Steam Turbine Materials for Advanced

Ultrasupercritical (AUSC) Coal Power Plants

J. Shingledecker, Ph.D
Principal Project Manager, EPRI
U.S. DOE/OCDO A-USC Consortium Technical Lead
R. Purgert
President, Energy Industries of Ohio
2014 NETL Crosscutting Research Review Meeting
May 22, 2014: Pittsburg, PA USA
Acknowledgements: U.S. Department of Energy (US DOE) / Ohio Coal
Development Office (OCDO) A-USC Steam Boiler and Turbine Consortia
Federal – State – National Laboratory

Welding
Cost Sharing Consortium
Non Profit – For Profit

New Materials

Castings

Fabrication

Forging Field Test

© 2013 Electric Power Research Institute, Inc. All rights reserved. 2

 Accomplishments
A-USC Fact Book - EPRI 1022770 Fabrication Processes
(download free at: www.epri.com)
General design studies show
favorable economics

Welding Technology Developments

Steam-Side
Oxidation

Fireside Corrosion (High-Sulfur Coal Turbine Component Scale-up

& In-Plant Testing)
© 2013 Electric Power Research Institute, Inc. All rights reserved. 3
 Outline

• A-USC Steam Turbine (This Talk)

– General motivation for A-USC
– Results from Phase I study
– Current project approach and results (Phase II)
– Next Steps
• A-USC Boiler (Next Talk)
– Project Approach
– Successes and Recent Activities
– A-USC Economics and Future Applications

© 2013 Electric Power Research Institute, Inc. All rights reserved. 4

 Increasing Steam Temperature and Pressure Increases
Thermal Efficiency and Decreases Emissions

Note:
HHV Basis

“Least Regret” Strategy for CO2 Reduction

© 2013 Electric Power Research Institute, Inc. All rights reserved. 5

 Materials Limit the Current Technology
o
Average Temperature for Rupture in 100,000 hours ( F)
1100 1200 1300 1400
500 70
Inconel 740 Nickel-Based
Alloys 50
300
Haynes 282
CCA617 Std. 617
Age Hardenable = A-USC 30
760°C (1400°F)
°
Stress (MPa)

Stress (ksi)
100

80
10
60
9-12Cr Creep-Strength
Steels = USC 8
Solid Soln’ = A-USC
Enhanced Ferritic Advanced Austenitic Minimum
620°CSteels
(1150°F) ~700°C (1300°F)
40 (Gr. 91, 92, 122) Alloys (Super 304H, 6 Desired
347HFG, NF709, etc.) Haynes 230
Strength at
Application
550 600 650 700 750 800
o Temperature
Average Temperature for Rupture in 100,000 hours ( C)

© 2013 Electric Power Research Institute, Inc. All rights reserved. 6

 Primary Technical Goals of US A-USC Materials
Programs
• Materials Technology Evaluation
– Focus on nickel-based alloys
– Development of fabrication and joining technology for
new alloys
• Unique Conditions for US Program Considerations
– Higher-temperatures than Other International Programs
(760°C versus 700°C) means additional alloys are being
evaluated
– For Boiler:
• Corrosion resistance for US coals
• Data for ASME code acceptance of new materials
• Phase II Boiler work includes Oxycombustion

© 2013 Electric Power Research Institute, Inc. All rights reserved. 7

 A-USC Steam Turbine Program: Phase I
(complete: 2005-2009)

Design & Econ Studies Review State of the Art Material property data characterization,
(ALSTOM) and Identify Candidates microstructural and steam oxidation
Assistance (Siemens & for 760oC Application studies
GE Energy) (All) (ORNL)
Task 12. 5

Rotors, Buckets Oxidation & SPE Castings (Siemens)

Bolting Studies Task 12. 4
Task 12. 3 (Siemens, ALSTOM)
Task 12.1

Non Welded Welded

Rotors (GE) Rotors (Siemens,
Task 12. 3 Alstom
Task 12. 2

Mechanical
Weldability Studies Mechanical Properties Mechanical
Properties of
(Siemens, ALSTOM) (Siemens,ALSTOM) Properties
Materials (GE)
Task 12. 2 Task 12. 2 (Siemens)
Task 12. 3
Task 12. 4

• Scoping Studies – Downselect Materials

• Key Issues – Air Casting
– Welded rotors materials – Erosion resistance
– Non-welded rotor materials
– Oxidation resistance
© 2013 Electric Power Research Institute, Inc. All rights reserved. 8
 Initial Material Selection for A-USC Turbine:
Behavior of HP/IP Rotor Alloys (Phase I) Waspaloy
52 IN 740
Udimet 720Li
5 50 Haynes 282

4.5 H282-P e a k a g e d Nimonic 105

48
4
Microstructure
1450F , 32.5ksi
1450F , 27.5ksi

LMP (C = 20)
46
3.5

3
44
Strain (%)

2.5 42
2
40 Creep-Rupture
1.5
38
1

0.5 36

0
1 10 100
0 200 400 600 800 1000 1200 1400
Stress (ksi)
T im e (h ) 120

Forging Cooling 100

Fatigue Behavior
( )
Nimonic 105 - 760C
Simulations 80

Strength (ksi)
10.00 Haynes 282 - 760C
Udimet 720 - 750C
Alloy 617 - 750C 60
Total Strain Range (%)

40

1.00 Haynes 282SA-0.2% YS

20
Tensile Strength
Haynes 282PA-0.2%YS

Haynes 282OV-0.2%YS

0
0 200 400 600 800 1000 1200 1400 1600
Temperature (F)
0.10
100 1,000 10,000 100,000 1,000,000
Cycles to Initiation (Ni)

Best Candidates: Nimonic 105, Haynes 282, Waspalloy

© 2013 Electric Power Research Institute, Inc. All rights reserved. 9

 Successes: Large Forgings Research Requires an
Understanding of Microstructure & Properties as a
Function of Heat-Treatment

50 nm 50 nm

Solution Annealed PA = SA + 8h @ 790°C OV = PA + 250h @ 775°C

Studies on Haynes 282:
•Creep-rupture strength was relatively insensitive to heat-treatment
•Detailed microstructural studies on gamma prime precipitates after
heat-treatment and creep were conducted
•Both mechanical property data and microstructure studies suggest
the alloy has a large processing window making it attractive for steam
turbine forgings
Source: R. Viswanathan, J. Shingledecker, J. Hawk, S. Goodstine. “Effect of Creep in Advanced Materials for Use in Ultrasupercritical
Power Plants.” Proceedings: Creep & Fracture in High Temperature Components, 2nd ECCC Creep Conference, April 21-23, 2009,
Zurich, Switzerland.” © 2009 DEStech Publications, Inc. 31-43
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 Erosion and Oxidation of Blade Materials and
Coatings
• Oxidation studies
•Oxidation rates/kinetics
•Scale morphology
•Internal penetration vs.
oxide thickness Cross-section of bare metal after steam exposure

•Bare metals
(substrates)
and coatings • Erosion Testing
• High-temperature
erosion tests were
conducted at
1400°F (760°C)
• Coating and
substrates
• 12 Coatings
Program Start evaluated

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 T400C (Tribaloy)
good resistance
Coating Conclusions
760°C Erosion Test Results for Coatings

Stellic 6B
visible erosion

• Oxidation rates (both internal penetration and

mass gain) of candidate bare metal substrates
were acceptable based on laboratory studies
– Oxidation testing showed unacceptable rates
for some coatings including top performing
erosion resistant coatings Surface morphology of
coatings after
T400C (Tribaloy) was only coating to perform 760°C erosion tests
well in oxidation and erosion at 760°C with magnetite

© 2013 Electric Power Research Institute, Inc. All rights reserved. 12

 Phase I casting work helped guide the program
• A casting sub-team of OEM and National Laboratories (ORNL & NETL)
was formed to address potential issues with nickel-based casing/shells
– Seven trial alloys were cast
– An innovative homogenization heat-treatment cycle was developed
– Mechanical property testing identified the best performing alloys
– Some alloys were eliminated due to lower strength or ductility
compared to the wrought alloy counterpart
Alloy 263 casting –
• Haynes 282, 263, and N105 were judged the fluidity trial
best alloys for casting and castability trials
were performed

Range of microstructures in a
slow-cooled casting

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 Phase I Welded Rotor Trials

• Successfully produced a thick-section

263-617-Ferritic Steel joint concept using
traditional welding techniques.
– Joint toughness was acceptable after
aging (simulated service exposure)
• A second welded rotor configuration was
evaluated for Haynes 282 to Udimet
Trial I Trial II Trial III
720Li.
– Welding development was successful
and heat-treatment studies showed no
evidence of strain age cracking after
welding
– Non destructive evaluation capability of
joint was verified

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 DOE/OCDO A-USC Steam Turbine Consortium
Phase II
• Selected Materials from Phase I
• Rotor/Disc Testing (full-size forgings, environmental interaction)
• Blade Alloy Testing (and erosion resistant coatings)
• Cast Casing Scale-Up Alloy Testing
• Casing Welding and Repair
Pipe-to-casing
1400°F (760°C) Casing
Steam Turbine
Conceptual
Design (HP) –
Bolted
Construction
Rotor/Disc

Blading Bolting
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 Casting scale-up and turbine casing welding is
progressing
Haynes 282
centrifugal
casting: 635kg
(1,400lbs)
300mm3

Haynes 282 and Alloy 263 Step Castings Long-term

135-450kg sizes (300 to 1,000 lbs) creep of
weldments &
microstructural
assessment

Simulated casting weld defect repair

Properties: tensile, creep,

aging/toughness, fatigue, weldments
740H Pipe to 282 Casting Weld
© 2013 Electric Power Research Institute, Inc. All rights reserved. 16
 Casting Modeling and Next Steps

• Casting simulation are being

utilized for nickel-based alloys
• Cooling rate and secondary
dendrite arm spacing
predictions are being validated
for different cooling rates

~2700kg (6,000lb) ½ Valve body

(simulate full-size valve)
Casting planned for mid 2014
© 2013 Electric Power Research Institute, Inc. All rights reserved. 17
 Casing to Pipe Weld

• Boiler to turbine
connection
• Leverage A-USC
boiler knowledge
from Inconel 740H
welding
• Successful weld
completed

© 2013 Electric Power Research Institute, Inc. All rights reserved. 18

 Two ingots now produced:
A-USC Turbine Highlight
1. Chemical homogeneity /
Haynes 282 Rotor Scale-Up grain size / defects evaluation
2. Disc forging

World’s First Haynes 282 Triple Melt Ingot

© 2013 Electric Power Research Institute, Inc. All rights reserved. 19

 Haynes 282 (Triple Melt) has been successfully
forged into a disc for detailed evaluations

Characterization Plan:
Tensile, Creep, LCF,
Disc meets criteria for HCF, FCGR and
largest Toughness + fatigue in
A-USC forging needed
steam (ORNL)
(IP turbine)
© 2013 Electric Power Research Institute, Inc. All rights reserved. 20
 Next Steps: ComTest 1400

• Evaluation of advanced materials and components under

coal fired, A-USC conditions.

• Minimize risk for a utility desiring to build an A-USC Plant.

– Demonstrate turbine operation
– Demonstrate reliability and safety
– Understand manufacturing and cost

• Evaluation of the constraints in the supply chain

• Validation of fabrication techniques, and the ability to

construct, install and repair ComTest with on-site labor.

© 2013 Electric Power Research Institute, Inc. All rights reserved. 21

 Specific Goals
• Boiler: Design, install, start-up, operate and cycle high
temperature nickel components (740H & others)
• Large diameter piping
• Header and tubes (gas fired heater)
• Superheater materials exposure (at pressure)
• Turbine: Design, install, start-up, operate and cycle full size
Steam Valves & COMTEST steam turbine for 760°C (1400°F).
– Periodic testing of steam valves at high temperature
– Materials & coatings
– Turbine architecture
– Oxidation, deposits, SPE
– NDE/NDT
• Fabrication methods &
supply chain for super-alloys Proposed ComTest 1400 Turbine

© 2013 Electric Power Research Institute, Inc. All rights reserved. 22

 ComTest 1400 Schematic
BYPASS EXHAUST BYPASS

HP, HT VALVE TEST

1400F, 2400-3500 PSIA
100,000 LB/HR THICK WALL PRESSURE LET- AUXILLIARY
DESUPER
SECTION DOWN SYSTEM REHEATER
SV CV 1400F, 700 PSIA

SV CV NATURAL
BFW DESUPERHEATER AND GAS
THICK WALL SECTION

COMTEST TURBINE

MAIN STEAM
TO TURBINE
1400F, 2400-3500 PSIA
100,000 LB/HR
WATER
BRAKE

EXHAUST TO
CONDENSER
OR TURBINE
CROSSOVER

BFW
Unique feature compared to other component tests:
•Higher-Temperature operation 760°C (1400°F)
•Turbine Demonstration
•Aux. Heaters for cycling / control independent from boiler
•Innovative membrane wall concept
© 2013 Electric Power Research Institute, Inc. All rights reserved. 23
 ComTest 1400

TO EXISTING MAIN STEAM

AQCS

COMTEST
SUPERHEATER

GAS FIRED
REHEATER
VALVE
TEST

Membrane wall
(not shown)

GAS FIRED
TURBINE
SUPERHEATER

© 2013 Electric Power Research Institute, Inc. All rights reserved. 24

 ComTest 1400 - Schedule

Task 1 is underway and has proven to be challenging

© 2013 Electric Power Research Institute, Inc. All rights reserved. 25

 Major shift from Coal to Gas in the United States
impacted opportunities for testing/demonstration
Electricity Production in United States
Shift from coal to gas

Plant Retirements in U.S.

Accelerating Retirements for Coal

Source: FEDERAL ENERGY REGULATORY COMMISSION Coal

www.ferc.gov/oversight
© 2013 Electric Power Research Institute, Inc. All rights reserved. 26
 ComTest approach for first A-USC turbine

• Host identified: municipal steam source (coal-fired)

• Advantages:
– Coal + Natural Gas onsite for gas-fired heater to
maintain desired temperature/cycling
– Favorable options for layout including existing building
for turbine
– Staff for operation
• Disadvantages
– Pressure will be lower than desired (turbine test was
planned to be at lower pressure)
– No membrane wall or heavy wall cyclic header test
Exploring options to split into 2 projects but achieve same objectives

© 2013 Electric Power Research Institute, Inc. All rights reserved. 27

 Summary

• A-USC = Least Regret Strategy

• Materials are key enabling technology
• U.S. Program continues to make excellent progress on the
materials technology for A-USC Turbines
– Rotor scale-up and testing
– Casing scale-up
• Planning work for a 760°C (1400°F) test facility is ongoing
– New possibilities including a host site for a portion of the
test program have been identified

© 2013 Electric Power Research Institute, Inc. All rights reserved. 28

 Together…Shaping the Future of Electricity

© 2013 Electric Power Research Institute, Inc. All rights reserved. 29