Electric Power Research Institute 2008 Portfolio

171 Thermal Fatigue Cracking in the Waterwalls of Supercritical Boilers

Program Overview
Industry Needs and Issues Addressed Thermal fatigue cracking on waterwalls is the leading failure mechanism in supercritical boilers Cracking has also occurred in weld overlays installed to mitigate fireside corrosion in many units The mechanism of cracking is well understood but the root causes and their solutions need clear definition There may be as many as 16 different possible root causes of thermal fatigue (different boilers have different root causes) Key Accomplishments This issue program was initiated in 2007 with key parts from two other programs (Programs 71 and 87) and joint project activities with Programs 63 and 64 A comprehensive state-of-knowledge document was developed that described the fireside and fluidside influences, and provided direction for the needed research An initial thermalhydraulic model was developed to provide a clearer understanding of internal fluid flow and pseudo film boiling characteristics

Value Comprehensive understanding for the major root causes and solutions for thermal fatigue, or approaches to root causes Elimination of repeat tube failures due to thermal fatigue cracking Improved availability

Anticipated Deliverables Deliverables from P71.001 of the Combustion Performance and NOX Control Program will be provided to members of Program 171. Deliverables from a number of joint project activities with Program 64 (Cycle Chemistry Program) and Program 63 (Boiler Life and Availability Improvement Program) will also be provided to members of Program 171. These will address internal oxide/chemical cleaning and NDE solutions, respectively. Deliverables in P171.001 will address the root causes of thermal fatigue. Program Technical Lead Anthony Facchiano 650-855-2494 afacchia@epri.com

Industry Involvement Estimated total 2008 budget: $0.5M Program financial leverage:

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EPRI 2008 Portfolio

171 Thermal Fatigue Cracking in the Waterwalls of Supercritical Boilers

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Summary of Projects
Project Number Project Title Value

P171.001

Development of Solutions for Thermal Fatigue

The mechanism of thermal fatigue has multiple root causes related to increased tube wall temperature and frequent thermal transients. The project will provide: an understanding of the thermalhydraulic aspects of supercritical walls; important fireside corrosion parameters as a function of heat flux and combustion conditions; assessment of internal oxide formation and chemical cleaning; optimum tube and weld overlay materials and application; inspection and crack sizing capability; CFD modeling to quantify the impacts of low-NOX combustion systems.

Project Descriptions
P171.001 Development of Solutions for Thermal Fatigue (063569)
Issue Thermal fatigue boiler tube failures (BTF) result in a series of parallel circumferential cracks on the OD surface of the tube or in the overlay if applied. The cracking is driven by two factors: an increasing tube surface temperature, and frequent thermal transients. In the case of tubes with overlay, there is an instant increase in tube skin temperature once the overlay is applied. In most cases of thermal fatigue, a thick internal oxide has been observed, which resembles an oxide grown in steam circuits. This also results in elevated temperature. Tube surface temperature can also increase due to increased heat flux and flame impingement. There are 16 possible root causes for thermal fatigue. The supplemental EPRI project on thermal fatigue was conducted to demonstrate how to determine the actual root cause for each boiler and the time in operating space when the thermal driver occurs. This is a vital process so that solutions can be applied. A state-of-knowledge document was initiated in 2007; it will be completed in 2008 and define the highest priority root causes that need to be addressed. Description Once the root causes of thermal fatigue are defined, it will be necessary to accurately size and monitor the cracks. Reliable nondestructive evaluation (NDE) techniques will be developed in conjunction with Program 63. In conjunction with Program 71, the project will deploy advanced CFD modeling to quantify the impacts of the combustion processes on corrosion (especially under low-NOX firing conditions), waterwall temperatures, boiler heat release rates and other design characteristics. The project will also develop tools to comprehensively assess the thermalhydraulic and thermodynamic influences on internal fluid flow, including aspects of pseudo-film boiling. In conjunction with Program 64, the project will develop tools to assess internal oxides, and how and when to optimally chemical-clean tubes. Finally, the project will assemble a guideline on how to address all aspects of fatigue. Value

Improve supercritical boiler availability. Develop and apply NDE tools to size thermal fatigue cracks. Develop and apply guidelines to address all aspects of thermal fatigue. Provide input for design specification for new supercritical plants to mitigate thermal fatigue cracking risks.

EPRI 2008 Portfolio

171 Thermal Fatigue Cracking in the Waterwalls of Supercritical Boilers

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How to Apply the Results Members will first apply the techniques and philosophies encompassed in the supplemental project to identify actual root causes of thermal fatigue for their boilers. They will have a set of NDE tools to size the cracks and a guideline that provides solutions to all the high-priority causes. 2008 Deliverables
Deliverable Title & Description Planned Completion Date Deliverable Type

State of Knowledge of Thermal Fatigue: This document will provide knowledge on all aspects of thermal fatigue, including the international literature and summaries of all EPRI work. Most importantly, it will provide comprehensive coverage of all the possible root causes of thermal fatigue. Initial Thermalhydraulic Model: Thermodynamic parameters change drastically around the supercritical point. The model will provide a quantitative understanding of fluid flow in the tubes as a function of boiler position and heat flux. Fireside Impacts on the Prediction of Thermal Fatigue Behavior: Model development will include an analysis of the key fireside parameters including heat fluxes, surface temperatures, surface deposits, and weld overlay properties. CFD and finite element analysis may be used in the development of this model. Guideline for Chemical Cleaning of Internal Oxides on Supercritical Boilers: This joint activity with Program 64 will address cleaning criteria and processes to remove internal oxide from supercritical walls. Guidelines for NDE Procedures: An NDE protocol was developed in 2006 in the supplementary project on root cause determination. This joint activity with Program 63 will consolidate all NDE procedures involving thermal fatigue cracking into a guideline. NDE Workshop (As-requested): This NDE Workshop will be a joint project activity with Program 63. Upon request, EPRI staff will visit a member site to provide a workshop on the optimum NDE processes for thermal fatigue. Thermal Fatigue Damage and Analysis (As-requested): Upon request, EPRI staff will provide assistance in identifying the key features of thermal fatigue in a members boiler. This may include an on-site workshop or a metallurgical analysis of the fluid and fire sides of the tube. Future Year Deliverables
Deliverable Title & Description

3/31/2008

Technical Report

12/31/2008

Technical Report

12/31/2008

Technical Report

12/31/2008

Technical Report

3/31/2009

Technical Update

12/31/2008

Workshop, Training, or Conference

12/31/2008

Technical Resource

Planned Completion Date

Deliverable Type

Advanced NDE Procedures: In parallel to producing the NDE Guidelines for Thermal Fatigue, in conjunction with Program 63 EPRI will conduct research on advanced crack depth detection techniques. Demonstration of Coating Technology: In conjunction with Program 87, work will be conducted to advance the established weld overlay approach. This may involve nanotechnology or new processes for overlay coatings.

2009

Technical Report

2009

Technical Report

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171 Thermal Fatigue Cracking in the Waterwalls of Supercritical Boilers

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Deliverable Title & Description

Planned Completion Date

Deliverable Type

Final Model for Thermal Fatigue: The thermalhydraulic model will be fine tuned, tested, and linked with the CFD analysis. This will be a vital tool in the root cause analysis for each boiler. Input will include monitored heat flux and thermocouple data from each boiler, as well as fluid flow and thermalhydraulic parameters. The model will provide insight into thermal fatigue crack initiation and growth. Guidelines for Thermal Fatigue: Guidelines will be developed to encompass all work from the program and associated programs. The anticipated deliverable will provide solutions for all the high-priority root causes. Optimum Supercritical Waterwalls: Weld overlays increase the skin temperature of supercritical walls. Manufacturing tubes from a corrosion-resistant material would provide a major benefit for thermal fatigue. Nickel-based alloys offer such an opportunity and will be tested in a host boiler.

2009

Technical Report

2009

Technical Report

2010

Technical Report