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AD700 – Advanced 700C PF Power Plant

A Clean Coal European Technology


October 27th 2005, Milan

Advanced Materials for


AD700 Steam Turbines

R.W. Vanstone (ALSTOM Power)


AD700 Turbine Group leader

AD700 Advanced 700°C PF Power Plant


Steam turbine material development
Objectives

¾ Identify suitable alloys


¾ Demonstrate prototype manufacturing/welding
¾ Define properties which determine allowable stresses
¾ Investigate failure mechanisms

AD700 Advanced 700°C PF Power Plant


Steam turbine materials:
selection, demonstration and characterisation
AD700-1
AD700-2
COMTES 700 Turbine Valve
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
Identification of 1st generation
candidate alloys
Screening tests
Selection of 2nd generation
candidate alloys
Prototype manufacture
Long term test programme
Turbine valve manufacture
Turbine valve operation
Turbine valve examination

October 2005

AD700 Advanced 700°C PF Power Plant


COMTES 700
AD700-1 AD700-2
Turbine Valve
Turbine makers
Alstom Power
Ansaldo Energia
Siemens
Foundries
Doncaster FVC
Goodwin Steel Castings
Howmet
Santasalo
Voest-Alpine
Forgemasters
Participants in steam
Aubert & Duval
Boehler turbine material
Saarschmiede
SdF Terni
Wyman Gordon
development
Research Institutes
Ansaldo Ricerche
CESI
CSM
ENEA
JRC
VGB
Generators
EDF
Electrabel
Elsam
Energi E2
EnBW
EON
Public Power Corp Contractor
RWE
Vattenfall Sub-contractor

AD700 Advanced 700°C PF Power Plant


Existing alloys in new applications

Alloys used for Aerospace and


land based gas turbines

New operating regime


(stress, temperature, environment)

New product forms


(heavier, larger sections)
AD700 Advanced 700°C PF Power Plant
Materials requirements
Flue gas corrosion Steam oxidation

Minimum Cr content
?
Solid solution hardening: ?
Mo, W, Co Manufacture
2nd phase hardening: ? Weldability
Creep Ti, Al, Nb
Minimum cost: Fe
Thermo-mechanical
cycling Economic feasibility

AD700 Advanced 700°C PF Power Plant


1st generation candidate materials
Product form
Static Centrispun
Alloy casting casting Powdermet Forging
155
230
263
617
625
706
706M
718
718M
901
901M
waspaloy

AD700 Advanced 700°C PF Power Plant


Screening tests on 1st generation
candidate materials
• tensile
• creep
• low cycle fatigue
• toughness
• as-received and long term aged conditions
• evaluation of ultrasonic inspectability and
weldability

AD700 Advanced 700°C PF Power Plant


Kinetics of long term ageing in alloy 617
1000 50.0

800 40.0

600 30.0
Stress (MPa)

Stress (MPa)
Cv (650C ageing)
Cv (700C ageing)
400 20.0

Rp0.2 (650C ageing)


Rp0.2 700C ageing)
200 Rm (650C ageing) 10.0

Rm 700C ageing)

0 0.0
0 500 1000 1500 2000 2500 3000 3500 0 1000 2000 3000 4000

Time at ageing temperature Tim e at ageing tem perature

AD700 Advanced 700°C PF Power Plant


Forgings

Forgings: Minimum measured proof strength Forgings: Minimum measured proof


strength after ageing at 650 or 700°C
1200 1200

718: 13J
1000 718 1000
Waspaloy: 25J
706M 901M: 4J
800 706 800
901: 8J
Stress (MPa)

Stress (MPa)
Waspaloy 263: 13J
600 901M 600
625: 24J
901
617: 10J
400 263 400
625
200 617 200

0 0
0 200 400 600 800 0 500 1000 1500 2000 2500 3000
Tem perature Tim e (hours)

AD700 Advanced 700°C PF Power Plant


Castings/PM
Castings and PM: Minimum measured proof
strength after ageing at 650 or 700°C
800

700
625PM: 24J

600
Castings and PM: Minimum measured proof strength

500 500
263: 13J
450

Stress (MPa)
625: 7J
400 400 617: 18J
350 625PM 230: 13J
300 263 300
Stress (MPa)

155: 8J
625
250
155
200 200
230
150 617
100 100

50

0 0
0 200 400 600 800 0 500 1000 1500 2000 2500 3000

Tem perature Tim e (hours)

AD700 Advanced 700°C PF Power Plant


Fracture toughness v impact strength
250

200
0.5

617
263
Fracture toughness MPam

263
150

100 617

50

0
0 5 10 15 20 25 30 35
Im pact strength (J)

AD700 Advanced 700°C PF Power Plant


Castings LCF, 700C

10.00%
Total Strain %

1.00%

0.10%
10 100 1000 10000

Cycles

AD700 Advanced 700°C PF Power Plant


Welding trials
THERMIE / Alloy C-263 / ASSESSMENT OF WELDABILITY
HARDNESS ACROSS THE WELD
450

400 WELD METAL

350

HARDNESS HV2
300

250

200 ALLOY 263 CAST "G" /SAW

ALLOY 263 CAST "G"/ MMA


150 BASE METAL
ALLOY 263 FORGED "KN" / SAW
100
-10 -5 0 5 10 15
DISTANCE (mm)

THERMIE / Alloy IN 617 / ASSESSMENT OF WELDABILITY


HARDNESS ACROSS THE WELD
450

400 IN617 FORGED "M" / SAW


IN617 CENTRISP. "U" /SAW
350 IN617 CENTRISP. "U" / MMA
HARDNESS HV2

BASE METAL
300

250

200

150 WELD METAL

100
-10 -5 0 5 10 15
DISTANCE (mm)

AD700 Advanced 700°C PF Power Plant


Ultrasonic detectability
20

18

16
S1/trans.I

DETECTABILITY LIMIT (mm)*


14
S3/trans.II
12

Forgings <2.5mm
10

6
3
4

2
2.5 S1/trans.I 0
S2/long.

6)

4)
(3

(4

(5
2

19

20
(2

(2

(1

(1
5C

7C

0C
DETECTABILITY LIMIT (mm)*

7(

3(
5

3C

5C
2 S3/trans.II

61

26
62

23
62

61

23

26

15
O

O
O

O
R

R
R

R
C

C
C

C
VI

VI

VI

VI
* Limit =mmFBH(flat bottomhole)
1.5

1
Castings
0.5
>10mm
0
625PM(1) 625F(13) 718F(6) 718F(12) 718F(9) 263F(8) 263F(11) 617F(10) WASP(7) 901F(15)
* Limit =mmFBH(flat bottomhole)

AD700 Advanced 700°C PF Power Plant


2nd generation candidate materials

• Solutions were identified for alloy and product form


selection 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

AD700 Advanced 700°C PF Power Plant


Prototype rotor forgings
Saarschmiede:
•HP (700mm dia) forgings in
617 and 625
•IP (1000mm) forging in 617
Boehler:
•IP (980mm) forging in 625
SdF Terni:
•HP (700mm dia) forging in
718
Fortech
•HP (600mm dia) forging in
263

AD700 Advanced 700°C PF Power Plant


Rotor welding procedure

• 617/625 : 10%Cr steel


• TIG
• Ni weld metal
• PWHT defined by
10%Cr HAZ
• Inspection by UT and
radiography

AD700 Advanced 700°C PF Power Plant


625 valve chest cast by
Voest-Alpine, April 2005

LIQUID WEIGHT = 6.035 kg ROUGH WEIGHT = 3.245 kg

AD700 Advanced 700°C PF Power Plant


AD700 Advanced 700°C PF Power Plant
AD700 Advanced 700°C PF Power Plant
Prototype characterisation: parent
• As received condition: • After 650C, 1000 hours:
– tensile – tensile
– fracture toughness – fracture toughness
– creep
– fatigue crack growth – fatigue crack growth
– creep-crack initiation and growth
– low cycle fatigue – low cycle fatigue
– creep-fatigue – creep-fatigue
– steam oxidation

AD700 Advanced 700°C PF Power Plant


Prototype characterisation: weldments

– 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

AD700 Advanced 700°C PF Power Plant


Blading, bolt, valve components

• Alloys and product forms available


• Near-net shape manufacturing v machining
from bar

• Wear resistance
• Solid particle erosion resistance

AD700 Advanced 700°C PF Power Plant


Component demonstration and
characterisation: status October 2005
• HP and IP rotor forging prototypes : manufactured and test
programme in progress (>35,000 hours)
• Rotor weldments: procedure defined and demonstrated, long term
testing launched in 2005

• Model and prototype castings: manufactured and test programme in


progress (>35,000 hours): service operation in progress
• Casting weldments: manufactured and test programme in progress
(15,000 hours)

• Blading: alloy/manufacturing procedure identified. SPE testing


complete. 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

AD700 Advanced 700°C PF Power Plant


Steam turbine materials:
selection, demonstration and characterisation
AD700-1
AD700-2
COMTES 700 Turbine Valve
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
Identification of 1st generation
candidate alloys
Screening tests
Selection of 2nd generation
candidate alloys
Prototype manufacture
Long term test programme
Turbine valve manufacture
Turbine valve operation
Turbine valve examination

October 2005

AD700 Advanced 700°C PF Power Plant


Conclusions
• Alloys for 700-720C steam turbines identified
• Prototype components manufactured
• Comprehensive materials test programme in
progress

• Underpinning technology for mitigation of


carbon emissions
• Facilitate transition to zero-emission
technologies

AD700 Advanced 700°C PF Power Plant


Acknowledgement

• Partners in AD700 and COMTES


700 Turbine Valve projects
• AD700 funding bodies
– European Commission
– UK govt
– Swiss govt

AD700 Advanced 700°C PF Power Plant

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