Welding
New Materials
Castings
Fabrication
Field Test
Forging
Accomplishments
A-USC Fact Book - EPRI 1022770
Fabrication Processes
Steam-Side
Oxidation
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
Note:
HHV Basis
1200
1300
1400
500
70
Nickel-Based
Alloys
Inconel 740
50
300
30
Stress (ksi)
Stress (MPa)
Haynes 282
Std. 617
CCA617
100
80
10
60
40
9-12Cr Creep-Strength
Steels = USC
Enhanced Ferritic
620CSteels
(1150F)
(Gr. 91, 92, 122)
550
600
650
700
6
Haynes 230
750
800
o
Minimum
Desired
Strength at
Application
Temperature
(All)
(ORNL)
Task 12. 5
Rotors, Buckets
Bolting
Task 12. 3
Castings (Siemens)
Task 12. 4
Task 12.1
Non Welded
Rotors (GE)
Task 12. 3
Welded
Rotors (Siemens,
Alstom
Task 12. 2
Mechanical
Properties of
Materials (GE)
Weldability Studies
(Siemens, ALSTOM)
Mechanical Properties
(Siemens,ALSTOM)
Task 12. 3
Task 12. 2
Task 12. 2
Mechanical
Properties
(Siemens)
Task 12. 4
52
Udimet 720Li
50
5
H282-P e a k a g e d
1450F , 32.5ksi
1450F , 27.5ksi
4.5
LMP (C = 20)
3.5
Strain (%)
Nimonic 105
48
Microstructure
Haynes 282
3
2.5
2
46
44
42
Creep-Rupture
40
1.5
38
36
0.5
0
0
200
400
600
800
1000
1200
10
1400
Fatigue Behavior
10.00
Forging Cooling
Simulations
100
Strength (ksi)
Stress (ksi)
120
T im e (h )
1.00
100
80
60
40
20
Haynes 282SA-0.2% YS
Tensile Strength
Haynes 282PA-0.2%YS
Haynes 282OV-0.2%YS
0
0
200
400
600
800
1000
Temperature (F)
0.10
100
1,000
10,000
100,000
1,000,000
1200
1400
1600
50 nm
Solution Annealed
PA = SA + 8h @ 790C
OV = PA + 250h @ 775C
10
Bare metals
(substrates)
and coatings
Erosion Testing
High-temperature
erosion tests were
conducted at
1400F (760C)
Coating and
substrates
12 Coatings
evaluated
Program Start
2013 Electric Power Research Institute, Inc. All rights reserved.
11
T400C (Tribaloy)
good resistance
Coating Conclusions
760C Erosion Test Results for Coatings
Stellic 6B
visible erosion
12
Surface morphology of
coatings after
760C erosion tests
with magnetite
Range of microstructures in a
slow-cooled casting
2013 Electric Power Research Institute, Inc. All rights reserved.
13
14
Pipe-to-casing
Casing
Rotor/Disc
Blading
2013 Electric Power Research Institute, Inc. All rights reserved.
15
Bolting
16
17
18
19
Characterization Plan:
Tensile, Creep, LCF,
HCF, FCGR and
Toughness + fatigue in
steam (ORNL)
20
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 760C (1400F).
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
BYPASS
BYPASS
SV
CV
THICK WALL
SECTION
DESUPER
SV
BFW
DESUPERHEATER AND
THICK WALL SECTION
AUXILLIARY
REHEATER
NATURAL
GAS
COMTEST TURBINE
MAIN STEAM
TO TURBINE
1400F, 2400-3500 PSIA
100,000 LB/HR
WATER
BRAKE
EXHAUST TO
CONDENSER
OR TURBINE
CROSSOVER
BFW
23
ComTest 1400
TO EXISTING
AQCS
MAIN STEAM
COMTEST
SUPERHEATER
GAS FIRED
REHEATER
VALVE
TEST
Membrane wall
(not shown)
GAS FIRED
SUPERHEATER
TURBINE
24
25
26
Coal
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 760C (1400F) test facility is ongoing
New possibilities including a host site for a portion of the
test program have been identified
28
29