Due to their continuing role in electricity generation, it is important that coal power plants operate as efficiently and cleanly as possible. Coal Power Plant Materials and Life Assessment reviews the materials used in coal plants, and how they can be assessed and managed to optimize plant operation. Part I considers the structural alloys used in coal plants. Part II then reviews performance modelling and life assessment techniques, explains the inspection and life-management approaches that can be adopted to optimize long term plant operation, and considers the technical and economic issues involved in meeting variable energy demands. * Summarizes key research on coal-fired power plant materials, their behavior under operational loads, and approaches to life assessment and defect management* Details the range of structural alloys used in coal power plants, and the life assessment techniques applicable to defect-free components under operational loads* Reviews the life assessment techniques applicable to components containing defects and the approaches that can be adopted to optimize plant operation and new plant and component design
Contributor contact details xi
Woodhead Publishing Series in Energy xv
Part I Materials for coal power plant 1 (168)
construction
1 Grade 91 heat-resistant martensitic steel 3 (49)
F. Abe
1.1 Introduction 3 (1)
1.2 Chemical compositions, heat 4 (9)
treatments and microstructure
1.3 Estimation of long-term creep strength 13 (18)
1.4 Microstructure evolution 31 (7)
1.5 Degradation in welded joints: type IV 38 (4)
fracture
1.6 Creep-fatigue properties 42 (1)
1.7 Steam oxidation and exfoliation of 42 (3)
oxide scale
1.8 Sources of further information and 45 (1)
advice
1.9 References 46 (6)
2 Grade 92 creep-strength-enhanced ferritic 52 (35)
steel
Y. Hasegawa
2.1 Introduction 52 (1)
2.2 Chemical composition and alloy design 53 (4)
of Grade 92 steel
2.3 The manufacturing process and 57 (1)
microstructure
2.4 Physical properties 58 (3)
2.5 Other mechanical properties of Grade 61 (4)
92 steel
2.6 Creep rupture and strain properties 65 (5)
2.7 Optimizing the chemical composition 70 (12)
for creep rupture strength of Grade 92
steel
2.8 Equilibrium phase diagram of Grade 92 82 (1)
steel
2.9 Continuous cooling rate 83 (1)
transformation diagram (CCT diagram)
2.10 Field test record 83 (1)
2.11 Production records 84 (1)
2.12 References 85 (2)
3 T23 and T24 - new generation low alloyed 87 (20)
steels
S. Paddea
F. Masuyama
A. Shibli
3.1 Introduction 87 (1)
3.2 Developments in low alloy steels 87 (3)
3.3 The metallurgy of low alloy steels 90 (4)
3.4 Welding and weld performance 94 (7)
3.5 Service and lifetime properties 101(1)
3.6 Fabrication issues 102(2)
3.7 Conclusion 104(1)
3.8 References 105(2)
4 Traditional low alloy steels in power plant 107(20)
design
D.G. Robertson
4.1 Introduction 107(1)
4.2 Metallurgy of low alloy 108(6)
creep-resisting steels
4.3 Low alloy steels used for other 114(2)
components
4.4 History of the use of low alloy steels 116(3)
4.5 Properties of low alloy steels 119(3)
4.6 Design stress values for low alloy 122(1)
steels
4.7 High-temperature properties of welds 123(1)
4.8 Conclusion 124(1)
4.9 References R 124(3)
5 Creep strength of austenitic stainless 127(20)
steels for boiler applications
R. Sandstr?m
5.1 Introduction 127(1)
5.2 Creep strength 128(7)
5.3 Modelling of creep strength 135(7)
5.4 Conclusion 142(1)
5.5 References 143(4)
6 Nickel-base alloys for advanced power plant 147(22)
components
P.J. Ennis
6.1 Introduction 147(1)
6.2 Development of nickel-base alloys 148(2)
6.3 Critical components 150(1)
6.4 Materials testing programmes 151(3)
6.5 Candidate alloys 154(6)
6.6 Properties of the candidate alloys 160(5)
6.7 Conclusion and future trends 165(1)
6.8 References 165(4)
Part II Performance assessment of coal power 169(220)
plants
7 In-service loading data and life assessment 171(28)
procedures in coal power plants
A. Tonti
7.1 Introduction 171(2)
7.2 Data collection 173(12)
7.3 Fundamental techniques and data 185(3)
collation
7.4 Data analysis and life assessment 188(4)
7.5 Modelling performance and life 192(1)
assessment
7.6 Application towards improving service 193(2)
life
7.7 Advantages and limitations of 195(1)
approaches
7.8 Emerging trends 195(2)
7.9 References 197(2)
8 Residual life evaluation techniques, defect 199(30)
assessment procedures and monitoring in coal
power plants
A. Tonti
8.1 Introduction 199(3)
8.2 Residual life evaluation techniques 202(12)
8.3 Defect assessment procedures 214(5)
8.4 Monitoring 219(2)
8.5 Future trends 221(6)
8.6 Sources of further information and 227(1)
advice
8.7 References 227(2)
9 Fracture mechanics and testing for crack 229(36)
initiation and growth assessment in coal
power plants
F. Mueller
M. Oechsner
9.1 Introduction 229(1)
9.2 Experimental determination of 230(9)
high-temperature crack initiation and
growth
9.3 Analysis of crack data 239(3)
9.4 Crack initiation 242(9)
9.5 Crack growth 251(9)
9.6 Conclusion 260(1)
9.7 References 261(3)
9.8 Appendix: nomenclature 264(1)
10 Risk-based inspection and life management 265(23)
in boilers in coal power plants
J.W.H. Price
10.1 Introduction 265(2)
10.2 Fundamentals of risk-based life 267(6)
management of boilers
10.3 Example of a maintenance strategy 273(4)
for a tube bank
10.4 Example of problems with repeated 277(2)
measurements
10.5 Management of creep-affected 279(2)
components
10.6 Management of creep cracks 281(2)
10.7 References 283(1)
10.8 Appendix 1: a background to risk 284(1)
10.9 Appendix 2: risk-based inspection 285(3)
(RBI)
11 Practical determination of probability of 288(30)
failure in risk-based inspection and life
management of coal power plants
A. Jovanovic
P. Auerkari
J.M. Bareiss
11.1 Introduction 288(2)
11.2 Basic principles and requirements 290(3)
for Risk-based Inspection (RBI) in CWA
15740:2008
11.3 Risk-based Inspection and 293(3)
Maintenance Procedures for European
Industry (RIMAP) procedure
11.4 Requirements for Probability of 296(2)
Failure (PoF) analysis
11.5 PoF and damage/failure rates data 298(1)
11.6 RIMAP method for determination of PoF 299(7)
11.7 Practical application of the approach 306(8)
11.8 Conclusion 314(1)
11.9 References 315(3)
12 Preservation of power plant boilers/heat 318(15)
recovery steam generators (HRSGs) during
short- and long-term shutdowns
A. Shibli
D.G. Robertson
W. Moore
12.1 Introduction 318(3)
12.2 Lay-up monitoring and maintenance 321(4)
12.3 Dry storage 325(2)
12.4 Wet storage 327(3)
12.5 Water treatment plant and cooling 330(2)
water systems
12.6 Other parts of power plants/combined 332(1)
cycle gas turbines (CCGTs)
12.7 Conclusion 332(1)
12.8 Sources of further information and 332(1)
advice
13.9 Reference 332(1)
13 Damage to coal power plants due to cyclic 333(25)
operation
A. Shibli
J. Ford
13.1 Introduction 333(1)
13.2 UK experience with two-shifting 334(2)
13.3 Commercial reasons for cyclic 336(2)
operation/two-shifting
13.4 Failure mechanisms and implications 338(16)
for key components
13.5 Miscellaneous issues 354(3)
13.6 Conclusion 357(1)
13.7 References 357(1)
14 Cost modelling of coal power plant 358(31)
start-up in cyclical operation
P. Keatley
14.1 Introduction 358(1)
14.2 Historical background 359(2)
14.3 Component-level engineering studies 361(4)
14.4 Plant- and unit-level studies 365(2)
14.5 Statistical studies 367(3)
14.6 Cost of cycling estimates 370(4)
14.7 The Irish single electricity market 374(11)
study
14.8 Conclusion 385(1)
14.9 References 386(3)
Index 389
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