 CO2-reduction
Source: GE (Alstom)
(Business €€€)

 Higher
efficiency

 Higher steam
parameters

 New materials

     
 Increases in steam temperatures
105h Creep Rupture Strength [MPa]

require the transition from

previously proven to newly
developed high-temperature
resistant materials (or in other
(average)

words: martensitic materials)

Typical representative materials :

for membrane walls
for headers and pipework
for superheater/reheater tubes

Temperature [°C]
     
 Advantages:
› Reduction of wall thickness 
Source: MPA Stuttgart
› Reduction of weight 
› Reduction of material costs 
› Increase of temperature gradients 
› Increase of flexibilization

°
     
 105h Creep Rupture Strength at 600°C

Source: Maile MPA 1999, after Masyama

     
 700 °C Power Plant
Unit HKW 1 HKW 2 RDK 8 (proposal from manufacturer)
Comissioning date (COD) 1985 1997 2014 -
Gross capacity [MWel] 420 380 912 -
Net efficiency factor (el) 39% 42% >46% >50%
Steam parameters
540 / 540 °C 545 / 568 °C 603 / 621 °C 700 / 720 °C
HP/Reheat
(boiler outlet) 196 / 40 bar 249 / 59 bar 285 / 59 bar 350 / 70 bar
Materials 16Mo3 16Mo3 16Mo3 16Mo3
(boiler and 15NiCuMoNb5-6-4 15NiCuMoNb5-6-4 15NiCuMoNb5-6-4 13CrMo4-5 (T/P 12)
water-steam cycle) 13CrMo4-5 13CrMo4-5 13CrMo4-5 10CrMo9-10 (T/P 22)
10CrMo9-10 10CrMo9-10 10CrMo9-10 15NiCuMoNb5-6-4
X20CrMoV11-1 X20CrMoV11-1 X10CrMoVNb9-1 (T/P91) X10CrMoVNb9-1 (T/P 91)
X10CrMoVNb9-1 (P91) 7CrMoVTiB10-10 (T24) 7CrMoVTiB10-10 (T/P24)
X10CrWMoVNb9-2 (T/P92) X10CrWMoVNb9-2 (P92)
VM12-SHC X3CrNiCu18-9-3
Super 304H (SP) (Super 304 H)
X8CrNi25-20 (HR3C) X8CrNi25-20 (HR 3C)
Alloy 617 (black-white Sandvik Alloy 174 (Sanicro 25)
HKW 2 connections) NiCo20Cr20MoTi (Alloy 263)
HKW 1 NiCr23Co12Mo (Alloy 617)
NiCr25Co20TiMo (Alloy 740)
     
 The application of
45 ~ 2,5 % optimized technology and
Net-Efficiency (%)

+ 0,1 %
+ 0,7 % the benefit of site

> 46 %
+ 3,1 %
+ 1,5 % conditions (cooling water
from river rhine and
40 district heating) are the
supposition for the high
ca. 38 %

gas cleaning plants, water

(u.a. optimised flow in flue
optmized cooling system
ultra super critical
steam parameters

efficency of RDK 8.

additional measures
turbine design

additional HP-
Preheater

turbine)
Starting Point RDK 8
Power station at the Most influence for the
end of 1980 complete improvement
(540 °C-technology with
closed cooling water system)
come from the use of new
materials !
     
     
     
Standard VGB-S 109 „Materials specification for components in fossil-fired power plants“, 3rd edition 2012
Structure Ongoing activity:
1. Abbreviations http://www.vgb.org
2. Terminology A working group at the
3. Field of application association VGB is still
4. Basis of the material acceptance in the process of
5. Requirements on the Material Manufacturers or Suppliers establishing a standard
6. Requirements on the materials for pressure equipment for the application of
7. Further processing within the component Manufacturer martensitic steels
8. Test activities within the material Inspection Working title:
9. Occurrences, deviations “Martensitic materials –
10. Order placed with the Material Manufacturers or Suppliers guideline for design,
11. Additional regulations manufacture and safety
12. Castings concept”
13. List of material data sheet
13.1 til 13.12 separately shown materials
14. Requirements on filler material
     
Standard VGB-S 109 „Materials specification for components in fossil-fired power plants“, 3rd edition 2012

Topic: Requirements for separately

listed materials respectively types of
products which exceed the applicable
standards
e.g. P91 (extract of requirements only):
- Chemical composition:
Al <=0.03, S <= 0.006%, N 0.04 –
0.06%, Cu <=0.3%, P<=0.020%
(forgings)
- Austenitizing temperature: >=1050°C
- Charpy notch test with 41/68J
(transvers/longitudinal direction)
- Hardness 200-260 HV10

     
- …
Standard VGB-S 109 „Materials specification for components in fossil-fired power plants“, 3rd edition 2012

Topic: Order
Requirements for
not seperately
listet materials

     
 ›
›
›
›

›
›
›
›

     
 ›
›

›
›
›
›

     
Quality problems Source: J. Hald
 Heat treatment errors due to lack of experience with martensitic steels
 HRSG in CCGT plants particularly affected different quality tradition
 Heat treatment after hot bending
 On site heat treatment of welds

Type IV cracking damage evolution

 Replacment headers in UK particularly affected (high Al materials
 Welded bends in Japan, and other places have leaked
 Creep damage evolution in martensitic steels different to low alloy steels

Reduction of allowable stresses

     
P91 and P92 – Previous ECCC evaluations, ECCC WG3A (Source: J. Hald/ECCC WG3A Convenor)

ECCC: Minor strength reduction of

8-10% for both steels based on
more available longterm data;
Current new assessment:
ASME (Grade 91): 10-15%
reduction of allowable stresses;
Japan (Grade 91): Reduction
based on poor long-term creep
(tube/plate). Pipe data more
stable;
Validated extrapolations to 200,000 hours for P91 and 100,000 hours for China: National data indicate
P92 at application temperatures -> Basis for EN standards better stability.
     
P91 – New ECCC assessment, ECCC WG3A (Source: J. Hald/ECCC WG3A Convenor)

Data from multiple sources worldwide (Europe, Japan (NIMS and others), US);
Significant increase of long-term data since 2009:
• 2009: 125 tests (broken and unbroken) with durations >30,000 hours, 3 tests broken with durations >100,000 hours,
• 2017: 304 tests (broken and unbroken) with durations >30,000 hours, 15 tests broken and 16 unbroken with durations
>100,000 hours;

Reduction of 5-10%
as compared to
ECCC datasheet!

     
P92 – New ECCC assessment, ECCC WG3A (Source: J. Hald/ECCC WG3A Convenor)
Global data collation 2017 (10M testing hours , 7 tests > 100 kh;
Preliminary assessments show similar strength values as for the 2005 assessment;
ePATs carried out on new database with old model equation -> result: passed
(ePAT = electronic post assessment tests: Predicted rupture times compared with measured times both
for complete dataset, for most tested temperatures and for individual heats. Only limited deviations are
allowed to pass the test)

Analysis of Grade 92 indicate more stable behavior;

ECCC provisional data sheet for steel92 in 2018:
 Strength values from 2005 !
 Data extrapolations to 200,000 hours at 580 650⁰C
allowed !

     
     
 T24 (7CrMoVTiB10-10) f

Source: GE (former: Alstom)/EnBW

     
 Photo: SWD/van Treek

HKW3, Stuttgart-Gaisburg (gas engines)

     
 Other applicable specifications and
regulations (EN 12952, EN 13480, VGB-
Standards, AD2000, VdTÜV material data
sheets, ...);
Certifications and qualifications;
Requirements for process tests and
production samples before production
(welding, bending processes);
Personnel qualifications (welders, operators,
NDT examiners and supervisors);
Instructions / factory codes for the heat
treatment, cold / warm straightening,
forming and re-stamping processes;
Requirements for incoming inspection /
provision of material, mechanical
processing, welding and bending work, heat
treatment, NDT tests (execution, evaluation,
mandatory scopes) and dimensional checks;
Identification/marking;
Scope of the monitoring of the test steps by
the supplier, system manufacturer, the
notified body (NoBo) and the customer's
construction supervision, type and scope of
the documentation;
     
Preservation, storage, packaging, transport.
 Test and delivery conditions;
Dimensional / tolerance standard;
Requirements for material manufacturers
/ material dealers;
Binding tests according to harmonized
standard;
Supplementary checks and requirements
(options), such as:
• Steelmaking,
• chemical composition,
• delivery condition,
• checking unit / sampling,
• mechanical-technological tests (hot tensile test,
impact test, ring trial),
• microsection,
• longitudinal error, transverse error and double
test,
• surface cracks,
• hardness testing,
• dimensional check, actual measurement of the
wall thickness, and
• finish;
Identification/marking;
Scope of the monitoring of the test steps
by the notified body / manufacturer, type
and scope of the acceptance test
certificate;
      Storage, packaging, transport.
 Quality Engineering Documents

… includes parameters:
 weld preparation,
 welding process,
 filler material,
 processing and
parameter for
preheating and
interpass termperature,
heat treatment and
     
 kind & scope of NDT
Example: Unsatisfying storage / transport Example: Missing hand skills of welders
Saltwater attack on the material VM12-SHC Slag inclusions, header nozzels material P92

Corrosion layer inner

surface 50-120 μm
Local attack on grain
boundary up to 160 μm

     
 Design of components
grade 91 was carried out
with values of creep
strength from VdTÜV
(2001)
Header superheater stages2 and 3
HP steam gate
Cyclone separator
Range 481 to 559°C

Deviation (reserve) between used

Design data for these components
is more than 2,5% to the data from
ECCC 2018

     
Special case “Reduction of strength parameters of materials”
see VGB-S-506 3rd revision 05/2019
Therefore, the following alternative approaches are:
Verification of the material (utilisation of calculation reserves);
Use of material of a higher quality;
Wall thickness increase;
Reduction of operating temperature and, where necessary, operating pressure;
Shortening of the operating time compared to its calculated value;
Shortening of inspection periods;
Increase of the extent of tests and examinations.

     
The following measures were implemented for grade 92 in RDK8-project:
Material specification for semi-finished products , which i.a. contains the following special requirements:
Austenitizing termperature with lower limit 1050°C;
Tempering temperature with lower limit 760°C;
Impact test with a required energy absorption of 41J/68J (transverse/longitudinal direction);
Micro section (magnification 200:1 and 500:1) to prove a pure martensitic structure;

Hardness test in the range 200 HV10 to 260HV10;

Specifications and requirements for further processing such as bending, welding and heat treatment;
Creep tests with planned running times in the range up to 70,000 h for pipe and forged material for header
For the high-stressed components in the creep-fatigue area, replicas were prepared as a zero test. Likewise, there are
wall thicknesses and ovalities for individual cross sections measured;
Monitoring of the high-stressed components in the creep-fatigue area and calculation of life consumption or exhaustion
factor to creep and fatigue according DIN EN 12952-4 (linear damage accumulation);
To recognize temperature imbalance additional operational temperature measurements were applied on individual
header tubes of final superheater and reheater stage.

     
 Creep rupture tests at 600°C
and 650°C
One test is still running with
more than 61.000 hours at
650°C for each type of
material
The meaningful long-term
creep rupture data are well
above the lower scatter band
limit, in the case of 650 °C
almost on the middle value
curve.
The deformation values are
with total creep rupture
strain between 12 and 16%
for the long-term creep
tests within the expected
range
     
Documentation of location of tests

Replication BM – HAZ – WM (- HAZ - BM)

Measurements (wall thickness, ovality,…)

     
 To monitor the planned
behaviour of steam and hot
reheat pipeline force and
displacement measurement
were implemented for an
advanced evaluation

     
 https://www.kettner-edelmetalle.de

Set additional requirements for semi-finished products, e.g. material specification according to the VGB Standard VGB-S-109.
For RDK8 project >35 individual material specifications were used for the products for boiler;
Set additional requirements for manufacturing the components, especially further processing such as bending, welding and heat
treatment, e.g. VGB Standard VGB-S-013 for steam boiler, VGB Guidelines VGB-R-507L and VGB-R-508L for pipelines.
For RDK8 project more than 35 individual inspection test plans were used for the different component types (fin tubes,
supporting/connecting tubes, tube panels, headers, injection coolers, separating vessels, etc.);
Prepare replicas and measurement protocols (wall thickness, ovality) on selected components as a zero test before start of
operation, see VGB Guideline VGB-R-509. For RDK8 the scope includes approximately 60 positions on boiler and piping components;
Ensuring the creep properties by performing some creep tests on selected material batches.
For RDK8 some creep tests for pipe and forged material of the header of final superheater stage were done with planned running
times in the range up to 70,000 h. In addition, unpublished extensive creep-fatigue investigations on P92 welds were performed to
provide a database for possible future FEM-calculations;
Monitor the exhaustion due to creep and fatigue on selected components of boiler and pipelines according to the calculation rules of
DIN EN 12952-4. For RDK8 project more than 30 components will be monitored;
Monitor the temperature on individual header tubes of final superheater and reheater stage to recognize temp. imbalance of header;
Monitor the planned behaviour of steam and hot reheat pipeline. For RDK8 in total 24 force and 47 displacement measurements
were implemented for an advanced evaluation.
Restoring samples of zero state used as comparative material for later material investigations on service material.
     
     
 °