Research Papers: Gas Turbines: Electric Power

New Steel Alloys for the Design of Heat Recovery Steam Generator Components of Combined Cycle Gas Plants

[+] Author and Article Information
Jorge Pinto Fernandes

ETD, European Technology Development, ISEL, Instituto Superior de Engenharia de Lisboa; ETD–6 Axis Centre, Cleeve Road, Leatherhead, Surrey KT22 7RD, UKjfernandes@etd1.co.uk

Eduardo Manuel Dias Lopes

ISQ, Instituto da Soldadura e Qualidade, ISEL, Instituto Superior de Engenharia de Lisboa; ISQ–Rua Dr. Cavaco Silva, no. 33, Tagus Park 2740-120 Porto Salvo, Portugaledlopes@isq.pt

Vicente Maneta

 Alstom Power, Estrada Nacional 10-4, Mitrena 2910-738 Setúbal, Portugalvicente.maneta@power.alstom.com

J. Eng. Gas Turbines Power 132(5), 051801 (Mar 03, 2010) (7 pages) doi:10.1115/1.3204563 History: Received March 22, 2009; Revised May 24, 2009; Published March 03, 2010; Online March 03, 2010

Demand for power is growing everyday, mainly due to emerging economies in countries such as China, Russia, India, and Brazil. During the last 50 years steam pressure and temperature in power plants have been continuously raised to improve thermal efficiency. Recent efforts to improve efficiency leads to the development of a new generation of heat recovery steam generator, where the Benson once-through technology is applied to improve the thermal efficiency. The main purpose of this paper is to analyze the mechanical behavior of a high pressure superheater manifold by applying finite element modeling and a finite element analysis with the objective of analyzing stress propagation, leading to the study of damage mechanism, e.g., uniaxial fatigue, uniaxial creep for life prediction. The objective of this paper is also to analyze the mechanical properties of the new high temperature resistant materials in the market such as 2Cr Bainitic steels (T/P23 and T/P24) and also the 9–12Cr Martensitic steels (T/P91, T/P92, E911, and P/T122). For this study the design rules for construction of power boilers to define the geometry of the HPSH manifold were applied.

Copyright © 2010 by American Society of Mechanical Engineers
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Figure 1

General representation of the modules displacement of a HRSG

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Figure 2

High pressure superheater module for the finite element analysis purpose

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Figure 3

Simplified high pressure superheater module for the finite element analysis purpose

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Figure 4

Trimetric view of the HPSH upper outlet manifold

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Figure 5

Representation of stress and number of cycles for P91 and comparison with 214 Cr steels P24 and P23

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Figure 6

Number of cycles for SA-335 P91 grade

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Figure 7

Logarithmic representation of stress and number of cycles for P122 comparison with 9Cr steel defining one S-N curve or Wohler curve

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Figure 8

Fatigue analysis of HPSH manifold subjected to the cyclic loading defining an S-N curve

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Figure 9

Master curve for 9% Cr steels P91, P92, and E911 representing the average rupture stress values and the range of Manson–Brown parameter for 584°C

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Figure 10

General equivalent stress representation from the finite element analysis

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Figure 11

Master curve for 9% Cr steels P91, P92, and E911 representing the range of stress and the range of rupture time resorts to Manson–Brown extrapolation parameter and HPSH module

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Figure 12

Stress evolution in the temperature range of 400−700°C for P91 and P92



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