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https://doi.org/10.1007/s11668-019-00662-6
TECHNICAL ARTICLE—PEER-REVIEWED
Abstract T92 steel is widely used in high-temperature temperature of the wall metal. Relevant calculations show
superheater of supercritical power station boiler, and the that for every 0.025 mm oxide increase, the superheater
researches on its remaining life have always been the hot wall temperature increases by about 1.67 C. At the same
spot of scholars around the world. In this paper, based on time, exfoliated oxide skin will block the steam flow and
the analysis of high-temperature creep rupture strength cause superheater tube over-temperature explosion. This
data, the optimum C value of Larson–Miller parameter has become the second major cause of boiler tube failure in
formula for T92 steel is obtained by using isothermal the world [1]. T92 steel is widely used in high-temperature
extrapolation method. On this basis, combining the rela- superheater of supercritical power station boiler. Therefore,
tionship between the thickness of the oxide layer and the it is of great significance to evaluate the remaining life of
operating time, the relationship between the thickness of T92 steel for superheater tubes. Rolf Sandström et al. [2]
the oxide layer and the temperature of the tube wall and the combined the precipitation hardening model to derive the
relationship between the thickness of the oxide layer and life assessment model for ductile fracture of austenitic
the stress of the tube wall, a new remaining life evaluation heat-resistant steel. Purbolaksono et al. [3] found that the
formula is deduced. Finally, based on the cumulative creep major contributor which results in the failure of the tube
damage life evaluation method, the service life of super- was interaction between the excessive scale formation on
heater tube is divided into three stages, which provides a the inner surface and outer wall thinning due to coal-ash
new reference for the service life evaluation of superheater corrosion. Kapayeva et al. [4] presented the method that
tube of ultra-supercritical boiler. considers a combined effect of overheating and wall thin-
ning. They used LMP method for creep evaluation, while
Keywords Larson–Miller parameter Superheater adding the effect of wall thinning. The actual data for the
Oxide layer growth Remaining life evaluation thickness of tube wall and thickness of internal oxide layer
Cumulative creep damage were taken from measurements using nondestructive test-
ing methods. Ilman et al. [5] found the cause of failure was
overheating due to deposit buildup inside the superheater
Introduction tube. In this paper, based on the LMP formula, considering
the relationship between the thickness of the oxide layer
Due to the large heat transfer resistance of the oxide layer, and the operating time and the relationship between the
the heat exchange between the steam medium and the wall thickness of the oxide layer and the temperature and stress
metal is blocked, which leads to the increase in the of the tube wall, a new remaining life evaluation formula is
derived to evaluate the use of the ultra-supercritical boiler
superheater tube life.
J. Li H. Wei (&) Z. Yuan
School of Mechanical and Automotive Engineering, South China
University of Technology, Guangzhou 510641, Guangdong,
People’s Republic of China
e-mail: 469713239@qq.com
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Table 1 Linear fitting results of lgtr and temperature 1/T under by the European Creep Collaborative Committee (ECCC)
different stress values database [7]. It can be seen from the figure that the life
r/Mpa T/C Fitting equation C value prediction equation derived from the LMP method when
the parameter C = 29.40979 is selected is relatively accu-
80 625–650–675 y = 20.92 ? 23159.23x C1 = 20.92 rate for the life prediction of T92 steel.
90 625–650–675 y = 24.89 ? 26614.63x C2 = 24.89
100 625–650–675 y = 27.29 ? 28551.98x C3 = 27.29
110 625–650–675 y = 32.30 ? 32905.4x C4 = 32.30 Relationship Between Growth Thickness of Oxide
130 600–625–650 y = 29.41 ? 29714.09x C5 = 29.41 Layer and Operation Time of Boiler
140 600–625–650 y = 26.76 ? 27209.87x C6 = 26.76
160 600–625–650 y = 24.98 ? 25100.97x C7 = 24.98 The oxide layer on the inner wall of the ultra-supercritical
180 550–575–600 y = 35.29 ? 33641.73x C8 = 35.29 boiler superheater tube is formed by chemical reaction
190 550–575–600 y = 33.96 ? 32126.39x C9 = 33.96 between the inner wall of the high-temperature tube and the
210 550–575–600 y = 38.91 ? 35803.57x C10 = 38.91 high-temperature and high-pressure steam. In the high-
Average value C = 29.47 temperature and high-pressure steam environment, the
formation of oxide layer in the tube is a natural process.
The thickness and growth rate of oxide layer are the result
lg r ¼ 8:64311 8:5289 104 P of multiple factors. According to the study of Wright and
ðEq 5Þ
þ 3:97613 108 P2 þ 6:2093 1013 P3 Pint of oak ridge national laboratory (ORNL), the thickness
growth of the oxide layer is as follows [8]:
P ¼ Tð29:40979 þ lg tr Þ ðEq 6Þ
e ¼ A eQ=RT t1=n ðEq 7Þ
where r is stress; T is temperature (K); and tr is fracture
time where e is the thickness of oxide layer; A is the Arrhenius
Figure 3 shows a comparison between the life prediction constant; Q is the process rate control activation energy; R
results of the T92 steel LMP model and the data published
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The Formula of Remaining Life is Obtained formation of the oxide layer is stable, the rate of decline
by Combining L–M Formula tends to moderate, but, at this time, the remaining life of
the superheater tube has been greatly reduced, and the
Through the analysis of the operating stress of superheater safety risk of the unit operation has intensified.
tube, the initial stress value of tube wall is about 47 MPa.
The initial stress value is taken into Eq 5 to obtain
P(r) = 32215.8 and bring P(r) into the LMP formula to get Remaining Life Assessment Method Based
the remaining life of T92 steel as follows: on Cumulative Creep Damage
tr ¼ 10ð Þ
32215:8
T 29:40979 ðEq 9Þ
The life assessment method for cumulative creep damage is
The equation between the thickness of oxide layer and to consider the problem from a dynamic perspective.
the maximum wall temperature (outside wall temperature) During the operation of the unit, the temperature and stress
is obtained by numerical simulation as follows: of the tube are varied. In order to adapt to this change,
Robinson’s life fraction rule [11] proposed a cumulative
T ¼ 917:78 þ 0:072e ðEq 10Þ
creep damage life assessment method. For the calculation
where T is the highest wall temperature of the tube (K) and of cumulative creep damage, each damage unit is calcu-
e is thickness of oxide layer. lated according to each temperature and stress level. When
Substituting Eq 10 into Eq 9 yields: the sum of these damages reaches 1, it can be deemed as
the failure of the pressure tube. The cumulative creep
tr ¼ 10ð917:78þ0:072e29:40979Þ
32215:8
ðEq 11Þ
damage formula is as follows:
And substituting Eq 8 into Eq 11 yields: X n
ti
D1 ¼ 1 ðEq 13Þ
32215:8 29:40979
t
i¼1 ri
917:78þ0:16494768t0:5
tr ¼ 10 ðEq 12Þ
where ti is the operating time of the pressurized tube under
where tr is fracture time an t is operation hours. ith stress and temperature and tri is the creep rupture time
Thus, the relationship between the remaining life of of pressure tube under ith stress and temperature.
superheater tube of ultra-supercritical boiler and the oper- From Eq 12, it is known that the remaining life of the
ating time of the unit can be obtained. According to Eq 12, superheater tube is different under different operating times,
the relation diagram of remaining life of tube with unit that is, the remaining life of the tube is time-varying under
operation time is made, as shown in Fig. 4. As the unit’s different temperatures and stresses. So Eq 13 can be
operating time increases, the remaining life of the super- expanded as shown in Eq 14. Since the operating conditions
heater tube decreases gradually and approaches zero. Since are constantly changing, the corresponding t1, t2…tn are
the growth of the oxide layer exhibits a parabolic law, the consecutive infinitesimal instantaneous time periods, and
remaining life of the tube in the initial stage of service these instantaneous times can be represented by Dt. Equa-
declines drastically, and the rate of decline is large. As the tion 14 can be transformed into Eq 15. Since tr is a function
of the unit operating time t and is continuous, 1/tr can be
regarded as a function of the unit operating time t, denoted as
f(t). Then, Eq 16 can be regarded as the definite integral of
the integrand function f(t), so that Eq 17 can be obtained.
X n
ti t1 t2 t3 tn
¼ þ þ þ þ ðEq 14Þ
t
i¼1 ri
tr1 tr2 tr3 trn
X
n
ti X
n
1
¼ lim Dt ðEq 15Þ
t
i¼1 ri
Dt!0 t
i¼1 ri
X
n Z t
1
lim Dt ¼ f ðtÞdt ðEq 16Þ
Dt!0 t
i¼1 ri 0
Z t
D1 ¼ f ðtÞdt ðEq 17Þ
0
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10. J.M. Sarver, J.M. Tanzosh, Steamside oxidation behaviour of Publisher’s Note Springer Nature remains neutral with regard to
candidate USC materials at temperatures between 650 and 800 C. jurisdictional claims in published maps and institutional affiliations.
Energy Mater. 2(4), 227–234 (2013)
11. F.R. Larson, J. Miller, A time-temperature relationship for rup-
ture and creep stresses. Trans. ASME 7, 765–775 (1952)
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