SUPERGEN 2 - Conventional Power Plant Lifetime Extension Consortium - CORE
Lead Research Organisation:
Loughborough University
Department Name: Materials
Abstract
The focus of the current Supergen Plant Lifetime Extension consortium project is the development of novel tools and methodologies to extend the life of existing conventional (ageing) steam and combined cycle power plant which utilise well established materials systems that have been in service for many years. The R&D is focussed on the areas of: condition monitoring/NDT, environmental degradation and protection, microstructural degradation, mechanical modelling and the development of lifetime prediction tools. In terms of the failure modes, it focuses primarily on creep and corrosion.The current work provides a detailed understanding about the 'older' conventional materials and the ageing plant they operate in. In terms of moving forward, the indications from the 2007 Energy White Paper are that there will be less emphasis on life extension and more emphasis on 'new-build', high efficiency plant, possibly including CO2 capture technologies (but certainly allowing for their later addition). The plant technologies being considered in the UK are: high temperature USC steam plant, co-firing, pre/post combustion CO2 capture plant, e.g. gasification, oxy-firing, amine scrubbing, etc. In addition, general fuel flexibility will also remain a key issue.One of the main drivers for the next generation of power plant is not only reduced environmental impact but also security of electricity supply, i.e. reliability. Significant R&D into the technologies and methodologies for the lifing of the next generation power plant is needed now, to ensure reliability targets are met. This means a comprehensive understanding of the behaviour of the materials being used and their in-service degradation is needed.The new proposal 'Plant Lifing of High Efficiency, Low CO2 Emission Power Plant.' is moving the R&D to the 'next level', and is seen as a natural progression to the current project, as its primary focus will be on the above 'novel' advanced plant. In this way, it will take the methods already developed in the current programme and further enhance them and more importantly develop new tools and methods for the new materials and environments that will be present in the advanced power plant of the future. This shows a natural transition and progression for the PLE project and its consortium.The proposal, which has been developed after extensive consultation with stakeholders, is based around three integrated and coordinated technology themes and a dissemination theme. These include; advanced steam systems, advanced gas turbines, advanced cycles (including biomass co-firing, oxy-firing). Within each theme there are a number of Tasks that together constitute the whole programme of work. A key feature of the programme of work is the essential and close interaction between the Themes and the individual Tasks that define the proposed programme in more detail. The interactions take a wide range of forms, from providing materials for testing to the development of collaborative integrated models for validation of the component life extension toolbox to be developed. The dissemination will involve national and international collaboration and events.In addition a number of key proposals have been submitted under the 'plus' part of the Supergen programme which will provide additionality to the overall project.The project has the full support of a large industrial consortium representing the full UK Power Generation supply chain.
Organisations
- Loughborough University (Lead Research Organisation)
- National Physical Laboratory (Collaboration)
- RWE AG (Collaboration)
- E ON (Collaboration, Project Partner)
- Siemens AG (Collaboration)
- Mitsui Babcock Energy Ltd (Collaboration)
- Siemens (United Kingdom) (Project Partner)
- Qinetiq (United Kingdom) (Project Partner)
- Mitsui-Babcock Ltd (Project Partner)
- National Physical Laboratory (Project Partner)
- RWE (United Kingdom) (Project Partner)
- Rolls-Royce (United Kingdom) (Project Partner)
- Sermatech International (Project Partner)
- Tata Steel (United Kingdom) (Project Partner)
- Alstom (United Kingdom) (Project Partner)
Publications
Hermosilla U
(2008)
MCrAlY creep behaviour modelling by means of finite-element unit cells and self-consistent constitutive equations
in Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications
Sun W
(2009)
Effects of prior damage on the creep failure behaviour of similar and dissimilar welded CrMoV main steam pipes incorporating a partial repair
in International Journal of Pressure Vessels and Piping
Hermosilla U
(2009)
Modelling the high temperature behaviour of TBCs using sequentially coupled microstructural-mechanical FE analyses
in Materials Science and Engineering: A
Hyde T
(2009)
Evaluation of conversion relationships for impression creep test at elevated temperatures
in International Journal of Pressure Vessels and Piping
West GD
(2009)
Combined EBSD/EDS tomography in a dual-beam FIB/FEG-SEM.
in Journal of microscopy
HYDE T
(2009)
Some issues on structural integrity analysis of P91 welds in power plants subjected to high temperature creep*
in Fatigue & Fracture of Engineering Materials & Structures
Peravali S
(2009)
An Anisotropic Creep Damage Model for Anisotropic Weld Metal
in Journal of Pressure Vessel Technology
Hilson G
(2009)
Spatial variation of residual stresses in a welded pipe for high temperature applications
in International Journal of Pressure Vessels and Piping
Zhang Y
(2009)
Characterisation of creep-weak zones (white bands) in grade 91 weld metal
in Science and Technology of Welding and Joining
Hyde T
(2010)
Creep crack growth data and prediction for a P91 weld at 650 °C
in International Journal of Pressure Vessels and Piping
Hyde T
(2010)
Testing and modelling of creep crack growth in compact tension specimens from a P91 weld at 650°C
in Engineering Fracture Mechanics
Hyde T
(2010)
On the interpretation of results from small punch creep tests
in The Journal of Strain Analysis for Engineering Design
Yaghi A
(2010)
A Comparison Between Measured and Modeled Residual Stresses in a Circumferentially Butt-Welded P91 Steel Pipe
in Journal of Pressure Vessel Technology
Yaghi A
(2011)
Finite element simulation of welded P91 steel pipe undergoing post-weld heat treatment
in Science and Technology of Welding and Joining
Seraffon M
(2011)
The development of new bond coat compositions for thermal barrier coating systems operating under industrial gas turbine conditions
in Surface and Coatings Technology
Karunaratne M
(2011)
Modeling of Microstructural Evolution in an MCrAlY Overlay Coating on Different Superalloy Substrates
in Metallurgical and Materials Transactions A
Tanner D
(2011)
FE analysis of a notched bar under thermomechanical fatigue using a unified viscoplasticity model
in Procedia Engineering
Saad A
(2011)
Cyclic softening behaviour of a P91 steel under low cycle fatigue at high temperature
in Procedia Engineering
Saber M
(2011)
Determination of creep and damage properties for P92 at 675 °C
in The Journal of Strain Analysis for Engineering Design
Syed A
(2012)
Fireside corrosion of superheaters: Effects of air and oxy-firing of coal and biomass
in Fuel
Kyaw S
(2013)
Predicting failure within TBC system: Finite element simulation of stress within TBC system as affected by sintering of APS TBC, geometry of substrate and creep of TGO
in Engineering Failure Analysis
Sumner J
(2013)
Type II hot corrosion: Behavior of CMSX -4 and IN 738 LC as a function of corrosion environment
in Materials and Corrosion
Karunaratne M
(2013)
A multicomponent diffusion model for prediction of microstructural evolution in coated Ni based superalloy systems
in Materials Science and Technology
Hussain T
(2013)
Trends in fireside corrosion damage to superheaters in air and oxy-firing of coal/biomass
in Fuel
Oikonomidis F
(2013)
Prediction of crack propagation and arrest in X100 natural gas transmission pipelines with the strain rate dependent damage model (SRDD). Part 1: A novel specimen for the measurement of high strain rate fracture properties and validation of the SRDD model parameters
in International Journal of Pressure Vessels and Piping
Darnbrough J
(2013)
Micro-scale testing of ductile and brittle cantilever beam specimens in situ with a dual beam workstation
in Measurement Science and Technology
Dudziak T
(2014)
Steam oxidation of TP347HFG, super 304H and HR3C - analysis of significance of steam flowrate and specimen surface finish
in Corrosion Engineering, Science and Technology
Syed A
(2014)
Microscopy of fireside corrosion on superheater materials for oxy-fired pulverised fuel power plants
in Materials at High Temperatures
Lukaszewicz M
(2014)
Characterisation of oxide scales developed on high temperature resistant alloys in pure steam environments
in Materials at High Temperatures
West G
(2014)
Microstructural characterisation of oxide formation from MCrAlY coatings on nickel-based superalloys
in Materials at High Temperatures
Seraffon M
(2014)
Performance of thermal barrier coatings in industrial gas turbine conditions
in Materials at High Temperatures
Oikonomidis F
(2014)
Prediction of crack propagation and arrest in X100 natural gas transmission pipelines with a strain rate dependent damage model (SRDD). Part 2: Large scale pipe models with gas depressurisation
in International Journal of Pressure Vessels and Piping
Li S
(2014)
Boundary conditions resulting from cylindrical and longitudinal periodicities
in Computers & Structures
Mogire E
(2014)
Microstructural characterization of oxide scales formed on steels P91 and P92
in Materials at High Temperatures
Saad A
(2014)
Thermal-mechanical fatigue simulation of a P91 steel in a temperature range of 400-600°C
in Materials at High Temperatures
Liu D
(2015)
Effect of substrate curvature on the evolution of microstructure and residual stresses in EBPVD-TBC
in Journal of the European Ceramic Society
Karunaratne M
(2016)
Modelling the coefficient of thermal expansion in Ni-based superalloys and bond coatings
in Journal of Materials Science
Kyaw S
(2017)
Effects of three-dimensional coating interfaces on thermo-mechanical stresses within plasma spray thermal barrier coatings
in Materials & Design
Karunaratne MSA
(2017)
Modelling of microstructural evolution in multi-layered overlay coatings.
in Journal of materials science
Holcomb G
(2019)
Simulated fireside corrosion of T91 in oxy-combustion systems with an emphasis on coal/biomass environments
in Materials at High Temperatures
Description | Note - This project was extended and completed on 31/12/12. The key aim of this research programme is to develop a portfolio of innovative and novel research tools which can be implemented by industry to enhance the performance and/or extend the life of existing power generation plant and provide spin-off benefits for future advanced power plants. Research is focussed in 3 main Technical Workpages covering Advanced Steam Systems, Advanced Industrial Gas Turbines and Advanced Operating Cycles. Key achievements to date include the following: Advanced Steam Systems • Development of a holistic structural integrity assessment procedure for prediction of weld failures, incorporating the effects of both creep and fatigue • Methods for identification of 'suspect' low alloy steel pipes after very long term service. This work is being exploited in a pilot project at the moment to trial the techniques on plant rather than in the laboratory • Development of a miniaturised sample extraction technique for sampling of power plant components • Understanding of the role of boron in MarBN steels for next generation, higher temperature, more efficient power plant • Identified several issues associated with deployment of advanced Ni alloys in new, high temperature plant • Development of a method for predicting creep crack growth developed in high temperature welds • Development of advanced characterisation techniques for quantification of microstructures linked to creep lifing models Advanced Industrial Gas Turbines • Established an internationally-leading approach to modelling complex coatings systems, unifying various previously separate strands of chemical, metallurgical, microstructural and mechanical predictions • Extended and validated model for multilayered coating systems for industrial gas turbine blades • A novel multilayered coating system has been developed using the above modelling approach and is currently being manufactured • Designed and manufactured three new coating powders, for high temperature oxidation protection on industrial gas turbine blades (based on coating selection maps developed using modelling approach). These are currently being tested at high temperature. • Quantification of oxidation, thermal cycling and hot corrosion of gas turbine materials and the development of a series of predictive models for oxidation and hot corrosion damage to gas turbine materials Advanced Cycles • Generation of quantitative data and models for fireside corrosion of heat exchanger materials for current coal/biomass fuels & operating conditions • Development of an on-line monitoring method for fireside corrosion • Developed a method for measuring the operating stress of plant at temperature, currently being trialled up to 500oC • The provision of a trained resource for the power generation industry |
Exploitation Route | In addition to the use of innovative science and the development of R&D tools and methods, the value of the programme can be measured by its relevance to industry and the 'take-up' of the technologies. This project has to date provided procedures for component lifing and materials modelling, in addition to a large amount of materials data (e.g. microstructural degradation, mechanical properties) improved materials characterisation techniques and a supply of young talented engineers entering the energy industrial sector. The primary route to exploitation of this research is through the consortium of 10 major companies, covering a substantial part of the power engineering supply chain, from original equipment manufacturers to generators. These include: Alstom Power Ltd., Doosan Power, E.ON, National Physical Laboratory, Praxair Surface Technologies Ltd, QinetiQ, Rolls-Royce plc, RWE npower, Siemens Industrial Turbomachinery Ltd. and Tata Steel. In terms of the exploitation of the academic outputs, there have been several publications relating to this work. Several members of the consortium have given invited and keynote presentations at international conferences, and have additionally organised / been organising committee members of a number of conferences related to the work of the Consortium during the lifetime of the project. The modelling methodologies developed during this research programme have been published in high impact factor journals. In particular, the modelling approach to coatings on gas turbine blades is unique in its combination of thermodynamics, kinetics, physical and mechanical property models. The integration approaches taken will be of benefit to other researchers working in different areas. In addition, developments have been made in finite element techniques to allow modelling of weld phenomena, which is also internationally leading research. A number of advanced microstructural characterisation techniques, particularly in 3D, have been developed for power plant materials which are now being applied to a number of other materials systems in other application areas, for example, for the characterisation of photovoltaic devices and nuclear materials. |
Sectors | Aerospace Defence and Marine Energy |
URL | http://www.supergenple.net |
Description | The outputs from this grant have been used in the power generation sector across a wide spectrum of uses. We have previously supplied EPSRC (directly and through ROS) with a range of case studies demonstrating the use of the outputs. |
First Year Of Impact | 2010 |
Sector | Aerospace, Defence and Marine,Energy |
Impact Types | Societal Economic |
Description | A Teaching Resource for Sustainable Power Generation |
Amount | £17,496 (GBP) |
Funding ID | EP/H044078/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start |
Description | Advanced surface protection to enable carbon abatement technologies |
Amount | £538,000 (GBP) |
Funding ID | 100516 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start |
Description | Degradation mechanisms in high chromium power plant steels |
Amount | £121,000 (GBP) |
Organisation | Electric Power Research Institute (EPRI) |
Sector | Charity/Non Profit |
Country | United States |
Start | 12/2011 |
End | 11/2014 |
Description | Degradation mechanisms in high chromium power plant steels |
Amount | £121,000 (GBP) |
Organisation | Electric Power Research Institute (EPRI) |
Sector | Charity/Non Profit |
Country | United States |
Start | 01/2011 |
End | 12/2014 |
Description | Improved modelling of power plant to accommodate carbon capture technologies |
Amount | £110,000 (GBP) |
Funding ID | TP11/CAT/6/I/BP074G |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 03/2010 |
End | 12/2013 |
Description | JOINT: an Indo-UK collaboration in joining technologies |
Amount | £317,859 (GBP) |
Funding ID | EP/I01215X/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start |
Description | Modelling fireside corrosion of heat exchanger materials in advanced energy systems |
Amount | £293,000 (GBP) |
Funding ID | 100257 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 01/2007 |
End | 01/2010 |
Description | Small punch creep testing |
Amount | £60,000 (GBP) |
Organisation | Electric Power Research Institute (EPRI) |
Sector | Charity/Non Profit |
Country | United States |
Start | 12/2011 |
End | 11/2014 |
Description | Small punch creep testing |
Amount | £60,000 (GBP) |
Organisation | Electric Power Research Institute (EPRI) |
Sector | Charity/Non Profit |
Country | United States |
Start | 01/2011 |
End | 12/2014 |
Description | E ON UK |
Organisation | E ON |
Department | E ON UK |
Country | United Kingdom |
Sector | Private |
Start Year | 2004 |
Description | Mitsui Babcock Energy Ltd |
Organisation | Mitsui Babcock Energy Ltd |
Country | United Kingdom |
Sector | Private |
Start Year | 2004 |
Description | National Physical Laboratory NPL |
Organisation | National Physical Laboratory |
Country | United Kingdom |
Sector | Academic/University |
Start Year | 2004 |
Description | RWE nPower |
Organisation | RWE AG |
Department | RWE nPower |
Country | United Kingdom |
Sector | Private |
Start Year | 2004 |
Description | Siemens Lincoln |
Organisation | Siemens AG |
Department | Siemens Industrial Turbomachinery Ltd |
Country | United Kingdom |
Sector | Private |
Start Year | 2004 |