Comprehensive investigation of the metal in drums of boilers at thermal power stations

A comparative investigation of the metal of drums of two TP-100 boilers at the Starobeshevskaya and the Lugansk thermal power stations (TPS) was performed. Their operation time was approximately 300000 hours; the shell of one drum was ruptured during a hydraulic test, and the other drum is in operation. According to the results of the technical diagnostics and a strength analysis, both drums comply with the applicable regulatory requirements. The objects of the investigation were fragments of the ruptured drum and a “plug” cut out of the shell during a scheduled inspection. The investigation was carried out by microscopic metallography methods and the scanning electron microscopy technique. Mechanical tests of metal specimens were performed, and the hydrogen content in these specimens was measured. Prior to the material research, the metal was examined using a magnetic memory method. The investigation yielded specifics of the metal microstructure, mechanical properties, and fracture patterns of the metal specimens at various temperatures. An investigation performed by the method of thermal-desorption mass spectrometry revealed no considerable difference in the hydrogen content in the metal of both drums, thereby excluding the effect of hydrogenation in analyzing the rupture causes. It was established that the drum at the Starоbeshevskaya TPS had been damaged due to its low impact strength at room temperature and high brittle-ductile transition point. Comparison of the metallographic study data with the results obtained using the magnetic memory method suggests that the fracture was caused by local formation of the Widmannstatten pattern at points where accessories are welded to the shell. The prospects are demonstrated of the comprehensive approach to nondestructive examination (NDE) of TPS drums using the magnetic memory technique and metallographic methods.     

Change in working characteristics of the steam turbine metal with operating time of more than 330000 hours

Research of a metal of the stop valve case (SVC) of the K-300-23.5 LMZ turbine (steel grade 15Kh1M1FL), destroyed after operation for 331000 hours, is performed. It’s chemical composition and properties are determined as follows: a short-term mechanical tensile stress at 20°C and at elevated temperature, critical temperature, fragility, critical crack opening at elevated temperature, and long-term strength. Furthermore, nature of the microstructure, packing density of carbide particles and their size, and chemical composition of carbide sediment are estimated. A manifestation of metal properties for the main case components by comparison with a forecast of the respective characteristics made for the operating time of 331000 hours is tested. Property-time relationships are built for the forecast using statistical treatment of the test results for the samples cut out from more than 300 parts. Representativeness of the research results is proved: the statistical treatment of their differences are within the range of ±5%. It has been found that, after 150000 hours of operation, only the tensile strength insignificantly depends on the operating time at 20°C, whereas indicators of strength at elevated temperature significantly reduce, depending on the operating time. A brittle-to-ductile transition temperature (BDTT) raises, a critical notch opening changes in a complicated way, a long-term strength reduces. It has been found empirically that the limit of a long-term strength of the SVC metal at 540°C and the operating time of 10⁵ hours is almost 1.6 times less than the required value in the as-delivered state. It is possible to evaluate a service life of the operating valves with the operating time of more than 330000 hours with respect to the long-term strength of the metal taking into account the actual temperature and stress. Guidelines for the control of similar parts are provided.     

水管锅炉锅筒低周疲劳寿命计算

根据相关标准,调峰负荷机组必须进行锅炉锅筒的低周疲劳寿命计算,否则,严重影响机组的安全、经济运行.为此,针对锅炉锅筒运行时容易产生疲劳损耗的几种情况,给出锅筒低周疲劳寿命损伤的计算方法,同时介绍了利用计算机程序人机界面来计算锅炉锅筒低周疲劳寿命损伤流程,对于基层技术人员有一定的参考价值.     

Experience in Reconstructing the PT-60-90 Turbine by Reconditioning Heat Treatment of the High-Pressure Cylinder Shell

Experience in reconstructing the PT-60-90 turbine at Salavatskaya CHPP upon the operation for more than 350000 h is described. In the course of reconstruction, the life of the turbine was restored, its economic efficiency was increased, process extraction of 1.27–1.57 MPa was changed to uncontrolled extraction, and additional extraction of 3.43 MPa was arranged. The high-pressure cylinder (HPC) shell was restored by reconditioning heat treatment (RHT), and the rotor was replaced by a new modernized one. To select the optimal conditions of the reconditioning heat treatment of the HPC shell (of the PT-60-90 turbine) manufactured from 20CrMoPL grade steel, the results of previously conducted tests of the shell metal of the same grade were integrated. The heat treatment was carried out on modernized furnace equipment using means of and methods for controlling the temperature and heating and cooling rates. Detailed nondestructive inspection of the upper and lower HPC halves was performed. The locations, distribution, sizes, and types of the defects were identified. The detected defects and austenitic build-ups were removed, welded with pearlite electrodes, examined, and subjected to heat treatment (tempering). The actual heat treatment conditions were analyzed and, based on the obtained data on the mechanical properties of the metal, the tempering temperature and time were specified. Complete investigation of the metal of both HPC halves was conducted prior to the reconditioning heat treatment. The reliability of the metal of the cylinder shell after RHT was evaluated by the mechanical properties, such as tensile strength, critical ductile-to-brittle transition temperature (crack resistance), and stress-rupture strength. It was established that, after RHT, the characteristics of the metal, such as yield strength, ultimate strength, elongation per unit length, contraction ratio, hardness, and impact toughness, significantly improved and, on the whole, the quality of the metal met the requirements of the normative documentation for newly manufactured castings. The heat resistance of the metal of the cylinder shell after RHT also increased, which can ensure the operation of the HPC shell for more than 200 000 h provided that the recommendations for regular inspections of its condition are followed.     

电站锅炉汽包的安全性评定和剩余寿命评估

低周疲劳损伤是电站锅炉汽包的主要失效形式。分析了电站锅炉汽包在运行工况下的应力状态,认为介质内压应力和温差热应力是影响汽包低周疲劳寿命的主要因素;描述了采用有限元数值计算法评定无缺陷和有缺陷汽包的安全性及剩余寿命的一般方法。     

Brittle fractures of the drums of high-pressure boilers: Main causes and methods for preventing them

Factors causing damage to the metal of the drums of high-pressure boilers, as well as the known cases of drum failures, are analyzed. The totality of factors determining the operational reliability of drums is systematized. The process-related mechanism governing the destruction of the drums at the Kurgan cogeneration station and TETs-3 Yaroslavl cogeneration station, and the general factors caused these drums to fail are identified. Recommendations for reducing the risk of drum failures are formulated.     

20t/h锅炉汽包强度校核与安全性分析

按照锅炉汽包开孔较多，且节距不同，其强度亦各不相同的原则，对林口电厂两台炉汽包的缺陷进行了分析，确认该汽包在不降低参数的情况下可安全运行3年。     

The influence of short-term strength on the notch sensitivity and crack growth resistance of the metal of rotors under creep conditions

Comparative assessment of the effect the yield strength has on the characteristics of EI-415 steel under creep conditions is carried out based on the results from long-term (for more than 70000 h) tests of notched samples at an elevated temperature. The metal of three rotors (EI-415 steel) (one after it had been in operation for 137000 h and the other two in the delivery state with relatively increased and decreased levels of yield strength) was used as material under study. The notch sensitivity was evaluated from the ratio between the long-term strength of smooth samples and that of notched samples tested for long-term strength with recording the crack opening width. The resistances to crack incipience and to crack growth with a preset rate were determined from the lengths of cracks appeared at the end of two auxiliary notches of a smaller depth, and the creep fracture toughness was calculated from the break conditions. It is shown that the metal the properties of which are at the lower boundary of yield strength requirements is slightly more advantageous in the level of the above-mentioned characteristics.     

超超临界机组新型不锈钢Super304H、HR3C运行5 400 h后的性能试验

对华能玉环电厂二级再热器运行达到5 400 h的HR3C和Super304H管段取样进行了阶段性能试验,结果发现HR3C运行管强度很高,但脆性明显增加;Super304H运行管的室温抗拉强度有所增加,650℃抗拉强度有所降低,断后伸长率降低,但韧性显著优于HR3C。 HR3C和Super304H经过5 400 h运行后,材料状态良好,均可继续安全运行,但HR3C脆性明显增加,需加强金属监督。     

银铜复合电触点复合强度检测方法的讨论

贵金属及其合金铆钉型复合电触点除了应考核其冷态复合强度之外，还必须增加在热态下复合强度的考核，只有这样才能满足用户在产际运行时对复合触点复合强度的要求。     

Investigations of structural transformation within metal (austenite chromium-manganese steel) at the external surface of steam superheating tubes

The elemental composition of an altered layer at the external surface of a steam superheating tube of grade DI59 steel is investigated after long-term operation. It is shown that the layer is located between a scale and a matrix and depleted by silicon, manganese, copper, and chromium with the maximum oxidizer affinity, enriched by iron and nickel to 90%, and mainly composed of the α-Fe phase (ferrite) with the ferromagnetic properties. The layer formed as a result of selective oxidation and diffusion from the matrix into the metal scale with the less standard free energy of the formation of sulfides and oxides. A magnetic ferrite meter is used in the experimental investigation of the layer evolution by testing grade DI59 steel for heat resistance in air environment at temperatures of 585, 650, and 700°С for 15 × 10³ h; creep at a temperature of 750°С and a stress of 60 МPа; and long-term strength at temperatures of 700 and 750°С and stresses of from 30 tо 80 МPа. Specimens for tests are made of tubes under as-received conditions. The relationship between the ferrite phase content in the surface metal layer and the temperature and time of test is determined. The dependence is developed to evaluate the equivalent temperature for operation of the external surface of steam superheating tubes using data of magnetic ferritometry. It is shown that operation temperatures that are determined by the ferrite phase content and the σ phase concentration in the metal structure of steam superheating tubes with the significant operating time are close. It is proposed to use magnetic ferritometry for revelation of thermal nonuniformity and worst tubes of steam superheaters of HPP boilers.     

锅炉汽包钢板高温强度及硬度的研究

对锅炉汽包用ＳＡ２９９、ＢＨＷ３５钢的强度、硬度进行了研究，给出了在不同温度下硬度与强度的对应关系曲线和按硬度计算高温强度的方法；同时，研究了这两种钢的应变硬化指数随温度变化的规律，用高温硬度法研究了ＳＡ２９９、ＢＨＷ３５钢的挤压应变能随温度变化的规律。     

波纹板式SCR催化剂性能检测及其失活原因分析

催化剂性能检测对火电厂烟气脱硝运行和管理有重要意义。选取了某电厂运行23 500 h的波纹板式催化剂（旧催化剂）和同品牌新催化剂,采用XRF,XRD,H2-TPR,DRIFT等手段进行微观性能表征并测试了其活性。结果表明：与新催化剂相比,旧催化剂中Fe、K、Na和Mg等元素的含量明显增多,比表面积和孔容分别下降了38.7%和14.3%,氧化还原性能和Bronsted酸性位数目均有较大程度的下降,脱硝效率由原来的96.2%下降为91.3%,活性系数下降25.3%;烟气飞灰中碱金属和碱土金属的毒害作用是催化剂活性下降的主要原因。指出：波纹板式催化剂易被飞灰堵塞,应保持催化剂吹灰装置良好运行,并利用机组停运机会对催化剂进行清灰,以提高脱硝效率和延长催化剂使用寿命。     

锅筒筒体和圆筒型集箱体弯曲应力的计算机校核

本文介绍了按照GB9222－88的规定，利用计算机在Win95－Win98环境下对锅筒筒体和圆筒形集箱筒体的弯曲应力进行核核的方法。     

Study on Varying Metallic Properties of Straight and Elbow Pipes of Main Steam Piping after Long-Time Service

The mechanic properties, lasting strength and microstructural properties of straight and elbow pipes of 12CrMo, 10CrMo910 and 12Crl MoV low alloy steel main steam piping system after long-time service were tested and studied. The testing results showed that, for straight and elbow pipes of main steam piping under the conditions of high temperature and high pressure, the numerical operating performance indexes of their metal changed with little difference, generally both within 5%, and the values of elbow were higher than those of straight pipes. These phenomena proved that the aging processes of pipe metal at difterent positions are the same. And the cause lot higher numerical performance indexes of elbow and higher failure rate at elbow position during operation of steam pipes were investigated.     

Operational reliability and longevity of the feed pipelines of power units at thermal power stations

A wide range of matters relating to the operational reliability of feed pipelines at power stations is analyzed. Results from investigations into the mechanical properties and parameters characterizing the cracking resistance of the metal of feed pipelines that have long been in operation are presented. The role of the main factors as possible causes of damages to the components of feed pipelines is evaluated. The results from calculations of feed pipeline components for strength and longevity are briefly analyzed, and the main requirements for their field inspection procedure are formulated.     

Restoration of metal properties of circulation pump blades by the method of surface ultrasonic impact treatment

During the transition period to a market economy, the works producing equipment for the nuclear industry became lame duck companies. The market of heavy industry equipment reduced dramatically, and quality control requirements imposed to goods became lower. Deviations from regulations' requirements and technical specifications for equipment manufacture results in inevitable decrease of reliability during operation but also to failure during check tests. It is not always possible to replace promptly ill-conditioned equipment; in such cases, it is necessary to carry out compensatory measures for restoring working properties up to an acceptable level in order to ensure operational reliability due to the strength improvement of the components of machines and constructions during the whole service life or up to the scheduled date of equipment replacement. This paper is dedicated to development and practical implementation of restorative technology of strengthening ultrasonic treatment used for the metal of the blades of impellers of 16DPA10-28 circulation pumps of 10URS unit pump station located at Novovoronezh NPP-2. The dynamic surface treatment was implemented for compensating the technological defects of the metal of blades. It was revealed that the impact elastic-plastic deformation has a comprehensive compensation effect on the metal of blades in the initial state of delivery and creates the surface-strengthening layer with higher strength properties (strain hardening) of the depth up to 1.5 mm. The surface strain hardening increases the cyclic strength, re-distributes beneficially the residual technological and repair stresses, and heals small surface cracks improving the surface quality. The developed technology was used for treatment of 32 blades of impellers of 10PAC01AP001, 10PAC02AP001, 10PAC03AP001, 10PAC04AP001 circulation pumps. The implemented 100-h full-scale test of the pumps revealed the high efficiency of the developed technology and made it possible to recommend it for application at both the stage of blade manufacture and during the pump operation for prolongation of their service life.     

Investigation of service characteristics of casing fasteners’ metal of 300-MW steam turbines exhausted their rated service lifetime

Presented are generalized results of investigation of fasteners metal (steel EP-182) that have exhausted their fleet resource (more than 220000 h) in 300-MW steam turbines, and analysis of impact of operation time, structure, and service conditions on mechanical properties of the metal. Comparison of the results obtained with the permitted values is conducted. Conclusions regarding the possibility and conditions of the further use of fasteners after exhaustion of their fleet resource are given.     

Complex amine-based reagents

Amines for a long time have been applied to maintaining water chemistry conditions (WCC) at power plants. However, making use of complex reagents that are the mixture of neutralizing and the filmforming amines, which may also contain other organic components, causes many disputes. This is mainly due to lack of reliable information about these components. The protective properties of any amine with regard to metal surfaces depend on several factors, which are considered in this article. The results of applying complex reagents to the protection of heating surfaces in industrial conditions and estimated behavior forecasts for various reagents under maintaining WCC on heat-recovery boilers with different thermal circuits are presented. The case of a two-drum heat-recovery boiler with in-line drums was used as an example, for which we present the calculated рН values for various brands of reagents under the same conditions. Work with different reagent brands and its analysis enabled us to derive a composition best suitable for the conditions of their practical applications in heat-recovery boilers at different pressures. Testing the new amine reagent performed at a CCPP power unit shows that this reagent is an adequate base for further development of reagents based on amine compounds. An example of testing a complex reagent is shown created with the participation of the authors within the framework the program of import substitution and its possible use is demonstrated for maintaining WCC of power-generating units of combined-cycle power plants (CCPP) and TPP. The compliance of the employed reagents with the standards of water chemistry conditions and protection of heating surfaces were assessed. The application of amine-containing reagents at power-generating units of TPP makes it possible to solve complex problems aimed at ensuring the sparing cleaning of heating surfaces from deposits and the implementation of conservation and management of water chemistry condition on the TPP equipment.     

Study of the structure and properties of metal of the major steam lines of a CCGT-420 unit made from high-chromium Х10CrMoVNb9-1 (P91) steel

The technology of manufacture of live steam lines and hot reheat lines at FINOW Rohrsysteme GmbH are discussed. These pipelines are designed for high-performance CCGT units and are made from high-chromium martensitic steel X10CrMoVNb9-1 (P91). The principles of certification and evaluation of conformance of thermal and mechanical equipment made from new construction materials with the TRCU 032-2013 technical regulation of the Customs Union are detailed. The requirements outlined in Russian and international regulatory documents regarding the manufacture of pipes and semifinished products for pipeline systems are compared. The characteristic features of high-chromium martensitic steel, which define the requirements for its heat treatment and welding, are outlined. The methodology and the results of a comprehensive analysis of metal of pipes, fittings, and weld joints of steam lines are presented. It is demonstrated that the short-term mechanical properties of metal (P91 steel) of pipes, bends, and weld joints meet the requirements of European standards and Russian technical specifications. The experimental data on long-term strength of metal of pipes from a live steam line virtually match the corresponding reference curve from the European standard, while certain experimental points for metal of bends of this steam line and metal of pipes and bends from a hot reheat line lie below the reference curve, but they definitely stay within the qualifying (20%) interval of the scatter band. The presence of a weakened layer in the heat-affected zone of weld joints of steel P91 is established. It is shown that the properties of this zone govern the short-term and long-term strength of weld joints in general. The results of synthesis and analysis of research data support the notion that the certification testing of steam lines and other equipment made from chromium steels should necessarily involve the determination of long-term strength parameters.