Material For Advance Ultra Supercritical Turbine Presentantion - 20160420 - 1300A - FE0026294 - EIO

Materials for Advanced Ultra-
supercritical Steam Turbines -

Advanced Ultra-supercritical
Component Demonstration
DOE Contract Number DE-FE0025064
Robert Purgert
Principal Investigator
Energy Industries of Ohio
Horst Hack
Presenter
Electric Power Research Institute
2016 Crosscutting Research Portfolio Review

April 20, 2016
Pittsburgh, PA, USA
© 2016 Electric Power Research Institute, Inc. All rights reserved.
What is “Advanced Ultra-Supercritical” ?
Higher efficiency fossil fuel cycles

- Burn less coal
- Produce fewer pollutants
- Generate less CO2
Higher temperatures and pressures

- Allow higher plant cycle efficiency
- Require advanced materials
2
Background of A-USC Materials Programs
 Present work builds upon 15-year effort supported by U.S.

Department of Energy, Ohio Coal Development Office, and
industry participants
– Boiler Materials for Advanced Ultra-supercritical Coal Power Plant
 DOE Contract: DE-FG26-01NT41175
 OCDO Grant: CDO-D-05-02(A)
– Materials for Advanced Ultra-supercritical Steam Turbines
 DOE Contract: DE-FE0000234
 OCDO Grant: CDO-D-05-02(B)
3
Materials Limit the Current Technology:
Today’s State-of-the-Art (USC) are defined by steel 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
Steels = USC
620°C (1150°F) Solid Soln’ = A-USC 10
60
9-12Cr Creep-Strength ~700°C (1300°F) 8
Enhanced Ferritic Steels Advanced Austenitic Minimum Desired
40 (Gr. 91, 92, 122) Alloys (Super 304H, 6
347HFG, NF709, etc.) Haynes 230 Strength at
Application
550 600 650 700 750 800 Temperature
o
Average Temperature for Rupture in 100,000 hours ( C)
4
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 evaluated
– For boiler:
 Corrosion resistance for US coals
 Data for ASME code acceptance of new materials
 Evaluate the effect of combining technology with other carbon capture
technologies such as Oxycombustion
5
U.S. DOE/OCDO: A-USC Steam Boiler Consortium
1: Conceptual Design
2: Material Properties
3: Steamside Oxidation
4: Fireside Corrosion 8: Design Data & Rules

(including Code
5: Welding interface)
6: Fabricability
7:
Coatings
Develop the materials technology to

fabricate and operate an A-USC steam boiler with
steam parameters up to 1400°F (760°C)
6
DOE/OCDO A-USC Steam Turbine Consortium
 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
7
Turbine
 Final Phase 2 technical report recently published by DOE

– “Materials for Advanced Ultrasupercritical Steam Turbines”
– http://www.osti.gov/scitech/biblio/1243058
8
Consortia Accomplishments Summary
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)
9
ComTest is the Next Step for the Highly Successful and Highly Leveraged
U.S. Department of Energy (US DOE) / Ohio Coal Development Office (OCDO) A-USC Steam
Boiler and Turbine Consortia
Federal – State – National Laboratory
Welding
New Materials
Cost Sharing Consortium
Non Profit – For Profit
Castings
Fabrication
Forging Field Test
10
Project Objectives of ComTest
 Evaluate advanced materials and components under A-USC
service conditions
 Minimize risks
– For a firm to own and operate an A-USC plant
– For the OEM to provide commercial guarantees
 Understand manufacturing, cost, and supply chain issues

– First of a kind
 Validate fabrication, construction, installation and repair of A-

USC components
11
ComTest Project Team
 Energy Industries of Ohio (EIO): prime contractor / administrative lead
 Electric Power Research Institute: technical lead organization
 Team members
– AECOM EPC contractor
– Youngstown Thermal (selected host site)
– Advanced USC ComTest Consortium
 EPRI
 Babcock & Wilcox
 General Electric Power (turbine design group)
 General Electric Power (former Alstom Power)
12
Utility Advisory Committee
 Formed in 2014 to support the development of a U.S. based

A-USC Component Test Facility
• Prioritize needs, from utility perspective,
 Current membership and provide critical input to build confidence
in using A-USC technology
– Southern Company • Ensure A-USC technology is ready
when needed by industry
– AEP • Support project by defining technology
needs, justifying technical approach,
– Duke providing potential host site(s),
– FirstEnergy collaborating with the project team,
and informing stakeholders
– Tri-State
13
ComTest Schematic
EXHAUST
HIGH PRESSURE, HIGH

TEMPERATURE VALVE TEST Superheater Header
MEMBRANE TEMPERATURE,
STEAM FROM SV CV RETURN TO
WALL AND PRESSURE
HOST HOST
SUPERHEATER ADJUSTMENT
STOP CONTROL THICK WALL
VALVE VALVE SECTION
Turbine Inlet
NATURAL Valves EXHAUST
Conditions
GAS
1400ºF, 600 psig,
Membrane Wall / ~130,000 lb/hr
PRESSURE LET-
Superheater DOWN SYSTEM
REHEATER
SV
CV
NATURAL
- Plan up to 14,000 GAS
hours at A-USC WATER

A-USC Turbine
temperatures BRAKE
- Steady state and

TEMPERATURE,
ramping conditions Testing of full scope may require testing PRESSURE
RETURN TO
HOST
ADJUSTMENT
- Complete by 2020 at additional facilities in the future
14
ComTest Technical Project Goals
 Demonstrate high pressure boiler reliability and safety
– Design, install, start-up, operate and cycle high temperature nickel
components (Inconel 740H & others)
– Large diameter thick-section piping
– Membrane wall with advanced steels and alloys
– Cycling header and tubes
– Superheater materials exposure (at pressure & temperature)
 Demonstrate high temperature turbine and components in operation Proposed ComTest Superheater
– Design, install, start-up, operate and cycle full size steam valves & ComTest
steam turbine at 760⁰C
– High temperature steam valves
– Materials & coatings
– Turbine architecture
– Oxidation, deposits, solid particle erosion (SPE)
– NDE/NDT
Proposed ComTest Turbine
15
Primary A-USC ComTest Site Youngstown, Ohio
(Former Ohio Edison Generation Plant)
Preliminary layout
16
16
Equipment Arrangement Plan at Youngstown Site
ComTest Existing
turbine building boiler
and control building
room
ComTest
superheater
tower
New water New
New cooling
package treatment
towers
boiler
17
Alternate A-USC High Pressure Test Site Mobile, Alabama
18
Accomplishments
 Multiple potential host sites evaluated

 Primary and alternate host sites identified
 Pre-FEED and FEED tasks completed
– Preliminary capital cost estimate prepared
– PFD and P&ID documents developed
– Interface conditions defined for scope boundaries
– Equipment arrangement defined for host site
 US-based supply chain development ongoing
 NEPA for primary host site proceeding
19
Next Steps
 Proceed with Detailed Engineering effort

 Complete NEPA procedure in support of environmental
assessment for host site
 Finalize testing operating plans
 Develop procurement specifications for equipment
 Construct ComTest facility
 Operate for two years (ending in 2020)
20
A-USC ComTest Preliminary Schedule
Key:
Milestone (i.e. meeting, presentation)
Deliverable (i.e. report)
2015 2016 2017 2018 2019 2020
• Pre-FEED Final Report

• NEPA NEPA Report
• FEED Prelim Cost Estimate
• Detailed Engineering Final Cost Estimate
• Procurement & Construction

• Operation
a. Membrane Wall & SH
b. Cycling Header & Valves
c. Steam Turbine
• Evaluation & Reporting
21
Transformational technologies will need the A-USC materials
and components demonstrated in ComTest
A-USC Materials R&D Consortium
(Boiler and Turbine) sCO2 R&D
A-USC ComTest sCO2 PILOT
A-USC DEMO A-USC DEMO

sCO2 DEMO
Plant Topping/Retrofit/Repowering
ComTest provides options to

enable transformational
technologies
22
Together…Shaping the Future of Electricity
23

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Materials for Advanced Ultra-

supercritical Steam Turbines -

2016 Crosscutting Research Portfolio Review

Higher efficiency fossil fuel cycles

Higher temperatures and pressures

 Present work builds upon 15-year effort supported by U.S.

4: Fireside Corrosion 8: Design Data & Rules

Develop the materials technology to

 Selected materials from Phase I

 Final Phase 2 technical report recently published by DOE

Welding Technology Developments

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

Forging Field Test

 Understand manufacturing, cost, and supply chain issues

 Validate fabrication, construction, installation and repair of A-

 Electric Power Research Institute: technical lead organization

 Formed in 2014 to support the development of a U.S. based

HIGH PRESSURE, HIGH

hours at A-USC WATER

- Steady state and

 Multiple potential host sites evaluated

 Proceed with Detailed Engineering effort

2015 2016 2017 2018 2019 2020

• Pre-FEED Final Report

• Procurement & Construction

A-USC ComTest sCO2 PILOT

A-USC DEMO A-USC DEMO

ComTest provides options to

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