermodynamics and design of the steam and water
circuits 44
3.5 Design and operation of furnace and boiler 48
3.6 Superheater design issues 53
3.7 Two shift cycling 60
3.8 Material issues in the development of advanced steam
plants 62
3.9 Discussion 64
3.10 Conclusions 66
3.11 References 66
4 Nuclear power plants: types, components and
material requirements 69
J. F. Knott, The University of Birmingham, UK
4.1 Introduction 69
4.2 UK gas-cooled reactors: Magnox and advanced gas-
cooled reactors (AGR) 74
4.3 The pressurised water reactor (PWR) 88
4.4 ‘Generation IV’ systems: the fusion reactor 95
4.5 Conclusion 99
4.6 References 100
Part II Structural alloys and their development 103
5 Austenitic steels and alloys for power plants 105
Y. yin and R. FaulKneR, Loughborough University, UK and
F. staRR, Consultant, European Technology Ltd, UK
5.1 Introduction 105
5.2 The Fe-C phase diagram and austenitic steels 106
5.3 Microstructure and properties of austenitic steels 108
5.4 Other problems with the use of austenitics 137
5.5 Modern Japanese alloys 142
5.6 Discussion and future work 146
Contents vii
5.7 Sources of further information and advice 147
5.8 References 148
6 Bainitic steels and alloys for power plants 153
M. J. peet, University of Cambridge, UK
6.1 Introduction 153
6.2 Transformations in steels 156
6.3 Tempering heat treatment and service 173
6.4 Desirable properties for high temperature components
used in power plants 176
6.5 Developments of bainitic power plant steels 178
6.6 Conclusion 182
6.7 References 183
7 Ferritic and martensitic steels for power plants 188
P. J. ennis, University of Leicester, UK
7.1 Introduction 188
7.2 Metallurgical background 191
7.3 Power plant ferritic, bainitic and martensitic steels 196
7.4 Steam oxidation 209
7.5 Production and fabrication of power plant components 212
7.6 Power plant experience with most recently developed
steels 214
7.7 Further development of power plant steels 215
7.8 Sources of further information and advice 216
7.9 References and further reading 217
8 Structural materials containing nanofeatures for
advanced energy plants 221
W. HoFFelneR, RWH consult GmbH, Switzerland
8.1 Introduction 221
8.2 Oxide dispersion strengthening (ODS) 224
8.3 Ferritic-martensitic ODS steels 226
8.4 ODS materials based on a non-ferrous matrix 231
8.5 Production of nanoparticles containing alloys and
components 232
8.6 Components manufactured from ODS alloys 234
8.7 Properties of nanoparticle-containing steels 235
8.8 Other nanofeatures used to strengthen alloys for high
temperature applications 238
8.9 Conclusion 242
8.10 Acknowledgement 243
8.11 References 243
viii Contents
9 Development of creep-resistant steels and alloys for
use in power plants 250
F. abe, National Institute for Materials Science (NIMS), Japan
9.1 Introduction 250
9.2 Basic methods of strengthening steels and alloys at
elevated temperatures 255
9.3 Development progress of creep-resistant steels and
alloys 259
9.4 Degradation in creep strength of components subjected to
elevated temperature 268
9.5 Advanced alloy design of creep-resistant steels and
Ni-base superalloys to mitigate materials
degradation 277
9.6 Conclusion and future trends 289
9.7 References 290
10 Development of advanced alloys with improved
resistance to corrosion and stress corrosion
cracking (SCC) in power plants 294
S. pRaKasH, Indian Institute of Technology, India
10.1 Introduction 294
10.2 Overview of corrosion and stress corrosion 297
10.3 Development of alloys 301
10.4 Creep-fatigue behaviour of steels and superalloys 308
10.5 Advanced design and use of alloys 309
10.6 Future trends 314
10.7 References and further reading 314
11 Design and material issues in improving fracture/
fatigue resistance and structural integrity in power
plants 319
J. F. Knott, The University of Birmingham, UK
11.1 Introduction 319
11.2 Engineering design and brittle fracture 321
11.3 Linear elastic fracture mechanics 322
11.4 Yielding fracture mechanics: the failure assessment
diagram (FAD) 324
11.5 Brittle fracture in power plant steels 327
11.6 Inter-granular fracture in turbine disc steel 329
11.7 Potential concerns in nuclear reactor pressure vessel
(RPV) steels 333
11.8 Fatigue: S-N curves, Miner’s Law, stress concentrators 335
11.9 Fatigue crack propagation 340
Contents ix
11.10 Fatigue induced by thermal strain 343
11.11 Fatigue crack growth and interactions 345
11.12 Conclusion 350
11.13 References 353
12 Radiation damage to structural alloys in nuclear
power plants: mechanisms and remediation 355
G. S. Was, University of Michigan, USA and P. L. andResen,
General Electric Global Research, USA
12.1 Introduction 355
12.2 Overview: the radiation damage event 356
12.3 Physical degradation 360
12.4 Stress-related degradation 370
12.5 Environmental factors in cracking 381
12.6 Environmental factors in fracture 385
12.7 The response of stainless steel to irradiation 389
12.8 The response of pressure vessel steels to irradiation 402
12.9 The response of advanced alloys to irradiation 407
12.10 Conclusion 410
12.11 Sources of further information and advice 411
12.12 References 412
13 The use of advanced alloys to resolve welding
problems in power plants 421
D. J. abson, TWI, UK and G. matHeRs, Consultant, UK
13.1 Introduction 421
13.2 Parent steel behaviour and the analysis of creep rupture
data 427
13.3 Welding and the resulting residual stresses 428
13.4 Advantages and limitations of particular alloys 433
13.5 Advanced design and use of newer alloys 436
13.6 Future trends 436
13.7 Sources of further information and advice 442
13.8 References and further reading 442
14 Modelling creep in nickel alloys in high temperature
power plants 447
H. V. atKinson and S. P. A. gill, University of Leicester, UK
14.1 Introduction 447
14.2 Empirical methods 449
14.3 Semi-empirical models 451
14.4 Neural network approaches 453