Component test facility

for a 700 C power plant

(Comtes700)
Research and
Innovation EUR 25921 EN
EUROPEAN COMMISSION
Directorate-General for Research and Innovation
Directorate G Industrial Technologies
Unit G.5 Research Fund for Coal and Steel
E-mail: rtd-steel-coal@ec.europa.eu
RTD-PUBLICATIONS@ec.europa.eu
Contact: RFCS Publications
European Commission
B-1049 Brussels
European Commission
Research Fund for Coal and Steel
Component test facility for a 700 C power plant
(Comtes700)
G. Schmidt, K. Fo, C. Hlzel, D. Rossberger
Alstom Power Systems GmbH Augsburger Strae 712, 70329 Stuttgart, GERMANY
O. Krogh
Burmeister & Wain Energy A/S Lundtoftegardsvej 93A, 2800 Kgs. Lyngby, DENMARK
S. A. Jensen, J. L. Madsen
DONG Energy A/S Nesa All 1, 2820 Gentofte, DENMARK
P. Billard
EDF R & D Site des Renardieres Ecuelles, 77818 Moret-sur-Loing, FRANCE
G. Gierschner, C. Ullrich
E.ON New Build & Technology GmbH Alexander-von-Humboldt-Strae 1, 45896 Gelsenkirchen, GERMANY
L. Ghiribelli
ENEL Ingegneria e Innovazione SpA Via Andrea Pisano 120, 56122 Pisa PI, ITALY
K.-G. Tak, F. Klauke
Hitachi Power Europe GmbH Schifferstrae 80, 47059 Duisburg, GERMANY
S. Huysmans
Laborelec GDF Suez Rodestraat 125, 1630 Linkebeek, BELGIUM
R. Mohrmann, A. Mbius
RWE Technology GmbH Huyssenallee 2, 45128 Essen, GERMANY
H. Edelmann
Siemens AG Freyeslebenstrae 1, 91058 Erlangen, GERMANY
C. Stolzenberger, S. Polenz
VGB PowerTech e.V. Klinkestrae 2731, 45136 Essen, GERMANY
Grant Agreement RFCP-CT-2004-00003
1 July 2004 to 31 December 2011
Final report
Directorate-General for Research and Innovation
2013 EUR 25921 EN
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TABLE OF CONTENTS


1 Final Summary ...................................................................................................................... 5
1.1 Objectives ............................................................................................................................. 5
1.2 Results obtained and their usefulness ................................................................................... 5
2 Scientific and Technical description of the Results ............................................................ 19
2.1 Work Package 1: Engineering ............................................................................................ 19
2.2 Work Package 2: Material & Manufacturing ...................................................................... 40
2.3 Work Package 3: Valves & Measuring Devices ................................................................. 58
2.4 Work Package 4: C & I ....................................................................................................... 71
2.5 Work Package 5: Erection and dismantling ........................................................................ 85
2.6 Work Package 6: Operation ................................................................................................ 92
2.7 Work Package 7: Evaluation ............................................................................................. 118
2.8 Work Package 8: Coordination ......................................................................................... 153
2.9 Exploitation and Impact of the Research Results ............................................................. 157
3 List of tables and figures ................................................................................................... 165
4 Glossary ............................................................................................................................ 170

3

1 FINAL SUMMARY
1.1 OBJECTIVES
The objective is to design, manufacture, erect and operate a Component Test Facility (CTF) to test high
temperature durable new materials needed to realise a coal-based power plant with efficiencies above
50 %.
The host plant of the CTF is the German power plant Scholven F owned by E.ON. It is a coal-fired
power plant with steam conditions of 535 C and maximum 230bar, a maximum output of 740 MW and
an average operation time of more than 5,000h a year. These are the general conditions of a testing pe-
riod of approx. 20,000 hours of operation with the following focuses:
manufacturing, bending and welding also dissimilar of the materials used,
long-term creep behaviour linked with real plant dimensions and other design features,
in-plant monitoring,
determination and evaluation of residual service life,
in-service inspections,
operational testing of Ni-based alloys for tubes, pipes and valves,
gaining information on magnetite layer on the ribs of internal ribbed tubes,
operational behaviour of all components,
fluegas corrosion and steam oxidation behaviour of the materials and
erosion effects due soot blowing.
The results of the CTF flow back into engineering and design of components to optimise them for the
next phase of a 700 C power plant, the erection and operation of a demonstration plant power plant in
Europe.
The project is divided into eight work packages and covers the following parts: engineering (WP 1),
material and manufacturing (WP 2), valves and measuring devices (WP 3), control and instrumentation
(WP 4), erection (WP 5), operation (WP 6), evaluation (WP 7), and coordination (WP 8).

1.2 RESULTS OBTAINED AND THEIR USEFULNESS
1.2.1 Work Package 1: Engineering
The CTF had to be designed to fit within the steam generator of unit F of the host Plant. One target was
that the plant operation should not be affected. The heating surfaces of the evaporator and superheater
were designed to reach a temperature of 700C in a wide load range. The connecting and auxiliary
components such as pipes, headers, valves, spray attemperator and drainages were designed to the spe-
cific temperature to transport, cool down and launch steam to a superheater or reheater. The pressure
part was designed for a lifetime of 200,000 hours according to TRD. The requirements according Pres-
sure Equipment Directive guideline Module G (PED) for the pressure-loaded parts such as steam pip-
ing, superheater or evaporator had to be fully implemented. The permit for the design was given from
TV.
The evaporator consisted of 44 parallel tubes with a tube-fin-tube arrangement and made from T24,
HCM and Alloy 617B. The material for the inlet header was 13 CrMo44 and the material for the outlet
header was P92. Internally riffled tubes were designed in the T24 section in order to improve the heat
transfer properties. A FEM analysis fixed a maximum average wall metal temperature for stress calcula-
5

tion. The average evaporator outlet temperature was in operation around 50C, lower than expected,
caused by the geometry and heat flux.
The superheater was calculated for an arrangement in the convective pass of host superheater 2. The
chosen materials for the two panels were Sanicro 25, HR3C and DMV310 N (austenitic steel) and Alloy
617B and Alloy 740 (nickel based alloys). Two tubes of Alloy 263 were designed and integrated later.
The inlet header was adjusted to P92, the outlet header to Alloy 617B.
The HP steam pipe was calculated for Alloy 617B and a lifetime of 200,000h with an OD of 220mm
and a wall thickness of 50mm.
Four spray attemperators were designed. One was designed for a temperature of 610C to control the
main steam temperature before the superheater. Two others were designed for a temperature of 700C
to reduce steam temperature to 540C before re-entry into the final host superheater. All three were
similarly designed for horizontal operation. The OD was 220mm and the wall thickness was reduced to
30mm. Missing drainages lead to a two-phase flow in the high temperature region. The fourth attem-
perator was integrated in the HP-bypass valve to cool down the steam to the host reheater.
The draining system was divided into three sections depending on the temperature level and was im-
proved during operation to avoid a two-phase flow.
The insulation layer thickness was calculated for a maximum surface temperature of 60C. It was nec-
essary to switch to a microporous insulation material where the required space was not available.
The operation mode of the CTF was flexible to follow the host plant operation constantly. The follow-
ing modes were possible:
y normal operation at full load of the main steam generator,
y part load operation at part load with sliding pressure,
y controlled HP-bypass operation where the steam was expanded and cooled in the HP-bypass
valve and discharged to the hot reheater system and
y start-up operation with special attention to sufficient cooling of the evaporator surface.
Boiler cleaning was not planned during commissioning because it was not possible to blow out in any
direction.
1.2.2 Work Package 2: Material & Manufacturing
The chosen materials were ordered in general according to EN 10204 with a 3.1 A certificate. Only
minor material components were ordered with a 3.1 B certificate. Some materials like Alloy 740, Alloy
617B, P92 or Sanicro 25 had to be ordered via a PMA because they were not specified in codes and
standards at that time.
The material was processed according to common standards such as EN 10216. To minimise any trials,
material specifications have been compiled for all materials before ordering. Additional tests were con-
sidered for new materials, if necessary. All manufacturing steps, like bending and welding and qualifi-
cation procedures followed the EN standards. The Notified Body TV was responsible for interim cer-
tificates and the final approval of the CTF as a whole.
The superheater showed indications at all Alloy 617B tubes after manufacturing. The tubes had to be
peeled due to overleaps with a depth of up to 1.6mm on the outer surface from 44.5 x 10mm to 41 x
8.5mm. The flaws were not found during longitudinal UT and standard Eddy Current testing, but by a
specific Eddy Current Circograph combined with UT for wall thickness measurement. The weldability
of the material was good (TIG welding). RT was used for volumetric testing instead of UT as planned.
6

The dissimilar P92/Alloy 617B stubs of the superheater inlet header were welded using P91 filler metal,
whereas Alloy 617B filler metal had been specified. All stubs had to be welded again.
Alloy 617B evaporator tubes showed surface defects and had to be ground. Flaws were similar to those
observed at superheater tubes. The circumferential welds of HCM12, 13CrMo4-5 and P92 had to be
heat treated to keep the hardness low and achieve good ductility. Tube-fin-tube welding and fin-fin-
welding were carried out by SAW with the suggested wire/flux combinations and without pre-heating.
Hardness measurements showed expected values for chosen evaporator material.
The first forgings of thick-walled components displayed a larger grain size (-3) the than specified grain
size (2-4) in one half of each part. A new heat treatment procedure was developed achieving a grain size
in total up to 1, which was acceptable according to investigations. The temperature of the solution heat
treatment and re-heating up to hot working temperature level was reduced in the forging process. The
holding time at solution annealing temperature was also reduced. Heat treatment was done by step-
heating to achieve holding time compensating temperature differences between the core area and the
outlying area below solution temperature. The high toughness of Alloy 617B required special tools for
machining and low cutting speeds were applied. On average machining consumed five times more time
compared to ferritic steels. TIG welding of thick-walled components was performed without filler metal
(pure fusion of base material) and combined TIG/SMAW welding with filler without heat treatment. RT
was applied 100% after the root or first filler pass. PT was performed 100 % at 1/3, 2/3 and 3/3 of the
wall thickness. PT during welding of nickel based alloys implied that the metal temperature had to be
cooled down from the interpass temperature of 150C to a level lower than 50C before use. This pro-
cedure increased manufacturing time. Especially the time frame for manufacturing of circumferential
butt welds was time consuming.
1.2.3 Work Package 3: Valves & Measuring Devices
The valve design was applied according the relevant codes and the high steam temperature of 710C
demanded the use of Ni-based Alloy 617B for all pressure retaining parts. The design followed in sev-
eral cases a monobloc design that led to increased material volume and machining time compared to
alloyed steel but was necessary from the point of view of structural strength.
Check and swing check valves were designed similar to the design which is used for conventional pow-
er plants. Gate valves had a two-part design and the sealing surfaces on the seat rings and wedges were
clad with Stellite 6 material. The surface of the stem shaft has been coated. The packing temperature
had to be reduced by prolongation of the stem. The stuffing box at the upper end of the cover was de-
signed with cooling fins at the outer surface to use graphite gaskets with stainless steel caps. The globe
valves had a monobloc design and followed the concept of standard high pressure valves. The valve
neck was prolonged in order to reduce the temperature of the stuffing box. The Safety Relief Valve was
made out of Alloy 617B in the high temperature parts and a steel material in the conventional tempera-
ture zones. A spring loaded safety relief function with an additional pneumatic load actuator was
adapted to avoid overpressure. Screw bolts had a comparatively high elongation length because the
intermediate flange was designed especially long to avoid overheating of the spring. The start-up valve,
the control valve and the HP-bypass valve were designed as angle valves. The stuffing box was placed
at a sufficient distance and equipped with cooling fins to avoid oxidation of the graphite sealing materi-
al. The HP-bypass valve was designed with the aid of numerical methods to optimise temperature dis-
tribution, flow dynamics and wall thickness. It was carried out with one integrated water injection noz-
zle to cool down the steam of the host power plant reheater temperature.
7

The manufacturing processes were rather challenging in view of the mechanical and machining proper-
ties of the Alloy 617B. Material machining passed a learning curve although special cutting tools and
cutting edge geometries were applied. At the end of the process, the machining time was approx. 6
times higher compared with a high grade steel material. Tool lifetime of the cutting tool was reduced
due to increased wear. The welding was a major issue because Alloy 617B tends to show hot cracks.
Excessive heat had to be avoided and TIG-welding and manual electrode welding were applied which
resulted in an interpass temperature of 100C. NDT of the root, 1/3, 2/3 of the weld volume, and the top
layers were done. The valves were subjected to a water pressure test and none of them showed major
problems.
Future R&D projects should include investigations in order to reduce the manufacturing efforts. Espe-
cially manufacturing processes which lead to near net shape raw pieces, like forging or HIP metallurgy,
are the most interesting approaches.
The safety relief valve, the start-up valve, the control valve and the HP-bypass valve were monitored
with thermocouples in the operation period. The temperature measurements showed in combination
with other tests, e.g. visual inspection that the functionality of the valves was given. The wear of the
internal parts was within the normal range. Only some problems occurred with the C-ring gasket at the
HP-bypass bonnet sealing. Leakages at the C-ring gasket needed a replacement every six months. A
future HP-bypass valve will need some improvements.
In general, it was found that pressure sealed cover material, such as graphite or metallic gaskets, were
appropriate for 700C applications. The same was found for gland packings consisting of graphite, be-
cause this part was replaced with design measures for cooler zones.
Material investigations of two gate valves showed cracking within the weld connection between the
lower valve body and the valve body neck. The number of cold and warm starts as well as the tempera-
ture transient levels of the temperature measurements seemed to impact significantly on cracking within
the welds. The used hard facing layers, Stellite 6, in the seating or guiding surfaces tolerated in general
the operational loads. In the main steam isolation valve, remarkable abrasive wear was found.
Globe valves showed deformation of the planarity of the Stellite seating surfaces due to high tempera-
ture transients; but if applicable and where appropriate for flow isolation under heavy duty conditions
globe valves are recommended.
The surfaces of the seats of the steam control valve and the start-up valve were well preserved. Indica-
tions of erosion were found in the start-up valve at the lower area of the throttle bores and the control
edge of the piston.
The control edge of the piston of the HP-bypass valve showed obvious indications of erosion. The
welded joints of the perforated discs in the outlet of the HP-bypass valve had a circular, visible crack
following the entire welded joint. Ultrasonic and radiographic testing with a linear accelerator of a
crack on the outer surface suggesting a possible crack did not confirm a crack. The cross section of the
HP-bypass part showed cracks, at thread pitches and at transitions of the cross section. Redesign
measures have to be taken in order to prevent premature formation of cracks. Additional R&D work
should be carried out in future to investigate the thermal shock behaviour of Alloy 617B components.
PWHT of welded thick-walled valves is needed. Alternatively, monobloc designs could be considered.
8

1.2.4 Work Package 4: C & I
The control and instrumentation system was designed according to EN codes and standards (e.g. EN
60584-2, Accuracy of temperature sensors and EN 50156-1, Safety regulations for DCS and BMS Sys-
tems). The control system was linked to the existing host power plant to visualise all information from
the sensors in the control room and to protect and control the CTF and the host plant. The recorded data
were forwarded to the COMTES700 partners for further analysis (lifetime). A remote control system
was established.
More than 50 Type S thermocouples (PtRh-Pt) were installed to measure steam or inner and outer wall
temperatures. This type of thermocouple was chosen due to its tolerance of +/-1K in the range from 0 to
1,000 C. Gold plates at the tip end were mounted for fast and accurate measurement. The electrical
insulation material was MgO (purity above 99.4 %) with a high resistivity of more than 1.0 *10
12

Ohm*cm at 700C in comparison with 5.0*10
7
Ohm*cm for TiO2. A polynomial calculation of tem-
perature values calculated from thermo voltage demanded much higher accuracy than typical for stand-
ard solutions. Compensation cables were avoided to increase the accuracy. Due to the increased heat
conduction the length of the sheath tube had to be extended to ensure that temperatures at the connec-
tion head remained below 120C. After four years of operation and more than 160 starts the thermo-
couples showed no thermal drift. It could be assumed they would reach the same operation time again.
A self-calibrating thermocouple was tested alternative to type S thermocouples, see WP7.
The pressure measurement was tailor-made due to standard design, although materials were not appli-
cable for this temperature range. The pressure gauge valve was made of Alloy 617B and designed with
cooling fins and heat shield to reduce the sealing temperature. The measurement worked satisfactorily
and no problems occurred.
The flow measurement was designed as a Venturi flow measurement. Standard materials could not be
used at 700C. The manufacturing material was Alloy 617B but it had to be taken into consideration
that the expansion factor rose from 14.4*10
-6
/K at 600C to 15.1*10
-6
/K at 700C and could lead to
failure of the steam flow measurement. Steam flow failures of up to 5 % can appear if the wrong expan-
sion factor was chosen. The measurement worked excellently during operation.
1.2.5 Work Package 5: Erection
The CTF had to be installed within the steam generator of unit F of the host plant. The unit was com-
missioned in 1979 and produces electricity with a net output of 676 MW
e
and thermal output of 1,860
MW
th
by burning hard coal. The installation had to take place within the tight schedule of an ordinary
overhaul period of the power plant. After installation, the unit could not be operated without the CTF.
Despite the very ambitious time schedule, the power plant was able to go into commercial operation in
J uly 2005 with a delay of only two weeks.
The service exposed materials are of a very high scientific and technological value. Many material
samples were taken not only for evaluation purpose of the project but also in order to test the material in
other European research projects.
The call for bids for erection of the CTF was issued in December 2004. In March 2005 a consortium
was awarded the erection (steel works, pipes, valves, evaporator and superheater). The start date with
regard to components outside the boiler was in April 2005 and the start date with regard to the more
time critical components located inside the boiler was in May 2005. It was planned to perform the pres-
sure test end of J une.
9

The design of the evaporator suspension had to be revised due to a bulge in the membrane wall of the
existing boiler, which was the exact planned location of the test evaporator, and the test evaporator had
to be lifted twice.
Some components were delivered quite late and the design of the piping and steel structures had to be
revised because of collisions with the existing pipes. This caused a delay of 12 days. Non-functionality
of the control technology and a leakage of the hydraulic actuator of the stop valve caused another two
days of delay.
In 2006, installations in the host plant as well as minor modifications of devices and safety aspects were
completed.
It was decided to dismantle the CTF on 11 August 2009 and the dismantling started immediately. Dis-
mantling was finished end of March 2010.
All components which were located inside the boiler had to be removed as fast as possible to start-up
the power plant again. Pipe connections to the steam generator were cut and open pipe or stub ends
were closed with caps. The remaining 700C piping system, including valves outside the boiler was
dismantled in the first quarter of 2010.
The dismantled components were marked and transported to the storage hall. The material was stored
for approx. two years in the hall and was available for further sampling. The remaining material was
scrapped at the end of 2011 after the final samples had been taken.
Finally, more than 100 material samples were taken from evaporator, superheater, headers and the
steam piping system. A number of valves were sent to the valve manufacturers for investigation.
1.2.6 Work Package 6: Operation
The operation of the CTF started in J uly 2005. As it was closely connected to the host plant, this could
not be operated without the CTF. In 2007 the first problem with a crack in a thick-walled Alloy 617B
component occurred. In the following years these problems increased. Several repairs had to be carried
out and a high number of laboratory investigations led to deeper understanding of the material.
Finally, it was decided to stop the CTF after more than 20,000 hours of operation in August 2009, as
initially planned, and to dismantle the CTF. In the meanwhile plans were revised to extend the opera-
tion period with approx. two years in order to gain additional experience; however this could not be
realised. The decision was taken due to problems with the conventional part of the facility and the
700C part of the facility. Unpredictable time and cost for further repair works led to the decision.
The operation of the CTF demonstrated that full-scale 700C components made of Ni-based alloys can
be operated in power plants. It also showed, however, that improvement of the material handling with
regard to manufacture, installation and maintenance is necessary. Challenges with thick-walled alloy
components still exist and additional tests in future test rigs are necessary.
Several macro cracks with partial steam leakages occurred and a high number of microcracks at repair
welds were detected:
- Cracks occurred in areas with a high degree of additional stresses, such as attemperators with
two-phase flow.
- Cracks were present in the area of stub welds and circumferential welds.
- Welds from the erection time and repair welds were affected.
10

- Two circumferential repair welds in the thick-walled 700C area without heat treatment, neither
before nor after welding, caused the most severe cracks, which were detected after some months
of daily start/stop cycles.
- Heat treated repair welds (980C/3 h) showed micro cracks (dye penetrant test indications) but no
macro cracks.
- Cracks started at the outer surface and crack propagation was interdendritic and intergranular.
The operation showed that a post-weld heat treatment at 980C for thick-walled Alloy 617B compo-
nents has a good effect on the weld. This kind of heat treatment can be applied to erection welds and
repair welds. It was not possible to develop and to verify a final repair concept for thick-walled Alloy
617B components during the operation time. Open questions have to be solved in follow-up investiga-
tions and projects. Promising ideas are already available.
The experience from the CTF is being considered in subsequent projects such as ENCIO and HWT II.
Post-weld heat treatment at 980C is considered for thick-walled Alloy 617B components where the
steam is cooled down with colder steam or a combination of water and flowing steam in order to
achieve good dispersion of the water and thereby avoid a two-phase flow.
22,400 hours of operation were achieved between 2005 and 2009. The facility was operated for 13,000h
at steam temperatures above 680 C. A maximum steam temperature of 725C was reached in the outer
tubes of the test superheater. Unit F was operated with many starts and stops during the operation peri-
od thereby making it possible to test the components under cyclic loading conditions, which was origi-
nally not expected. 576 starts were counted until the end of operation.
Some problems occurred with the control technology and the valves in the first months of operation
which caused minor non-availabilities. Valve problems were mainly caused by leaky gaskets and actua-
tors and could be solved.
Apart from one tube damage in the superheater end of 2006, no incidents of damage to materials ap-
peared in the first two years of operation. Cracks on thick-walled Ni-based alloys were detected for the
first time in spring 2007. Further cracks were detected in the following years. Cracks and problems with
repair welds led to a long outage period in the last year of operation.
Modifications of the facility were carried out during the 2008 summer outage. Additional drain pipes
were introduced and the slope of some pipes was optimised. Problems with condensate, especially at
spray attemperators, led to these measures.
The first samples from the superheater were taken in the 2007 summer outage. The final sampling was
carried out after the dismantling in 2009 and 2010.
Several defects at thick-walled Alloy 617B components outside the boiler had to be repaired, whereas
thin-walled components suffered only one failure. Cracks occurred in the highly stressed spray attem-
perators 2 and 3, where feed water reduced the steam temperature from 700 to 540C. Small indications
were detected at repair welds of Alloy 617B components. Repair welds were made in parts where mate-
rial was cut out and fitting pieces had to be installed.
The following failures were observed:
x Superheater
o Leakages were detected at two tubes in the area of welds connecting Alloy 617B with
Sanicro25 in October 2006. The crack was initiated by stress relaxation cracking in Alloy
617B, induced by manufacturing related issues like hardness, grain structure, etc., and op-
erational loads. A successful repair weld was applied.
11

x Spray attemperator 2
o PT indications were observed on stubs of injection nozzle assemblies in August 2008. La-
boratory investigation showed that the cracks ran interdentritically with carbides and pores
on the grain boundaries in front of the crack tip. Indications were ground out and weld
build-up was made using TIG welding. Heat treatments were avoided due to the various
thermal expansions of the attemperator assembly. Cracks were detected in the weld metal
in February 2009.
o Indications were observed at a bracket in September 2008. The bracket and the affected
part of the attemperator were removed and metallographic investigation confirmed the in-
dications as cracks. The affected attemperator part was replaced with a fitting piece with-
out the bracket. During this repair strong deformations at the protective pipe were detected.
o Visual inspection showed a crack of the protective pipe close to the injection nozzle as-
sembly. The end part was cut out and replaced with the end part of spray attemperator 3.
Heat treatment was carried out only on the side connecting the attemperator to the steam
pipe.
o In this fitting piece crack propagation was detected in February 2009. In order to ensure
continued commercial operation of the host plant, spray attemperator 2 was immediately
replaced with spray attemperator 3.
x Spray attemperator 3
o The regular outage in 2006 revealed strong deformations and cracks of the protective pipe
of spray attemperator 3. The pipe was replaced and the attemperator was connected to the
steam pipe with two circumferential welds without heat treatment. One of the repair welds
failed in April 2007.
o In March 2007, a weld failure at the Alloy 617B counter bearing of a spray injection noz-
zle assembly had to be ground out and was welded again. New leakage was detected in
February 2008.
o In April 2007, a deflection of the turbine valve was detected and the pipe, which includes
spray attemperator 3, was slightly bent. Water, injected through a preheating pipe before
the turbine valve, had accumulated at the bottom of the turbine valve and spray attempera-
tor 3 area impacting weld failures. Two welds were replaced with fitting pieces applying
prWHT.
o In February 2008, the turbine valve was inclined and the pipe, which includes spray attem-
perator 3, was obviously deflected. Cracked welds at the protective pipe and water puddles
were observed. One crack was located in the HAZ of an electrode welded circumferential
weld in the middle part of the attemperator, the other at a near stub weld. Both welds were
manufactured during erection. Further PT indications were detected at stubs installed to
centre the protective pipe. Replacement with three fitting pieces was carried out using elec-
trode welding. While the base metal was not heat treated, the main pipe was annealed at
980C for 3h in a furnace. PT and UT showed indications at stub welds after annealing.
Cracks were propagating interdendritically in the weld metal. Crack flanks showed strong
oxidation with accumulation of Al, interdendritic areas and grain boundaries displayed
significant accumulation of carbides containing Mo. The cracks propagated into the base
material and the crack flanks were covered with Mo-Cr carbides. Indications disappeared
after grinding and welds were built-up with filler metal. The new circumferential repair
weld showed indications at the stubs. Cracks of 1-2mm length propagated interdendritical-
ly in the weld metal and intergranularly in the HAZ of the base material. The interdendritic
areas of the weld metal as well as the grain boundaries of the base material displayed mas-
12

sive saucer-type accumulation of carbides containing Mo and Cr. The repair welds were
ground, cut out and TIG built-up using a filler metal with a lower boron content. Two
welds were filled with TIG orbital. This welding technique was applied with good results.
Attemperator 3 was annealed again in a furnace before installation of the protective pipe in
early 2009.
x Circumferential repair welds of steam pipes
o In 2007 all thick-walled circumferential welds of the 700C steam pipe part were checked
with mechanised UT. Manufacturing failures were found, which were not detected using
RT during erection. Four welds were replaced with fitting pieces in 2008 using electrode
welding and PWHT at 980C/3 h. After some months of operation PT indications (UT
showed acceptable indications) had to be eliminated again by grinding, cutting and built-up
welding.
o The available repair concept was not appropriate. Different kinds of optimisations were
tested, which led to better results, but local indications were still found quite frequently
during the works. The works were extremely time and cost intensive. All repair works
were finished in May 2009 after more than two months of standstill.
1.2.7 Work Package 7: Evaluation
Most of the findings within Work Package 7 are a result of a comprehensive scope of material investi-
gations carried out by several laboratories. The scope of investigations was defined in an evaluation
matrix describing the samples and the relevant investigations. All relevant component types and materi-
als were covered in this matrix. The scope included investigations of oxidation, corrosion and micro-
structure with microscopy, hardness test, impact test and other mechanical tests.
In addition to the material investigations; investigations of consumed lifetime and evaluation of relevant
design assumptions have been carried out. A limited scope of other activities have also been investigat-
ed and reported.
Due to failures in thick-walled components further studies were initiated, leading to additional results
regarding failure analysis, repair procedures and non-destructive testing.
The membrane wall was manufactured using T24, HCM12 and Alloy 617B and showed no cracks or
leakage during operation. The materials performed as expected with respect to oxidation and corrosion
considering the alloy compositions and operating temperature. High scatter in corrosion data for T24
exposed at metal temperatures above 546C suggests that the operating temperature should be limited
for this material without further investigation. Investigations of welds showed similar oxidation and
corrosion characteristics as base metals. Hardness measurements added results regarding hardness pro-
files across welds in conformity with the expected profiles for the investigated materials. Decarburisa-
tion was also observed as expected in cases where non-matching filler metal was used. Only minor im-
perfections were observed in the investigations of the welds.
The results have proven that it is partly possible to design, manufacture and operate a membrane wall in
a 700C component test facility; in view of the fact that no damage, no excessive oxidation or corrosion
and no considerable microstructural changes were observed. Results indicate that the maximum operat-
ing temperature for the steel alloys should be considered. It should be noted that design and operational
loads may have deviated from a full scale plant.
The superheater was manufactured using DMV310N, HR3C, Sanicro 25, Alloy 617B and Alloy 740.
During operation a tube leakage occurred in Alloy 617B adjacent to a dissimilar weld. The crack was
initiated as stress relaxation cracking, induced by cold deformation, grain structure and stresses. A re-
13

pair concept including annealing heat treatment was applied successfully. Investigation of the oxidation
provided results describing oxide morphology, oxide thicknesses and the internal oxidation zones of Ni-
based alloys. The lowest oxide thickness on austenitic steels was observed for Sanicro 25 and on Ni-
based alloys the oxide layer thickness was comparable for Alloy 617B and Alloy 740. Alloy 740 did,
however, show the most pronounced internal oxidation along grain boundaries. Investigation of corro-
sion provided results describing corrosion layers, corrosion rates and presence of internal corrosion. The
majority of the investigated materials showed minor thickness reductions, comparable to the deviation
from nominal thickness for the as-received samples. Locally, large thickness reductions for Sanicro 25
and Alloy 617B suggest that a more detailed study should be initiated in the critical temperature ranges
and considering the coal sulphur content. Microstructural investigations added results regarding grain
sizes and precipitates, and in combination with creep tests it was suggested that the version of Alloy
740 used may suffer from microstructural instability. Investigations of welds generally showed similar
oxidation and corrosion characteristics as base metals; although in some cases with local effects near
fusion line. Hardness measurements added results regarding hardness profiles across welds. Only minor
imperfections were observed in the investigations of welds.
The results have proven that it is partly possible to design, manufacture and operate a superheater in a
700C component test facility. The tube leakage which occurred during operation showed that the as-
received condition of Alloy 617B tubes and the manufacture can affect the susceptibility for stress re-
laxation cracking; and it led to the development of a repair concept which was applied successfully. The
observations of local high corrosion rates for some alloys indicate that it is very likely that the operation
time of the superheater will be less than the design lifetime; and further studies of corrosion in critical
temperature ranges should be considered.
The thick-walled components was manufactured using mainly Alloy 617B, and with some use of P92
and low alloy steel. The planned microstructural investigations of thick-walled Alloy 617B added re-
sults regarding grain size distribution, precipitates, and characteristics at grain boundaries and in the
matrix. Hardness tests and mechanical tests confirmed that service exposed materials have increased
hardness and tensile strength but with lower ductility. Increased hardness on inner surfaces compared to
bulk hardness was also observed. Thin chromium oxide caused local depletion of Cr and dissolution of
precipitates. In some cases shallow oxidation pits and grain boundary attack were observed. Only minor
imperfections were observed in the investigations of the welds.
The first crack in thick-walled components was observed after approximately 15,000 hours of opera-
tion, and in the following period additional cracks were observed. This led to further detailed investiga-
tion of the welds and components concerned. In most cases, cracks were reported to nucleate in the
weld and to propagate in an interdendritic and intergranular manner to the base material. It was suggest-
ed that residual stresses and operational stresses promoted the failure mechanism.
The results have proven it partly possible to design, manufacture and operate a piping system in a 700C
component test facility. Code requirements were the background for not applying PWHT, but results
suggest that PWHT should be applied for the welding of Alloy 617B components. The horizontal spray
attemperator design was used due to limited space, but in combination with insufficient drainage this
may have contributed to the observed failures.
The observed failures in thick-walled Ni-based components led to the necessity of repair procedures. In
the first attempts the weld sequence for the reduction of residual stresses was optimised, initially within
the range of qualification of the welding procedures used during manufacture, followed by improve-
ment in the selection of welding processes and filler materials. It also became obvious that heat treat-
ments, both pre-welding and post-welding, should be investigated and applied to reduce re-cracking
14

susceptibility. Heat treatment studies included microstructural studies with focus on precipitates and
precipitate behaviour at various temperatures. An experimental test of site heat treatment for solution
annealing documented the applicability of the developed equipment and the thermal cycle of the pipe
material. A weld test programme was then initiated to develop an optimised weld repair procedure,
based on selected combinations of welding processes and heat treatments. Preliminary results indicate a
good potential for the development of a repair concept.
During manufacture of thick-walled Alloy 617B components for the CTF; volumetric testing was only
applied for the first 1/3 of each weld, due to limitations in the available techniques for volumetric test-
ing. After the observations of cracks in thick-walled components it became obvious that mechanised
ultrasonic testing should be introduced for inspection purposes in the following operation period.
Mechanised ultrasonic testing became qualified and verified during the project and was applied success-
fully for the inspection of a large number of welds in the piping system. With this method a number of
welds with indications were identified and replaced. Verification was done by comparing non-
destructive test results with destructive laboratory investigations, and the results were in good agree-
ment. The mechanised ultrasonic test method can be recommended for further application of thick-
walled Ni-based components for the power generation industry and other industries.
Calculations of consumed lifetime and design review were performed for a selected position in the Al-
loy 617B part of the superheater, for selected components in the main steam piping system and for
spray attemperators 2 and 3. The results from calculations of consumed lifetime and design review have
generally shown moderate consumed lifetime in the operation period. Only for the spray attemperators
the lifetime consumption was found to be high as a result of the two-phase flow thereby confirming the
importance of an improved attemperator concept and a sufficient drainage system. The results have also
identified the necessity for further corrosion studies in selected temperature ranges for the superheater
and the importance of post-weld treatment and the extent of NDT for the reduction of notch factors and
thereby the consumed lifetime for thick-walled components.
Three additional technologies were tested; self-calibrating thermocouples, compact insulation material
and nanoceramic coating. The self-calibrating thermocouples were promising.
1.2.8 Work Package 8: Coordination
The COMTES700 continued the idea of the 700C power plant started in 1998 with the AD700 phases
1 and 2 projects. The project has impacted on European and national research projects, namely ENCIO
and GKM HWT II, and has challenged China, India and J apan to plan their own 700C technology re-
search programmes.
Coordination was required for the relationships between six contractors and eighteen co-financing part-
ners (suppliers and utilities) from eight European countries. Several groups were established to manage
major tasks (Steering Committee, Project Management Group, Temporary Support Group Financial,
Editorial Group, WP 6 Operation, WP 7 Evaluation).
By joining forces, the installation of the CTF could be ensured with a delay of only two weeks. The
project was extended for two years exploiting operation experience for a future 700C demonstration
power plant. The unexpected termination of CTF operation was compensated by an increase in the in-
vestigation efforts. Additional resources needed were covered by acceptance of a new partner, know-
how access agreements and additional funding of all partners. These activities required the establish-
ment of a complex agreement structure. Requests from other 700C projects for investigation material
were generally approved against return of results.
15

In order to enhance operation experience, the COMTES700 parties successfully applied for a project
extension of two years. Simultaneously, operation problems forced the host plant to shut down the pro-
duction unit, which was not separable from the CTF. As time and costs for repairs were unpredictable,
the host plant decided to dismantle the CTF. Consequently, all project resources were focussed on the
evaluation part and a comprehensive programme of additional laboratory investigation was established
to exploit the operating experience.
Various consortium internal projects were supported with material free of charge, or materials were
provided to third parties. Generally, the COMTES700 parties appreciated and supported other projects
in favour of the advancement of 700C technologies. These activities are planned to be supervised by a
700C Group.
The total budget increased from EUR 15.3 mio. up to more than EUR 26 mio. The CTF caused outages
of the host power plant unit for several weeks. Related costs were covered by RWE and E.ON. The
budget increase was balanced by the project partners, acceptance of a new party and know-how access
agreements. Complex payments between the parties had to be arranged and controlled. Tax questions
had to be settled.
The COMTES700 results were communicated to all partners in workshops and a web-based document
file system was established and maintained. The public was informed by a project web page and more
than 40 publications.
1.2.9 Conclusion and possible applications and patents
Key components have been designed, manufactured, erected and operated in the host power plant in
order to demonstrate if the necessary technical solutions to realise a 700C demonstration power plant
are available.
x An evaporator panel made up of three sections with three different materials: T24, HCM12 and
Alloy 617B.
x Two superheater panels for the final superheating up to 700 qC. Tested materials are HR3C,
DMV310N, Sanicro25, Alloy 617B and Alloy 740.
x Valves including a HP-bypass valve.
x Thick-walled components such as headers and spray attemperators. All components for 700 qC
were made of Alloy 617B.
x Control and instrumentation devices.
A turbine control valve was simultaneously tested outside the scope of this project.
1.2.9.1 Evaporator
Since the obtained outlet temperature was approx. 50qC below the planned value, the project has not
demonstrated that the required materials are found. In addition, the tested panel was not subjected to
external static loads as will be the case in a coil section of a tower boiler.
For practical reasons a membrane wall had to be erected without PWHT on site. However, all of the
three tested materials have shown shortcomings:
x The section made of T24 performed without problems, but many problems with this material
has been experienced lately as described in VGB news 2011 volume 11.
16

x In the course of the project, the creep strength values for HCM12 were reduced with the result
that this material is no longer a relevant material for membrane wall applications.
x Tests of the Alloy 617B evaporator panel were performed. However, it is questionable due to
the result from the membrane wall in the MARCKO700 project which demonstrated a very
short lifetime when subjected to external loads.
Therefore, it must be concluded that further testing of materials for membrane walls is needed.
1.2.9.2 Superheater
Corrosion rates that were found locally for Alloy 617B tubes result in lifetime estimates as low as
50,000h. These parts would have to be exchanged depending on the chosen design.
Even though actual lifetimes of the final stages of a superheater are often found to be less than the gen-
eral design lifetime of 200,000h, the cost of replacing parts of the superheater is very high due to high
material cost. Longer lifetimes are needed in order to make a 700C power plant economically feasible.
1.2.9.3 Thick-walled components
Due to the susceptibility to stress relaxation cracking, post-weld heat treatment of thick-walled compo-
nents in Alloy 617B becomes mandatory for thick-walled sections. Since the superheater sections in this
material performed satisfactorily without PWHT, a thickness limit above which PWHT is required re-
mains to be determined.
Developed procedures for performing repair welds using prWHT on service exposed materials in Alloy
617B must be further tested to demonstrate that proper solutions have been found. Testing of the long
term properties of the most promising procedures are underway.
NDT methods and acceptance levels for in-service evaluation of thick-walled components must be de-
veloped further. Mechanised UT seems to be a promising technique.
In spray attemperators special care must be taken to reduce thermal stresses as well as avoiding two-
phase flow. Two-stage injections of steam and water, respectively, are suggestions for further develop-
ment.
1.2.9.4 Valves
Thick-walled valves, e.g. HP-bypass valves, showed crack formation starting on the inside of the valve
bodies. Since the cracks were undetectable by NDT in the in-service state it is questionable if the tested
valves could be operated safely for long periods.
Therefore, in order to reduce the risk of both fatigue and creep cracking, it is vital to test available im-
proved designs where local stress concentrations due to thickness changes are reduced, and reduce tem-
perature differences across the wall thickness during load changes (including start and stop sequences).
17

1.2.9.5 Summary
Table 1 gives an overview on to which degree the CTF project has succeeded in demonstrating that the
necessary technical solutions needed for a real 700qC power plant are available.

Table 1: Availability of technical solutions for critical components
Component
Design of
CTF
Manufacturing Erection
Operation of
CTF
Design and
Operation of
700C Power
Plant**
Evaporator* Partly Yes Yes Partly Partly
Superheater Yes Yes Yes Partly Partly
Valves Partly Yes Yes Partly Partly
Thick-walled
components
Partly Yes Yes Partly Partly
C&I Yes Yes Yes Yes Yes

* See glossary for definition
** Design life 200,000h and the current design principles
The project did not succeed in demonstrating that all the necessary materials and designs of the critical
components needed to realise a 700 C power plant had been found.
Much new knowledge has been gained but critical issues, basically related to reliable operation, still
need to be solved before a 700 C demonstration power plant can start operation.
1.2.9.6 Patents
Patents are not registered.
18

2 SCIENTIFIC AND TECHNICAL DESCRIPTION OF THE
RESULTS
2.1 WORK PACKAGE 1: ENGINEERING
2.1.1 Work Package Objectives
x Design of the whole Component Test Facility (CTF)
- basic thermal calculation
- adaption to host plant
x Design of the several components of the CTF:
- evaporator
- superheater
- headers
- attemperators
- steam pipe
- valves
x Permission from the authorities for operation of the CTF
2.1.2 Comparison of Initially Planned Activities and Work Accomplished
The operational experience showed that no major deviations with scientific relevance occurred.
2.1.3 Description of Activities and Discussion
2.1.3.1 CTF Design
2.1.3.1.1 Description of the CTF
The CTF was installed in the steam generator of unit F of the E.ON Power Plant Scholven (bituminous
coal-fired once through steam generator), Germany. Unit F was commissioned in 1979 and produces
electricity with a net output of 676 MW and thermal output of 1,860 MW by burning hard coal. The
unit produces 2200 t steam per hour, 40 t of this were taken for the CTF and heated up to 700C. The
steam was cooled down and returned to the main boiler at the end of the facility.
The CTF was erected in 2005 and started up 14 days later than scheduled (15 J uly 2005) due to unex-
pected problems with the production of the components. The CTF was planned to operate until 2009.
The installation of such a test facility within a commercially operating power plant poses many chal-
lenges and any operational problems experienced by the CTF would immediately affect the commer-
cially operating power plant and might lead to full stop. With this reason, even from the start of the
project, reliability was an important criterion for the CTF.
19

Basically, the following components were installed:
x evaporator (44 pipes, manufactured from T24, HCM 12 and Alloy 617B; dimensions: approx. 8m
x 9m,
x superheater (2 x 16 pipes as superheater batch conducted, from Sanicro 25, HR3C, Alloy 740 and
Alloy 617B, length: 17m each,
x HP header,
x safety valve, HP-bypass valve and start-up valve,
x turbine inlet valve (no EU-sponsorship), and
x connective and thick-walled piping.
The whole chain from engineering and manufacturing to operational behaviour, creep properties, steam
oxidation and corrosion was covered.
The test evaporator of the CTF was installed at a height of between 56.5 and 66.2 meters in front of the
boiler membrane wall (Figure 1).


Figure 1: Construction of the test heat exchange surfaces and location in the boiler

Both of the superheater batches were suspended in between already existing superheater surfaces of the
unit F on a supporting tube structure.
A new platform at a height of 76m within the boiler was constructed for a spray cooler, the turbine inlet
valve, the HP-bypass valve, gate valves and other valves.
The components of the CTF, which were exposed to 700 C, were manufactured from Alloy 617B. In
addition to Alloy 617B some other materials were tested (Alloy 740, Alloy 263, Sanicro 25,
DMV310N, HR3C, T24 and HCM12).
A turbine control valve was also installed in the CFT. Investigation of this valve was not covered by the
COMTES700 project. The CFT only served as a host for this valve.
The water/steam process is shown in the P&I-diagram 9.21602/00010-0001 which is based on the flow
diagram of the description of the CTF in the proposal submission forms. Figure 2
20


Figure 2: Isometric drawing of the CTF

The cold steam for the CTF was extracted from the SH1-inlet header (390C) of the main steam genera-
tor. The steam flow was measured (26NA45F001-003) and controlled (26NA45S002) with respect to
the steam temperature downstream from the first heating surface (evaporator 26NA45). A 100% bypass
valve (26NA45S004) with fixed minimum flow position ensured minimum flow through the CTF. The
steam was heated in the first heating surface (evaporator 26NA45) to the controlled outlet temperature
of 610C. On the way to the next heating surface (superheater 26NA65) the first injection stage
(26NA55Z015) was arranged. The steam temperature was reduced in order to control the superheater
outlet temperature. While passing through the superheater surface the steam reached the live steam
temperature (705C) of the CTF.
In the piping system downstream from the superheater surface the following components were installed:
- start-up injection station (26NA75Z015)
- HP-bypass valve (26NA77S003)
- safety valve (26NA77S094)
- start-up control valve (26NA79S002)
- turbine valve (26NA76S005)
- final injection (26NA76Z020)
The CTF conformed to the task described in the work package description of WP1 in the proposal sub-
mission forms.
The start-up injection station (26NA75Z015) was only in operation during start-up and while switching
from normal operation mode to bypass operation mode for controlled temperature increase in the down-
stream piping system.
The turbine valve (26NA76S005) and a long HP steam pipe (26NA76Z010) made of Alloy 617B were
introduced in the CTF downstream from the start-up injection for test purposes.
21

The HP-bypass valve was used for test purposes or when the available pressure difference of the SH
system of the main steam generator did not ensure sufficient cooling mass flow in part load operation
mode.
In normal operation mode in the final injection stage (26NA76Z020) the steam temperature of the CTF
was further reduced to meet the live steam parameters of the main steam generator (538C). Before
being discharged to the SH system of the main steam generator (SH4 outlet), the steam flow was meas-
ured (26NA76F001) in order to balance mass flows and detect leakages.
The calculated mass flow rates and the steam temperatures of the CTF when the main steam generator
operated at full load were as Table 2 following:
Table 2: Calculated data of the CTF at full load of the boiler
Location
Pressure
bar
Temperature
C
Mass flow rate
kg/s
Inlet conditions downstream
SH1 222 390 11,57
Inlet evaporator 219 390 11,57
Outlet evaporator 216 610 11,57
Downstream 1st injection 216 580 12,00
Inlet superheater 215 580 12,00
Outlet superheater 212 705 12,00
Downstream final injection 210 536 14,59
Downstream HP-bypass valve 41 538 13,43

If the steam leaving the CTF at the superheater outlet (12kg/s, 705C and 212bar) was expanded via a
turbine this could generate 16MWe. The calculated values of the pressure drop at full load of the CTF
can be seen in Table 3.
Table 3: Pressure drop of the CTF
No. Designation Quantity Length di Oper. Pres. Oper. Temp. Pressure loss
[m] [mm] [bar] [C] [bar]
1. Inlet Pipe (from SH1 Inlet) 1 ca.100 123,9 222,0 390,0 0,6*
Control Valve 390,0 1,5
Isolating Valves +Flow Meter 1 390,0 0,5
2. Evaporator 44 ca. 50 19,5 219,4 390,0 - 610,0 3,0
3. Pipe incl. Spray Cooler 1 1 ca. 40 155,1 216,4 610,0 - 580,0 0,4
4. SH 32 ca. 50 24,5 216,0 580,0 - 705,0 2,6
5. Pipe incl. Spray Cooler 2 / 3 1 ca. 60 119,1 213,4 705,0 - 536,0 2,0
6. Pipe to SH4 Outlet 1 ca. 60 163,1 211,4 536,0 0,9
Isolating Valves +Flow Meter 2 536,0 0,5
After Isolating Valves 210,0 536,0
Total 12,0
* included a level difference of above 50m
According to measurements, the available pressure drop of the main steam generator between SH1 inlet
and SH4 outlet resulted in approx. 14bar.
22

2.1.3.1.2 Modes of Operation
The CTF was arranged in parallel to the superheater system of the main steam generator. For sufficient
cooling of the test surfaces the steam mass flow through the CTF had to be high enough. Since the
available pressure difference for the CTF was given by the operation of the main steam generator at
lower loads the cooling of the surfaces had to be assured by discharging the steam to the hot reheat sys-
tem of the main steam generator.
Normal operation
The main steam generator was operated at full load in once-through operation mode. The CTF was sup-
plied with cold steam from the SH1 inlet header. The steam flowed via the evaporator, the first injection
and the superheater stage with control of the outlet temperatures. Having passed the piping upstream
from the final injection, the steam was cooled down to the main steam generator live steam conditions
and discharged to the SH4 outlet header.
In this operation mode the HP-bypass was closed as well as the isolation valve to the auxiliary steam
supply (26RQ65S502), the safety valve (26NA77S094) and the start-up control valve (26NA76S002).
The start-up injection (second injection stage 26NA75Z015) was out of operation.
Controlled HP-bypass operation
Steam supply and temperature control were the same as for normal operation mode. The steam was
expanded and cooled in the HP-bypass valve and discharged to the hot RH system.
Part load operation
The main steam generator operated at part load in sliding pressure mode. The temperatures of the steam
downstream evaporator and superheater stage were controlled (610C downstream evaporator and
705C downstream superheater). When further decreasing the boiler load and the resulting pressure
difference did not ensure a sufficient cooling the operation mode had to be changed from normal opera-
tion mode to controlled bypass operation mode.
Start-up operation
Attention had to be paid to ensure sufficient cooling of the evaporator surface during start-up operation.
For the T24 grade a max. temperature limit of approx. 600C (metal temperature) had to be respected.
Two start-up modes were foreseen:
- cold start-up (after inspection or long standstills)
- warm start-up after weekend or over-night shut-down, restart after emergency shut-down
Cold start-up
The main steam generator and the CTF were at zero pressure. The start-up procedure should be carried
out with the lowest burner level at a firing capacity of approx. 5%. This resulted in a flue gas tempera-
ture of approx. 600C below the evaporator panel of the CTF in the furnace chamber.
The cooling of the CTF was realised with auxiliary steam when the pressure in the start-up vessel of the
main steam generator was below the level of the auxiliary steam line (16bar). The control valve
(26NA45S002) and the isolating valve upstream turbine (26NA76S503) valve were closed, the isolating
valve in the auxiliary steam pipe (26RQ65S504) and the start-up control valve (26NA75Z015) were
open. The auxiliary steam quantity was controlled in order to reach the set point of 610C at the evapo-
rator outlet while respecting the allowable temperature gradients of the installed surfaces, their headers,
the HP steam pipe and the turbine valve. The auxiliary steam travelled through the superheater stage
and was discharged to the atmosphere via the start-up control valve.
23

The steam supply was switched to the main steam generator (extraction from SH1 inlet header) when
the pressure in the start-up vessel of the main steam generator was high enough. The control valves in
the main line and in the bypass line (26NA45S002/S004) were opened and the start-up control valve
and the auxiliary steam isolating valve were closed. The steam from the main steam generator was heat-
ed and discharged via the HP-bypass valve the hot RH pipe.
In case that the available pressure difference was too small it could be necessary to discharge the steam
to the atmosphere.
In case of increasing pressure difference the operation mode could be switched from bypass operation
to normal operation mode.
The firing capacity should not be increased until the outlet temperature of the evaporator was below or
equal to 610C.
Warm start-up
The main steam generator and the CTF were in standby operation mode. A start-up procedure with the
lowest burner level was recommended. Cooling of the CTF was realised with steam from the main
steam generator. The isolating valves in the auxiliary steam pipe and the start-up control valve were
closed, while the control valve in the feeding pipe and the HP-bypass valve were open. The isolating
valve upstream the turbine valve was closed. The steam was heated in the evaporator and the superheat-
er and was discharged via the HP-bypass valve to the hot reheat system of the main steam generator.
It could be necessary to discharge the steam to the atmosphere in case of insufficient pressure differ-
ence.
The increase of the firing rate was limited to sufficient cooling of the evaporator surface. The steam
outlet temperature should not exceed 610C.
In case of sufficient available pressure difference the operation mode could be switched to normal oper-
ation mode.
Switch from HP-bypass operation to normal operation and vice versa
The steam pipe downstream the turbine valve was kept warm by means of HP-steam from the main
steam generator (approx. 490C).
The steam pipe downstream the HP-bypass control valve was kept warm by means of RH-steam from
the main steam generator (approx. 470C).
When switching from normal operation mode to bypass mode or vice versa the steam temperature in the
discharge piping was reduced to approx. 535C with the start-up injection. Then the temperature was
increased by a rate of 10
-15
K/min. up to the set value of 705C with the start-up injection. When the set
value was achieved, the injections in the HP-bypass valve and the final injection reduced the steam
temperature to the set values for the main steam generator.
All details of the operation modes were summarised in an operating manual.

24


Figure 3: P&I diagram of the CTF

25

2.1.3.2 Components Design
The CTF consisted of the following components:
- evaporator with headers
- superheater with headers
- HP steam pipe
- attemperators
- valves
TV Nord was chosen as the Nominated Body who was to check the design of the pressure part. The
pressure part was designed (according to TRD) for a life cycle of 200,000h.
The materials for headers, pipes and tubes, the codes for stress values and the tolerances are summa-
rised in Table 4:

Table 4: Materials for headers, pipes and tubes and the applied codes

26

2.1.3.2.1 Evaporator with Headers
The evaporator surface of the CTF consisted of 44 parallel, smooth tubes with a tube-fin-tube arrange-
ment. They formed one surface panel which was installed close to the left wall of the furnace chamber
between level +57m and +67m near the SH1 panels of the main steam generator. In order to simulate
the situation of the evaporator wall in a furnace chamber, the rear side of the panel was isolated permit-
ting single edge heat radiation. Taking into consideration the occurring temperatures three different
materials were selected (T24, HCM12, Alloy 617B). Additionally in the first section (T24 material) two
parallel tubes were partly made as riffled tubes with reduced wall thicknesses.
The evaporator tubes were fed by an inlet header and discharged the steam to an outlet header mounted
outside of the furnace chamber. These headers were fed unilaterally.
The geometrical data are summarised in Table 5.
Table 5: Geometrical data of the evaporator
Section No of parallel
tubes
Outer diameter
mm
Wall thickness
mm
Pitch
mm
Material
Wall tubes 1 42 33,7 7,1 48 T24
Wall tubes 1 2 33,7 5,6 48 T24
Wall tubes 2 44 33,7 7,1 48 HCM12
Wall tubes 3 44 33,7 7,1 48 Alloy 617B

Inlet header 1 168,3 28 - 13CrMo4-5
Outlet header 1 219,1 45 - P92
The data for stress calculation (according to TRD) are shown in Table 6.
Table 6: Data from stress calculation
Section Operation
pressure / bar
g
Design pres-
sure / bar g
Operation tem-
perature / C
Design temper-
ature / C
Wall tubes 1 217,4 247,4 505 575
Wall tubes 2 216,6 246,6 560 630
Wall tubes 3 216 246 610 680

Inlet header 219 249 410 425
Outlet header 216 246 610 625
The evaporator panel is shown in Figure 4.

Figure 4: Outline of the evaporator panel

27

The thermal design data for the evaporator is summarised in Table 7.
Table 7: Thermal design data of the evaporator
Steam at evaporator inlet: p =219 bar, t =390 C h1 = 2650 kJ /kg
Steam at evaporator outlet: p =216 bar, t =610 C h2 = 3553 kJ /kg
Steam mass flow to evaporator: m = 11,57 kg/s

Injection water mass flow: m3 =m4 (h4 - h2)/(h3 - h2) = 0,43 kg/s
Injection water conditions: p =250 bar, t =265 C h3 = 1158 kJ /kg
Steam after injection: p =215 bar, t =580 C h4 = 3468 kJ /kg
Steam mass flow after injection: m4 = 12 kg/s

Heat absorption: 10451,42 kW

Heat flux (in the area of evaporator panels) q = 145 kW/m
Heating surface: A =Q/q = 72,08 m

Evaporator Tubes (selected):
Outer diameter of the tubes: da = 33,7 mm
Wall thickness of the tubes: s = 7,1 mm
Inside diameter of the tubes: di = 19,5 mm
Long. tube pitch of the panel: tl = 48 mm
Connections to header: n = 44
Mass flow density: F =m/A = 880,80 kg/ms

Effective width of the tube panel: l = 8,8 m
Effective heating surface: A = 72,65 m

Table 8 shows the steam and wall temperatures calculated for the evaporator panel.
Table 8: Calculated steam and wall temperatures of the evaporator
Steam and Wall Temperature Calculation at
Evaporator T24 Panels
HCM12
Panel
Alloy 617B
Panel

Length of the tube panels m l = 19,7 8,8 6,7
Local heat flux (at the end of panels) kW/m q = 150 130 130
Inside heat transfer coefficient (at the end) kW/mK a, inside = 4,6 4,2 4,0
Steam temperature (full load) C t, medium = 495 555 610
Steam temperature (max.) C t, medium max = 505 560 610
Wall temperature at crown apex C t, wall max = 585 643 695
Wall temperature at crown mid wall C t, mid wall = 569 626 678
Wall temperature at fin tip C t, fin tip = 577 635 687

The results for the wall temperature with a finite element analysis calculation are shown in Figures 56.
Ranges of the same temperature and heat flux are illustrated by the same colour, the heated tube side is
marked by arrows.
28


Figure 5: Calculated wall temperatures for T24


Figure 6: Calculated wall temperatures for HCM12 and Alloy 617B

The FEM calculations show the temperature distribution for the cross section of the evaporator pipe.
The parameters for the resulting temperature distribution are the outer heat flux, internal heat transfer,
steam temperature and geometrical data (OD, wall thickness, fin geometry) and material parameters
(thermal conductivity). Sections with the same colour represent areas with the same temperature and
heat flux range as indicated in the legend. Important temperatures resulting from the FEM analysis are
the max. metal temperature found for thermal durability of the applied material and the max. mid wall
temperature found for stress calculation. Due to the location and the geometrical properties the parame-
ters steam temperature, outer heat flux and inner heat transfer vary.
29

2.1.3.2.2 Selected Design for T24 Riffled Tubes for Wall Tubes 1
The geometry of the T24 internally riffled tubes used in the section Wall Tubes 1 of the CTF evapo-
rator heating surface was designed by Siemens Figure 7.
The riffled tubes were installed when the evaporator tubing was not inclined in order to improve the
heat transfer properties and to avoid local overheating under subcritical two-phase operation conditions.
Compared to the design of the smooth tubes the design of the internally riffled tubes had to be based on
the following specific parameters:
- equivalent ID
- equivalent wall thickness.
These parameters used for the geometry identification of riffled tubes could be explained as follows:
- D: rib lead angle
- E: rib side angle
- d
a
: tube OD
- d
eq
: equivalent ID
- s
eq
: equivalent wall thickness (=0.5* ( d
a
d
eq
))


Figure 7: Geometry of riffled tubes

For T24 riffled tubes used for the evaporator heating surface of the CTF the following tube data was
selected in Table 9:

Table 9: Geometrical data of the riffled tubes
Item Unit Value
Riffled Tube Outside Diameter mm 33,7
Equivalent Internal Diameter mm 20,1
Equivalent Wall Thickness mm 6,8
Min. Wall Thickness mm 5,6
Rib Lead Angle D 30
Rib Side Angle E 55
Rib Profil - B *)
*) According to data from the supplier V&M Tubes
30

2.1.3.2.3 Superheater with Headers
The superheater surface was arranged in the convective pass of the main steam generator in the area of
the SH2 surface and consisted of two assemblies. The tubes of the surface had a U-shape and were in-
stalled between two adjacent SH2 assemblies. The surface was supported by hanger tubes. The trans-
versal pitch of the original SH2 surface was split in the area where the CTF superheater surface was
arranged. The geometrical data are summarised in Table 10.

Table 10: Geometrical data of the superheater
Section No of parallel
tubes
Outer diameter
mm
Wall thickness
mm
Transversal
pitch
mm
Material
Wall tubes 1 32 44,5 10 720 Alloy 174,
HR3C,
DMV310N
Wall tubes 2 32 44,5 10 720 Alloy 617B,
Alloy 740

Inlet header 1 168,3 45 - P92
Outlet header 1 219,1 50 - Alloy 617B

The data for stress calculation (according to TRD) is shown in Table 11.

Table 11: Data for stress calculation
Section Operation pressure
/ bar g
Design pressure /
bar g
Operation temper-
ature / C
Design tempera-
ture / C
Wall tubes 1 214 244 635 685
Wall tubes 2 212 242 705 755

Inlet header 215 245 580 585
Outlet header 212 242 705 720

The arrangement of the superheater in the convective pass is shown in Figure 8.

31


Figure 8: Arrangement of the superheater surface in the host boiler

One part of the superheater outlet header was designed by Alstom, the other by BWE and welded by
Alstom.

The thermal design data for the superheater is summarised in Table 12.
32

Table 12: Thermal design data of the superheater

2.1.3.2.4 HP Steam pipe
A 59.3m long steam pipe was installed in the CTF, downstream from the start-up injection with the
following technical data:
OD 219.1mm
Wall thickness 50mm
Material Alloy 617B
Operation pressure 212bar g
Design pressure 242bar g
Operation temperature 705C
Design temperature 710C
2.1.3.2.5 Attemperators
Four attemperators were installed in the CTF:
1. first injection E1 downstream from the evaporator
2. second injection E2 downstream from the superheater (start-up injection)
3. final injection E3 downstream from the turbine valve
4. injection in the HP-bypass valve
The calculation of the mass flows is summarised in Table 13-15.

33

Table 13: Calculated flows of the CTF
Location Pressure Temp. Mass Flow Spray Inject.
bar C kg/s kg/s
Inlet pipe 222 390 11,57
Evap. inlet 219 390 11,57
Evap. outlet 216 610 11,57
After injection 1 216 580 12 0,43
SH inlet 215 580 12
SH outlet 212 705 12
After injection 3 210 536 14,59 2,59
After HP-bypass valve 41 538 13,43 1,43

Table 14: Design data final injection
Final Injection

Steam at superheater outlet p =212 bar, t =705 C h1 = 3814 kJ /kg
Steam mass flow from superheater m = 12 kg/s

Injection water mass flow m2 =m (h1 - h3)/(h3 - h2) = 2,59 kg/s
Injection water conditions p =250 bar, t =265 C h2 = 1158 kJ /kg
Steam after injection p =210 bar, t =536 C h3 = 3342 kJ /kg
Steam mass flow after injection m4 = 14,59 kg/s

Table 15: Design data HP-bypass injection
HP-bypass Injection

Steam at superheater outlet p =212 bar, t =705 C h1 = 3814 kJ /kg
Steam mass flow from superheater m = 12 kg/s

Injection water mass flow m2 =m (h1 - h3)/(h3 - h2) = 1,43 kg/s
Injection water conditions p =250 bar, t =265 C h2 = 1158 kJ /kg
Steam after injection p =41 bar, t =538 C h3 = 3531 kJ /kg
Steam mass flow after injection m4 = 13,43 kg/s

The E1-3 injection consisted of two stages, one stage could be isolated. For E2 and E3 the first stage
(Spray injection A) had two nozzles and the second stage (Spray injection B) had three nozzles (see
Figure 9).

Figure 9: Outline of attemperator arrangement

34


Figure 10: Pressure drop of nozzles vs. flow capacity of attemperator


Figure 11: Details of spray attemperator 3

Due to arrangement circumstances the spray attemperators were installed in horizontal positions. This
caused severe problems due to attemperator leakages which could not be drained properly by the drain-
ing system. The drainage system was optimised during the plant operation period Figure 11.
35

2.1.3.2.6 Drains
The drainage system was divided into three sections according to the maximum operation temperature
ranges. Every section was connected to an individual lance of the flash tank Figure 12. An additional
lance on the flash tank was installed for venting.


Figure 12: Flash tank
2.1.3.2.7 Insulation
The insulation of the complete CTF was specified by Alstom and ordered by E.ON. Special attention
was given to the max. operation temperatures of the applied materials and the need for exponentially
increased layer thicknesses due to the high temperatures. Due to the fact that the CTF had to be de-
signed to fit the free space in the existing boiler, the required spaces was not always available, and
therefore a special microporous insulation material had to be applied.
2.1.3.2.8 Valves
This subject is discussed in WP3.
2.1.3.2.9 Design Feedback
The early operation of the CTF resulted in defects defect in the liquid tightness of all installed valves.
The reason for this was found in magnetite particles which were released from the inner surface of the
pipes and tubes.
Persistent leakage of the HP-bypass spray cooler necessitated a change in the arrangement of the pipe
from the HP-bypass to the hot reheat due to severe distortion of the affected pipe.
36

There were constant problems at all spray coolers due to leakage and insufficient drainage of the sec-
tion. The horizontal spray cooler arrangement had to be adapted to suit the existing plant layout which
made it difficult to ensure proper drainage.
2.1.3.3 Commissioning
Generally the commissioning of the CTF differed not much from the commissioning of conventional
plants, the commissioning tasks were basically identical. The following were carried out:
x Checks for completeness and correct erection
x signal check for each gauge and motor,
x trial runs of all drives and motors,
x check of measurements for plausibility,
x logic tests,
x preparation of plant or equipment for inspection by authorities and
x set-up of closed control loops.
x Optimisation of closed and open control loops and check of operational parameters
x trial run and hand over to host/client.

2.1.3.3.1 Course of Commissioning

Table 16: Course of Commissioning
DATE
Plan Achieved
First commissioning engineer on site J une 06
th
2005 J une 6
th
2005
End of mechanical erection with last actuator in place J une 22
nd
2005 J uly 10
th
2005
Authority (TV)test of safety/protective functions J uly 13
th
2005
First steam to CTF J uly 13
th
2005 J uly 14
th
2005
First ignition of boiler after implementation of CTF J uly 14
th
2005 J uly 14
th
2005
First commercial operation after implementation of CTF J uly 14
th
2005 J uly 15
th
2005
First time reached 705C at SH 2.5 outlet J uly 18
th
2005
First operation of CTZ to SH 4 (normal mode) Aug. 5
th
2005
Manual operation of CTF in three shifts with pre-setting
of closed control loops until
Aug. 11
th
2005
Commissioning of open loop controls Aug./Sept. 2005
End of trial run and take over by host J uly 21
st
2005 Oct. 14
th
2005
37

2.1.3.3.2 Delay for Conventional Reasons
x The delayed end of erection of the CTF was partly caused by supply problems.
E.g. the hydraulic drive for the shut-off gate in front of the turbine valve was delivered just three
days prior to start of the plant.
x Due to late hand-over from erection to commissioning, it was only possible to carry out cold
erection of most of the equipment before going over to steam.
x Sequences to be commissioned in parallel with commercial operation of boiler, with priority of
safe operation.
x Lack of support by control systems supplier (rare presence on weekends and unusual working
hours; often change of people).
x Break-down of communication between existing control system and new control system.
x Unavailability of boiler (PA-fan damage; load programme changes by load dispatcher)
2.1.3.3.3 Delay due to Scientific Reasons
Within the commissioning time further obstructions and delays were generated by:
x On-site machining of Ni-based materials was underestimated.
E.g. in black steels the reaming of thermowells takes one shift for 10 pieces. In Ni-based material
only 3 to 4 pieces could done at the same time.
x The turbine control valve was not properly designed and was leaking heavily.
Different thermal expansion values for casing and inside material led to low tension of the head
seal causing leakage of the valve. The steam was lead directly out the boiler house thereby caus-
ing sound emissions above 120 dB(A). Therefore normal operation was possible during restricted
daytime hours only.
x The boiler cleaning concept was not available/skipped during the project thereby causing much
debris to be caught in drain valves or safety valve (see next chapter).
2.1.3.3.4 Boiler Cleaning
The boiler was not cleaned during the commissioning since the plant could not be blown out in any
direction.
x Blow-out from the conventional boiler through the black material piping into the stainless steel
parts of the CTF to the atmosphere was not possible without contamination of the stainless steel
piping.
x Reverse blowing from the SH 4 to the SH 1 inlet headers would have caused similar problems,
especially after the boiler had been overhauled too.
x Partial blow-out only was not an option, since it would have required several long standstill peri-
ods to build and rebuild the provisional piping for each stage of the blowing procedure.
For the next steps of the COMTES700 programme it is very import to take the ability for easy cleaning
into account and to organise the material selection accordingly.
38

2.1.4 Conclusions
2.1.4.1 General
The realisation and the operation of the CTF proved a partly successful design, manufacturing, con-
struction and integration of equipment and components made of new materials (e.g. heating surfaces
and valves in alloys) into an existing system.
The technical difficulties resulting from different materials and different operation temperatures were
mostly successfully solved. The different operation temperatures occurred for example when joining the
CTF evaporator to the main evaporator resulting in significant differences in operation temperatures and
temperature ranges.
Complex automatic operation of the CTF was successfully implemented.
During the operation, sufficient cooling of the CTF components was continuously ensured without any
impact on the firing system.
The design, manufacturing and operation of the CTF showed partially successful co-operation by dif-
ferent engineering groups from different companies (e.g. Alstom engineering, E.ON engineering etc.).
Generally, the assumptions that were made in the design process were confirmed by the operation of the
CTF.
Damage occurred at the injections where the protective pipe suffered cracks and deformations due to
the high temperature differences. This has to be considered in the design for commercial application.
At present, all the tools are available which are needed to design a commercial plant with the high
steam temperatures (according to EN norms and standards).
Due to the arrangement and the geometrical facts of the evaporator surface the temperature range of the
exhaust steam was much wider than expected. Consequently, the heat pick up of the evaporator surface
was determined by the tube with the highest outlet temperature. The resulting average temperature in
the steam pipe downstream the evaporator surface was lower than the design temperature.
2.1.4.2 Actual Applications
There is no commercial 700C plant today. Part of the CTF was used as reference for the new projects,
ENCIO and HWT II. The design parts are in general applied in conventional USC power plants.
2.1.4.3 Technical Potential for the Use of the Results
The intensified use of FEM analysis for the design is a prerequisite.

39

2.2 WORK PACKAGE 2: MATERIAL & MANUFACTURING
2.2.1 Work Package Objectives
x Ordering materials
x Proof of weldability and bendability
x Development of testing technologies for the new materials
x Manufacturing of the following components:
o evaporator
o superheater
o headers
o attemperators
o steam pipe
x Proof of manufacturability
x Qualification through inspecting bodies (e.g. TV)
2.2.2 Comparison of Initially Planned Activities and Work Accomplished
Since it was the first time that components from Ni-based raw materials were to be manufactured, the
manufacturing of the thick-walled components, such as headers and steam piping, proved to be very
time-consuming and prohibitive. Alloy 617B tubes for the superheater part had to be peeled from the
initial dimensions of OD 44.5x10mm to OD 41x8.25mm, since overleaps were found after bending. At
the evaporator tubes of Alloy 617B (OD 33.7 x 7.1mm), flaws were discovered too. After the tubes had
been welded to the fins, 100% penetration testing was carried out which revealed 130 crack indications.
These had to be ground until no more flaws were detected while maintaining the minimum wall thick-
ness. It also proved very time-consuming to do the NDT on welds of Ni-based alloys, since UT is too
imprecise on materials with an austenitic structure. Therefore, a PT/RT testing sequence had to be exe-
cuted. At the SH-inlet header, the dissimilar P91/Alloy 617B stubs to the header made of Alloy 617B
had been welded using P91 filler metal. After Alloy 617B was specified, the stubs had to be reconnect-
ed using the correct filler metal. During solution annealing in the manufacturing process of the thick-
walled Alloy 617B raw material (for pipe), the grain size exceeded the specified grain size of the mate-
rial specification. Therefore, the solution annealing process had to be changed from an one-step to a
two-step heating process in order to achieve even temperature distribution up to the core of block in the
first step and then heat up to the solution annealing temperature.
40

2.2.3 Description of Activities and Discussion
2.2.3.1 Ordering Material
This chapter discusses the materials used for several parts of the CTF.

Evaporator
The evaporator part included the heating surface with the materials T24, HCM12 and Alloy 617B. Ta-
ble 17 gives an overview of the different materials and the corresponding supplier.

Table 17: Dimensions and suppliers of the evaporator materials
Material Dimension in mm Supplier Certificate
Tubes T24 33,7 x 7,1 V&M 3.1A
Riffled tubes T24 33,7 x 7,1 V&M 3.1A
Fin material T24 6,00 x 15,1 Guelde 3.1B
Tubes HCM12 33,7 x 7,1 Sumitomo 3.1A
Fin material HCM12 6,00 x 15,1 Guelde 3.1B
Tubes Alloy 617B 33,7 x 7,1 DMV PMA
Fin material Alloy 617B 6,00 x 15,1 Guelde PMA


The materials were ordered with a 3.1A certificate accord-
ing to EN 10204 with the exception of the fin materials
which were ordered with a 3.1B certificate. A grade 3.1A
acceptance certificate means that it was issued and con-
firmed by an expert listed in the official regulations, in
accordance with these and the associated technical rules.
Alloy 617B is excluded since a Particular Material Ap-
praisal (PMA) was applied. The PMA was made according
to the corresponding or equivalent VdTV data sheet. Be-
cause of the melting loss during welding it was especially
important for the modified version of Alloy 617 to show
aluminium content not lower than 0.8 mass-%.
Figure 13 as an example, shows the 3.1A certificate for the
ordered HCM12 by Sumitomo.


Figure 13: 3.1A certificate of HCM12 evaporator tube





41

Piping
The steam piping includes the inlet and outlet of the evaporator and superheater besides the piping to
the bypass, superheater and reheater and the start-up and safety valve. Table 18 gives an overview of
the different materials and the corresponding suppliers.

Table 18: Dimensions and suppliers of steam piping materials
Material Dimension in mm Supplier Certificate
SH1 Evaporator inlet 13CrMo4-4 168,3 x 22,2 Buhlmann 3.1A
Evaporator outlet P92 219,1 x 45 Saarschmiede PMA
SH-Inlet P92 219,1 x 32 Saarschmiede PMA
SH-Outlet
Spray Cooler 3
Alloy 617B 219,1 x 50 Saarschmiede PMA
Pipe to HP-Bypass Alloy 617B 219,1 x 50 Saarschmiede PMA
Start-Up Valve / Safety
Valve
Alloy 617B 133,0 x 25 Saarschmiede PMA
Pipe to SH4-Outlet P91 219,1 x 28 V&M 3.1A
Pipe to RH2-Outlet 10CrMo9-10 244,5 x 20 Buhlmann 3.1A

As for the evaporator parts, if applicable a 3.1A certificate was ordered. P92 and Alloy 617B were ex-
cluded since a PMA was applied Figure 14. As an example, shows some pages of the PMA for Alloy
617B.

Figure 14: PMA of Alloy 617B


42

Superheater
The superheater was manufactured by HPE using the high strength/corrosion resistant materials
Sanicro 25, HRC3/DMV310N, Alloy 617B and Alloy 740. Table 19 gives an overview of the different
materials and the corresponding suppliers.

Table 19: Dimensions and suppliers of the superheater materials
Material Dimension in mm Supplier Certificate
Tubes Sanicro 25 44,5 x 10 Sandvik PMA
Tubes HR3C 44,5 x 10 Sumitomo 3.1A
Tubes DMV310N 44,5 x 10 DMV 3.1A
Tubes Alloy 617B 44,5 x 10 DMV PMA
Tubes Alloy 740 44,5 x 10 Special Metals PMA

Filler Materials
The ordered filler materials and the respective suppliers for the evaporator parts are listed in Table 20.
Figure 15 shows the 3.1B certificate of the Alloy 617B welding rod (S Ni6617 mod).

Table 20: Dimensions and suppliers of filler materials
Material Dimension in mm Supplier Certificate
TIG welding rod T24 OD2,4 Boehler 2.2
SAW electrode T24 OD2,0 Boehler 2.2
SAW flux T24 - Boehler 2.2
TIG welding rod Alloy 617B. OD 2,4 Boehler/Thyssen 3.1B
SAW electrode Alloy 617B. OD 2,0 Boehler/Thyssen 3.1B
SAW flux Alloy 617B. - Boehler/Thyssen 3.1B
SMAW electrode Alloy 617B. OD 2,5 Boehler/Thyssen 3.1B
SMAW electrode Alloy 617B. OD 3,2 Boehler/Thyssen 3.1B
Orbital electrode Alloy 617B. OD 1,2 Boehler/Thyssen 3.1B
TIG welding rod P92 OD 2,4 Boehler/Thyssen 3.1B
SMAW electrode P92 OD 2,5 Boehler/Thyssen 3.1B
SMAW electrode P92 OD 3,2 Boehler/Thyssen 3.1B

43


Figure 15: 3.1B certificate of Alloy 617B welding rod

44

Table 21 gives an overview of the chemical composition of novel materials.

Table 21: Chemical composition of novel materials applied for the CTF
45

Adherence to Formal Requirements

Installation
For the installation of the CTF into Scholven Unit F, several formal procedures based on code require-
ments had to be taken into consideration. Since Scholven is an existing plant, the requirements accord-
ing to PED Directive, guideline Module G (PED) for the pressure-loaded parts such as steam piping,
superheater or evaporator, and TRD201 had to be fully implemented.
Since several novel materials were im-
plemented in the CTF which were not
specified at that time in the codes and
standards, the implementation was han-
dled according to given standards such
as EN 10216. To minimise any trials,
material specifications were compiled
for all materials before ordering. It has
been considered whether additional test-
ing of new materials is necessary.
The materials specifications and the
welding lists and the drawings had to be
approved by the Notified Body before
ordering or manufacturing.

Figure 16: Interim certificate of the Notified Body (RWTV)

Approval Process
The Notified Body has followed the project from the early planning phase for design approval, over
issue of the interim certificates for the different parts of the CTF until final approval of the erected facil-
ity (Figure 16).

Manufacturing Process
For all manufacturing steps, like bending and welding, qualification procedures (WPQR and BPQR)
according to EN standard and the VGB-guideline have been followed.
46

Bending
The evaporator tubes with the dimension 33.7 x 7.1mm were cold bent with a radius of 60mm which
corresponds to an R/D ratio of 1.78. According to the relevant VdTV material data sheets, stress relief
of T24 and HCM 12 and solution annealing following by mechanical testing of Alloy 617B were car-
ried out. For this, all requirements have been fulfilled. The hardness deviation between unbent and bent
tubes is lower in conformity with DIN EN 12952-5. In addition, surface crack testing was carried out.
The thick-walled components were bent by inductive bending.























Figure 17: Cover sheet of WPQR HCM12/Alloy 617B BW

Welding
For the welding, WPQRs were carried out to meet the requirements of the guidelines. Tube-fin-tube
welding and fin-fin-welding were carried out by SAW with the suggested wire/flux combinations and
without pre-heating.
The requirements in accordance with VdTV451-68/1 have been fulfilled. The hardness testing showed
the expected hardness values for T24, HCM12 and Alloy 617B
The MT and PT at the membrane walls showed no indications or failures.
Figure 17 shows the WPQR cover sheet of the dissimilar butt weld HCM12/Alloy 617B. Also as re-
gards homogenous welds of HCM12, dissimilar welds were post-weld heat treated.
2.2.3.2 Manufacturing
Attention was paid to the manufacture of the thick-walled base materials. The final machining of the
inner surface was of utmost importance to ensure that no imperfections resulted in a corroding surface.
The machining of the final surface of Alloy 617B, which consumed more time and lowered the durabil-
ity of the cutting tools compared to ferritic steels can be seen in Figure 18.

47

For the forging of the thick-walled pipes, two steps were
carried out to ensure that the grain size was homogenous
over the whole wall thickness and within the specified
grain size range as provided by DIN EN ISO 643 (grain
size 24). In one particular case, a nonconformity report
(NCR) by Saarschmiede occurred, where the grain size of
the manufacturing lot reached up to -3 for Alloy 617B
(see Figure 19 for reference). These two pipes (OD 219.1
x 50mm), showed the mentioned grain size in one half of
each tube, while the other half showed the specified grain
size. Also a square block from Sempell intended for the
valve body showed grain sizes larger than specified.


Figure 18: Final machining of inner surface of Alloy 617B

The NCR by Saarschmiede referred to the
PMA from 8 J uly 2003 which was carried
out by TV Rheinland and the material
specification no. 9.21602/00 189-70013
and -7018. The PMA refers to the creep
rupture strength in the temperature range
600750C of Alloy 617 with the speci-
fied chemical composition according to
VdTV data sheet 485. The deviation of
grain size is according to enclosures in e-
mail from Saarschmiede from 22 Novem-
ber 2004.

Figure 19: Alloy 617B. with grain size number G=-3


48

The test reports by Saarschmiede have been accepted due to fulfilled mechanical technological tests
(impact test values) and an additional performed superficial fuse test which lead to satisfying results.
To ensure that even grain sizes with the specified value is achieved, two steps are needed for the forging
process:
- forging of the half of the pipe,
- reheating up to hot working temperature with a long holding time,
- forging of the second half of the pipe and
- solution heat treatment.
This resulted in:
- No further deformation on the half of the pipe which was forged in the first manufacturing step
- Two heat treatments with long holding times at a relatively high temperature caused no growth
of grain size instead of only one heat treatment.
In short, a long holding time at a rela-
tively high temperature during solu-
tion heat treatment and during the
heat-up phase to hot working tem-
perature ensures equal temperature
distribution between outlying area and
core area.
Figure 20 shows the forging of the
first half of an Alloy 617B pipe (OD
219.1 x 50mm) in two steps.



Figure 20: Forging of Alloy 617B (OD219.1 x 50mm)

To ensure that the materials with a non-conform
grain size do not pose a risk, TIG welding with-
out filler metal (pure fusion of base material
Figure 21) and combined TIG/SMAW welding
with filler at the materials were performed. The
stress caused by shrinkage of the weld seemed
strange given the range of the yield and should
give more precise information if the material can
avoid risks like cracks in the microstructure.






Figure 21: TIG fusion welding without filler metal

49


Figure 22: TIG welded base material and after PT on the right side

After welding, PT was performed and microsections cut out for the TIG welded materials and RT of
the root or first filler pass with PT at 1/3, 2/3 of the weld volume and the top layer had to be carried out.
It turned out that no cracks occurred as can be seen in Figure 22. TIG/SMAW welding process is shown
in Figure 23.










Figure 23: TIG/SMAW welding of Alloy 617 tube in fixed position

Finally, a grain size up to 1 was acceptable, whereas a grain size coarser than 1 had to be replaced by an
additional cast. Saarschmiede changed its manufacturing process accordingly to deliver the materials
with the specified characteristics.
The manufacturer reduced the temperature for solution heat treatment and reduced the temperature for
re-heating up to hot working temperature during the forging process. Also the holding time at solution
annealing temperature was reduced. Heat treatment was done by step-heating to achieve a holding time
that would compensate for the temperature differences between the core area and the surrounding area,
which is below solution temperature. Also heat treatment method was simulated on a test specimen
after forging, before solution heat treatment. This was done to determine the grain size on the test spec-
imen. Figure 24 shows the new heat treatment procedure. (The regular heat treatment method does not
show a cycling step).
50


Figure 24: New heat treatment method for Alloy 617 components

To provide better understanding of which grain sizes can be expected with a given grain size number G,
Table 22 gives an overview of the number G-7 up to G13. The values have been adopted from ASTM E
112 and EN ISO 643, since ASTM just shows the calculated values from 0 onwards (1 according to
the EN ISO standard). EN ISO shows values from 7 onwards. The logarithmic equation for calculating
the G-values differs slightly for both standards, the difference is G=0.05. This difference is negligible,
since the grain size cannot be determined more accurately than half a unit, even under the most favour-
able conditions.

Table 22: Grain size no G according to EN ISO 643 (G-7 G-1) and ASTM E 112 (G0 G13)
Grain size
number
G
Average grain
diameter
(mm)
Grain size
number
G
Average
grain
diameter
(m)
Grain size
number
G
Average
grain
diameter
(m)
-7 4000 0 359 7 32
-6 2828 1 254 8 23
-5 2000 2 180 9 16
-4 1414 3 127 10 11
-3 1000 4 90 11 7,9
-2 707 5 64 12 5,6
-1 500 6 45 13 4

T
e
m
p
e
r
a
t
u
r
e
Time
t
1
t
2
T
1
T
2
Regular solution heat treatment
- Faster heating up to solution
annealing temperature
- Longer holding time at solution
annealing temperature

51

All Alloy 617B tubes supplied by DMV
with dimensions of OD 44.5 x 10mm for the
superheater had to be mechanically peeled
to OD 41 x 8.5mm due to indications on the
outer surface of the tubes. The indications
were found during penetration testing after
bending of some tubes. Subsequently, some
straight tubes were tested too and showed
the same flaws. The indications have been
identified as overleaps with a depth of up to
1.6mm, which were not found in the lon-
gitudinal UT and Standard Eddy Current
testing since the morphology of the defects
were semi-circular or arrow-shaped. DMV
re-tested the surface of the peeled tubes
using a specific Eddy Current Circograph
together with UT to measure the wall thick-
ness. In addition, PT was performed on all
tubes to verify that the tubes were free of
indications.


Figure 25: and Figure 26: show the results
after dye penetrant testing before peeling.



Figure 26: Microsection of DMV 617 SH-Tube

The right side of the SH outlet header was manufactured by Babcock & Wilcox Volund ApS for BWE.
The left side was manufactured by Alstom Neumark, where the two parts were also welded together.
The high toughness of the Alloy 617B material required special tools for machining and low cutting
speeds which resulted in a narrow time window for the whole project. Because of this, the time frame
for the erection plan was also affected (see WP5 for more information).


Figure 27: Superheater outlet header

Figure 25: Indication of DMV 617 SH-Tube
52

In the manufacturing of the SH inlet header, the dissimilar P91/Alloy 617B stubs for the Alloy 617B
header were welded with P91 filler metal, whereas the design specified the Alloy 617B filler metal. For
this reason all stubs had to be reconnected with the correct filler metal.
A WPS and related WPQR were developed for welding
of Alloy 617B. The weldability of the material was found
to be good for TIG welding. However, for manual metal
arc welding a high proportion of the weld material had to
be scrapped due to problems with the cover falling off
during the welding process or drops forming at the elec-
trode ends that switched off the arc.
For the NDT it was found that due to the austenitic mate-
rial, the heavy attenuation and an unacceptable signal to
noise ratio ultrasonic testing could not be used as origi-
nally specified. For this reason a radiographic examina-
tion was made instead for volumetric testing. Dye pene-
trant testing was used for surface defects. All welds were
found to be acceptable.
It is believed that with special equipment and specially
trained operators it should be possible to use ultrasonic
testing for this type of components.

Overall, the scope of manufacturing included the inlet and outlet headers made of P92 for the evapora-
tor and for the superheater, which were made of Alloy 617B. The thick-walled parts also included the
spray attemperator and the steam piping, including a branch piece (Alloy 617B).
All components were manufactured and documented in accordance with the WPQRs, the welding lists
and the design approval by the Notified Body. Figure 2727 show some of the manufactured parts of
the thick-walled components.


Figure 29: Evaporator outlet header (P92)

Figure 28: Spray Attemperator
53

As described in the Evaporator section, PWHT had to be applied to 13CrMo4-5 and P92 materials of
the headers.
Manufacturing of the evaporator panel Figure 30 was carried out in accordance with VdTV data sheet
451-68/1 (manufacturing of gas-tight welded tube walls). The butt welding, tube-fin welding and fin-fin
welding were performed according to the required standards and documented for future purposes. No
post-weld heat treatment was applied to the welds of T24 since the material has been developed in such
a way that no heat treatment has to be done after welding.
The circumferential welds of HCM12, either homogenous or dissimilar, had to be heat treated to keep
the hardness low and achieve a good ductility. This also applies to the inlet and outlet headers
(13CrMo4-5 and P92) and the associated stub welds.


Figure 30: Manufactured panel with T24/HCM12/Alloy 617B.

Issues arose at the Alloy 617B tubes. After PT,
surface defects were found Figure 31. The fail-
ures that occurred (130 in total) were ground
since the evaporator part has already been manu-
factured. The remaining wall-thickness was
measured but since some of the tubes had a thin-
ner wall thickness after grinding than permitted
(for a design calculation of 100,000h), one quad-
ruplet (tubes no. 15 18) had to be replaced.
These were the same flaws as for the superheater
tubes.

Figure 31: Indication found after PT
54

Different scopes of NDT have been followed in the manufacturing and erection of the components. The
following table gives an overview of the scope of testing of the different materials and combinations.

Table 23: NDT conducted on CTF parts
Evaporator +
Superheater
Circumferential butt welds ferrit-
ic/martensitic alloys
homogenous / dissimilar
RT100%
PT25%
Hardness testing per heat treatment lot
Circumferential butt welds nickel
based alloys homogenous/dissimilar
RT100%
PT100%
Tube-Fin welds of ferritic and nickel
based alloys
PT100%
Thick walled
components
Circumferential butt weld ferritic al-
loys
100% UT
100% MT
HT per heat treatment lot, max 10%
for furnace heat treatment
Circumferential butt weld nickel based
alloys
100% RT after root pass with first
filler pass
100% PT after each layer
Circumferential butt weld
ferritic/nickel based alloys
UT100%
MT100%
HT per heat treatment lot, max 10%
for furnace heat treatment
Attachments (e.g. stubs) to header
nickel based alloys
PT100% after each layer
Attachments (e.g. stubs) to header
ferritic alloys
MT100%
HT per heat treatment lot

As it can be seen from Table 23, NDT of welded parts is time consuming. Especially the time frame for
manufacturing of circumferential butt welds of the thick-walled pipes needs to be considered. Since RT
cannot be applied for the most part to these components, ultrasonic testing is the right choice. Only for
ferritic materials, however, since nickel based alloys show an anisotropic behaviour. Penetration testing
during welding of Ni-based alloys Figure 32 means that after each layer the metal temperature has to be
cooled down to a level lower than 50C before applying the dye penetrant. Since the dwell time in-
creases from ferritic over austenitic materials to nickel based alloys this adds to the total time.










55


Figure 32: PT testing of Alloy 617B V-weld (OD219.1 x WT50mm) and while welding with
TIG/SMAW
2.2.4 Conclusions
2.2.4.1 General
The evaporator components were manufactured without major deviations or non-conformances for the
T24 and the HCM12 part. Material properties were kept as specified, with the only exemption being as
mentioned in 1.2.1 chapter for two pipes and one valve body block forged in Alloy 617B type material
where the grain size deviated from the specified grain size.
Welding procedures, quality assurance and quality control proved to be ready for processing Alloy
617B thereby attaining quality welding seams of very few NDT indications. Only one tube sections at
the evaporator part needed to be replaced after testing. This replacement came with indications of the
Alloy 617B tubes which had to be ground to an acceptable wall thickness after indications during
penetration testing. The Alloy 617B superheater tubes, showing the same flaws (overleap/tears), were
peeled to a smaller diameter (from OD 44.5mm to OD 41mm), still maintaining the minimum
calculated wall thickness for an operation time of 100,000h.
At the time of planning and manufacturing until erection of the CTF, the relaxation cracking
phenomenon of Alloy 617B was not known and therefore no post-weld heat treatment (stabilising
annealing) was applied. Also it was found to be really time-consuming and prohibitive to manufacture
the thick-walled pipes as massive forged pieces with subsequent drilling in order to achieve the final
dimensions. Since manufacturing was carried out according to state of the art for conventional power
plants in 2004, it proved insufficient and the gained knowledge has to be transferred to future
applications.
2.2.4.2 Actual Applications
Alloy 617B is part of subsequent test rigs, e. g. HWT I in Mannheim. Pipes made from Alloy 617B will
also be installed in the subsequent test plant, HWT II. Thus, testing of the material goes on either as
tube of heating surfaces or boiler external piping. All related test programmes will add new insight to
the COMTES700 test results and form the next steps towards implementation of a 700

C technology.
The knowledge learnt about relaxation cracking of welds of thick-walled Alloy 617B pipes transfers to
HWT II and to other projects such as ENCIO. At ENCIO, aged pipes from the CTF will be used to gain
knowledge about the cracking behaviour under different heat treatment and post-weld heat treatment
conditions (stabilising annealing at 980C for 3h).
56

Wyman-Gordon proved in 2009 on behalf of Siemens that it is indeed possible to extrude thick-walled
Ni-based alloys such as Alloy 617B, where two pipes had been manufactured.
2.2.4.3 Technical Potential for the Use of the Results
Especially, knowledge gained about manufacturing of thick-walled components which are made of
Alloy 617B helped avoiding repetitions of a grain size enlargement due to wrong heat treatment proce-
dures. The result also needs to be expanded to cover austenitic materials in general. Moreover, the
knowledge and skills obtained in relation to methods and techniques regarding how to join such really
divers materials for the heating surface of the evaporator are among the major achievements.
It proved insufficient to use longitudinal UT and Standard Eddy Current testing to find the overleaps or
tears of the Alloy 617B tubes, since the morphology of the defects were semi-circular or arrow-like.
According to DMV, the flaws can be detected using a specific ET Circograph by means of a rotating
probe where the UT testing still has to be maintained to measure the wall thickness.
As regards the use of thick-walled pipes, either austenite or Ni-based, the NDT takes a long time to
perform and also the manufacturing of these components is time-consuming. These aspects have to be
considered for future planning to organise the time schedules for manufacturing of the materials, manu-
facturing of the components and erection. Improvements of manufacturing methods, including welding,
are in the pipeline and will pave the way for commercial application. The cracking of thick-walled Al-
loy 617B welds mentioned above and the need for heat treatment are also achievements.
57

2.3 WORK PACKAGE 3: VALVES & MEASURING DEVICES
2.3.1 Work Package Objectives
x Design of valves
x Proof of concept
x Order of materials
x Manufacturing of valves
x Qualification through inspecting bodies (e.g. TV)
x Monitoring of valves
One of the main tasks of work package 3 (WP3) was to define the design parameters and the minimum
size of a HP-bypass valve for later scale-up. The following parameters were fixed:
x Operating pressure higher than 200bar
x Operating temperature equal to 700C
x Possible material selection for valve body and valve stem is Alloy 617B. The approval of valves
for 700C by the authorities is expected to be limited to the mechanical design
x Design steam mass flow 25 to 30kg/s for the HP-bypass
2.3.2 Comparison of Initially Planned Activities and Work Accomplished
In the course of the Comtes700 project the valve-manufacturers delivered 182 valves such as HP-
bypass valve, steam control valve, start-up valve and gate, globe, check valves as well as a safety valve
for the application in the test rig installed in the coal-fired power plant Scholven, unit F. All valves were
designed according to its design data respectively and were disassembled for further detailed visual
inspections after finishing the operation as scheduled.
The whole production procedure including the design and manufacturing of the valves could be per-
formed according to the initially planned way. No major deviations between planned and done work
could observed. Nevertheless, especially, Alloy 617B related design and manufacturing requirements
had to be taken into account.
2.3.3 Description of Activities and Discussion
At the start of the project, two valve manufacturers were chosen. They both were the partner company
in the AD700-project and exhibit required expertise for making high-performance valves in the temper-
ature range up to 700C. In the COMTES700 project, it was decided to share out the manufacturing
regarding to valve types. It was confirmed by the valve manufacturers the using only 50% of the valves
mass flow capacity would be sufficient to make all valve tests reliable and all conclusions regarding the
operational behaviour of the valve could be drawn. Therefore, in order to reduce investment costs of the
whole Component Test Facility (CTF) in Scholven, it was decided to design the CTF for a realistic
steam flow of 12kg/s. The detailed start-up and operation of the CTF can be found in the report Opera-
tion for work package 6 (WP6). The valve manufacturers considered the following test runs as neces-
sary:
58

(i) 100h-500h operation time at full load with the bypass station serving as a control valve. During
this operation period the valve was closed occasionally to check the attrition and shut-off prop-
erties.
(ii) 10-20 times operation in bypass mode at max. steam conditions at valve inlet in order to have a
high level of the heat up and cool down rate.
(iii) The bypass station should be installed in the test rig in such a manner that it would be possible
to check the valve and exchange the valve body seat, if relevant, during normal operation of the
host plant is possible.
(iv) Both valve manufacturers agreed that one HP-bypass valve is sufficient for test purposes.
(v) For integration of the bypass station in the test rig the following details were considered: (1)
tempering of the steam inlet and outlet connection lines, (2) tightness of the valve could be
monitored during operation by temperature increase at the outlet or by structure (3) Pneumatic
drive is possible due to the small valve size and cheaper.
(vi) Steam velocity in the HP-inlet piping up to 50 m/s, spray cooler separate, downstream of the
valve and insulation same as piping.
2.3.3.1 Design
The valve design showing the basic design elements and taking load arising from the 700C steam tem-
perature into account is given in the following. The design of the valves followed the basic design pro-
cedures and rules for high pressure and temperature valves. All relevant codes (e.g. the PED directive,
97, 97/23/EG; TRD 110, and also EN 12516-2:2004, Industrial valves casing strength Part 2: Calcu-
lation method for steel valve casings) have been applied. Due to the comparatively high design tem-
perature and design pressure conditions of the steam (T ~710C, p ~215bar) almost all pressure retain-
ing parts had to be made of the Ni-based Alloy 617B. The other valve parts, which were not highly
temperature loaded, were made of alloyed steel.
A main design issue was the economical use of the high-grade and therefore high price of the Alloy
617B. From a structural strength point of view the valve body should be made of a single piece without
any weld joints. This monobloc design would lead to comparatively increased material and machining
costs. Therefore, it was decided to make use of pre-manufactured parts as far as it seemed possible and
cost effective. In consequence welding of Alloy 617B was a main issue in connection with the valve
design as well as during manufacturing. The valves have been manufactured according to PED, module
H without approval by a notified body.
2.3.3.1.1 Gate valves
The valve bodies of the gate valves were made in a way as shown in Figure 33. The body (1) was a two-
part design, made of a lower valve body part and an upper valve body neck. Both parts were made of
forged rectangular raw pieces and connected by a weld joint. For joining of the body parts butt welding
was chosen. For isolation of the steam flow a two-piece wedge plate design (4) was chosen. To avoid
overpressure within the neck the valve has an overpressure nozzle (3). The overpressure was controlled
by a rupture disc device. The seat rings (2), the wedge (4), the cover (6) and the segment ring and thrust
ring were also made of Alloy 617B. The sealing surfaces on the seat rings and wedges were cladded
with Stellite 6 material.
For cover pressure sealing most of the gate valves had graphite gaskets with stainless steel caps (7). In
one case it was decided to use a silver plated metallic gasket. In order to have a very tight seal as well as
sufficiently low friction and wear between the stem shaft and the cover, it was decided to use graphite
59

packing rings (9) for all gate valves. In consequence the packing temperature had to be reduced by pro-
longation of the stem/cover protruding. Additionally, the stuffing box at the upper end of the cover was
designed with cooling gills at the outer surface. For the stuffing box design a so-called safety stuffing
box gland (8) using disc springs in order to control the packing pressure was chosen.
The stems of the gate valves (5) were made of the high temperature resistant steel 1.4922. The surface
of the stem shaft was treated in an HVOF (High Velocity Oxygen Fuel) thermal spray process with Cr-
carbide plating and diamond grinding. This procedure was chosen for the stem material and stems sur-
face treatment because of sufficiently low friction and wear between the stem surface, the gland pack-
ing and the guiding area within the cover and since this was considered to be the predominant technical
requirement.
The connections between the valve body and the actuator were made of 17%-Cr steel. A rod design (10)
was chosen for the valve yoke in order to minimise the heat transfer towards the actuator. Depending on
the valve purpose different actuators such as hand-wheel, electric and hydraulic actuators were mount-
ed.

Figure 33: Cross sectional drawing of gate valves GH 251 and DN125 (KKS no. 26NA76S004)
2.3.3.1.2 Globe valves
The valve bodies of the globe valves were in a monobloc design as shown in Figure 34. The inlet and
outlet geometries of the valve body (1) as well as the geometry of the valve seating are comparable to
those of the VA500 standard HP-pressure valve series. The seating surface of valve body was clad with
Stellite 6. The stem seating surface did not have a hard surface layer. The valve neck was prolonged in
order to reduce the temperature of the stuffing box. Additionally, the valve body was provided with
cooling fins between the lower valve part and the stuffing box, so that graphite packing rings could be
used for the stuffing box sealing (4). The Belleville spring loaded stuffing box gland bolts (3) made sure
that packing shrinkage could be compensated for and thus leakage of the stuffing box was avoided. For
almost all globe valve stems high temperature resistant austenitic steel was used. Only in two cases a
17%-Cr steel was applied. The stem seating surface had no surface hard cladding. Valve yokes (5) were
made of F91 steel and manufactured by die forging. For stem lifting a standard valve head (6) according
to DIN EN ISO 5210 was used.
60


Figure 34: Cross sectional drawing of the globe valves VHA510 and DN50 (KKS no. 26NE22S521)
2.3.3.1.3 Safety relief valve
In order to avoid system overpressure a spring loaded safety relief valve with an additional pneumatic
load actuator was installed in the test loop. This valve was designed according to TRD 421, AD 2000
and DIN EN ISO 4126-5. A cross sectional drawing is shown in Figure 35. The pneumatic load actuator
(10) is controlled by the control unit STE4.
The Alloy 617B was utilised for the temperature loaded, pressure retaining inlet nozzle only (1). In
order to keep the costs low the upper blow-off body (2) was made of steel 1.4910. The inlet nozzle was
inserted into the upper valve body by a thread. The tightness between inlet nozzle and blow-off body
has been obtained by a weld joint. A negative effect of the mismatch of the thermal elongation of nozzle
and valve body materials was reduced by a ring-shaped groove at the lower side of the valve body. A
FEM stress analysis was made in order to analyse the stress distribution between the inlet nozzle and
the upper valve body part. This showed that the stress level was within an acceptable range. The guid-
ing surfaces at the lifting support (5) and the guide (4) were clad with Stellite 6. Inititally, disc (3) was
made of the austenitic material 1.4980. As the project progressed it was decided later to change over to
a disc made of Stellite 6.
61


Figure 35: Cross sectional drawing of safety valve SOH (KKS no. 26NA77S094)

The intermediate flange (6) was given a particularly long design so that non-permissible overheating of
the pressure spring (8) could be avoided, thereby ensuring correct functioning of the safety valve. Due
to the especially long intermediate flange (6), the elongation of the screw bolts was relatively long. This
is advantageous when the valve opens and escaping steam heats up the upper part of the valve. The
spring material was 1.8159, which is a standard material for spring loaded safety valves in conventional
power plants.
2.3.3.1.4 Swing check valves
The basic design of this valve is similar to the design of the steel swing check valves used for example
in conventional steam power plants. Design rules and calculations were applied in the same manner.
The seat surfaces of the valve body (1) and on the disc (2) had no surface hardfacing. The purpose of
seat surface hardfacing for the steel swing check valves was to avoid corrosion. Due to the sufficiently
high corrosion resistance of Alloy 617B seat cladding was not needed.
The main design features of the check valve can be seen in Figure 36. The bearings of the swing axis
shaft (4) are positioned within a holding ring. The holding ring, disc (2) and disc lever (3) can be dis-
mounted as a hole. Thus a protruding of the shaft outside the valve body is not needed. For covering of
the valve body a pressure valve cover (7) was used. All parts of the valve were made of Alloy 617B
except for the shaft, screws and pins. For pressure sealing a graphite gasket with stainless steel caps was
used (7).

62


Figure 36: Cross sectional drawing of swing check valve KRH400 and DN80 (KKS no. 26NA76S508)
2.3.3.1.5 Check valves
The in-principle design of this high temperature check valve is similar to the design of the check valves
used in conventional power plants. A cross sectional drawing is given in Figure 6. The main valve parts
such as valve body (1) and valve cover (4) were made of forged raw blocks. All valve parts were made
of Alloy 617B, except for the guiding bush (8), bolts (5) and nuts (6). Bolts and nuts were made of a
high strength austenitic steel material. For cover sealing a bolted bonnet with a camprofile metallic
gasket (3) was chosen.

Figure 37: Cross sectional drawing of check valve VR500 and DN50 (KKS no. 26NE22S522)
2.3.3.1.6 Start-up valve, control valve and HP-bypass valve
All three valves were designed as angle valves (see Figure 38-40). The Stem and the seat were coated
with boron to achieve a high temperature anti-abrasive protection. To avoid burning out (oxidation) of
the graphite sealing material, the stuffing box was placed at a suitable distance from the bonnet. There
were also cooling vanes mounted around the stuffing box. Distance and active area as well as the shape
of the cooling vanes were tested in a special test rig (1:1 scale). The test rig was heated to 710C with
electric heaters. The sealing gasket between bonnet and body were metal gaskets in a "C" profile shape.
The seats were screwed in and the plug consisted of a cylindrical part with an additional cage. To avoid
overheating of the coupled actuators, a yoke assembly was designed in order to achieve a low heat
transfer rate. High mechanical stability was also considered. The valves had one or two separate
buttweld ends. In the outlet of the HP-bypass, there was a spray attemperator with an integrated water
injection nozzle. Two of the valves had electrical actuators; one valve (HP-bypass) had a pneumatic
actuator. The design work was carried out with the aid of numerical methods like Computational Fluid
Dynamics (CFD) and the Finite Element Method (FEM) to optimise temperature distribution, flow
dynamic and wall thickness.
63


Figure 38: Left: Cross sections of start-up valve (KKS no. 26NA76S002); Rright: control valve (KKS
no. 26NA76S006)


Figure 39: HP-bypass valve (KKS no. 26NA77S003)

64

2.3.3.2 Commissioning and Manufacturing
Most of the construction material needed was made of forged raw material, Alloy 617B. Alloy 617B
was purchased from the company Saarschmiede. The valves were manufactured at the Sempell or HO-
RA manufacturing sites.
Due to the mechanical and machining properties of Alloy 617B the manufacturing processes were ra-
ther challenging. The high mechanical strength of the material, especially at room temperature, and the
high ductility require dedicated machining parameters. Special cutting tools and cutting edge geome-
tries were needed. Although the machining of Alloy 617B was optimised machining time lasated be-
tween 4 and 8 times longer compared to machining of high grade steel materials. Also cutting tool wear
and therefore costs were considerably higher. The available machining and tooling technology was a
prerequisite to manufacture all valve components according to the quality requirements and within the
pre-calculated machining times and costs.
The welding of Alloy 617B was an important major issue. It is known that Alloy 617B tends to generate
hot cracks during welding. Therefore excessive heat input should be avoided and submerged arc weld-
ing with its high heat input could not be applied. The butt weld joints were made by multilayer welding
using TIG welding and manual electrode welding. In order to avoid overheating an interpass tempera-
ture of 100C could not be exceeded. Additionally NDT of the root, 1/3, 2/3 of the weld volume and the
top layers had to be carried out. At the end of the welding process all buttwelds were X-ray tested. The
butt welding and hard-facing procedures of Alloy 617B were qualified by performing welding proce-
dure qualifications procedures. It should be mentioned that the filler material type covered electrode
(UTP6170 Co mod.) and TIG welding rod (UTP A 6170 Co mod.) were used for the welding proce-
dure.
2.3.3.3 Function and material behaviour under 700C temperature conditions
The experiences gained during the operation of the plant together with the results of the visual inspec-
tion and test of movability of the valves showed that the functionality of the valves was given. After
termination of the test loop operation period extensive and detailed investigation of a variety of valves
were carried out.
The material investigations of the gate valve bodies revealed that two gate valves, which were exposed
to high thermal transients, showed cracking within the weld between lower valve body and valve body
neck. Cracks were limited to the welded area. Uninfluenced base material showed no cracking (Figure
40).
In this context the operational load of the valves has to be taken into account. The numbers of cold and
warm starts as well as the temperature transient levels seem to exert essential influence on cracking
within the welds. Additionally, the residual stresses within the weld joint resulting from the welding
process have to be considered.
Beside the investigation of the integrity of the pressure retaining valve parts, it was of interest the con-
dition of the isolating components like wedge plates, discs, seats and gaskets. Hardfacing material Stel-
lite 6 was used mainly for surface cladding of metallic seating surfaces as well as for guiding surfaces.
The investigations showed that in general the used hardfacing layers tolerate the operational loads. Re-
markable abrasive wear of seat rings and wedge plates had to be noticed only in the main steam isola-
tion valve (Figure 41).
At first view it might be concluded that wear resistance of Stellite is not sufficient for 700C conditions.
For a definite evaluation of the wear it has to be taken into account, however, that the main steam isola-
65

tion valve was exposed to extremely high temperature transients and high temperature differences dur-
ing operation. Thus deformation of the planarity of the seat ring and the wedge must be assumed. If
applicable and where appropriate for flow isolation under high duty conditions, globe valves are rec-
ommended.
Another important result was that graphite and metallic gaskets can be used successfully in 700C ap-
plications. Neither the graphite nor the metallic gaskets which were chosen for pressure sealed covers
were inappropriate. Especially the chosen graphite gaskets with metallic edge protectors showed no
oxidation or corrosive degradation. The same result was achieved for graphite gland packings.


Figure 40: Overview of casing neck weld of gate valve. Red arrows show cracks after dye penetrant
testing (KKS no. 26NA76S004-01)


Figure 41: Adhesion damage of seat ring (KKS no. 26NA76S004-01)

As regards the design of the HP-bypass valve there were some problems with the C-ring gasket at the
bonnet sealing. Due to leakage problems the C-ring gasket had to be replaced in a semiannual overhaul.
To avoid similar problems in future, improvements in other designs were made by Hora. The wear of
the internal parts was within normal variations, without any noticeable issues.
After finishing the operation of the CFT, the HP-bypass valve, the steam control valve and the start-up
valve were disassembled for further investigation. These control valves were made from Alloy 617B.
Each valve has been dismantled in HORAs workshop. The dismantling of the valves piece-by-piece
took place without any problems. The trims and the screws were in good or even very good condition,
given the operational lifetime. The surface of the seats of the steam control valve and the start-up valve
66

were well preserved. Only the surface of the seat of the HP-bypass valve showed slight but reasonable
indications of erosion. In the lower area of the throttle bores of the start-up valve and HP-bypass valve,
indications of erosion were found. Also, the control edge of the start-up valve piston showed slight
erosion, and the control edge of the HP-bypass valve showed clear obvious indications of erosion
(Figure 42). The safeguarding welded joints of the perforated discs in the outlet of the HP-bypass valve
showed circular, visible cracks following the entire welded joint. At the opposite outer surface of the
valve body there seemed to be visible crack-like indication at valve body surface. In addition to the
visual inspection a dye penetration test was also carried out in the presence of HPE, E.ON and Hora.
The dye penetration testing showed no indications of cracks.


Figure 42: Seat of the HP-bypass after 22,000 hours of operation

In view of these findings the parties jointly decided to focus further investigations on the HP-bypass
valve only. Therefore, after completion of the NDT, the valve body was cut into pieces that already
showed visual crack formation.
The two parts cut out of the HP-bypass valve were subjected to radiographic testing (source: Linear
Accelerator). Figure 43 shows the HP-bypass before the detailed investigation. The first part was the
one with the crack-like indications and the second part was the one with the welded end of the inlet
nozzle (seam A). The radiographs were evaluated by a HORA expert. Neither the radiographs of the
first part nor the one of the second part showed any indication of cracks. The crack-like indications at
the outer surface of the valve body could not be detected by radiographs as cracks. Figure 44 shows the
cross section of the HP-bypass valve with cracks, at thread pitches in the section (red arrows) and at
transitions of the cross section (blue arrows). The light optical micrograph gives a detailed view of a
crack propagated from a thread root.

67


Figure 43: Dissmanteld HP-bypass valve body for detailed investigation



Figure 44: Cross section of the HP-bypass valve (seam A) with cracks (arrows) and the appropriate
microscopic view on a crack propagated from a thread root

Before testing the surfaces of the welded end, the part was machined in order to obtain parallel surfaces
which are a precondition for ultrasonic testing. The mechanised ultrasonic testing was carried out at
Mller und Medenbach GmbH.
After 22,000 hours of operation at intermittent temperature stresses of up to approx. 720C, the HP-
bypass valve was disassembled when the CTF was shut down, and the valve was subjected to a
thorough examination. The examination included, amongst others, NDT of the material. On completion
of the NDT process the valve body was cut in the planes that already showed visual crack formation.
This revealed that the outlet of the HP-bypass valve in the section of the safeguarding welded joints of
the perforated discs was particularly conspicuous (viewed in the direction of the flow, it is located
upstream from the spray evaporator nozzle). It should be noted that sharp-edged tools must be avoided
for the machining of the hardened surface.
The hardness detected in the area with visual cracks decreases continuously from approx. 280HV10 for
the outer diameter to as little as 260HV10, until approx. 12mm before the inner diameter and then it
seam A
68

increases for the remaining cross section of the inner diameter to 350HV10 (Figure 45). This steep but
steady increase in hardness over a distance of 12mm cannot be explained by hardening during the shape
cutting process, since the significant increase in hardness is found to take place all through the cross
section of the inner wall over a distance of 12mm. A conservative explanation could be that this effect
is the result of the stress induced -precipitation.


Figure 45: Hardness gradient in valve cross section
2.3.4 Conclusions
2.3.4.1 General
The CTF suffered no major outages due to valve problems which mean that the main function of the
valves in the CTF lived up to their intended purpose. The process demonstrated that effects could be
gained from the welding procedure and the heat treatment procedure before and after welding.
The results and experience gained in the project show that the chosen basic valve designs, including the
additional 700C related design features, were adequate to tolerate the loads arising from the operation.
In addition to this, it is also evident from the project that weld joints of thick-walled components under
certain conditions tend to develop relaxation cracks. A possible counter measure that can be taken to
overcome this is to apply a post-weld heat treatment procedure. Another solution is to design a mon-
obloc valve body.
The valve sealing components such as graphite gaskets and packings, were sufficiently resistant to the
extremely high steam temperatures. Actuators could be applied to the valves so that no heat induced
damage could take place.
Machining and welding of Alloy 617B are complicated processes which required machining times 4-8
times longer compared to steel materials. Therefore, it would be reasonable for future R&Dprojects to
include investigations of this in order to reduce the manufacturing efforts. Especially the manufacturing
processes which led to near net shape raw pieces, such as forging or Hot Isostatic Pressing (HIP), are of
topical interest. One other important point in future R&D activities could the thermomechanical behav-
iour of Alloy 617B components.
69

There are still some concerns about the operating safety of thick-walled Alloy 617B valves that are
frequently subjected to operationally unavoidable heating and cooling cycles. Careful operating
practices, limited design adaptations, technological processes (heat treatment) or a combination of
various measures should be taken into consideration with respect to the application of a HP-bypass
valve in future 700C applications.
It has to be investigated if the heat-up and cool-down rates during start-ups and shut-downs can be
decelerated in order to maintain an operational pattern suitable for the materials/components that are
designed accordingly. It should be investigated if the Alloy base material can be improved in order to
reduce the operations-related tendency to hardening by employing metallurgic and/or technological
measures. Redesign measures have to be taken, such as reduction in material accumulation (which
cannot be avoided completely), the use of the largest possible cross-over radii and smooth transitions
from one wall thickness to another, in order to prevent premature crack formation.
2.3.4.2 Actual Applications
After the completion of the design and manufacturing of the COMTES700 valves the two valve manu-
facturers designed high performance valves made of Alloy 617B for the project 50+performed by
E.ON. Here the net efficiency climbed up to 50% in a coal-fired power plant mainly by developing new
materials. Future projects would benefit from experience acquired in the framework of the
COMTES700 project.
The manufacturers HORA and Sempell plan to deliver a variety of valves for later projects, such as
ENCIO (partially funded by RFCS) and GKM HWT II (partially funded by BMWi (German ministry)),
will focus on the 700C material main issues such as proof of thick-walled components, investigations
to qualify pipe manufacturing, welding procedure standards, repair and erection concepts and modelling
with validation of material and component behaviour.
2.3.4.3 Technical Potential for the Use of the Results
Based on the existing know-how from the manufacturing of HP and high-temperature valves additional
dedicated knowledge of the design and manufacturing of valves for 700C applications was developed
in the process. Assumptions and/or simulation results which had been carried out during the design
phase could be proven by the experience and the results from the test rig operation.

70

2.4 WORK PACKAGE 4: C & I
2.4.1 Work Package Objectives
1. Select and develop instrumentation to monitor temperature, pressure and flow and control of the
CTF and more sophisticated parameters for future plants with the highest accuracy.
2. Implement advanced closed loop control and safe operation. Work out strategies for monitoring
and detecting wear and tear of components.
3. Collecting data, storage and visualisation for fault detection, stress and consumed lifetime calcu-
lation.
4. Control flow and temperature within a narrow band corresponding to future boiler operating con-
ditions.
The objectives required the application of hook-up equipment which was able to measure steam and
pipe material temperatures of 700 C or more and tolerate the temperature differences during start-up,
shut-down and load changes.
For the engineering and delivery of the C&I equipment the following tasks had to be covered:
o process engineering, in cooperation with other WPs,
o development and adaptation of measuring devices and corresponding hook-up, e.g. temperature
pockets,
o workshop tests,
o integration into DCS and boiler protection system,
o supervision and coordination of erection ,
o commissioning of the CTF including optimisation of the C&I system,
o data storage, fault detection, data export for evaluation in WP7,
o development of risk assessment and development of field test procedures and
o clarifications with the Notified Body.
Lessons learnt and suggestions gathered for future development were carried on with the design part-
ners involved.
2.4.2 Comparison of Initially Planned Activities and Work Accomplishment
2.4.2.1 Separate Projects integrated During Project Execution
Turbine Control Valve
Additional temperature measurements and an operation programme had to be integrated into the DCS
System. One temperature gradient limitation control loop was added in the operation programme. A
silencer had to be installed afterwards for the turbine control valve.
Fixed Point Temperature Measurement System
Sheath tubes had to be welded to the pipes to enable tests at approx. 600C and 700 C. For control of
the measurement system a separate PC was installed in the control room.
71

2.4.2.2 Commissioning Disturbances
Plant optimisation of the control loops needed longer time than anticipated. Tests were often only
allowed during start-up and shut-down sequences of the steam generator.
Torque set points from control actuators needed to be readjusted. Lubrication intervals had to be
reduced. The types of grease had to be harmonised.
2.4.3 Description of Activities and Discussion
WP4 stipulated that:
x the control system was to be integrated in the normal control system of the plant;
x data logging could either be implemented in a separate system or using the plants data acquisi-
tion system;
x data to be measured were:
o flow,
o pressure,
o steam temperature,
o inner and outer wall temperatures together with mid wall temperatures at strategic posi-
tions,
o hanger positions; and
x data were to be measured and recorded during the whole operation period.
The scope comprised definition of relevant measuring points and control strategies (in connection with
WP1) and specification and procurement of transmitters and control equipment.
The host facility assumed the responsibility for supervising the erection and commissioning.
Definition of measurements and means to implement the control strategy can be seen from the P&I
diagram of the CTF.
The control strategy was finally expressed in the operating manual which refered to the engineering
documents
o P&I Diagram,
o List of Measuring Points,
o List of Electrical Consumers,
o System Description and
o Functional Plans and Control Specifications.
These documents served as input for the detailed description and specification of the operation and
control of the CTF.
72

2.4.3.1 Engineering of Hook-up and Special Components
For this WP the project team had to select and develop instrumentation to enable temperature, pressure
and flow monitoring and control of temperature and minimum steam flow in the CTF with the best ac-
curacy that is technically possible. The major challenge was related to the very high temperatures in the
context of state-of-the-art power plant technology.
The following high temperature measurements were required for the CTF:
o 13 thermocouples in Alloy 617B protective tube for 705 C operation temperature,
o 8 thermal elements for wall differential temperature for 705 C operation temperature,
o 30 sheath tube thermocouples for wall panel for 705 C operation temperature,
o 44 sheath tube thermal elements for wall panel for 620 C operation temperature,
o 3 pressure transmitter to measure the operation pressure in 705C pipes and
o 2 pressure switches to measure the operation pressure in 705C pipes for control of the high tem-
perature safety valve had to be installed.
Several other sheath tube thermal elements were installed to monitor valve design tests.
Remark:
The thermocouples which were to be applied for operation in the range of up to 705C had to be de-
signed for 745C.
2.4.3.1.1 Temperature measuring
Type S thermocouples with accuracy class 1 (tolerance +/-1K in the range 01,000C) were selected to
measure the temperature.
The associated thermo wells were made from piping material. Gold plates were mounted at their tips to
maximise the thermal conductivity for fast and accurate readings.
The electrical insulation material chosen for the temperature sensors in the CTF was MgO. For future
applications above 705C it is recommended to select materials with higher electrical resistance against
temperatures above 700C.
As of the investigation date, no manufacturer insulating material has been found of that can live up to
all requirements appropriate for this test plant. Therefore, mats made of various material coats had to be
used to achieve a higher insulation thickness and thereby meet the challenging requirements of the de-
sign and engineering of a steam generator running above 700 C.
Further investigations focused on HfO (Hafnium oxide) materials instead of MgO for future projects.
Due to the increased heat conduction at higher parameters, the length of the protection pipes had to be
extended to ensure that temperatures at the connection heads were less than 120C (see Figure 46).

73


Figure 46: Outer temperature profile of a thermocouple

From left to right Figure 46 shows extended protection pipes of the measuring device. The change in
colours clearly indicates the temperature drop of the external parts as they protrude from the thermal
insulation. The hot spots at the connection head are caused by thermal conduction through the thermal
sensor.
Floating cold reference point compensation was used to avoid additional inaccuracy which can arise
because of the compensation cable. The temperature was calculated using the digital control system.
During project design phase a dedicated high quality transmitter was not commercially available. High
speed calculation consumes remarkable resources from the control system.
Zoom technology was utilised to reduce the digitalisation fault to less than 0.2K for appropriate spray-
water control.
The response time setting of the spray-water control was optimised to a loop time below 20 sec under
full load conditions.
74

2.4.3.1.2 Pressure Measuring
A tailor-made hook-up design (see Figure 47) had to be carried out for pressure measurements under
high temperature conditions. Standard design materials were not available. Special solutions were re-
quired for every single component. Figure 48 shows a drawing of the pressure gauge valve Alloy 617B
and Figure 49 shows the valve installed for permanent testing in the CTF.

Figure 47: Pressure measurement equipment as used for the CTF. First shut-off valves (see WP3
Valves), impulse pipes and transmitter shut-off valve made of Alloy 617B

1) Pressure tap welded to steam pipe Alloy 617B
2) Primary insulation valves Alloy 617B
3) Impulse pipe Alloy 617B
4) Pressure gauge valve Alloy 617B (see Figure 48)
5) Pressure gauge support
6) Sealing washer
7) Transmitter
8) T-connect
9) Drain valve
75


Figure 48: Design drawing of pressure gauge stop valve tailor-made for the CTF


Figure 49: Pressure gauge stop valve built in for long-term design testing under high temperature
conditions (insulation dismantled). The white insulation is high temperature insulation microtherm, the
other is a standard insulation material.
2.4.3.1.3 Flow Measuring Device for High Temperature Conditions
Standard design materials were available for operation temperatures up to 540C. Solutions for higher
temperatures required regulatory approval.
In the temperature range concerned the expansion factors of the respective materials needed particular
attention. The specific expansion factors vary in a band from 12.2 *10
-6
/K to 17 *10
-6
/K.
Surfaces otherwise identical at room temperature may differ by approx. 2.3% at 700 C. Other instances
show the alteration of specific expansion factors over temperature, e.g. the expansion factor for Alloy
617 that fluctuates from 14.4 * 10
-6
/K at 600 C up to 15.1 * 10
-6
/K at 700C.
76

Choosing the wrong specific expansion factors could result in flaws in the steam flow readings of up to
5%. Figure 50 is shows the flow nozzle design, and Figure 51 shows the nozzle ready for insulation.


Figure 50: Flow measuring venture nozzle design as chosen for the CTF

For proper flow calculation based on thermal expansion above 500 C the accurate material value is
used instead of the simplified material class.



Figure 51: External view of the installation position of the venture flow nozzle
2.4.3.2 Commissioning
Sensors and measuring loops were calibrated with the accuracy as is standard for accredited institutes
with their particular equipment Figure 52 and 53. Control loop optimisation was required in a wide
operating range considering the complex interlocks with boiler operation and the specifics of the CTF.
The polynomial calculation of temperature values out of received mV signals demands much higher
accuracy than is typical for standard solutions. A larger number of reference points than normal had to
be calculated for accurate definition of the calibration curves. The reference points were positioned in
specific areas to achieve higher accuracy.
77


Figure 52: Readings during commissioning of the closed loop control

The diagram was printed during commissioning with the closed loop control as part of defining the
dynamic characteristics.


Figure 53: Evaporator and superheater temperture control monitor screen shot

The screen shot shows the temperatures of all wall panel tubes in the test evaporator and superheater.
Temperature variations result from the pipe position in the panel.
78

2.4.3.3 DCS and Boiler Protection System Integration
2.4.3.3.1 Control Strategy
The outlet temperature of the test evaporator was primarily controlled by 2 x 100 % flow control valves.
The outlet temperature of the superheater was primarily controlled by spray cooler 1 between the
evaporator and the superheater in the CTF. In case of operational disturbances or cold start-up
conditions the HP-bypass valve would increase the steam flow to imitate the max. temperature at the
evaporator or superheater outlet as the third stage start-up control valve would open. 705 C live steam
would be cooled down by spray cooler 3 or the HP-bypass valve.
Spray attemperator 2 operated during start-up und shut-down sequences. Under extremely hazardous
conditions the boiler tripped.
Flow and temperatures were continuously calculated in the DCS based on raw data. In future plants,
calculations can be realised using a tailor-made transmitter. Figure 54 shows the tolerance band at
different operating conditions


Figure 54: Temperature differentials vs. the temperature band

The interpolation points are optimised to increase the accuracy between 640C and 780C. The blue
line represents the accuracy of the reference temperature.
The set-up of data collection and recording to allow subsequent calculations by the COMTES700
partners are illustrated in Figure 55.

-2,00
-1,00
0,00
1,00
2,00
3,00
4,00
0,0 100,0 200,0 300,0 400,0 500,0 600,0 700,0 800,0
Temp. C
D
i
f
f
e
r
e
n
z

P
o
l
y
n
.
-
S
t

t
z
s
t
.

C
Tpolyn.-Tstuetzst. Tpolyn.-Tvergleichsmessst.
79


Figure 55: Control system architecture

The specification and procurement of the transmitters and control equipment were to expand into ranges
so far not common to power plant technology. The range of temperature measurements and operation
temperature would change from 450 to 650C in actual plants to 600C to 800C in the CTF. For future
pressure measurements the feed water pressure will rise up to 800bar under hazardous conditions and
up to 520bar for live steam. An additional target for the temperature measurement is to keep the
resolution below 0.2K.
A major task was to provide proof of the applicability of materials which can be utilised to manufacture
hook-ups e. g. fittings, protection sleeves, shut-off valves etc. for operation under high temperature
condition.
Temperature sensors were monitored under long-term operating conditions, such as Type S thermocou-
ples (PT Rh PT) and were confirmed to deliver the expected quality attributes (1K sustained accuracy
up to 1000C, 4 years (24,000 h) operation with no measurable deviations). During the four years the
CTF started 180 times a year.
For base-load coal-fired power plants and warm standby power plants it can be expected that the live
time of sensors can be double. For quick start boilers new materials are to be selected for the sensor
coatings or other noble elements are to be referred. Materials, other than noble metals, are subject to
several metallurgical restrictions.
Self-calibrating thermocouples with build in reference point still require further investigation into ways
of adopting their designs to extreme operating condition (see WP7).
Field tests of new electrical insulation materials for thermocouples are strongly recommended. The
purity of the electrical insulation material is very important for high temperature measurements. Since
compensation cables add to the measuring deviations the use of these cables in power plants for exact
measurements must be avoided. New types of transmitters for temperature measurements appear on the
market which are particularly ideal for noble metal thermocouples and facilitate external floating point
compensation.
80

The achievable control precision is highly dependent on the degree of resolution that the temperature
measurements can detect. For high temperature applications the resolution must fall below 0.2K.
Impulse pipes and fittings for pressure measurements need to adopt the new boiler design data. Codes
and standards such as VGB regulations need to be updated and they must be extended to include new
materials capable of tolerating 750C (live steam temperature) under increased pressures up to 800bar
(max. feed pump pressure under fault conditions). Some transmitter connections are actually limited to
413bar.
The following codes and standards were taken into account:
o Machinery Directive98/37/EG (same as currently used version)
o Pressure Equipment Directive 97/23/EG (same as currently used version)
o DN EN 12952, boiler codes
o DIN EN 50156-1, safety regulations for DCS and BMS systems
o EN 60584-2, accuracy of temperature sensors
o IEC60751, industrial platinum resistance platinum temperature sensors
o DIN 19211, levelling vessel
o DKD_r_5_3
o DIN 53763, protection tube
o VGB R 123, collection of recommendation for measurements as a guideline
2.4.3.3.2 Monitoring
Long-term monitoring and data logging enable fatigue and ageing calculations based on data drawn
from the process control system of the host unit and from the CTF. Specific attention has to be paid to
events and incidents that are signs of abnormal operation and of relevance to component lifetime, such
as trips, load shedding and excessive parameter ramps.
Process data were continuously collected and recorded for process control and subsequent scien-
tific/technical assessment by the COMTES700 partners in accordance with the defined scopes of work.
The host plant made the recorded data available on CD every six months to the COMTES700 partners
for analysis and stress calculations. This provided input for later calculation of lifetime consumption.
Alstom managed the data collected by Provia.
81

2.4.3.3.3 Control room
For proper control and less disturbance of the normal operation of the host plant, additional operation
VDUs and engineering station monitors were installed. An additional programming and engineering
computer with monitor was installed for commissioning and service (Figure 56-57) purposes.


Figure 56: Old Scholven F control room


Figure 57: COMTES700 area of the control room
x 5
th
and 6
th
Scholven plant operation
and alarm monitoring system
x 3
rd
and 4
th
VDU CTF operation and
alarm monitors
x 2
nd
engineering station of the CTF
for data utilisation and analysis
x Monitor in front wall panel for tem-
perature profile monitoring
82

2.4.3.3.4 Engineering
A pressure gauge stop valve designed for temperatures of up to 740C and made of Alloy 617 was test-
ed. The valve passed the test for type approval.
Type S thermocouples were adapted for use above 705 C.
The melding points of aluminium (660.323 C) and silver (961.78C) were initially used for calibration.
When testing the Type S thermo sensors at the beginning and end of test programme, thermal drift
could not be detected during the four years of operation with more than 180 starts a year.
Avoidance of soiling effects was identified as a major point of concern for the design of the calibration
equipment. For measurement above 700C, the specific electrical resistance of the material drops sharp-
ly (see Figure 58). Traces of elements like ZrO3 or TiO2 strengthen this effect. For measurements
above 700C the purity of MgO must be above 99.4%. Iron oxide must be very low since starts to de-
compose above 750C.



Figure 58: The specific insulation factor of insulation materials at different temperatures
2.4.3.3.5 Commissioning
Achievements are:
x proof of applicability and functionality of valve leakage detection sensors at spray-water attem-
perators and
x implementation and operation of closed loop control under fluctuating heat transfer rates.
Commissioning and plant operation motivates for further research and developments in the fields of
x valve disc tightness and avoidance of leakages under 700
o
C conditions,
x 700
o
C steam cooler design and
x pipe routing including venting / draining system optimisation.
The CTF was commissioned and made operational under normal operating conditions and controlled
process parameters.
83

2.4.4 Conclusions
2.4.4.1 General
Todays norms and standards need to be revised to allow for the high temperature and pressure applica-
tions. With particular purposes in mind new norms under EN code will have to be worked out and is-
sued. The revision of VGB R 123C, collection of recommendations for measurements, as a guideline is
currently under way.
The following were identified as items that deserve additional consideration:
The first operation experience with the new electrical insulation material (HfO) applicable for tempera-
ture ranges around and above 700 C were gained and from this options and guidelines for design can
be defined.
The project enabled development of transmitters that worked well with Type S thermocouples and
floating cold reference temperature solutions provided by several suppliers.
Non precious thermo elements e.g. type N for existing and actually built power plants are being tested.
The accuracy required according to DIN EN12952-3 part 6.1.5 can be reached. The long-term stability
of Type N remains to be proven.
Different materials for different fix points and design of fix point sensors were tested to cover the whole
range of operating conditions for actual und future power plants. Particular attention was thereby paid
to long lasting properties such as long-term stability of measuring signals (see WP7).
2.4.4.2 Actual Applications
Reference is made to the subsequent test rig installation, GKM 725C HWT, focusing on material tests
with dynamic temperature exposure of tubing and piping applicable for power units of up to 50% effi-
ciency. Another project testing material above 700C is the ENCIO project. Future investigations will
also have to focus on cost reduction.
2.4.4.3 Technical Potential for the Use of the Results
Material combinations allowing improved long-term stability and not using noble metal became feasi-
ble.
Higher accuracy can make it possible to operate the steam generator with 2K higher steam temperatures
using the same pipes. Higher operation temperatures at the turbine inlet will increase the thermo dy-
namic efficiency of the process.
84

2.5 WORK PACKAGE 5: ERECTION AND DISMANTLING
2.5.1 Work Package Objectives
x Installation of the Component Test Facility (CTF) in host plant
x View of structural conditions as received
x Removal of the CTF following completion of the test programme
2.5.2 Comparison of Initially Planned Activities and Work Accomplished
In general, the planned activities could be transferred completely into reality. Some problems during
manufacturing and installation of the facility and an ambitious erection schedule led to two weeks de-
lay of the CTF. It has to be mentioned that the host plant could not be operated without the CTF since
the test facility was very closely connected with it. The consequence was two weeks non-availability of
the host power plant.
2.5.3 Description of Activities and Discussion Erection
The CTF was installed in the steam generator of unit F of the E.ON Power Plant Scholven (bituminous
coal-fired once through steam generator), Germany. Unit F was commissioned in 1979 and produces
electricity with a net output of 676 MW and thermal output of 1,860 MW by burning hard coal. The
unit produces 2200 t steam per hour, 40 t of this were taken for the CTF and heated up to 700C. The
steam was cooled down and returned to the main boiler at the end of the facility.
The CTF was erected in 2005 and started up 14 days later than scheduled (15 J uly 2005) due to unex-
pected problems with the production of the components. The CTF was planned to operate until 2009.
The installation of such a test facility within a commercially operating power plant poses many chal-
lenges and any operational problems experienced by the CTF would immediately affect the commer-
cially operating power plant and might lead to full stop. With this reason, even from the start of the
project, reliability was an important criterion for the CTF.
Basically, the following components were installed:
x evaporator (44 pipes, manufactured from T24, HCM 12 and Alloy 617B; dimensions: approx. 8m
x 9m,
x superheater (2 x 16 pipes as superheater batch conducted, from Sanicro25, HR3C, Alloy 740 and
Alloy 617B, length: 17m each,
x HP header,
x safety valve, HP-bypass valve and start-up valve,
x turbine inlet valve (no EU-sponsorship), and
x connective and thick-walled piping.
The test evaporator of the CTF was installed at a height of between 56.5 and 66.2 meters in front of the
boiler membrane wall (Figure 1).
Both of the superheater batches were suspended in between already existing superheater surfaces of the
unit F on a supporting tube structure.
85

A new platform at a height of 76m within the boiler was constructed for a spray cooler, the turbine inlet
valve, the HP-bypass valve, gate valves and other valves.
The components of the CTF, which were exposed to 700 C, were manufactured from Alloy 617B. In
addition to Alloy 617B some other materials were tested (Alloy 740, Alloy 263, Sanicro 25,
DMV310N, HR3C, T24 and HCM12).

Figure 59: The companies involved in the erection phase of the CTF

On 10 November 2004 the erection meeting was held and the tender for the erection was prepared.
E.ON issued the call for bids for erection of the CTF on 23 December 2004 and a lockable storage hall
was erected on the parking lot between Unit F and G. On 15 March 2005 the erection (steel works,
pipes, valves, evaporator and superheater) of the CTF was assigned to a consortium consisting of EHR
(EssenerHochdruck-Rohrleitungsbau GmbH) and EAS (E.ON Anlagenservice GmbH). The start date of
the CTF erection for the components outside the boiler was 23 April 2005 and the start date for the
components located inside the boiler was 23 May 2005. It was planned to perform the pressure test at
the end of J une 2005. On 23 April 2005 the erection of the CTF started as planned. The steelworks and
piping were almost completed on time due to the increased effort of the involved companies (Figure
59).
At the end of J une 2005 most of the steelworks, piping, insulation etc. was completed. The design of the
evaporator suspension had to be revised due to a bulge in the membrane wall of the existing boiler,
which was exactly at the place where it was the plan to locate the test evaporator, which had to be lifted
twice.
However, some of the components were delivered quite late and the design of the piping and steel struc-
tures had to be revised because of collisions with the existing pipes. This caused a delay of 12 days.
Non-functionality of control technology and a leakage of the hydraulic actuator of stop valve caused
another two days of delay. This resulted in a delay of the first firing of the CTF of approx. two weeks.
The CTF was first fired on 14 J uly 2005 instead of 1 J uly 2005 (Table 24).
During 2006, installation of the CTF in the host plant and the necessary minor modifications of devices
and safety aspects were completed.
86

Table 24: Erection and start-up of the major components

2.5.4 Description of Activities and Discussion Dismantling
It was decided to dismantle the CTF on 11 August 2009 and the dismantling started immediately (see
work package 6). The work was finished by the end of March 2010.
All components which were located inside the boiler had to be removed immediately in order to start-up
the power plant without the CTF as fast as possible. All pipe connections to the steam generator were
disconnected and the open pipe or stub ends were closed with caps.
The remaining 700C piping system including the valves outside the boiler was dismantled in the first
quarter of 2010.
A storage hall was erected at the beginning of the dismantling activities. The dismantled components
were marked and transported to the storage hall.
The dismantling took place in 2 phases.
2.5.4.1 1st phase (August September 2009)
The Scholven Unit F had to go on steam as fast as possible without the CTF after the decision of dis-
mantling as mentioned in the chapter on WP6 (operation). Since the CTF was very closely connected
with the power plant, unit F could not go into operation without CTF directly after the dismantling deci-
sion. Comprehensive works had to be done:
x The evaporator and the superheater would have been destroyed if the power plant had gone into
operation without the CTF. Therefore these components, including the headers, had to be re-
moved immediately in order to avoid damage to the power plant and to make an investigation of
the material afterwards possible.
x All pipes that connected the facility with the power plant had to be disconnected. The open pipe
or stub ends at the steam generator had to be closed with caps.
x The control and communication system of the facility had to be disconnected from the power
plant.
The evaporator was cut in 4 segments before the removal. Scaffolding was installed at the entire front
side of the component up to a height of approx. 50 m. Furthermore, a platform inside the boiler had to
be installed (Figure 60).

87


Figure 60: Scaffolding in front of the evaporator inside the boiler

The two superheater panels (Figure 61) were not removed in one piece. A comprehensive scaffolding
system was installed inside the boiler up to a height of approx. 70 m. The superheater was removed by
cutting it in approx. 500 parts. Every single tube part was marked with a numbering system in order to
make a sampling afterwards possible. In a next step, the tubes were severed and taken out of the boiler.


Figure 61: Left: superheater tubes inside the boiler. Right: marks on superheater


Figure 62: Left: superheater outlet header before dismantling. Right: end of 700C steam pipe at the end
of the first dismantling phase


88

The following components were removed in the first dismantling phase:
x evaporator,
x superheater,
x headers,
x first parts of the steam pipes in connection with the headers, and
x spray attemperator 1 and 2.
The control and communication system of the facility was disconnected from the host plant. The power
plant was able to go on steam without problems at the end of dismantling phase 1.
2.5.4.2 2nd phase (February March 2010)
The 700C piping system, including the valves outside the boiler, was dismantled in the first quarter of
2010. All parts that could be of interest for future examination or use were marked before (Figure 63)
being severed.


Figure 63: Left: Determination of cutting points. Right: Pipe parts with identification marks after
severing

The 700C steam piping system was removed and transported to the storage hall within the power plant
site as well as all Ni-based alloy valves. The material was stored for approx. two years in the hall and
was available for further sampling. The remaining material was scraped at the end of 2011 after the
final samples had been taken.

Findings during the dismantling
Swarf was found in all pipes due to the cutting operations which were done during the dismantling.
Deposits were detected in one instance in preheating pipe KKS no. 26NA71Z010 before valve KKS no.
26NA76S507 (Figure 64).

89


Figure 64: Deposits in a pre-heating pipe detected during the dismantling

A crack was detected in the spray injection nozzle directly after the HP-bypass valve Figure 65. The
HP-bypass valve was picked up by a valve manufacturer for investigation.

Figure 65: Crack in spray injection nozzle after HP-bypass valve detected during the dismantling

Sampling
Many material samples were taken from the CTF during the operating phase and several investigations
were carried out (Figure 66-67).


Figure 66: Left: Superheater tubes in shelves. Right: Evaporator

90


Figure 67: Left: Stored pipes. Right: Stored valves

Finally, more than 100 material samples were taken from the following components:
x evaporator,
x superheater,
x header, and
x steam piping system.
In addition, a number of valves were sent to the valve manufacturers for investigation, such as the HP-
bypass valve or the turbine control valve.
2.5.5 Conclusions
2.5.5.1 General
In spite of all problems during the erection, the COMTES700 group was able to manufacture and to
install a 700 C test facility with full-scale power plant components made of Ni-based alloys in a power
plant. Despite the very ambitious time schedule, the power plant was able to go in operation with a de-
lay of only two weeks.
2.5.5.2 Actual Applications
The service exposed material is of a very high scientific and technological value. Many material sam-
ples were taken in order to test the material in other European research projects (see chapter WP8 for
details).
2.5.5.3 Technical Potential for the Use of the Results
The erection of the CTF was an important step on the way to the first 700C power plant. The project
showed that full-scale power plant components can be manufactured and be implemented in a 700C
power plant.
91

2.6 WORK PACKAGE 6: OPERATION
2.6.1 Work Package Objectives
x Start up of the Component Test Facility (CTF)
x Operation of the CTF
x Monitoring of operational data
2.6.2 Comparison of Initially Planned Activities and Work Accomplished
The task of Work Package 6 was start-up and operation of the CTF. The operation started in J uly 2005
and lasted until August 2009. After the first start-up the COMTES700 group had to realise that the pro-
ject package Operation involved more work than initially planned. This work package played an im-
portant role in the project. Problems in relation to C&I and to valves could be solved after some months
of operation.
In 2007, the first problem with a crack in a thick-walled Alloy 617B component occurred. In the follow-
ing years an increased incidence of these problems was found. The group members had to face un-
envisaged challenges. Several repairs were carried out and a high number of laboratory investigations
led to a high increase of knowledge and a deeper understanding of the material.
2.6.3 Description of Activities and Discussion
The COMTES700 partners had to face many challenges during the operation time as mentioned above.
Therefore, the following description will only deal with activities or problems, which are in relation
with the operation of the Ni-based components at 700 C.
2.6.3.1 Operational Data
22,400 hours of operation could be achieved between 2005 and 2009 and the facility was in fact in ser-
vice for 13,000h at temperatures above 680 C (Figure 68).

Figure 68: Hours of operation

0 h
1.000 h
2.000 h
3.000 h
4.000 h
5.000 h
6.000 h
7.000 h
8.000 h
9.000 h
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above 680C
Long outages
92

Unit F was operated with many starts and stops during its operating period. This made it possible to test
the components under cyclic loading conditions; 576 starts were counted (Figure 69) in total during this
period.


Figure 69: Number of starts

A maximum steam temperature of 725C was achieved in the outer tubes of the test superheater (Figure
70: ).

Figure 70: Temperature distribution in the superheater
2.6.3.2 Main Activities and Non-availabilities during Operation
Some problems during the manufacturing and installation of the facility and an ambitious erection
schedule led to a start-up delay of approx. two weeks (see chapter on erection).
There were some problems with the control technology and the valves in the first months of operation
which caused short periods of non-availability. The problems with the valves were mainly caused by
leaky gaskets and the actuators. These problems could be solved (see chapter 3.3.3.3).
The first samples from the superheater were taken during the 2007 summer outage.
Apart from damage to a single tube in the superheater towards the end of 2006, there was no damage
for the first two years of operation. Cracks on thick-walled Ni-based alloys were detected for the first
0
50
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warm starts
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Operation from
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until
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SH Outlet
SH Inlet
700C
average

C
up to 725 C
Design of the superheater: Hitachi Power Europe
93

time in spring 2007. Further cracks were detected in the following years. Cracks and problems with
repair welds led to a long outage period in the last year of operation.
Modifications of the facility were carried out during the 2008 summer outage. Additional drain pipes
were implemented and the slope of some pipes was optimised. Problems with condensate especially at
spray attemperators led to these measures.
The final sampling was carried out after the dismantling in 2009 and 2010. Figure 71


Figure 71: Main activities and non-availabilities

0
1
2
3
4
5
6
7
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Problems
with gaskets and
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Material
defects
5
Extension
of
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73
Non availabilities
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Main activities

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94

2.6.3.3 Failures at Test Components
During the operation of the CTF some defects were identified at thick-walled components outside the
boiler and had to be repaired.
The thin-walled components were not susceptible to defects. Only one failure can be reported from the
superheater.
Many defects were detected in the thick-walled 700C part of the CTF, which was made of Alloy 617B.
Cracks occurred in the very highly stressed spray attemperators 2 and 3, where feed water reduced the
steam temperature from 700C to 540C.
Small indications occurred in parts where repair welds were conducted at Alloy 617B components.
Repair welds were placed in parts where material was cut out and fitting pieces had to be installed.
These incidents of damage (Figure 72) are described in detail in the following text and in the chapter on
evaluation.


Figure 72: CTF parts with failures
2.6.3.4 Superheater Failure
The thin-walled components inside the boiler were not susceptible to damage. In four years of opera-
tion, only a single damage occurred at the superheater.
Damage was detected at two tubes in the area of welds. These welds connected Alloy 617B with
Sanicro 25.

Steam from
test super-
heater
700C
700C
700C
700C
540C
540C
Pipes to start-up and
safety valves
Turbine
Valve
Steam to hot
reheat pipe
Steam to
superheater 4
outlet header
Hp bypass valve
700C
Steam from
test super-
heater
700C
700C
700C
700C
540C
540C
Pipes to start-up and
safety valves
Turbine
Valve
Steam to hot
reheat pipe
Steam to
superheater 4
outlet header
Hp bypass valve
700C
Repair welds
with indications at
fitting pieces
Facility design: Alstom
S
p
r
a
y

i
n
j
e
c
t
i
o
n

c
o
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l
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r

3
S
p
r
a
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i
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e
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c
o
o
l
e
r

2
Failures in high
stressed spray
injection coolers
spray attemperator 3
spray attemperator 2
95


Figure 73: Failure in the superheater

Leakages were detected in the test superheater in the 9
th
and 10
th
tubes in October 2006. The defects
were located at the transition area within the tube of Sanicro25 to Alloy 617B. To determine the cause
of the failures, the tubes were sent to the Hitachi Power Europe laboratory for examination. The two
tubes were marked as Tube 1 and as Tube 2 (see Figure 73 picture). The primary defect occurred in
tube 1 (Figure 74). Tube 2 was eroded by escaping steam from tube 1.
No expansions or macroscopic deformations were detected. In the tube 2 (Alloy 617B) an intergranular
crack was detected approx. 35mm next to the fusion line of the circumferential weld to the material
Sanicro 25 at approx. 180 of the tube circumference.


Figure 74: Intergranular crack at tube 1

Crack initiation next
to the weld
Eroded by
escaping steam
Tube 1
Tube 2
super heater
turbine
valve
700C
536C
210 bar
hp- system
410C / 44 bar hot reheat system
attemperator 2
hp bypass
attemperator 3
96

The adjacent tube 2 eroded due to the escaping water/steam mixture. This caused leakage of tube 2. On
the external surface of the Alloy 617B tube 1 sample, cold deformation lines were detected in the struc-
ture. Next to the weld structure, recrystallisation up to a depth of approx. 0.25mm was detected on the
outer tube surface. The surface hardness was up to 440HV 0.2. The grain size of the Alloy 617B was
determined according to Euronorm 103 71 and EN ISO 643:2003. The resulting grain index for the
grain size was 34. Metallographically, there were grain sizes up to 1 which cannot be shown in the
assessed standard evaluation. The oxidised surface areas and grain boundaries showed high Al and Fe
contents. The inner surface the tube showed plastic deformations. This indicates high longitudinal
stresses on the tube. The metallographic results of tube 1 (Figure 75), i.e. intergranular cracks, high
surface cold deformations, recrystallisations and grain sizes -1 to 4, were confirmed in tube 2.


Figure 75: Left: Inner surface. Right: Outer surface

The evaluation of the results led to the following conclusions:
The crack was initiated by relaxation crack formation (stress relief cracking, stress induced cracking,
relaxation cracking) in Alloy 617B. The inducing characteristics were present:
x high hardness due to cold deformation >380HV,
x coarse grain in the structure, and
x stresses (internal stresses of the weld, operational stresses, e.g. also due to different expansion
coefficients of Sanicro 25 and Alloy 617B and frequent temperature changes).
The high surface hardening was generated by the machining carried out to eliminate surface defects in
the tube during the manufacturing process. Surface hardening during the manufacture of components of
Ni-based alloys and austenitic materials, especially by machining after solution heat treatment, has to be
avoided.
97

2.6.3.5 Damages at Spray Attemperator 2
Spray attemperator 2 was installed after the test superheater. The attemperator controlled the tempera-
ture only in a small range. The attemperator did not reduce the temperature from 700 to 540C in nor-
mal operation mode. It reduced the temperature to 540C only in special operation modes if problems
with the following spray attemperators occurred (Figure 76-77).


Figure 76: Location of spray attemperator 2 in the CTF


Figure 77: Spray attemperator 2


spray injection noz-
zle assembly 1
spray injection noz-
zle assembly 2
flow direction
connection to outlet
header of superheater
pipe to hot reheat
pipe of host power
plant
pipe to turbine
valve and spray
injection cooler 3
hp bypass valve
spray injection cooler 2
spray attemperator 2
super heater
turbine
valve
700C
536C
210 bar
hp- system
410C / 44 bar hot reheat system
attemperator 2
hp bypass
attemperator 3
98

2.6.3.6 Indications at the Stubs of the Injection Nozzle Assemblies in August 2008
Dye penetrant tests showed indications at both stubs of the injection nozzle assemblies in August 2008.
The indications had to be ground out (Figure 78-79).


Figure 78: Indications at stub welds of the injection nozzle assembly


Figure 79: Injection nozzle after grinding

A TIG build-up weld had to be made at both injection nozzles after grinding due to the under sizing of
the minimum wall thickness. Heat treatment was avoided since it was not possible to achieve homoge-
nous thermal expansion of parts inside the injection nozzle assembly during heat treatment.
99

2.6.3.7 Failure of Stub Welds in February 2009
Cracks in the weld metal were detected with dye penetrant tests at both stubs of the spray injection as-
sembly of spray attemperator 2 in February 2009 see Figure 80. The cracks were located in the areas
where repairs took place in 2008 (see 3.6.3.6). The stubs were not heat treated in 2008 after the TIG
build-up welding.


Figure 80: Cracks at the stubs of spray injection nozzle assemblies and extraction of boat-shaped
samples

Boat-shaped samples were taken for laboratory investigation. They were sent to the Ruhr-Universitt
Bochum. The results were as follows:
The cracks in the weld ran interdentritically and were massively covered with oxides. Covering with
carbides (carbides containing Mo and Cr) of the interdentritic areas and the grain boundaries of the top
layers was comparatively low. Hot cracks developed in the manufacturing process were possibly the
primary damage to the weld metal. This was not clearly verifiable due to heavy oxidation of the crack
surface. J ust before the crack tip, the material showed carbides and pores on the grain boundaries.
1 2
100

2.6.3.8 Indications at a Support of Spray Attemperator 2 in September 2008
Mechanised ultrasonic (UT) and dye penetrant tests (PT) showed indications at a bracket of spray at-
temperator 2 (Figure 81) in September 2008 during a regular outage (Figure 82-83). The bracket was
removed and an UT was carried out again. Cracks in circumferential direction were detected. The indi-
cations had a depth of up to 20mm. Metallographic investigation in the laboratory of VGB basically
confirmed the UT results.

Figure 81: Spray attemperator 2 support construction with bracket


Figure 82: Indications at bracket of spray attemperator 2

Bracket after detaching
UT test after detaching of bracket
Indications in area of bracket
support construction
bracket
spray attemperator 2
101


Figure 83: Results of the UT of spray attempeartor at bracket

A V-groove weld was required according to the drawing. In reality there was no v-groove and the weld
was not fully penetrated.
The pipe system in this part was calculated using Rohr2 by Alstom after detecting the cracks. The
attemperator rotated in operation 1.15 around the x-axis. A design without the bracket seemed to be
better. Therefore the bracket was not installed again.
The attemperator part with the cracks was detached in order to undertake investigations and was re-
placed with a new fitting piece.
Deformations at the protective pipe were detected after having cut off the crack-affected part (Figure
84). A pin which was installed at the end of the attemperator led to strong deformations of the protec-
tive pipe.


Figure 84: Condition of protective pipe, seen after cutting off crack-affected pipe section

Visual inspection of the internal attemperator parts was made. A crack in the protective pipe close to the
injection nozzle assembly was detected (Figure 85). Replacement of the protective pipe could not be
carried out in the facility. Dismantling of the complete attemperator to replace the protective pipe would
collision with
end pin
Indication 1: 19 mm depth

Indication 2: 16 mm depth

Indication 3: 13 mm depth

Indication 4: between 5 and 9 mm depth

Indication 5: 9 mm depth

Indication 6: 14 mm depth

Indication 7: between 15 and 20 mm depth


1
2
3
4
5
6
7
102

have taken too much time considering the host power plant was not able to operate without attemperator
2. It was accepted just to cut off the end part of the protective pipe and to replace it with a new part. The
new part was 60mm shorter in order to avoid further collision with the end pin.


Figure 85: Results of the visual inspection, crack of protective pipe in the area of injection nozzle
assembly

To manufacture a new fitting piece would be too time consuming. Therefore, the end part of spray at-
temperator 3 was cut off and used as a fitting piece (Figure 86). This was possible due to the identical
design of attemperator 2 and 3.
Local heat treatment of the fitting piece welds was carried out only on the side which connects the at-
temperator with the steam pipe and where no protective pipe is located inside the attemperator. Heat
treatment of the other fitting piece weld was too risky due to the protective pipe inside the attemperator.


Figure 86: Different cuttings during the repair works

damaged area
103

2.6.3.9 Failure of Circumferential Weld in February 2009
A steam leakage was detected at the end of the Alloy 617B spray attemperator 2 in February 2011. The
crack propagation was fast and unit F had to be shut down. A crack appeared in the area of a circumfer-
ential weld of the attemperator 2 (Figure 87). The crack reached from the 3 oclock to the 11 oclock
positions. In addition, cracks in the longitudinal direction started from the main crack.


Figure 87: Damage affected area before and after removal of insulation

The effected weld belongs to a fitting piece which was installed during the regular outage in 2008 (see
3.6.3.8).
The filler metal (electrodes) was the same as the one which was used during the erection of the CTF and
in earlier repairs.
However, there is one important difference to other repair welds in the CTF: Heat treatment was not
carried out, neither before nor after welding. Heat treatment was too risky due to the protection pipe
inside the attemperator. There was only one repair weld in the 700C area which was not heat treated
either before welding nor after welding. This repair weld from 2006 was located at the beginning of
spray attemperator 3 and cracked in 2007 (see 3.6.3.10ff.).

The crack affected area in the spray attemperator was cut off (Figure 88). Samples were sent to the
Ruhr-Universitt Bochum and the following results were reported:
The large crack started in the area of the weld and ran in an intercrystalline way through the base mate-
rial, the grain boundaries were slightly covered with carbides. The cracks in the weld ran interdendriti-
cally. The cracks were heavily oxidised. The covering with the carbides (carbides containing Mo and
Cr) of the interdendritic areas in the weld was even more considerably discernible than the grain bound-
aries of the base material. In immediate proximity of the weld, the heat affected zone exhibited separa-
tions of the grain boundaries.
There were no pores on the grain boundaries. Hot cracks generated in the production process could be
the primary damage. Yet this was not clearly verifiable due to the heavy oxidation of the crack surfaces.
The cracks of the base material may have been caused by internal tensions after welding.

104


Figure 88: Investigation of the crack

2.6.3.10 Installation of Attemperator 3 at the Position of Spray Attemperator 2
Spray attemperator 2 was replaced with the repaired spray attemperator 3 after the damage suffered end
of February 2009. Repair of the attemperator 2 would have been too time consuming.
105

2.6.3.11 Damages at spray attemperator 3
Spray attemperator 3 was installed at the end of the 700C part of the CTF (Figure 89). The Alloy 617B
attemperator reduced the steam temperature from 700C to 536C. The wall-thickness of the main Al-
loy 617B pipe was 35mm. The cooled steam was led back into the water steam cycle of the host power
plant. Inside the pipe was a protective pipe (Figure 90).


Figure 89: Location of spray attemperator 3


Figure 90: Spray attemperator 3

spray injection
nozzle assembly 1
flow direction
spray injection
nozzle assembly 2
Circumferential inlet weld
pre
heating
pipe
turbine
valve
hp
bypass
valve
pipe from
super heater
outlet header
pipe to super
heater 4
outlet header
of host plant
(536C)
s
p
r
a
y

in
je
c
t
io
n

c
o
o
le
r

3
spray attemperator 3
super heater
turbine
valve
700C
536C
210 bar
hp- system
410C / 44 bar hot reheat system
attemperator 2
hp bypass
attemperator 3
106

2.6.3.12 Defective Weld at Spray Injection Nozzle Assembly
A steam leakage was detected at spray attemperator 3 in March 2007. A weld at the Alloy 617B counter
bearing of a spray injection nozzle assembly was defective (Figure 91). The weld was ground out and
welded again. All stub welds of the attemperator were dye penetrant tested without negative results. It
was assumed that the quality of the failed weld was insufficient.



Figure 91: Defective weld at counter bearing of spray injection nozzle assembly

The power plant staff detected a leakage at the repaired weld in February 2008. Probably missing clear-
ance at the counter bearing of the spray attemperator nozzle assembly led to failure of the weld. The
defective weld was cut off for laboratory (Figure 92) investigation.


Figure 92: Sample for laboratory investigation

Metallurgical investigation of the stub weld showed a crack formation in the weld metal with crack
portions that ran in the circumferential direction and radially (Figure 93). The crack shape was inter-
crystalline and without deformation and ran along the crystal boundaries. The measured material hard-
ness varied between 300 and 315HV in the weld metal, and between 290 and 310HV in the HAZ and
base material.

protective pipe
counter bearing of
spray injection nozzle
assembly
defective weld seam
minimum clearance
of 6 mm
steam
107


Figure 93: Metallographic investigation
2.6.3.13 Cracked Circumferential Weld and Inclination of Turbine Valve in 2007
A steam leakage was detected at the inlet weld of spray attemperator 3 (Figure 94) in April 2007. The
weld showed a crack in the circumferential direction.
The defective weld was an electrode repair weld and not an erection weld. The attemperator was re-
moved in the regular 2006 outage due to strong deformations and cracks at the protective pipe. A new
protective pipe was installed and the attemperator was integrated into the facility at the end of the
works. The attemperator was connected to the steam pipe with two circumferential welds (wall-
thickness: 35mm). Heat treatment before or after welding was not applied.
One of these two welds failed as mentioned above after 9 months of operation.


Figure 94: Crack of spray attemperator 3 inlet weld

In addition, deflection of the turbine valve was detected in April 2007, and the pipe, which includes
spray attemperator 3, was slightly bent (Figure 95). Water at the bottom of the turbine valve and the
spray attemperator 3 area could have led to these deformations. Probably the water was injected through
a preheating pipe before the turbine valve. Most probably, the water affected the weld failure.

108


Figure 95: Deflection of turbine valve

The investigations took place in the laboratories of Hitachi and Alstom.
Hitachi made a number of microsections, SEM and analysis samples were taken (Figure 96). The fol-
lowing was detected:
x Between the 12.00 oclock and the 5.00 oclock positions cold deformations in the HAZ were de-
tected on the inner surface of the pipe.
x Across the axis 12.00 oclock / 6.00 oclock a linear misalignment of up to 3.9mm was detected
on the inner surface.
x Starting at the 12.00 oclock position intercrystalline cracks were detected in the HAZ on the in-
ner surface of the pipe.
x In the weld metal interdendritic cracks and in the 12.00 oclock position hot cracks were also de-
tected at localised areas.
x In the HAZ reheat cracks were detected. In the base metal grain sizes up to G=-3 were detected.
x The surface hardness of the base metal was up to 447HV0.2.
x Around the 6.00 oclock position transcrystalline cracks started from inside the pipe. Moreover,
the formation of a crack network was detected in this area.
x Precipitates at the grain boundaries in the base metal showed higher Cr, Mo and C contents. The
precipitates were not due to operation but were present already from the start. Possibly, a slight
particle growth could be stated.
x The base metal showed oxidised, intercrystalline cracks which had concentrations of Co, Ni, Al,
Cr and Fe
x In the weld metal typical hot cracks as well as coarse, interdendritic cracks were detected.



pre
heating
pipe
turbine
valve
hp
bypass
valve
pipe from
super heater
outlet header
pipe to super
heater 4
outlet header
of host plant
(536C)
s
p
r
a
y

in
je
c
t
io
n

c
o
o
le
r

3
spray attemperator 3
109


Figure 96: Laboratory investigation of crack at spray attemperator 3 inlet weld

It can be derived from the test results that welding was carried out under stresses and high heat input.
During operation high additional stresses probably acted in the longitudinal pipe direction. In the lower
pipe area (6.00 oclock position) a temperature cyclic stress was present. The base metal showed risk
factors of relaxation crack formation. The crack characteristics in the base metal and in the weld metal
indicate relaxation cracks.
A further weld before the turbine valve was cut out in order to get an impression of the conditions of
other welds in the damaged area. This weld was investigated in the laboratory of Alstom. The conclu-
sion of the investigation was:
x Initiation of shrinkage cracks during the welding process at root notch based on high heat input
and impeded thermal expansion (stretcher strains at root). Initiation of cracks was supported by
impeded thermal expansion.
x Additional fatigue cracks in base and weld metal especially at 6 oclock position.
x Fatigue cracks can be associated with water input.
x Propagation of shrinkage cracks due to fatigue.
Non-destructive tests such as radiographic tests and dye penetrant tests were carried out in the area of
the turbine valve and the spray attemperator.
The two welds were replaced with two fitting pieces. Heat treatment with 980 C for 3h at the four pipe
ends was carried out before welding in order to improve the behaviour of the service exposed material.
Some changes were introduced in the process control technique in order to avoid the injection of water.

Pos. 2
Pos. 1
Pos. 1: 12 oclock, root /HAZ
Pos. 2: 12 oclock, root /deformations, recrystallisations
Pos. 3: 12 oclock, top layer, hot crack
Pos. 4: oxidized crack in the root area
Pos. 4
Pos. 3
110

2.6.3.14 Repeated Deformations and Cracks in the Main Pipe of Spray Attemperator 3 in
2008
It was detected in 2008 that the turbine valve was inclined and obviously the pipe, which includes spray
attemperator 3, was deflected. The same incident occurred in 2007 as described above. The assumed
reason for the deflection in 2007 was water, which was injected through the preheating pipe before the
turbine valve. This led to some changes in the process control technique. Obviously water was still be-
ing injected. Furthermore, endoscopy of the attemperator showed cracked welds at the protective pipe
inside the attemperator. Also water puddles, deformations of the protective pipe at the bottom area and
deformations of the protective pipe in the injection nozzle assembly parts were observed (Figure 97).


Figure 97: Old protective pipe. Left: Pipe broken in 5 segments. Right: deformation at injection nozzle
assembly part of the attemperator

Many improvements were carried out in the regular 2008 outage in order to avoid further induction of
water:
- A second shut-off valve was installed in the spray-water injection system of spray attemperator 3.
- A new drainage was installed behind the attemperator.
- One of the existing drainages was extended in order to drain attemperator 3.
- The slope of the steam pipe and the slope of attemperator 3 were changed.
Spray attemperator 3 was cut and taken out for repair before the regular 2008 outage. The facility was
in bypass operation due to the missing attemperator from this moment.
Two cracks in the Alloy 617B main pipe of the attemperator were observed during the works (Figure
98). One crack was located in the heat affected zone of an electrode welded circumferential weld, which
was located in the middle part of the attemperator. The weld connected the two segments of the attem-
perator main pipe. The other crack was located at a stub not far away from the defective circumferential
weld. Both welds were made during the erecting of the CTF in 2005.
111


Figure 98: crack at circumferential weld and stub weld of the Alloy 617B main pipe

The crack affected parts were cut out and sent to VGBs laboratory for investigation:
x The crack started from the weld area.
x The macroscopic, surface crack shape showed a slight offset and no visible secondary cracks.
x Surface imperfections, being a potential crack cause, were not present.
x Across the wall thickness, there was a crack with a slightly branched shape that ran vertically
with respect to the surface up to close to the inner pipe surface.
x The fractographic examination of an opened crack plane showed only intercrystalline rupture
portions with low deformation.
x The crack surface was completely oxidised.
x Microscopically, the major portion of the crack ran in the base material or in the HAZ, whereas
only a small part of the crack ran in the weld metal. There was a purely transcrystalline crack
shape without deformation present; it ran along the crystal boundaries in the weld seam area.
x The crack flanks were all oxidised. The oxide layer decreased clearly in thickness from the outer
surface towards the inner surface.
x Pore formation could be observed that ran on ahead of the crack formation.
x In the weld metal, the material microstructure showed a markedly dendritic structure with carbide
coverage of the crystal boundaries and cloudy fine precipitations in the grain. The precipitations
were chiefly carbides with a high molybdenum content of the type M6C. The measured material
hardness was between 320 and 365HV.
x The material microstructure of the base material and the HAZ showed a similar structure and
consisted of austenite with reticularly precipitated carbides on the grain boundaries and very fine-
ly spread precipitated carbides in the grain. The precipitations were mainly carbide with a high
chromium content of the type M23C6. The measured material hardness was between 290 and
320HV.
x Depletion of the carbide-forming elements chromium and molybdenum in the area close to the
grain boundaries could not be found with the employed examination methods.
112

2.6.3.15 Further Tests and Indications at the Alloy 617B Main Pipe
Further indications were detected with PT at some stubs in addition to the detected two cracks (Figure
99). The stubs were installed in order to centre the internal protective pipe.


Figure 99: Further indications at stubs

The findings at the stubs were ground. Some findings disappeared in a dept of <1mm. Other findings
did not disappear in a depth of 45mm. Therefore, replacement of the crack affected parts with two
fitting pieces was necessary.
2.6.3.16 Installation of Fitting Pieces at the Alloy 617B Main Pipe and Annealing
Three fitting pieces with partly new stubs were installed in the spray attemperator by electrode welding.
Heat treatment of the base metal was not carried out before welding. The main pipe of the attemperator
was annealed for 3h at 980 C in a furnace after replacing the crack affected parts with fitting pieces.
Finally, all welds were subjected to dye penetrant and mechanised ultrasonic tests.
2.6.3.17 Indications in the Stub Welds after Heat Treatment
Indications were found at stub welds of the spray attemperator injection assemblies after the annealing
process (Figure 100). These welds were not made during the repairs. They were welded during the erec-
tion of the attemperator and were in service for approx. 19,000h. An important fact is that the attem-
perator was completely tested two months before the heat treatment. No indications were found in these
areas at that time. This means that there could be a relationship between the heat treatment and the
cracks. It is also possible that the cracks were already present before the heat treatment but too small to
be detected. Small boat samples were investigated in the laboratories of Ruhr-Universitt Bochum. The
indications disappeared after grinding. The welds were built-up with filler metal.
The laboratory of Bochum found out that the investigated cracks occured interdendritically in the weld
metal. The crack flanks showed strong oxidation with accumulation of aluminium. The interdendritic
areas as well as the grain boundaries of the weld metal displayed significant accumulation of carbides
containing Mo. The cracks propagated into the base material, and the crack flanks were covered with
Mo- Cr carbides.

113


Figure 100: Indications at stubs after the heat treatment
2.6.3.18 Indications in the Area of Circumferential Welds after Heat Treatment
Indications at the new circumferential repair welds occurred in addition to the indications at the stubs
after the heat treatment (Figure 101).


Figure 101: Indications at circumferential welds after heat treatment

Many indications were located on the fusion line between the filler metal and the base material. The
Ruhr-Universitt Bochum made an investigation based on a boat-shaped sample of one weld. The la-
boratory came to the following results:
The findings were cracks approx. 12mm long which progressed interdendritically in the weld metal
and intergranularly in the heat-affected zone of the base material. The interdendritic areas of the weld
metal and the grain boundaries of the base material displayed massive saucer-type accumulation of
carbides containing Mo and Cr. Possibly the deterioration of the weld metal was a consequence of hot
cracks which occurred during welding. Due to the strong etching of the crack surfaces this could not be
verified unmistakably.
repair
weld
114

It could not be clarified if a higher boron content of the filler metal had a negative influence on the
weld. Anyway, it was decided to use the not modified Alloy 617B filler metal with a lower boron con-
tent for further repairs.
The repair welds were ground and cut out (Figure 102) and TIG built-up with filler metal. Two welds
were filled with TIG orbital. This welding technique was applied for the first time in the CTF. It was
possible to achieve good results.

Figure 102: Cutting of indications
2.6.3.19 Final Heat Treatment of the Complete Spray Attemperator 3 and Installation in the
CTF
The complete attemperator 3 and all small built-up welds were annealed again before the installation of
the protective pipe at the end of the repairs in a furnace.
A big crack appeared at spray attemperator 2 at the end of February 2009. Since the CTF and the host
power plant were not able to operate without spray attemperator 2 and the repair of the attemperator
would have taken too much time, attemperator 2 was replaced with the repaired spray attemperator 3.
2.6.3.20 Circumferential Repair Welds of Steam Pipes
Some circumferential repair welds were conducted during the operation time of the CTF. It was realised
that the welding of service exposed Alloy 617B material is very challenging.
All thick-walled circumferential welds of the 700 C steam pipe part were checked with mechanised
ultrasonic testing (UT) in 2007 due to the problems that occurred with thick-walled Alloy 617B welds,
as mentioned in previous chapters. It was the first time that UT was applied at these welds. Manufactur-
ing defects, which could not be detected with radiographic tests during the erection time, were found
with UT. Four welds were removed and replaced by electrode welding with fitting pieces. Heat treat-
ment after welding at 980 C for 3h was carried out. These eight repair welds from 2008 were tested in
March 2009 after a few months of operation.
Indications at the welds were found at all welds. Only acceptable indications with UT testing were
found. However, unacceptable dye penetrant indications (Figure 103) had to be eliminated by grinding
and cutting and a build-up welding was necessary.

115


Figure 103: Indications at repair weld

The indications at the fitting piece welds showed that the present repair concept was not appropriate.
Different kinds of optimisations were tested (described in the chapter 3.7.4.1.4) such as the change from
electrode welding to TIG welding in order to reduce the heat input or the application of a pre-weld heat
treatment at the service exposed base material in order to increase the ductility of the material. These
optimisations led to better results, but local indications were still found quite frequently during the
work. Several indications had to be ground out. The procedure were extremely time and cost intensive.
All repairs were finished in the beginning of May after more than two months of standstill. A final re-
pair concept could not be elaborated during the operation period of the CTF, this had to be done during
the evaluation phase of the project.
2.6.3.21 End of Operation
End of operation was scheduled in the COMTES700project after more than 20,000 hours of operation
in August 2009. Finally, it was decided to stop operation in 2009 as initially planned and to dismantle
the CTF.
The extension of the operation time of the CTF for approx. two years planned in the meanwhile in order
to gain additional experience could not be realised. The decision was taken due to problems with the
conventional part of the facility and the 700 C part of the facility as described above. Very time and
cost consuming repair work lead to the decision to stop operation in August 2009 and to dismantle the
facility.
116

2.6.4 Conclusions
2.6.4.1 General
The operation of the CTF showed that components of Ni-based alloys are in principle feasible for a
700C power plant. However, challenges with thick-walled alloy components still exist and therefore
additional tests in future test rigs are necessary. Several macrocracks with partial steam leakages oc-
curred and a high number of microcracks appeared at repair welds (dye penetrant test indications).
The macrocracks can be summarised as follows:
y Cracks occurred in areas with a high ratio of additional stresses, such as attemperators where a
two-phase flow was detected .
y Cracks were present in the area of stub and circumferential welds.
y Welds from the erection time and repair welds were affected.
y There were only two circumferential repair welds in the thick-walled 700C area without heat
treatment (980C for 3h) either before or after welding. These two welds caused the most severe
cracks of the facility. The cracks were detected after some months of daily start/stop cycles.
y Heat treated repair welds (980C) showed microcracks (dye penetrant test indications) but no
macrocracks.
y Cracks started at the outer surfaces.
y Interdendritic and intergranular crack propagation was detected.
The operation demonstrated that postweld heat treatment at 980 C for thick-walled Alloy 617B com-
ponents has a good effect on the weld. This kind of heat treatment can be applied to erection welds and
repair welds.
It was not possible to develop and to verify a definite repair concept for thick-walled Alloy 617B com-
ponents during the operation. Open questions have to be solved in follow-up investigations and pro-
jects. Promising ideas in order to find answers to the open questions are already available.
2.6.4.2 Actual Applications
The experience from the COMTES700 project is being considered in subsequent projects, such as EN-
CIO and HWTII. Post-weld heat treatment at 980C is considered for thick-walled Alloy 617B compo-
nents and the steam is not cooled down using only water. It will be cooled down with colder steam or a
combination of water and flowing steam in order to achieve good dispersion of the water and thereby
avoid a two-phase flow.
2.6.4.3 Technical Potential for the Use of the Results
The operation of the CTF demonstrated that full-scale 700C components made of Ni-based alloys can
be operated in power plants. It also showed, however, that improvement of the material handling with
regard to manufacture, installation and maintenance is necessary.
The operational experiences from the CTF will be important to follow-up research projects and the first
700C demonstration plant.

117

2.7 WORK PACKAGE 7: EVALUATION
2.7.1 Work Package Objectives
x Assessment of consumed lifetime based on actual service data and finite element calculations
x Check of materials condition after two years based on component inspection, samples and rele-
vant metallurgical investigations (to allow preparations to start for the final full-scale demonstra-
tion plant)
x Check of materials condition after four years based on component inspection, samples and rele-
vant metallurgical investigations
x Review of design and design assumptions based on the previous investigations.
2.7.2 Comparison of Initially Planned Activities and Work Accomplished
Based on the work package objectives, a sampling plan and an evaluation matrix were developed to
define the investigations to be made. The evaluation matrix was adapted as the project progressed.
Failures on thick-walled components experienced during operation gave rise to a comprehensive study
of failures and repair concepts.
2.7.3 Description of Activities and Discussion
Samples were removed from the CTF after 11,600, 19,200 and 22,400 hours of operation (fire in boil-
er). The samples were investigated using various methods, including light optical microscopy (LOM),
scanning electron microscopy (SEM) with energy dispersive analysis (EDS), transmission electron mi-
croscopy (TEM), hardness measurements, impact, and other mechanical tests. Furthermore, creep test-
ing was performed on selected alloys.
The investigations were based on an evaluation matrix prepared before the commissioning of the CTF.
Samples from evaporator base materials and welds, superheater base materials and welds, headers and
steam piping including bends and branch pieces and spray attemperator were investigated by different
laboratories (see Table 25).
The majority of the results from superheater and evaporator were reported in the intermediate report.
This report includes the remaining results from the evaporator and superheater samples, as well as in-
vestigations of thick-walled components. Unless otherwise described the results are based on investiga-
tion of samples after 22,400 hours of operation.

Table 25: List of laboratories.
Alstom Power Systems laboratory
Centro SviluppoMateriali laboratory
DONG Energy Power laboratory
Electricite de France laboratory
Hitachi Power Europe laboratory
Laborelec laboratory

118

2.7.3.1 Evaporator
The additional results are summarised from deliverables.
2.7.3.1.1 Evaporator Base Material
The main results from evaporator investigations are summarised in Table 26, including hardness
(HV10) measurements.
Pit corrosion areas on the outer side of the tubes were found for all the tested materials. The dominant
elements in the corrosion layers were O, S, Cr. Significant thickness reductions (>0.3mm) were found
for HCM12 and Alloy 617B.
It was confirmed that, as in previous measurements, the highest steam oxidation thickness was found
for the HCM12 samples. The dominant elements in the steam oxidation layers were O, Cr, Fe. In par-
ticular, non-uniform scaling was observed in the T24 rifled tube. A significant increase of hardness
compared to non-exposed material was observed only for Alloy 617B, from 170 to peak values of ap-
prox. 290HV10.
Table 26: Summary of results for evaporator tubes. Hardness values refer to the highest reported value
in the references.
Sample Material Avg.
Metal
Temp.
(C)
Area Fireside Corro-
sion
Max.
thick.
reduction
(m)
Steam Oxidation Max.
oxide
thick.
(m)
Hardness
HV10
Hardness
HV10
E1 T24 526 Metal Pit-corrosion 160 36 217 213
Corrosion
layer
Enriched O, S,
Cr
Enriched O, Cr, Fe
E2 T24 562 Metal Pit-corrosion in
large areas and
locally
130 48 219 206
Corrosion
layer
Enriched O, S,
Cr
Enriched O, Cr, Fe
E3 - E4 HCM12 557 Metal Pit-corrosion in
large areas and
locally, interdis-
persed with fine
oxides
57 - 350 105 218 216
Corrosion
layer
Enriched O, S,
Cr
Enriched O, Cr, Fe
E5 Alloy
617B
556 Metal
(tube
with fin)
Pit-corrosion in
large areas
280 19 289 258
Corrosion
layer
Enriched O, S,
Cr
Enriched O, Cr, Fe,
Al

Fin Hot cracks in
HAZ

E6 Alloy
617B
584 Metal Pit-corrosion in
large areas and
locally
130 23 281 250
Corrosion
layer
Enriched O, S,
Cr
Enriched S, Cr, Fe,
Al

ER1 T24 -
rifled
502 Metal Pit-corrosion
("front inter-
crystalline")
100 Max. sp. 27 m 27 210 206
Corrosion
layer
Enriched O, S Non-uniform scal-
ing of fine oxides.
Enriched O, Cr, Fe,
Zn

119

2.7.3.1.2 Evaporator Welds
The main results for evaporator similar welds are summarised in Table 27. The characteristics of the
corrosion layers were similar to those found in the base materials. In one case (Alloy 617B) an imper-
fection of 35m was found on the fusion line.

Table 27: Summary of results for evaporator tubes similar welds. Hardness values refer to the highest
reported value in the references, except for microhardness that refers to average values in the reference.
Sample Material
Avg.
Metal
Temp
. (C)
Area Fireside Corrosion
Max.
thick.
Reduc-
tion
(m)
Steam
Oxidation
Max.
oxide
thick.
(m)

Hard-
ness HV1
Hard-
ness
HV10
Micro
hard-
ness
HV0.2
EW1 T24 526
Base/
Transition
Pile-like propagating
corrosion
214 - 224

WZ
CrMoV21Ti
B

Weld
metal
Severe Pit-corrosion

342 333 366


Corrosion
layer /
HAZ
Enriched O, S, Cr

Enriched O,
Cr, Fe, Mo
337 350- 362
T24
Base/
Transition
218 - 211
EW2 HCM12 571
Base/
Transition
Pit-corrosion in large
areas and locally
Oxidation
higher than
weld metal
214 - 226

S Ni 6617
(mod.)
Weld
metal
Pit-corrosion, lower than
base metal
313 246 316


Corrosion
layer /
HAZ
Enriched O, S, Cr

Enriched O,
Cr, Fe, W
239 235 246
HCM12
Base/
Transition
219 - 222
EW3 Alloy 617B 575
Base/
Transition
Pit-corrosion in large
areas. 35 m imper-
fection on fusion line.
Enriched O, Cr, Ni, Mo
340 - 354

S Ni 6617
(mod.)
Weld
metal
Pit-corrosion in large
areas, higher than base
metal

335 290 340


Corrosion
layer / HAZ
Enriched O, S, Cr

Enriched O,
Cr, Fe
319 299 370
Alloy 617B
Base/Transitio
n
333 - 358
EW4 T24 569
Base/Transitio
n
Pit-corrosion 215 - -

WZ
CrMoV21Ti
B

Weld metal Pit-corrosion

338 341 -


Corrosion
layer / HAZ
Enriched O, S, Cr

Locally
scaling with
cracks.
Enriched O,
Cr, Fe

357 328 -
T24 Fin 329 - -
EW5 HCM12 553
Base/Transitio
n
Pit-corrosion in large
areas and locally
180 94 218 - 250

S Ni 6617
(mod.)
Weld metal

218 195 240


Corrosion
layer / HAZ
Enriched O, S, Cr

Enriched O,
Cr, Fe
304 271 320
HCM12 Fin
Pit-corrosion higher than
tube, more pronounced in
HAZ
196 - 270
EW6 Alloy 617B 598
Base/Transitio
n
Pit-corrosion in large
areas and locally
160-260 20 365 - -

S Ni 6617
(mod.)
Weld metal

318 266 -


Corrosion
layer / HAZ
Enriched O, S, Cr, Al, Fe

Enriched O,
Cr, Fe, Al
357 328 -
Alloy 617B Fin hot fine cracks in HAZ 357 - -
The main results for evaporator dissimilar welds are summarised in Table 28.
120

In one case (transition between HCM12 and weld metal) an imperfection was found on the fusion line
(230m). Oxidation levels comparable to those found on base metals were observed.

Table 28: Summary of results for evaporator dissimilar welds. Hardness values refer to the highest
reported value in the references, except for microhardness that refers to average values in the reference.
Sam-
ple
Material
Avg.
Metal
Temp.
(C)
Area Fireside Corrosion
Max.
thick.
Reduc-
tion
(m)
Steam
Oxida-
tion
Max.
oxide
thick.
(m)
Hard-
ness
(HV1)
Hard-
ness
(HV10)
Micro
hard-
ness
(HV0.2)
DW1 T24
583
(cover)
Base T24
Pit-corrosion in large
areas and locally
48 205 - 238


542
(root)
Transi-
tion
255 240 284

S Ni
6617
(mod.)

Weld
metal
3 233 219 258


Corrosion
layer /
HAZ
Enriched O, Cr

En-
riched
O, Fe

- - -


Transi-
tion
large scaling. Enriched
O, Cr, Al, Si, Fe
220

277 276 276
HCM12
Base
HCM12
Pit-corrosion in large
areas and locally. En-
riched O, Cr, Al, Si, Fe
35 214 - 223
DW2 HCM12
573
(cover)
Base
HCM12
Pit-corrosion in large
areas and locally. En-
riched O, Cr

En-
riched
O, Cr,
Fe
113 214 - 226


538
(root)
Transi-
tion
230 mimperfection
fusion line. Enriched O,
S, Cr, Mo

65 274 276 307

S Ni
6617
(mod.)

Weld
metal
En-
riched
O, Cr,
Ni
3 300 249 303


Corrosion
layer /
HAZ

- - -


Transi-
tion
320 275 284

Alloy
617B

Base
Alloy 617
Pit-corrosion in large
areas and locally

En-
riched
O, Cr,
Fe
5 357 - 318
121

2.7.3.2 Superheater
The results are summarised from deliverables.
The main results are summarised in
Table 29.
The average grain size was between 50 and 120m (average grain size according to ASTM classifica-
tion between 5.3 and 2.9), with the lower values for Sanicro 25 and the higher for Alloy 617B. The
hardness in transverse sections was lower for the austenitic steels (230-250HV10), and higher for nickel
based alloys (approx. 290-310HV10 for Alloy 617B and up to 390HV10 for Alloy 740).
In the longitudinal sections across the welds, the highest values were reached in the weld material and
the HAZ, with peaks of 340-350HV10 for Alloy 617B and 390-400HV10 for Alloy 740. Microhardness
was also measured in the grains; the values showed a very high scatter, ranging from minimum values
of 100 up to maximum of 500HV0.5, up to 600700HV0.5 for Alloy 740.
Concerning fireside corrosion and steamside oxidation, the predominant elements in the layers are S, O,
Cr and Fe, Cr, O respectively, confirming the results found for the evaporator. The best fireside corro-
sion resistance is achieved by Alloy 740, showing negligible layer thickness compared to approx. 50
60m for Alloy 617B and higher values for austenitic steels.
122

Table 29: Summary of results for SH similar/dissimilar welds. Welds made with type Alloy 617B filler
metal. Hardness values refer to the highest reported value in the references.
Sample Material Area
Thickness
range
(mm)
Grain size
min-max
(m)
ASTM
grain
class,
average (-)
Hardness,
tranverse
section
(HV10)
Hardness,
longitudinal
section
(HV10)
Micro
hardness
across GB
(HV0.005)
DW8 (SH22) HR3C Metal 9.7 - 10.1 50.9 - 53.2 5.2 235 270
HAZ - - - - 300


Weld
metal
- - - - 350
HAZ - - - - 320
Alloy 617 Metal 6.5 - 8.8 78.0 - 141.9 3.3 317 330
DW9 (SH24)
DMV310
N
Metal 9.2 - 9.9 64.1 - 97.5 4.1 234 260
HAZ - - - - 320


Weld
metal
- - - - 340
HAZ - - - - 340
Alloy 617 Metal 8.0 - 8.6 82.1 - 120.0 3.5 316 350
DW10
(SH26)
SAN25 Metal 9.4 - 9.8 42.2 - 57.8 5.3 254 270 450
HAZ - - - - 280 -


Weld
metal
- - - - 340 -
HAZ - - - - 340 -
Alloy 617 Metal 7.5 - 8.5 90.0 - 93.6 3.7 318 330 500
DW11
(SH19)
Alloy 740 Metal

60.6 - 79.9
(longitud.)
4.5


HAZ


Weld
metal

HAZ
Alloy 740 Metal
AD09 Alloy 617 Metal 8.2 - 8.7 82.1 - 111.5 3.4 298
AD09 longi-
tudinal
Metal

80.7 - 105.4
(longitud.)
3.5


SH8 Alloy 617 Metal
8.2 - 8.7 79.3 - 99.7 3.7 327
290 420
HAZ 300 -


Weld
metal
320 -
HAZ - -
Alloy 617 Metal - 420
SH9 Alloy 617 Metal
78.0 - 91.8 3.8 389
- -
HAZ - -


Weld
metal
350 -
HAZ 400 -
Alloy 740 Metal 9.9 - 10.3 390 700
SH6 SAN25 Metal 9.5 - 9.9 55.1 - 63.3 4.9 254 270 450
HAZ - - - - 280 -


Weld
metal
- - - - 300 -
HAZ - - - - 330 -
Alloy 617 Metal 7.9 - 8.8 101.8 - 133.8 2.9 284 290 500

Microhardness measurements confirmed findings from the intermediate report. TEM investigations of
microstructures revealed the presence of precipitates, both intergranular and intragranular. In Alloy 740
-phase was found, coarsened in the aged material, together with needle-like -phase at the boundary
grain, enriched in Ti and Nb.
123

2.7.3.3 Thick-walled Components
2.7.3.3.1 Header and Piping Base Material
The results are summarised from deliverables.
Header and steam piping were manufactured in Alloy 617B.

Table 30: summarises the investigated components. Since all components were made from the same
material, exposed at similar temperatures, and in the same time period, similar features are observed in
the investigations of the samples.

Table 30: The investigated components
Component Sample Operation / design
temperature (C)
Condition
Alloy 617B (pipe) V10 Unaged
SP2 705 / 710 22,400h operation
Superheater outlet header H3 705 / 720 22,400h operation
- similar stub welds SHHW2
SHHW1
705 / 720 22,400h operation
Bend SPB2 705 / 710 22,400h operation
Branch piece BP1 705 / 710 22,400h operation
Bend BP2 705 / 710 22,400h operation
Steam line after spray attemperator,
inspection of water drop erosion
DE1 705 / 710 22,400h operation

The ASTM grain size no. of the investigated components was 4.0 to 3.5 (89.8-107m converted mean
grain diameter). The grain size varied; a bimodal grain size distribution with many small grains in some
areas and larger grains in others was observed. A reticular arrangement of small precipitates, possibly
M
23
C
6
, was observed in the LOM images of all service exposed samples (see Figure 104 left).


Figure 104: Left: LOM image of SP2. Right: BSE-SEM image of BP1 (arrows: see text).

124

The grains of all samples appeared dotted in SEM, possibly due to precipitation of small ' particles (see
Figure 104 right). In all samples few large primary precipitates of TiN/Ti(C, N) particles were observed
(orange arrow in Figure 104 right). Many globular particles rich in Cr and Mo were observed in grains
and along grain boundaries, dispersed irregularly throughout the structure (black arrows in SEM image
and dots in LOM image). These are most likely M
23
C
6
. In some samples, precipitates with similar com-
position were also present as elongated particles along grain boundaries. In addition, small Mo-rich
precipitates (most likely M
6
C) were observed at grain boundaries (white arrows Figure 104). Small
needle-like precipitates containing more Mo and less Ni than the matrix were identified in few samples.
Generally, grain boundaries contained more Cr, Fe and less Ni, Mo than the matrix.
The mechanical properties of the virgin (V10) and the service exposed steam pipe (SP2) differed; the
service exposed sample was harder, stronger, more brittle, and less ductile than the virgin sample (see
Table 31). The mechanical properties of bends (BP2 and SPB2) were similar in extrados and intrados.
Notice that the change in mechanical properties was more significant for bends than for straight pipe,
suggesting that deformation induced during bending might result in precipitation of larger amount of
precipitates. Most samples were slightly harder at the surfaces than in bulk.

Table 31: Mechanical properties of various samples. RT =room temperature, HT =700C
R
p0.2
(MPa) R
m
(MPa) El (%) Red. area Z (%) Impact (J ) Hardness
(HV10) RT HT RT HT RT HT RT HT
V10 351 234 747 558 54 66 50 54 237 174
SP2 442 318 864 636 41 45 45 55 105 218
BP1 539 893 21 21 66 252
BP2 558 996 31 35 71-83 253
SPB2 562 983 21 32-38 73-83 268

A thin Cr
2
O
3
layer, enriched with Fe at the surface, developed on the steam side of the components. Its
thickness was approx. 46m. Below this layer an internal oxidation zone of approx. 918m was ob-
served. This zone contains Al
2
O
3
(see Figure 105 left). The alloy adjacent to the oxide layer is depleted
in Cr and the reticular precipitates had dissolved (see Figure 105 middle). Shallow pits are observed on
the steam side of samples DE1 (see Figure 106) and SPB2.

Figure 105: Steam side oxide. Left: BSE-SEM image of H3. Middle: LOM image of SPB2 after
etching. Right: LOM image of BP1


125


Figure 106: Shallow pits developed on the steam side of DE1

Locally the inner surface of BP2 contained cracks and large voids, which might be defects introduced
during manufacture. Deep grain boundary attacks are observed on part of BP1 (Figure 105 right), SP2
and DE1. Whether these attacks are related to defects introduced during manufacture or to stress assist-
ed rain boundary oxidation is not known.
The similar stub weld showed no variation in composition nor in hardness. Furthermore, the oxide lay-
er, which had formed on the weld metal, appears similar to that formed on the base metal. A hot crack is
observed near the outer surface (see Figure 107 right).
Dye penetrant testing showed no bore hole cracking in the header, H3, at the stub weld connection
joints. Bore holes can be seen from Figure 107.



Figure 107: Left: View from inside header H3 with bore holes after penetrant testing. Right: Hot crack
observed in weld SHHW1 near outer surface
2.7.3.3.2 Spray Attemperator
The results are summarised from deliverables.
A piece of an Alloy 617B pipe and a similar weld from spray attemperator 2 were investigated. These
samples were exposed to similar temperatures as the samples from header and steam piping thus show-
ing similar features. Table 32 lists the mechanical properties for these samples. The fracture of the ten-
sile test piece manufactured from the weld was located in the base metal. The hardness of the weld met-
al is higher than the base metal for weld SAW1.
Table 32: Mechanical properties of pipe sample SA1 and weld SAW1. For SAW1, tensile testing is
cross weld and impact testing is in-weld. Values from impact testing and hardness measurements are
average values.
R
p0.2
(MPa) R
M
(MPa) El (%) Red. area Z (%) Impact (J ) Hardness (HV10)
SA1 595 996 29 31 81 281
SAW1 663 989 39 20 25 BM:281 / WM:335
126

2.7.3.3.3 Welds
The results are summarised from deliverables.
Table 33 summarises the investigated dissimilar welds. Three of the welds are between P92 and Alloy
617B but exposed at different temperatures.

Table 33: Investigated dissimilar welds
Weld Materials Operation temperature
DW3 Evaporator outlet stub weld Alloy 617B - P92 540C
DW4 Superheater inlet stub weld P92 - Alloy 617B 540C
DW7 Circumferential pipe weld Alloy 617B- P92 ~536C
DW8 Circumferential pipe weld Alloy 617B-10CrMo9-10 ~536C

Figure 108 shows hardness measurements performed at the root and top layer across these welds. No
relation between temperature and hardness profile is observed. A hardness increase is observed in P92
close to the transition zone for all welds. A hardness decrease is observed in the root layer of DW4 ad-
jacent to this increase. The root layer is harder than the top layer for DW4, whereas root and top layer
show similar hardness for DW3 and DW7. In the root layer of DW7, a large increase in hardness is
observed in Alloy 617B close to the transition zone. All welds show decreasing hardness in Alloy 617B
with increasing distance to the transition zone.


Figure 108: Hardness measurements performed across dissimilar welds between P92 and Alloy 617B. r
=root layer, t =top layer

127

Figure 109 shows the hardness profile measured across the dissimilar weld between 10CrMo9-10 and
Alloy 617B. A peak in hardness is observed at the transition zone between 10CrMo9-10 and weld met-
al.


Figure 109: Hardness measurements performed across the dissimilar weld between
10CrMo9-10 and Alloy 617B (DW8). r =root layer, t =top layer

LOM investigation of DW7 suggests transformation of P92 into ferrite in a zone close to the transition
line (see Figure 110). Microscopy investigations showed that the interface between weld metal and base
metal was well-defined for base metals P92 and 10CrMo9-10, whereas a gradual transition is observed
between Alloy 617B and the weld metal. A gradual change in composition is observed in an approx.
10m thick zone of the weld metal closest to the ferritic/martensitic base metals (see Figure 111); for
DW7 and DW8 particles are observed in this zone. A transition zone is observed on the 10CrMo9-10
side of the interface between weld metal and base metal (DW8).


Figure 110: Left: The HAZ of P92. Right: Alloy 617B (right) in dissimilar weld, DW7


BM
WM
P92 BM
WM
128



Figure 111: Left (DW3): SEM images and EDS line scan across the interface between weld metal and
P92. Right (DW8): Weld metal and 10CrMo9-10. The contents of Ni, Cr, Fe, and Co at end positions in
wt%

Thick double layered oxides were observed on the ferritic/martensitic base metals. For P92, an internal
oxidation zone was also observed. However, close to the transition line the inner layer is thin suggesting
that the weld metal had supplied Cr to the growing oxide layer. For DW8, a 1.4mm oxidised surface
defect is observed in 10CrMo9-10 close to the transition line (Figure 112 right), and smaller oxidised
surface defects with maximum depth of 470m are identified further into the base metal.
A crack was observed in the HAZ of Alloy 617B in weld DW7.


Figure 112: Left (DW4): Steam side oxide at the transition between, P92 and weld metal. Right (DW8):
10CrMo9-10 and weld metal
129

2.7.3.3.4 Failures
During the first two years of operation no serious damage was detected, with an exception of one leak-
age in a superheater close to a weld between Sanicro 25 and Alloy 617B. The investigation of the dam-
aged thin walled boiler tube showed hardness values up to 400HV10. During manufacture the base
material was cold deformed and this reduced its ductility. The ductility is important for the reduction of,
and to tolerate, the residual stresses being present due to the welding process. Details of the failure and
the cause analysis are described in Chapter 3.6.3.4, Superheater Failure. A repair concept for thin
walled material was developed, which included pre-welding heat treatment at 980C for 3h. After the
repair that solved this problem, no further damage in the thin walled tubes was experienced.
After approx. 15,000 hours of operation in the test rig, a crack was observed in a thick-walled Alloy
617B component (see Figure 94, WP6). Further cracks were observed afterwards. The areas which were
affected by cracks were investigated by metallographic investigation. Detailed investigation of the dam-
aged welds revealed an intergranular/interdendritic crack propagation in all cases. In most cases the
crack seemed to nucleate in the weld. After the nucleation the crack propagated to the base material. A
typical crack path and the associated microstructure are shown in Figure 113.


Figure 113: Crack that occurred during operation of the CTF. Left: Typical crack path close to a stub.
Right: Associated microstructure

The stub welds and the circumferential connection welds were affected. Because of the special design
of the coolers that were necessary in the CTF, this was more likely to induce additional stresses in these
areas. The detected damage to the thick-walled components made repairs necessary. Therefore, the
crack affected welds were cut off and replaced by fitting pieces.
In contrast to the erection, the first attempt to carry out a repair weld showed many indications in the
dye penetration tests directly after welding (see Figure 114). From this moment on it became obvious
that the repair process of the thick-walled pipes and the service exposed pipes made of Alloy 617B pre-
sented a special challenge. For this reason the welding concept for repair welds had to be developed.
Acceptance criteria for indications level 1 (linear indications 2mm accepted) according to EN
1289:1998 were used to evaluate the weld quality.

130


Figure 114: Indications that occurred directly after welding of service exposed Alloy 617B in the area
of welds: a) crack in the weld, b) PT-indications during non-destructive testing, c) crack in the heat
affected zone
2.7.3.3.5 Repair Concept
The first measure was to optimise the weld build-up and welding parameters within the range of quali-
fication of the WPS used during manufacturing and erection. The aim of the changes was to reduce the
residual stresses created during manufacture of the weld.
The Ni-based alloys showed significant shrinkage during cooling. Consequently high residual stresses
in the welded area were found. To reduce the stresses it was decided to modify the build-up. By weld-
ing alternately the quarters of the circumferential weld, stresses should be contributed more evenly. In
addition to this measure, the originally used electrode welding was changed to manual TIG welding
which can reduce heat input and at the same time reduce the Si content in the weld. Si reduces the melt-
ing point of the alloy and therefore widens the melting range. This enlarges the susceptibility of hot
cracks in the weld during the solidification phase. Therefore, it was desired to reduce the content as
much as possible. Using shielded metal arc welding for this alloy, the electrodes Si content cannot be
fully eliminated as it is needed for the electrode cover stability.
Changing the weld build up and the welding method led to a slight improvement of quality. However,
the result was still unacceptable due to indications in the weld and the HAZ.
As a next step, heat treatment at 980C was performed before welding on the service exposed material.
This was done to improve the mechanical properties of the material. The overall idea was to increase
the material ductility in order to tolerate and reduce stresses induced by the welding process.
In addition to the heat treatment the base material was buffered before connecting the pipes. This was
done with the intention of reducing the exposure on the heat affected base metal during the welding
process. The welding results improved significantly because of these measures. But there were still a
large number of indications still remained, however, that had to be removed. After a very long time and
intensive repairs, all repair welds were post-weld heat treated at 980C for 3h and the CTF could be
restarted again.
In view of the many problems during the repair it was decided to recheck all repair welds by non-
destructive testing after another 500h of operation, in August 2009. All welds that had been repaired
and tested showed several indications that had not been found before recommissioning of the CTF. Up
until today it has not been possible to finally determine the time of initiation of the cracks. There is a
strong belief that small imperfections were present already before the recommissioning and grew be-
131

cause of the service conditions. Figure 115 compares an indication that was detected before and after
the 500h of operation. The comparison in Figure 115 shows the general tendency of growth of small
imperfections.

Figure 115: Left: Indications before operation. Right: Indications after 500 hours of operation

Parallel to the repair on site mechanical testing as well as metallographic investigations were carried out
on the service exposed material. This was done to understand the observed significant difference in the
materials behaviour caused by a pre-weld heat treatment (prWHT) at 980C for 3h.
Therefore, the mechanical behaviour of the heat treated and non-heat treated, service exposed base ma-
terial was compared in a three point bending relaxation test. In this test the samples were deformed at
the testing temperature. The piston displacement was kept constant (4mm) during the test and the sam-
ples reaction during the relaxation phase (150 h) was observed (see Figure 116).


Figure 116: General test set-up of bending test

This investigation showed a significantly different behaviour of the heat treated and the non-heat treated
sample and supported the findings that were gained on site. The not heat treated sample showed a dra-
matic load drop caused by a macrocrack after a short period of time. The crack could easily be seen by
visual inspection (Figure 117a). In contrast to this result the heat treated samples exhibited a much bet-
ter behaviour. After 150h the test was aborted since no load drop was detected. The visual inspection
did not show any macrocracks (Figure 117c). The subsequent metallographic analysis showed only
some small microcracks that were acceptable.

132


a)

c)
b)

d)
Figure 117: Result of the 3-point bending test: a) service exposed sample, b) load-time diagram for
sample out of a), c) service exposed +980C for 3h, d) load time diagram for the sample out of c)

In order to understand the different behavioural pattern of the material under the different heat treatment
conditions, TEM investigations were carried out for both conditions. Additionally, the microstructure of
the service exposed material, heat treated at solution annealing temperature (1160C for 1h), was inves-
tigated by TEM.
The service exposed material revealed two types of precipitations that were responsible for the harden-
ing behaviour of the alloy. One type has a roundish appearance and an average size of approx. 70nm.
Test results showed that this type of precipitation was the intermetallic gamma prime phase. The second
type of precipitation in the material has a much sharper shape and is significantly smaller in size Figure
118a). Test results show that this type of precipitation a carbide type M
23
C
6
.
To understand the materials behaviour due to heat treatment at 980C for 3h that was observed during
the repair of the CTF, the mechanisms in the microstructure of the heat treated service exposed material
were investigated, too. In this material condition only one type of precipitation was found. Analysis
revealed that these precipitations presented the same contribution as the carbides before heat treatment.
The carbides did not dissolve but slightly changed morphology because of the heat treatment. The
gamma prime phase that was found in the service exposed condition cannot be found any longer (Figure
118b). Carbides present in the grain boundaries grew slightly in size.
Because of the 980C heat treatment before welding was not satisfactory it was decided to perform heat
treatment at 1160C for 1h on service exposed material in the laboratory to gain new experience for a
new future repair concept. Figure 118c shows the resulting microstructure. Generally, it can be said that
that the carbides present could not be dissolved by this heat treatment but their number and size
changed significantly. Compared to the heat treatment at 980C the carbides average size grew by a
factor of 4 (Figure 119).

133

a) b)
c)
Figure 118: Microstructure of service exposed Alloy 617B after different heat treatments (22,000h at
700C): a) service exposed, b) service exposed +980C for 3h, c) service exposed +1160C for 1h


Figure 119: Medium size of carbides in service exposed and heat treated Alloy 617B

Weld tests were carried out to develop an effective repair concept for service exposed and thick-walled
Alloy 617B material. Pipe material with a diameter of 219.1mm and a wall-thickness of 50mm was
taken from the 700C part of the facility after dismantling. The material was in operation for 22,400 h.
Six welds were conducted in total (see Table 34). Welds 1 and 2 show the influence of the weld tech-
nique on the weld result, and welds 3, 4, 5 and 6 the influence of heat treatment with 980 C and 1160
C on the service exposed base material before welding. On-site heat treatment using heating mats was
demonstrated successfully. Heat treatment at 980 C after welding was applied in any case.

medium size of car bides
0
20
40
60
80
100
120
140
160
180
200
i
n

n
m
after 980C
after 1160C
100nm 100nm
100nm
134

Table 34: Test programme with six different electrode and TIG orbital welds


To verify that heat treatment at temperatures above 1000C is possible under site conditions, this heat
treatment was simulated at these conditions. In comparison to a typical heat treatment at 1160C in a
workshop, only equipment which can be applied in a power plant was used. Quenching in water, which
is usually applied after the solution annealing in a workshop, is not possible due to the lack of practica-
bility in a power plant. The temperature has to be reduced to a temperature of 700C as rapidly as pos-
sible. A special spray-water device was manufactured for this task.
An experimental test heat treatment was carried out in order to investigate:
x if a temperature of 1160C can be reached by using heating mats;
x if rapid cooling is possible; and
x how the temperature decreases next to the heat treated part.
Figure 120 and Figure 122 show the experimental setup. A service exposed Alloy 617B pipe
(219,1x50mm) from COMTES700 was used for the test. 18 thermocouples were fixed for the test in
sum (see Figure 121). The right pipe end was closed with an insulation cap in order to avoid tempera-
ture losses

Figure 120: Test pipe with heating mats and insulation

X X Weld 6
X X Weld 5
X X Weld 4
X X Weld 3
X Weld 2
X Weld 1
1
1
6
0

C

S
o
l
u
t
i
o
n

A
n
n
e
a
l
i
n
g
9
8
0

C
/
3
h

H
T

b
e
f
o
r
e

w
e
l
d
i
n
g

M
e
c
h
a
n
i
z
e
d

T
I
G
E
l
e
c
t
r
o
d
e
X X Weld 6
X X Weld 5
X X Weld 4
X X Weld 3
X Weld 2
X Weld 1
1
1
6
0

C

S
o
l
u
t
i
o
n

A
n
n
e
a
l
i
n
g
9
8
0

C
/
3
h

H
T

b
e
f
o
r
e

w
e
l
d
i
n
g

M
e
c
h
a
n
i
z
e
d

T
I
G
E
l
e
c
t
r
o
d
e
135


Figure 121: Arrangement of 18 thermocouples for the 1160C heat treatment test


Figure 122: Heating of the test pipe

The pipe was heated at a maximum rate of 150C/h. The temperature of 1160C could be reached at the
outer and inner surface of the pipe. Defects to the heating mats were not observed. Temperature differ-
ences between the thermocouples, TE1 to TE10, could not be identified. Only the measured temperature
TE11 and TE12 was slightly lower during heat-up
Figure 123. The holding time at 1160C was one hour.

Figure 123: Measured temperatures during the heat treatment test
TE 7 TE 5 TE 3 TE 1 TE 9 TE 13 TE 14
TE 8 TE 4 TE 2 TE 6 TE 10
TE 11
TE 12
TE 15 TE 16 TE 17 TE 18
170 185 180
1070
170 165 200
400
900 annealing length 100 100 100 100 100 30
219,1
50
0
200
400
600
800
1000
1200
0 1 2 3 4 5 6 7 8 9
hours
t
e
m
p
e
r
a
t
u
r
e

i
n

C
TE1-TE10
TE11-TE12
TE18
TE17
TE16
TE15
TE14
TE13
136

Thermocouples TE13 to TE18 describe the temperature distribution in the pipe outside the insulated
area. TE 18 has a distance of 600mm to the heating mats. 132 C was measured as the maximum at this
location.
The pipe was cooled down as rapidly as possible after a holding time of one hour at 1160C (see Figure
124). Two spray-water cooling devices were manufactured for this task.
The insulation cap at the end of the pipe was removed at the beginning of cooling process and also the
first layer of the insulation at the outer pipe surface was removed. The rest of the insulation was re-
moved subsequently during cooling.

Figure 124: Rapid cooling down process after the heat treatment with water

The thermocouples at the outer surface could not be used for evaluation of the cooling process, since
these measurements are directly affected by the cooling water. The best and most conservative infor-
mation about cooling rates can be derived from TE11 and TE12. These thermocouples were fixed at the
inner pipe surface and therefore not affected by cooling water. Figure 125 shows the temperatures of the
two measurements during cooling. The cooling rate of the upper thermocouple, TE11, is higher than the
cooling rate of TE12. The spray-water device was mostly applied from above. This is the reason for the
temperature difference. A temperature of 700C was achieved in approx. 11 minutes for TE11 and in
approx. 15 minutes for TE12. This corresponds with an intermediate cooling rate of 42K/min for TE11
and 31K/min. for TE12. The maximum cooling rate achieved at the inner surface was 53K/min.
137


Figure 125: Measured temperatures during cooling in the heat treatment test

A comparison of an electrode weld with a TIG orbital weld is shown in Figure 126. The gap size of the
TIG orbital welds is only 12mm compared to a gap size of 26mm at the electrode welds. The reduction
of the weld gap size leads to a reduction of internal stresses due to reduced shrinking effects and there-
fore to an improved result.


Figure 126: Comparison between electrode welds and TIG orbital welds

The results of the metallographic investigation of the welds are shown in Figure 127. TIG orbital tech-
nique leads to better results. The welding tests on service exposed material without heat treatment be-
fore welding showed quite large widening of the grain boundaries in the heat affected zone. Heat treat-
ment of the service exposed material before welding had a positive influence on the results. The widen-
ing effects could be reduced significantly with heat treatment at 980 C. There could be no defects with
heat treatment at 1160 C.
400
500
600
700
800
900
1000
1100
1200
0 2 4 6 8 10 12 14 16
mi nutes
t
e
m
p
e
r
a
t
u
r
e

i
n

C
TE11
TE12
26 mm 12 mm
5
0

m
m
Electrode weld TIG Orbital weld
138

Figure 127: Metallographic investigation of the six test welds

The best results could be achieved with the parameters applied for welds 4, 5 and 6. These welds will be
reproduced and tested in a weld test rig at MPA Stuttgart. The welds will be heated up to 700 C and
stressed with internal pressure and external forces.
Furthermore, the repair concept will be verified in the ENCIO project, where repair welds produced
with the CTF material will be tested in a power plant test rig.
2.7.3.3.6 Non-destructive Testing
During the manufacture and erection phase of the CTF, the welded pipe to pipe connections of thick-
walled components (wall thickness up to 50mm) were investigated by a standard procedure:
x after production of the first 1/3 of weld; radiographic test (RT) and dye penetrant test (PT)
x after production of the second 1/3 of weld; dye penetrant test (PT)
x after production of the final 1/3 of weld; dye penetrant test (PT)
The RT and PT investigations were consistent with the standards (PT: EN 571-1+EN 1289 / RT: EN
1435 +EN 12517-1). It is obvious that this standard procedure does not fully exclude the presence of
volumetric defects. Therefore, mechanised ultrasonic testing was introduced in the operation phase of
the CTF.
Fluorescent dye penetrant test and mechanised ultrasonic test methods (MUT) were intensively used
during the operational phase of the CTF. For the latter, qualification and verification were performed.
For the former, acceptance criteria were defined according to EN ISO 23277. In most of the cases
where the dye penetrant test resulted an indication, the surface was ground. Figure 128 gives an exam-
ple of a mechanised ultrasonic test set-up.

400 Pm 400 Pm
400 Pm 400 Pm
Electrode Weld:
Service exposed
+ 980C/3h Pre-Weld-Heat-Treatment
Electrode Weld:
Service exposed
without Pre-Weld-Heat-Treatment
Electrode Weld:
Service exposed
+ 1160C/1h Pre-Weld-Heat-Treatment
400 Pm 400 Pm
Weld 1 Weld 3 Weld 5
TIG Orbital Weld:
Service exposed
+ 980C/3h Pre-Weld-Heat-Treatment
TIG Orbital Weld:
Service exposed
without Pre-Weld-Heat-Treatment
TIG Orbital Weld:
Service exposed
+ 1160C/1h Pre-Weld-Heat-Treatment
400 Pm 400 Pm
400 Pm 400 Pm
400 Pm 400 Pm
Weld 2 Weld 4 Weld 6
139


Figure 128: Test set-up for mechanised ultrasonic investigations

In 2008, 46 components or welds were investigated by mechanised ultrasonic testing. Six welds, which
were in service since the erection phase, were removed and replaced.
The mechanised ultrasonic testing was performed in accordance with EN ISO 22825. VGB guideline
VGB-R 516, following ENIQ methodology, was used for the qualification of the test method. The qual-
ification component was manufactured from Alloy 617B with the reflector positions given in Figure
129.


Figure 129: Cross section of qualification component with reflector positions (notches and drilled holes)

Detailed results from the examination zones and the UT inspection techniques were described in a
presentation at the COMTES700 Workshop IV.
Verification of mechanised ultrasonic testing was performed by destructive metallographic investiga-
tions on two welds after they had been removed from the CTF. Figure 130 compares the result of non-
destructive testing (left in Figure 130) with destructive testing (Figure 130 right). The results from
mechanised ultrasonic testing correspond very well with the destructive investigations carried out by
VGB.
140


Figure 130: Comparison of mechanised ultrasonic testing (left) and micro-section (right)

The numbers in Figure 130 and 131 refer to the failure types and positions listed in Table 35.
Table 35: Positions and failure types with reference to Figure 130 and 131.
Position Failure type
1 Hot crack
2 Slag line
3 Slag lines
4 Slag / lack of fusion
5 Slag







Figure 131: Microsections with higher magnification
141

2.7.3.4 Consumed Lifetime and Design Review
Based on the activities and results within WP6 Operation and WP7 Evaluation; calculations of con-
sumed lifetime and design review were performed for selected components and positions in the super-
heater, main steam piping and spray attemperators.
2.7.3.4.1 Superheater
The highest observed corrosion rate in the superheater was in relation to localised corrosion in Alloy
617B superheater tubing; reported as a corrosion attack of 3.3mm over the full operation period in the
intermediate report.

In order to estimate the consumed lifetime and the predicted lifetime, a simple calculation model was
applied. Assuming a pressure of 210bar, metal temperature of 700C and a constant corrosion rate of
1.5mm for 10,000h the accumulated fraction of consumed creep lifetime was calculated as a function of
operation time. The result is shown in Figure 132. At the end of the operation of the CTF, the consumed
lifetime was in the range of 0.6-2.2%, assuming material properties between average and a lower scatter
band of creep rupture strength. However, the predicted lifetime with this corrosion rate was as low as
42,00046,000h with the same boundary conditions. Considering that a 100,000h design life was veri-
fied after surface machining of the Alloy 617B superheater tubes, these results strongly indicate that the
design life could not be achieved with the observed corrosion.



Figure 132: Consumed lifetime in Alloy 617B superheater tubing

Design of superheaters with additional corrosion allowance up to for example 10mm is not considered
technically feasible and frequent replacement does not seem economically feasible. Further studies of
the corrosion behaviour of appropriate Ni-based superheater tubing are therefore recommended.
142

2.7.3.4.2 Main Steam Piping
The results are summarised from deliverables.
An assessment of consumed lifetime of the main steam piping was performed with calculation methods
from EN 12952-3 and EN 12952-4 using a simplified and conservative approach. The analysis focused
on eight selected components; four branch connections, three bends and one support lug. Components
were selected considering the geometry and service load.
The consumed lifetime assessment included calculation of fatigue lifetime consumption based on the
transient start-up process and creep lifetime consumption based on steady state operation. A typical cold
start was used for the transient analysis, even though only 4% of the 576 recorded starts were consid-
ered cold starts. The installation period of 35,620h at operating temperature and operating pressure was
used for the steady state analysis, even though the operation time was limited to 22,400h. Finite element
analysis was applied for both the thermal analysis and the stress analysis.
The EN 12952-4:2011 standard is generally used in the assessment phase and the lifetime analysis is
based on both fatigue and creep. The results of the analysis are given in Table 36. To evaluate the im-
pact of post-weld treatment and NDT the calculations were performed using two different notch factors,
Ck0 (not welded or ground welds with 100% NDT ) and Ck1 (not ground welds with reduced NDT).
This illustrates the importance of post-weld treatment and NDT for fatigue loaded components as the
fatigue damage is several orders of magnitude higher if this is not applied.

Table 36: Fatigue and creep lifetime consumption based on EN 12952-4:2011. Ck0 is used for not
welded components and for ground welds with 100% NDT, and Ck1 is used for not 100% NDT and/or
not ground welds
No. Component Fatigue damage
Ck0 [%]
Fatigue damage
Ck1 [%]
Creep
damage [%]
1 Bend (R650; D219.1) 0 0 0.9
2 Branch connection 0.16 9.84 6.3
3 Branch connection 0.08 7.50 4.5
4 Branch connection 0.18 10.2 4.4
5 Bend (R200; D33) 0 0.01 1.8
6 Support lug 0.01 4.11 7.6
7 Bend (R400; D133) 0 0.04 2.7
8 Branch connection 0.17 10.1 8.4

The total consumed lifetime is calculated by summation of fatigue damage and creep damage in con-
formance with EN 12952-4:2011. The results of total consumed lifetime are shown in Table 37. Evalu-
ating components with ground welds and 100% NDT, the results show moderate lifetime consumption.
This is the case when considering the planned operation time as well as the actual operation time with
respect to design lifetime. Considering that 100% volumetric testing of welds was not applied during
manufacture and erection, an evaluation of results for reduced NDT shows somewhat higher lifetime
consumption. As regards the planned operation time, the lifetime consumption is moderate. However,
looking at the actual operation time with respect to design life, this indicates that some components may
reach 100% consumed lifetime before reaching the design lifetime. It should be noted that these results
are based on a conservative approach.




143

Table 37: Total consumption of lifetime based on EN 12952-4:2011
No. Component Total consumed lifetime for
not welded components and
grinded welds with 100%
NDT [%]
Total consumed lifetime for
reduced NDT and/or not
grinded welds [%]
1 Bend (R650; D219.1) 0.9 0.9
2 Branch connection 6.5 16.1
3 Branch connection 4.6 12.0
4 Branch connection 4.6 14.6
5 Bend (R200; D33) 1.8 1.8
6 Support lug 7.6 11.7
7 Bend (R400; D133) 2.7 2.7
8 Branch connection 8.5 18.5

A similar analysis of the consumed lifetime was also made using the methodology from EN 12952-3.
Since EN 12952-3 is generally used for design of components it includes additional safety margins, and
as expected it resulted in higher fractions of consumed lifetime.
2.7.3.4.3 Spray Attemperators
With reference to WP6 Operation the majority of damages occurred at the spray attemperators. For this
reason a design review focusing on failure assessment of these components was carried out. The results
are summarised from deliverables.
Indications were observed during visual inspections of spray attemperators 2 and 3 of the CTF piping
system. Indications consisted of cracks and inelastic deformations of the piping which occurred during
operation between 2005 and 2009. In order to assess computationally the accumulation of the compo-
nent damage, thermomechanical finite element analyses of the piping system and the spray attempera-
tors under operational loads were performed (see Figure 133). The required tensile data on service ex-
posed material were derived from deliverables.


Figure 133: CAE geometry of spray attemperator

The thermomechanical analyses of the transient behaviour and steady state behaviour showed relatively
high values of the radial and axial expansion of the protective pipe compared to the main pipe in both
load cases. Due to the occurrence of the high temperature gradients it can be assumed that the protective
pipe is suffering from extensive plastic deformation caused by blocking of the axial and radial support
stubs of the main pipe.
144

Based on the non-homogenous temperature distribution at steady state conditions with insufficient
drainage, high thermal loading at the bottom of the main pipe led to moderate plastic deformation. The
equivalent stresses slightly exceed the yield strength. Therefore it can be concluded that a repeatable
interaction of condensed water at the inner surfaces of the incomplete drained main pipe results in an
intensive material fatigue damage.
Due to the relatively low values of the nominal equivalent (von Mises) stress (<60 MPa) in the global
piping system under steady state operational conditions, widespread creep damage across the pipe cross
section was not expected.
To simulate the far-field global time-dependent forces and moments at the boundaries of the spray at-
temperator, the global beam model from the piping system analysis was now combined with the three-
dimensional solid structure of the spray attemperator. The aim of the lifetime analysis was to demon-
strate quantitatively the impact of insufficient drainage on the lifetime consumption. Therefore the life-
time approximation compares the fatigue damage due to normal transient start-up conditions and the
fatigue damage resulting from insufficient drainage. The computed lifetime of spray attemperator 3
under long-term thermal design conditions was definitely reduced based on a two-phase fluid flow at all
verified positions compared to normal/regular transient operation. Here insufficient drainage reduced
the fatigue lifetime mainly at the bottom of the pipe.
In addition an extended lifetime analysis based on EN 12952 under realistic load conditions of the spray
attemperator structure was carried out. The measured values of the outer surface temperatures of spray
attemperator 2 installed in May 2009 were incorporated into the FEM model as the thermal boundary
conditions. Weld manufacturing issues, such as grinding of welds and the extent of NDT, influenced
distinctly on the fatigue strength of the analysed locations. Lifetime analysis according to EN 12952-3
showed that for a load cycle with a two-phase fluid flow, the analysed circumferential welds at posi-
tions 2 and 3 consumed theoretically more than 100% of fatigue life. Positions 2 and 3 are shown in
Figure 134. Lifetime assessment results according to EN 12952-4 of spray attemperator 2 showed also
that the transient load intensified by the two-phase fluid flow as well as the steady state load accelerated
the accumulation of the material damage. The maximum calculated total material damage reached 84%
at the circumferential weld at position 3.

Figure 134: Analysed part positions of spray attemperator 2

The cracks and plastic deformation found at the spray attemperators of the CTF main steam pipe system
were quantitatively verified to be caused by the two-phase fluid flow. It is believed that the two-phase
fluid flow is caused by leaking valves and insufficient draining systems. Temperature measurements at
6 oclock and 12 oclock positions at critical positions could have indicated this situation.
145

2.7.3.5 Other activities
2.7.3.5.1 Self-calibrating Thermocouples
While the increase in steam temperature allowed better utilisation of fuel, exceeding the maximum tem-
perature significantly decreased power plant lifetime with regard to material properties. Therefore self-
calibrating thermocouples based on miniature fixed-point cells, see Figure 135 were developed allowing
more precise measurements and thus enabling a mode of operation closer to the temperature limit. In
the temperature range from 535 to 545C the usual 5K safety interval to design temperature could be
reduced to 1K. Since 2005, industrial measuring devices based on this technique have been used in
power plants.

Figure 135: Fixed-point thermocouple principle

From August 2006 to December 2009 an accompanying project was carried out aiming to develop
fixed-point cells for self-calibrating thermocouples applicable at 700C to be tested in the CTF.
For the alloys chosen for these fixed-point thermocouples (bismuth-platinum (BiPt) and germanium-
palladium (GePd)) suitable container materials had to be found at short notice.
Samples of BiPt fixed-point thermocouples were manufactured with conventional Al
2
O
3
-ceramic cells.
In the first field test, started in November 2007, a thermal compound used so far for insulating and fix-
ing of the heating conductor material in the sensors turned out not to be applicable above 620C. An
alternative solution achieved sufficient stability also at a burn-in temperature of 750C. The melting
point temperature determined for BiPt amounted to 715.7C. After a short period of operation, however,
BiPt showed a strong tendency towards supercooling. Solidification after melting sometimes started
below 690C. At the same time, the melting plateau was reduced such that it could only be observed
under calorimetrical conditions in the laboratory. The BiPt alloy proved not to be applicable on a short-
term basis.
For GePd fixed-point cells, novel thin-walled Si3N4-ceramic containers were developed. The first sam-
ples, which still suffered from some geometrical defects, were available in August 2008. Therefore, the
field test could start until December 2008 allowing only approx. 1,000 hours of operation. However, the
materials used, just as the fixed-point temperature of 735.0C, showed promising stability. Continuation
of the test run for a minimum of 5,000h appeared necessary but was not possible.
146

2.7.3.5.2 Compact Insulation for Steam Pipes
From December 2007 to August 2008, an innovative insulation material was tested in the CTF aiming
at a reduction of insulation thickness and weight and a decrease of the insulation surface temperature.
Compared to conventional materials, the test insulation reduced the thickness from 295 to 200mm and
the weight reduction from 60 to 36kg/m. The surface temperature could be decreased from 70 to 50C.
For the field test approx. 3m of the insulation of an Alloy 617B live steam pipe (outer diameter
219.1mm, wall thickness 50mm) installed at level 73.8m was replaced by the new material. The maxi-
mum live steam temperature was at 705C with an ambient temperature of approx. 40C.
Due to maintenance the test insulation had to be removed in August 2008. The insulation cracked and
could not be used again. As a result, the stability of the material was increased with glass fabric on the
half-shell surface. The improved material was not tested.
2.7.3.5.3 Nanoceramic Coatings
From October 2008 to August 2009, an Alloy 617B superheater tube of the CTF protected against slag-
ging with a nanoceramic coating material was tested.
The tube located at the bottom of the superheater outlet was sand-blasted with silica sand for a length of
3m up to a surface quality of SA 2.5. The coating was stirred up according to the manufacturers speci-
fication before application. It was applied with a coating gun with a layer thickness of 180m (in dry
condition approx. 85m). The test tube was subjected to 3,200 hours of operation, 86 hot starts, 21
warm starts, 8 cold starts and a maximum steam temperature of approx. 685C.
Investigation of a sample taken after operation demonstrated total disappearance of the initial coating.
The test was not successful.
2.7.4 Conclusion
2.7.4.1 General
2.7.4.1.1 Evaporator
During operation, no cracks or leakages were observed on any of the membrane wall materials.T24 has
shown good corrosion and oxidation properties at temperatures up to 546 C (average metal tempera-
ture). Due to the scatter of data at higher temperatures, it is not possible to reach a conclusion as regards
the corrosion behaviour of T24. In the high temperature range (550-590 C), the steam side oxide thick-
ness of HCM12 was not higher than expected for a martensitic steel at these temperatures. Alloy 617B
showed superior corrosion and oxidation behaviour compared to HCM12, as expected for a Ni-based
alloy.
Fireside corrosion was observed on similar welds of T24, HCM12 and Alloy 617B in the evaporator.
Liquation cracks were observed in Alloy 617B tube-to-fin welds. Decarburisation near the fusion line
was observed for HCM12 on both tube and fin welds, as expected with a Ni-based filler metal. A resid-
ual gap between Alloy 617B and HCM12 fin and tube was observed.
Hardness measurements across dissimilar welded evaporator tubes showed a decrease in hardness from
HAZ to weld metal. Decarburisation took place on HCM12 to Alloy 617B and T24 to HCM12 dissimi-
lar welds as expected for dissimilar welds.
147

Areas with pit corrosion were found on all investigated samples and with thickness reductions larger
than 0.3mm for HCM12 and Alloy 617B.
The highest steam oxidation thickness was found on the HCM12 samples as expected considering the
service temperature. Significant increase of hardness during service was observed for Alloy 617B.
Significant higher hardness was observed in the weld metal and HAZ compared to the base material for
some T24 welds.
2.7.4.1.2 Superheater
HR3C, DMV310N, and Sanicro 25 developed duplex oxides during steam oxidation. They consisted of
an outer layer of Fe-oxide on top of Fe-Ni oxide, and an inner oxide layer containing all elements. The
thinnest oxide layer formed on Sanicro 25.On the Ni-based tube inner side, a zone with internal oxida-
tion of Al, Cr, and Ti was observed below a thin external Cr-oxide layer for Alloy 617B and Alloy 740.
The thickness of the internal oxidation zone was comparable for the two alloys in the range of 30 to
40m.
Corrosion layers covered with deposit were formed on all samples. More deposits were observed on the
fluegas side than on the rear side of the removed tubes. The deposits consisted of Ca/Na/Ka-Al silicates,
Fe oxides and small amounts of Ca sulphates. A duplex layered structure was observed for HR3C,
DMV310, and Sanicro 25. The inner part of the corrosion layer contained Cr, S, and O for all samples.
Layers of Ni-S were observed within the inner layer of Sanicro 25 and the Ni-based alloys. Internal
corrosion was observed ahead of the corrosion layer.
The thickness reductions for HR3C, DMV310N, and Alloy 740 were comparable to the deviation from
the nominal thickness for the non-exposed samples. Large local thickness reductions were observed for
some of the Sanicro 25 (up to 1.7mm compared to the nominal thickness) and the Alloy 617B (up to
3.3mm compared to the nominal thickness) samples.
Precipitates were formed along the grain boundaries of all samples during exposure resulting in in-
creased hardness. Furthermore, precipitates were observed in grains near the corrosion layer for HR3C
and DMV310N, whereas small gamma prime particles developed within the bulk grain throughout the
sample for Alloy 617B and Alloy 740. In addition, needle shaped precipitates developed in Alloy 740.
As expected, for most materials the precipitates were coarser and more numerous the higher the expo-
sure temperature.
Creep testing of Sanicro 25 and Alloy 617B showed gradual evolution of the creep rate with stress,
whereas a sudden drop in creep strength was observed for Alloy 740 which was considered an effect of
microstructural instabilities.
Hardness peaks of more than 400HV10 were measured inside the HAZ of similar tube welds of Alloy
740. Local corrosion attacks of the weld metal in Alloy 740, DMV310N and Sanicro 25 were observed.
For DMV310N and HR3C increased corrosion was observed close to the weld metal. A small weld
imperfection was observed for Sanicro 25 and a small crack within the root pass was observed for
DMV310N, both related to the manufacturing process.
A hardness increase was measured on the steam side of HR3C to Alloy 617B and Sanicro 25 to Alloy
617B dissimilar superheater tube welds. This increase was not observed at the fireside. Hardness values
above 430HV10 were measured for HR3C to Alloy 617B tube welds, and in the HAZ of Alloy 740
welds hardness values above 450HV10 were measured.
148

Corrosion attacks of up to 150m were observed for DMV310N to Alloy 617B and up to100m for
Sanicro 25 to Alloy 617B welds. Weld metal attacks were also observed for HR3C to Alloy 617B and
Alloy 617B to Alloy 740 welds.
A repair concept, mainly based on a three hour annealing heat treatment process on service exposed
Alloy 617B before welding was applied successfully.
Average grain size and hardness have been measured and reported, also including microhardness from
longitudinal sections and investigation of microstructures. The results confirm the conclusions of the
intermediate report.
Based on the measured local corrosion rates of Alloy 617B up to 3.3mm for 22,400h, it is very likely
that the operation time of the superheater will be less than the 200,000h design life. The local corrosion
attacks may partly be contributed to an increasing S content in the fuel during the operation period.
The best corrosion behaviour is observed for Alloy 740.
2.7.4.1.3 Thick-walled Components
For the thick-walled Ni-based alloy components investigated, a bimodal grain size distribution was
observed. Reticular M
23
C
6
precipitates were observed in all service exposed Alloy 617B. Grain bounda-
ries contained more Cr and Fe and less Ni and Mo than the matrix.
Service exposed samples were harder, stronger, more brittle, and less ductile than the virgin samples.
Similar mechanical properties were observed for extrados and intrados of bends. Increased hardness at
the inner surface compared to the bulk was measured.
A thin layer of Cr
2
O
3
developed on the steam side resulting in depletion of Cr and dissolution of reticu-
lar precipitates. Shallow oxidation pits and deep grain boundary attack were observed on a few samples.
Similar properties were observed for the spray attemperators as for header and piping.
The hardness across welds has been measured and reported, as well as EDS line scans across transition
lines. LOM investigations of welds close to the transition line revealed only minor weld imperfections.
2.7.4.1.4 Repair Concept for Thick-walled Components
Three potential concepts for repair welding of thick-walled Alloy 617B were developed and tested with
welding tests. The three most promising concepts are mechanised TIG with prWHT at 980C, mecha-
nised TIG with prWHT 1160C and electrode welding with prWHT at 1160C. All three cases included
PWHT. The potential has been documented by microstructural investigations which have shown prom-
ising results.
All three concepts will be further tested in a laboratory component test and also in the continuing test
project, ENCIO.
On-site heat treatment at temperatures up to 1160C using heat mats was demonstrated successfully.
Heat treatment at 1160C is likely to become the preferred solution for weld repairs.
149

2.7.4.1.5 Non-destructive Testing
Mechanised ultrasonic test methods were successfully applied, qualified and verified for thick-walled
Alloy 617B components of the CTF. Therefore, these test methods can be recommended for further
application of Ni-based materials for thick-walled components in power plant applications.
2.7.4.1.6 Consumed Lifetime and Design Review
Calculations of consumed lifetime and design review were performed for a selected position in the Al-
loy 617B part of the superheater, for selected components in the main steam piping system and for
spray attemperators 2 and 3.
Based on the highest observed corrosion rate in the superheater, the calculation showed that even
though only 0.6-2.2% of the lifetime was consumed at the end of operation, a total lifetime as low as
42,000-46,000h was predicted. Improved corrosion resistance in some temperature ranges is considered
necessary to have a feasible concept for the superheater.
Lifetime calculations of selected main steam pipe system components showed strong dependence of
notch factors which are affected by the post-weld treatment and the extent of NDT. Moderate total life-
time consumption was calculated assuming ground welds and 100% NDT in the range of 0.9-8.5%.
Assuming notch factors corresponding to non-ground welds or reduced NDT somewhat higher lifetime
consumption was calculated, in the range of 0.9-18.5%. Even though the consumed lifetime in this case
is moderate considering the planned operation time, it also indicates that the consumed lifetime could
have reached 100% in the design lifetime.
The indications found at spray attemperators of the CTF main steam pipe system were quantitatively
verified to be caused by a two-phase fluid flow. Consumed lifetime up to 84% was calculated in a spe-
cific circumferential weld of spray attemperator 2. It is believed that the two-phase fluid flow is caused
by leaking valves and insufficient draining systems. Temperature measurements at the 6 oclock and 12
oclock positions at critical positions would have indicated this situation.
2.7.4.1.7 Other Activities
In addition to the planned scope, three other technologies were tested, namely self-calibrating thermo-
couples, compact insulation material and nanoceramic coatings. Of these, the self-calibrating thermo-
couples showed promising potential.
2.7.4.2 Actual Applications
No commercial power plants use the 700C steam cycle tested in this project. However, several of the
materials are used in 600/610C conventional USC power plants in operation or under construction.
Test results from the COMTES700 project are scheduled to be applied in the ENCIO test facility and
HWT II.
A general interest in 700C coal-fired power plants is emerging in Asia.
150

2.7.4.3 Technical Potential for the Use of the Results
2.7.4.3.1 Evaporator
The present results have proven that it is possible to design, manufacture and operate a membrane wall
in a 700 C component test facility. This is based on the facts that there were no damage, no excessive
steam oxidation or corrosion, and no considerable microstructural changes were noted. The design and
evaluation of the material performance covered bends, similar, dissimilar and tube-to-fin welds which is
relevant for a full-scale demonstration power plant. The evaluation included T24 rifled tubes which
showed oxidation behaviour comparable to normal seamless tubes.
Due to the membrane wall design in the CTF, the operation loads may have deviated from that of a full-
scale plant. The design life was 200,000h compared to the actual operation time of 22,400h. The possi-
ble effect of these details is not included in the positive evaluation of the evaporator material perfor-
mance.
HCM12 performed as expected in the present evaluation. However the allowable stress of this material
has been reduced in various codes and standards. No substitute candidate material has been tested in the
CTF.
2.7.4.3.2 Superheater
The present results have proven that it is possible to design, manufacture and operate a superheater in a
700 C component test facility. This evaluation is based on substantial investigations of oxidation, cor-
rosion behaviour, similar and dissimilar welds. A superheater leakage was observed, identified as stress
relaxation cracking induced by a combination of manufacturing and operation issues. Sanicro 25
showed the best oxidation behaviour of the high alloy austenitic steels. Alloy 617B and Alloy 740
showed comparable internal oxidation. However, both Sanicro 25 and Alloy617B in some cases suf-
fered from local corrosion attacks, which very likely will lead to lifetimes less than the 200,000h design
life of these materials. Therefore, further clarification of this issue is recommended before using the
results for other applications.
The design of the superheater is comparable to a typical superheater design for a full-scale demonstra-
tion plant.
Due to the observed failure, a repair procedure was developed for the repair of the superheater tubes,
including a pre-welding heat treatment step. This procedure was successfully applied.
2.7.4.3.3 Thick-walled Components
The present results have shown that it is possible to design, manufacture and operate a piping system
for use in a 700C test facility. Since no PWHT was required by the codes; no post-weld heat treatment
was originally used. Due to limited space, a horizontal spray attemperator design was chosen, with the
risk of a two-phase flow. In addition, sufficient drainage was not applied. It is believed that this con-
tributed to the failure of several welds. Currently a repair weld concept for thick-walled Alloy 617B is
in progress.
Only one candidate material for thick-walled components was tested in the CTF.
151

2.7.4.3.4 Repair concept
A proven and well tested repair concept for repair weld of thick-walled Alloy 617B is crucial for the
realisation of a full scale 700C power plant. Three promising repair concepts have been developed.
The three concepts will be tested in laboratory component tests and in-service tests before the technical
potential is finally verified.
On-site heat treatment at temperatures up to 1160C, using heat mats, was demonstrated successfully.
The demonstration of heat treatment also included development of specialised equipment for cooling
and documentation of the heat treatment cycle by monitoring the temperatures with numerous thermo-
couples. Heat treatment at 1160C is likely to become the preferred solution for weld repairs.
2.7.4.3.5 Non-destructive Testing
Mechanised ultrasonic test methods were successfully applied, qualified and verified for thick-walled
Alloy 617B components of the CTF. Mechanised ultrasonic testing can be applied for NDT of welds
and for monitoring of crack growth. These test methods can be recommended for further use of Ni-
based materials for thick-walled components in power plant applications.
152

2.8 WORK PACKAGE 8: COORDINATION
2.8.1 Work Package Objectives
x Organise the management of the project effectively to secure project objectives, budget and time
schedule.
x Coordinate the project according to the provisions in the contract with RFCS.
x Establish the contracts between the utilities and the manufacturers, manage the financing and
make sure that IPRs are protected.
2.8.2 Comparison of Initially Planned Activities and Work Accomplished
The COMTES700 project experienced only one deviation that had an impact on the project, extending
it for an additional two years in comparison with the original time schedule. This extension should en-
sure an operational period of more than 20,000h and sufficient time for evaluation. This demand for an
extension was the result of several CTF outages. After procuring permission for extended operation of
the CTF it had to be stopped due to unpredictable costs of sudden indications at Alloy 617B repair
welds. Instead of more operation time the focus was on expanded investigation for better material un-
derstanding and a reliable repair procedure. Other additional investigative projects will run longer than
the COMTES700 project completion (31 December 2011). In addition, it is planned to supervise these
activities with a new 700C group.
2.8.3 Description of Activities and Discussion
2.8.3.1 Coordination
The coordinators task consisted of project management, arrangements with six contractors and eight-
een co-financing partners (suppliers and utilities) from eight European countries. Several groups were
established to support the coordinator in his management tasks.
x The COMTES700 Steering Committee (CSC) had the function of supervising the projects exe-
cution, Collaboration Agreement, contract and troubleshooting referred to by the coordinator. 16
meetings were held.
x The Project Management Groups (PMG) function included performance management of and be-
tween the parties, ensuring project work results in one integrated R&D project. 12 meetings were
held.
x The Temporary Support Group Financial (TSGF) had the function of analysing the financial doc-
umentation of each contractor and to give payment recommendations to the CSC accordingly. 11
meetings were held.
x The Editorial Group (EG) produced the final report. 4 meetings were held.
WPs 6 Operation and 7 Evaluation were supported by the participation of the coordinator in each meet-
ing.


153

Major Coordination Tasks
The coordinator had eight major tasks.
Erection of the CTF
The erection of the CTF was seriously affected delays in the delivery of various components. A task
force was established to prepare options and to give a recommendation. Three options were discussed:
1) project termination, 2) installation postponement to the following year and 3) concentration of all
resources to meet the planned start of the CTF within the time schedule. On 20 May 2005 a decision
was reached for option 3. All contractors met with massive man power close to the CTF erection time
schedule. The start of the host power plant and the CTF was delayed by only two weeks.
1. Extension Beyond 2009
According to the initial application, the CTF was scheduled to achieve 20,000h of operation. In order to
enhance operating experience, the COMTES700parties applied for a project extension of two years,
which was granted by the RFCS.
Simultaneously, problems with the conventional part of the facility occurred and Alloy 617B repair
welds again showed flaw indications. Both factors forced the host plant to shut down the production
unit, which was not separable from the CTF. As time and costs for repairs were unpredictable, the host
plant decided to dismantle the CTF (see WP 6).
Consequently, the project plan had to be rescheduled in total. All project resources were focussed on the
evaluation part and a comprehensive programme of additional laboratory investigation was established
to exploit the valuable operational experience.
2. Additional Investigations
After the decision to dismantle the CTF, several partners proposed to extend the evaluation plan with
additional investigations even though the evaluation programme was extensive and in many areas far
beyond the scope of the contract. Eight additional investigation projects were identified, two of which
were funded by additional contribution from each partner. Some projects will continue after the end of
the COMTES700 project in 2011. It is planned to supervise these projects through a new 700C
group.
3. Know-how Access Agreements and Full Additional Partnership of ENEL
In 2006, three utilities wanted to get access to COMTES700 know-how and did not intend to become
project partners. Agreements covering access to this know-how were drawn-up and signed. Receipts
were used to balance extra project costs.
In 2007, ENEL was interested in participating in the COMTES700 project as full partner. ENEL made
significant contributions to the project thereby balancing the extra project costs.
4. Use of COMTES700material in other Projects
Several requests to use COMTES700material in other projects were managed. Various consortium in-
ternal projects were supported with material free of charge, or material has been provided to third par-
ties. Generally, the COMTES700parties appreciated and supported other projects in favour of the ad-
vancement of 700C-technologies. Material was provided upon return of the investigation results. The
latest examples are:
x Pre-welding trials and related investigations of Alloy 617B with regard to ENCIO's Test Loop 1
x Pre-investigations and manufacturing of a hipped pipe to be tested in the ENCIO test facility
154

x Damage behaviour of critical pipe line components made of creep-resistant Ni-based super alloy
(Alloy 617B) under practical conditions, testing of components and simulation
x Alloy 617B membrane wall test
x Alloy 617B superheater outlet header as reserve material for ENCIO
x Impact of ageing on the charpy impact resistance of Alloy 617B on virgin and service exposed
material
x Investigation on two Alloy 617B gate valves
x Local repair and heat treatments on T24, HCM12 and Alloy 617B membrane walls
x Investigation on service exposed Sanicro 25 superheater samples
x Providing COMTES700 material (superheater tubes and pipes) to the MACPLUS project
These activities are planned to be supervised by a new 700C group.
5. Workshops
The project partners were informed regularly through workshops about the technical status and the re-
sults of the project. The coordinator organised five workshops strengthening the 700C network:
I. Workshop (J anuary 2005) focused on the technical concept of COMTES700.
II. Workshop (October 2005) focused on the erection.
III. Workshop (November 2007) focused on operation experience.
IV. Workshop (April 2011) focused on investigation results from evaporator and superheater.
V. Workshop (April 2012) will focus on investigation results from thick-walled components and ad-
ditional investigations as well as final conclusions.
6. Financial Management
The total budget increased from EUR 15.3 mio. to more than EUR 26 mio. The Component Test Facili-
ty caused outages of Scholven F lasting several weeks. These costs were covered by RWE and E.ON.
The budget increase was balanced by the project partners. Complex payments between the parties had
to be arranged and controlled. Tax questions with regard to the RFCS funding had to be settled.
7. Project Documentation
A public website and a web based document filing system accessible only for the project partners were
established and maintained for the COMTES700 project.
2.8.3.2 Reporting
Supported by the contractors the coordinator managed the 6-monthly reports, the midterm technical-
and financial report, the final technical and financial report incl. the external audits.
155

2.8.4 Conclusions
2.8.4.1 General
The main conclusion is that the COMTES700 project fulfilled its goals. By joining forces, the installa-
tion of the CTF could be ensured with a delay of only two weeks. The project was extended for two
years securing the necessary information for the next step a 700C demonstration power plant. The
unexpected termination of the CTF operation was compensated for by an increase in the investigation
efforts. Additional funds were covered by new partners, know-how access agreements and additional
funding of all partners. This activity was linked with a complex agreement structure. Requests from
other 700C projects for COMTES700 material for investigations were generally approved upon return
of results. The COMTES700 results were communicated not only in WP7 Evaluation but also to all
partners in workshops. Additional costs, such as outages and repairs, were paid by two major utilities
and all project partners. The public was informed about the project by a project website and more than
40 publications.
2.8.4.2 Actual Applications
The COMTES700 project was the continuation of the idea to develop a 700C power plant that started
in 1998 with the AD700 phase 1 and 2 projects. The AD700 programme bundled together more than 40
participants from 10 European power generators, power plant equipment manufacturers and material
suppliers. COMTES700 attracted additional European power generators and continued the European
700C network. The research activities lead to European and national research projects; one of them
being ENCIO successor of COMTES700 (started J uly 2011 and runs for a 6-year period). The net-
work has inspired China, India and J apan to plan their own 700C technology research programmes.
2.8.4.3 Technical Potential for the Use of the Results
The coordination principles of COMTES700 are adapted to the successor project ENCIO.
156

2.9 EXPLOITATION AND IMPACT OF THE RESEARCH RE-
SULTS
2.9.1 Actual applications and technical and economic potential for the use of
the results
Sustainable technologies for coal-fired power plants have to be developed to optimise environmental
protection and to preserve valuable resources. The power plant live steam temperature should be
brought up to 700C (Advanced USC) compared to 600C (USC) - the best commercial plants currently
available. Therefore, the application of Ni-based super alloys is necessary. Compared to todays Euro-
pean coal fired power plants, this will increase the average efficiency of around 36% up to 50%. Thus,
almost a third of CO
2
emissions are avoided and fuel is saved in the same amount.
COMTES700 was a demonstration project aiming at 700C live steam temperatures that generally uti-
lised available design codes and design practice, and selected materials identified within the preceding
THERMIE/AD700 Advanced 700C PF Power Plant project. Development of new materials was not
in the scope of COMTES700.
2.9.1.1 Learning Points from the Project
The COMTES700 test facility was designed and manufactured according to the European harmonised
standards. Design practice for the design of the test facility was generally corresponding to the practice
used for USC power plants; with the necessary adaptations to integrate the test facility to the host unit.
The integration required relative high attemperator cooling capacity, necessity of horizontal spray at-
temperators, which in combination with an insufficient draining system caused some operational chal-
lenges.
Materials for membrane walls: Even though all membrane wall materials tested in COMTES700 (T24,
HCM12, Alloy 617B) generally performed well, some reservations regarding all three materials were
stated.
T24 has become one of the most widely used materials for membrane walls in USC boilers which are
under fabrication or commissioning in Europe the recent years. Damages have occurred in these boilers.
Investigation of causes and measures are ongoing.
Evaluations of creep rupture strength for HCM12 issued after the COMTES700 engineering and manu-
facturing, have resulted in a reduction of the allowable design stress in several national standards. The
reductions are mainly caused by a microstructural instability during high temperature service. The al-
ternatives are to strictly limit the maximum metal temperature for this material or to replace it with a
different steel based material grade. Reduction of maximum metal temperature will lead to an increased
proportion of nickel alloys in the boiler design, and thereby increase investment costs. Introduction of a
different steel based grade would likely include the use of T91, T92 or other 9-12Cr steels, with the
challenges of mandatory post weld heat treatment of all welds on that part of the membrane wall.
Equipment and procedures for post weld heat treatment of site welds during the erection of martensitic
membrane walls are considered to be the largest challenge. There are currently no known manufactur-
ing and operation experience with 9-12Cr membrane walls (other than HCM12), and reduction of risks
may require further testing and demonstration.

157

Results from another project with simulated service loads have shown that tube-fin-welds in membrane
walls of Alloy 617B can fail [1]. Based on these results it has been questioned whether the membrane
wall test in COMTES700 have fully demonstrated the ability to operate an Alloy 617B membrane wall
for a 700C boiler. Further investigations and testing of Alloy 617B membrane wall samples has been
initiated. These investigations may result in improvements of material selection, fabrication procedures
and membrane wall design.
Materials for superheaters: Results have shown that the tested superheater materials (HR3C,
DMV310N, Sanicro 25, Alloy 617B, Alloy 740, Alloy C-263) generally performed well with limited
oxidation and corrosion, but Sanicro 25 and Alloy 617B did suffer from high corrosion rates in some
positions. The high corrosion rates are believed to be related to the fuel composition and the specific
temperature range, and all tested superheater materials are considered susceptible to the corrosion
mechanism, even though not observed on all materials and samples. Results from another project [2]
did not show corrosion rates in the same range. Further studies of corrosion rates at various tempera-
tures and fuel compositions are recommended to optimise superheater materials selection. Alternatives
include restrictions in fuel compositions or partial replacements of superheater sections within the unit
design lifetime.
Concern was raised regarding the microstructural stability of the tested version of Alloy 740. Structural
stability improvement of Alloy 740 is claimed to include increased Al/Ti ratio and reduced Si content,
which may have an effect on the corrosion properties. Testing of the modified material would be rec-
ommended.
Alloy C-263 was introduced late in the project as an additional candidate material for superheaters. The
operational time with this material was however too short to conclude on the feasibility. Further testing
would be recommended.
Header and piping components: The steepest learning curve in this project was realized with the opera-
tional and repair experiences with the thick walled components in Alloy 617B. It was recognised that
post weld heat treatment shall be applied to reduce the susceptibility to stress relaxation cracking, non-
destructive examination is crucial for the inspection of fabrication quality and for integrity assessment
of service exposed components as well as the necessity of a workable and verified weld repair concept
due to the ageing effects with Alloy 617B.
Mechanised ultrasonic testing was successfully qualified and verified in COMTES700 for the relevant
component thicknesses, but realization of an advanced USC power plant will require larger component
thicknesses and further qualification and verification would thus be required. Design guidelines for
nickel based components should include appropriate acceptance levels.
Extensive work on weld repair concepts is ongoing, and the outcome of the concept development and
verification are very important for the overall feasibility of thick walled components in Alloy 617B.
Finally it could be considered to introduce Alloy C-263 as material for header and piping, as it would
contribute with higher design stress. Introduction of C-263 would require extensive investigations, in-
cluding materials qualification, studies of stress relaxation cracking susceptibility, verification of repair
concepts and demonstration in general. Major activities have already been initiated within the ENCIO
project [3].

1 Material Qualification for the 700/720C Power Plant (MARCKO 700), VGB Research project 281,
http://www.vgb.org/en/research_project281.html
2 Esbjerg Test Rig, VGB Research project 260, http://www.vgb.org/en/research_project260.html
3 European Network of Component Integration and Optimisation (ENCIO), VGB Research project 355,
http://www.vgb.org/en/research_project355.html
158

Valves: Generally valves operated without major problems. Thick-walled valves, e.g. HP-bypass
valves, showed crack formation starting on the inside of the valve bodies. Since the cracks were unde-
tectable by NDT in the in-service state it is questionable if the tested valves could be operated safely for
long periods. Therefore, in order to reduce the risk of both fatigue and creep cracking, it is vital to test
available improved designs where local stress concentrations due to thickness changes are reduced, and
reduce temperature differences across the wall thickness during load changes (including start and stop
sequences). Furthermore, the design solutions should allow an adequate level of NDT capability. This
will be done in ENCIO and HWT II.
Turbine components: A cast Alloy 625 turbine control valve was included in the steam cycle of
COMTES700, as an activity in a separate project (COMTES700 Turbine Valve [4]). Additional demon-
stration of cast thick-walled Alloy 625 including welds is necessary and covered by the ENCIO-project.
Key components of an advanced USC power plant have been successfully designed, manufactured,
erected and operated for about 22.400 hours in order to demonstrate if the necessary technical solution
to realise a 700C demonstration power plant are available. The project did not succeed in demonstrat-
ing that all necessary materials and designs can currently be operated without economical risks. Much
new knowledge has been gained but critical issues still need to be solved to reduce risks for the imple-
mentation of a large scale demonstration plant.
COMTES700 impacted a number of follow-up projects on research and on demonstration level. Several
projects directly related to COMTES700-results or materials are ongoing, monitored by a follow-up
group. Accompanying research have been started on national level, e.g. within the framework of the
German COORETEC-initiative. Most important projects for the further development of 700C technol-
ogies are the European demonstration project ENCIO and the German demonstration project HWT II.
All these projects will be completed by 2018 allowing a final conclusion on the risks of a 700C power
plant.
The following brief summary indicates which issues should be avoided or to proceed with:
x Explore and test alternative candidate materials for membrane wall materials
x Improve corrosion properties for superheater materials
x Apply PWHT for thick walled A617B components
x Verify weld repair concepts for thick walled A617B components
x Further development of NDT methods and acceptance levels
x Minimise thermal stresses in component and process design
x Improved valve design
x Reduce manufacturing costs
2.9.1.2 Potential for use of the results
An engineering study carried out in parallel to COMTES700 determined the specific investment costs
of a commercial power plant with a gross capacity of 1,100 MW, which is based on COMTES700s
technology, at 2,000 /kW [5]. These costs are definitely above of the costs of state of the art coal-fired
power plants and have to be significantly reduced before achieving commercial viability. Cost reduc-
tions are to be expected from optimisations of the design concept, but main drivers would be increased
creep strength of alternative materials and optimisation of manufacturing methods.

4 COMTES700-Turbine Valve, VGB Research project 268, http://www.vgb.org/en/research_project268.html
5 Pre-engineering study NRW Power Plant 700C (NRWPP700), Final report, Translation February 2011,
p. 108, http://www.vgb.org/en/research_project297.html
159

Successful development of a new generation of martensitic steels with higher creep strength properties
than P92 would allow to raise the working environment of 9-12% chromium steels, thus enabling to
reduce the use of expensive Ni-based alloys in advanced USC power plants. Appropriate European
research projects are underway [6].
Since it was the first time that power plant components from Ni-based raw materials were to be manu-
factured, manufacturing in COMTES700 was basically carried out according to the state of the art. This
proved to be very time-consuming and prohibitive. Manufacturing methods for components made from
Ni-based materials were standing at the beginning of the learning curve in 2004 which implies a huge
potential for clear reductions of investment costs. Demonstration projects like HWT II and ENCIO now
include promising new approaches of manufacturing and will provide practical experience with these
(forging, HIP metallurgy, welding procedures, heat treatment, ).
The economic potential of advanced USC power plants is to be read against the background of an in-
creasing global demand for coal. Reduction of CO
2
-emissions from the use of coal as well as savings in
coal is of high importance for emerging economies owning huge own coal resources like India and Chi-
na. In consequence of the Fukushima accident, not only J apan is looking for a sustainable use of coal in
Asia. No wonder that these countries are interested in 700C power plant technology and are aiming at
starting research projects comparable to COMTES700. Europe is currently in the position of a techno-
logical leadership.
Also in Europe, 700C power plant technology offers potential for CO
2
-avoidance by modernizing the
coal-fired power plant fleet. In 2011, a study came to the conclusion that increasing renewables installa-
tion wont be sufficient to realize the 2020 CO
2
-reduction targets of the European Union. Replacement
of less efficient by advanced thermal power plants with highest efficiencies has to contribute to the
reduction targets [7], which will be the case even beyond 2020.
If the European Union sticks to the aim to realise carbon capture & storage, 700C power plant technol-
ogy remains an indispensable prerequisite for a sustainable implementation of this technique. Efficiency
losses of 7-12% in consequence of carbon capture & storage require highest efficient power plants to
minimize inevitable energy losses.
In some European countries where national incentive schemes - in addition to the European Union
Emission Trading System - have spurred rapid growth of renewables installed capacity, balancing of
fluctuating energy supply from variable sources like wind and solar is a very big challenge. If other
options like grid optimisation, storage facilities or energy demand management are limited, thermal
power plants will face the need for flexible operation (part load operation, frequent start-up/shut down).
Depending on the specific national energy mix coal-fired power plants might be used as back-up ca-
pacity. In particular, components made from Ni-based alloys could be also applied in USC power plants
at reduced wall thickness according to improved material properties. Investigations on this option have
been commenced [8]. But the same rapid growth of renewables, which requires back-up capacity, might
kick advanced coal-fired power plants off the market, if its utilisation is reduced beyond profitability.
Disregarding of the fact that cost reductions are to be expected as a result of the technically focussed
follow-up test programmes, the commercial viability of the 700C technology is depending on electrici-
ty prices, CO
2
-emission prices, fuel costs/availability and political priorities resulting in different regu-

6 Design of a new generation of 12% chromium steels, VGB Research project 348,
http://www.vgb.org/en/research_project348.html
7 Calculation of CO
2
-avoidance potential by modernizing coal-fired power plant in the EU until 2020, VGB
Research project 307, http://www.vgb.org/en/research_project307.html
8 Roland J eschke, et al., Flexibility through highly efficient technology, VGB PowerTech, 05/2012, p. 66.
160

latory frameworks. These conditions differ significantly subject to the reference framework. The Asian
view point might remain different from Europe, and national priorities may differ in Europe as well.
Last but not least coal is competing with the advantages of renewable energy which on the other hand
include risks related to the fact that these are still evolving technologies.
The technology of a coal-fired power plant with live steam temperatures of 700C provides an im-
portant option for sustainable energy generation with regard to climate protection and preservation of
resources. Its final marketability depends on the development of rapidly changing global energy mar-
kets.
161

2.9.2 Publications / conference presentations resulting from the project
(1) Bernd Epple, Siegfried Keil, Gnther Scheffknecht, Georg N. Stamatelopoulos, Neue Steinkohle-
kraftwerke mit hohen Wirkungsgraden, Brennstoff-Wrme-Kraft, Bd. 56 (2004) Nr. 7/8.
(2) Bernd Epple, Georg N. Stamatelopoulos, Franz Bauer, Entwicklungstrends bei berkritischen
Dampfkraftwerken, VDI-Expertenforum "Entwicklungslinien der Energietechnik", 78 September
2004, Bochum.
(3) Georg N. Stamatelopoulos, Friedrich Klauke, Christian Stolzenberger, Kohlekraftwerke mit einem
Wirkungsgrad von ber 50 % dargestellt am Projekt AD700 und COMTES700, XXXVI. Kraftwerks-
technisches Kolloquium, 1920 Oktober 2004, Dresden.
(4) Sven Kjaer, J rgen Bugge, Christian Stolzenberger, Europeans Still Aiming for 700 C Steam, The
AD700 Development Programme: What has been achieved, what is happening now, what are the next
steps? Modern Power Systems J ournal, November 2004, p. 1925.
(5) Helmut Tschaffon, J ohannes Ewers, Christian Stolzenberger, COMTES700 auf dem Weg zum
700 C Kraftwerk, COORETEC-Workshop auf der Fachmesse ENERTEC, 1011 March 2005,
Leipzig.
(6) Helmut Tschaffon, J ohannes Ewers, Christian Stolzenberger, COMTES700 auf dem Weg zum
700 C Kraftwerk, VGB-Konferenz Kraftwerke im Wettbewerb 2005, 2527 April 2005, Potsdam,
Vortrag 11.
(7) Christian Folke, Ulrich Franke, Helmut Tschaffon, Integration of a Component Test Facility into a
700 MW Coal-fired Power Station, 2nd International Conference on Clean Coal Technologies for our
Future, 1012 May 2005, Sardinia/Italy.
(8) Kai Wieghardt, Werner-Holger Heine, Holger Kirchner, J rg Meier, Christian Folke, Helmut
Tschaffon, Rod Vanstone, COMTES700-Turbine Valve The Worlds First 700 C Steam Turbine
Component, PowerGen Europe, J une 2005, Milano/Italy.
(9) Helmut Tschaffon, COMTES700 On the way to 700 C Power Plant, Workshop Performance
and Requirements of Structural Materials for modern high efficient Power Plants, Paper B 5, Darm-
stadt, 7 September 2005.
(10) Christian Folke, Helmut Tschaffon, On the Track towards the 700C-Power Station, E.ON-
Kundeninformationstag, 15 September 2005.
(11) Gerd J ger, Auf dem Weg zum 700C-Kohlekraftwerk Groversuch im Kraftwerk Scholven,
BWK 10/2005.
(12) Christian Folke, Helmut Tschaffon, Auf dem Weg zum 700C-Kraftwerk, Bayern-Innovativ, Ko-
operationsforum Konventionelle Kraftwerke Techniktrends und zuknftige Entwicklungen, Nrn-
berg, 27 October 2005
(13) Stephan Wegerich, COMTES700 Auf dem Weg zum Kohlekraftwerk mit 50 % Wirkungsgrad,
Fachkonferenz Kraftwerkstechnik NRW, Essen, 14 February 2006.
(14) J rgen Pick, COMTES700 Erhhung der Leistungsdynamik von Dampfkraftwerken durch ni-
ckelbasierte Werkstoffe fr 700 C und 300bar, Fachsymposium Kraftwerke, 1619 February 2006,
Kaprun/sterreich.
(15) Christian Folke, 8. Kraftwerkstechnik-Symposium, 23 February 2006 in Hamburg.
162

(16) Christian Folke, Symposium Material Innovativ, 29 March 2006, Universitt Bayreuth.
(17) Stephen L. Goodstine, et al., Developments in Materials Technology for Ultrasupercritical Steam
Power Plants, Clearwater Coal Conference, 2125 May 2006, Clearwater, Florida/USA.
(18) Ingo Telken, et al., Integration and First Operating Experience with a Component Test Facility
Installed into a 700 MW Coal-fired Power Station, PowerGen Europe, 30 May 1 J une 2006, Cologne.
(19) Andreas Helmrich, et al., Materials development for advanced steam boilers, Conference on Mate-
rials for Advanced Power Engineering, 1820 September 2006, Lige/Belgium.
(20) Helmut Tschaffon, The European Way to 700 C Coal-fired Power Plant, 8th Lige Conference on
Materials for Advanced Power Engineering, 1820 September 2006, Lige/ Belgium.
(21) Stephan Wegerich, COMTES700 Auf dem Weg zum Kohlekraftwerk mit 50 % Wirkungsgrad,
38. Kraftwerkstechnisches Kolloquium, Dresden/Germany, 2425 October 2006.
(22) Gerhard Weissinger, et al., European Development Program for the 700 C Power Plant, The Sec-
ond Annual Conference of the Ultra-supercritical Thermal Power Technology Collaboration Network,
Quingdao/China, October 2006.
(23) Thomas Grb, Schweitechnische Verarbeitung dickwandiger Komponenten aus Nickelbasiswerk-
stoff fr 700C-Kraftwerke, 2. FDBR-Werkstofftagung, Dsseldorf/Germany, 22 November 2006.
(24) Ingo Telken, COMTES700 Auf dem Weg zum Kohlekraftwerk mit 50 % Wirkungsgrad, Ruhr-
Universitt Bochum, 5 February 2007.
(25) Lutz Werner, Regelventile in der Kraftwerkstechnik, FDBR-Workshop Kraftwerke sind mehr als
Turbinen und Kessel, 28 February 2007, Gelsenkirchen.
(26) Gnther Kasparek et al., Projekt COMTES700 Neue Mastbe bei den Isolierdicken. ISOLIER-
TECHNIK J g. 33, Heft 2/2007, S. 2229.
(27) Kai Hesel, Planung einer Versuchsstrecke fr Hochtemperatur-Werkstoffe im Kraftwerk Scholven,
22. Rohrleitungstechnische Tagung des FDBR, 67 March 2007, Gelsenkirchen.
(28) Ralf-Udo Husemann et al., Status of Development of Materials for 700 C Technology in Coal-
fired Power Stations, 6th NIMS-MPA-IfW Workshop, Tsukuba/J apan, 14 March 2007.
(29) Christian Folke et al., Operating experience with COMTES700 on track towards the 50plus pow-
er plant, CCT2007, 1517 May 2007, Sardinia/Italy.
(30) Christian G. Stolzenberger, The European Roadmap for the 700 C USC Power Plant, 7th Interna-
tional Charles Parsons Turbine Conference, Glasgow/UK, 1113 September 2007.
(31) J rgen Bugge, et al., Development of PF-fired High Efficiency Power Plants (AD700), 20th World
Energy Congress "Energy Future in an Interdependent World", Rome/Italy, 1115 November 2007.
(32) Christian G. Stolzenberger et al., Aktueller Stand und Perspektiven der 700 C-Technologie, 39.
Kraftwerkstechnisches Kolloquium 2007, 1112 October 2007, Dresden/Germany.
(33) Christian Folke et al., Von COMTES700 zu 50plus Entwicklungsschritte auf dem Weg zum
Kohlekraftwerk mit 50 % Wirkungsgrad, 39. Kraftwerkstechnisches Kolloquium 2007, 1112 October
2007, Dresden/Germany.
(34) Gregor Gierschner, COMTES700 On the Track Towards the 50plus Power Plant, New Build
Europe 2008, Dsseldorf, 45 March 2008.
163

(35) Dr. M. Bader, H. Tschaffon, COMTES700 Betriebserfahrungen an dickwandigen Alloy617-
Komponenten bei 700C, VGB Konferenz "Kraftwerke im Wettbewerb 2009", Prague, 29. und 30 April
2009
(36) Reinhard Klemm, Auf dem Weg zur 700 C-Technologie, MESSTEC & Automation, Heft 5/2009
(37) J rgen Pick, Nickel-Basiswerkstoffe fr 700C-Kraftwerke Erste Erfahrungen, VDMA Technik
Forum Industriearmaturen, Frankfurt 21 J anuary 2010
(38) C. Ullrich, Dr. M. Bader, Dr. O. Wachter, G. Gierschner, First experience with the repair of service
exposed alloy 617 (700C), VGB Conference "Maintenance in Power Plants 2010", Bremen, 24 and 25
February 2010
(39) Christian Stolzenberger, COMTES700: a multinational EU R&D project for 700C technology
development, CSM Workshop Materials and Technologies for Energy Efficiency, Rome, 31 March
2010
(40) C. Ullrich, G. Gierschner, C. Stolzenberger, H. Tschaffon, Erfahrungen beim Testbetrieb von
Komponenten fr das 700C Kraftwerk, 10. VDI-Fachkonferenz, Kassel, 7 and 8 J une 2011
(41) Gregor Gierschner, Christian Ullrich, Helmut Tschaffon, E.ON New Build & Technology GmbH,
From COMTES700 to COMTES+ Component Tests for a Flexible 700C Power Plant, MPA Semi-
nar, 67 October 2011
164

3 LIST OF TABLES AND FIGURES
Table 1: Availability of technical solutions for critical components .................................................. 18
Table 2: Calculated data of the CTF at full load of the boiler ............................................................ 22
Table 3: Pressure drop of the CTF ...................................................................................................... 22
Table 4: Materials for headers, pipes and tubes and the applied codes ............................................... 26
Table 5: Geometrical data of the evaporator ....................................................................................... 27
Table 6: Data from stress calculation .................................................................................................. 27
Table 7: Thermal design data of the evaporator .................................................................................. 28
Table 8: Calculated steam and wall temperatures of the evaporator ................................................... 28
Table 9: Geometrical data of the riffled tubes..................................................................................... 30
Table 10: Geometrical data of the superheater...................................................................................... 31
Table 11: Data for stress calculation ..................................................................................................... 31
Table 12: Thermal design data of the superheater ................................................................................ 33
Table 13: Calculated flows of the CTF ................................................................................................. 34
Table 14: Design data final injection .................................................................................................... 34
Table 15: Design data HP-bypass injection .......................................................................................... 34
Table 16: Course of Commissioning..................................................................................................... 37
Table 17: Dimensions and suppliers of the evaporator materials ......................................................... 41
Table 18: Dimensions and suppliers of steam piping materials ............................................................ 42
Table 19: Dimensions and suppliers of the superheater materials ........................................................ 43
Table 20: Dimensions and suppliers of filler materials......................................................................... 43
Table 21: Chemical composition of novel materials applied for the CTF ............................................ 45
Table 22: Grain size no G according to EN ISO 643 (G-7 G-1) and ASTM E 112 (G0 G13) ....... 51
Table 23: NDT conducted on CTF parts ............................................................................................... 55
Table 24: Erection and start-up of the major components .................................................................... 87
Table 25: List of laboratories. ............................................................................................................. 118
Table 26: Summary of results for evaporator tubes ............................................................................ 119
Table 27: Summary of results for evaporator tubes similar welds ...................................................... 120
Table 28: Summary of results for evaporator dissimilar welds .......................................................... 121
Table 29: Summary of results for SH similar/dissimilar welds .......................................................... 123
Table 30: The investigated components .............................................................................................. 124
Table 31: Mechanical properties of various samples. RT =room temperature, HT =700C ............ 125
Table 32: Mechanical properties of pipe sample SA1 and weld SAW1. ............................................ 126
Table 33: Investigated dissimilar welds .............................................................................................. 127
Table 34: Test programme with six different electrode and TIG orbital welds .................................. 135
Table 35: Positions and failure types with reference to Figure 130 and 131. ..................................... 141
Table 36: Fatigue and creep lifetime consumption based on EN 12952-4:2011 ................................ 143
Table 37: Total consumption of lifetime based on EN 12952-4:2011 ................................................ 144


165

Figure 1: Construction of the test heat exchange surfaces and location in the boiler ........................ 20
Figure 2: Isometric drawing of the CTF ............................................................................................. 21
Figure 3: P&I diagram of the CTF ..................................................................................................... 25
Figure 4: Outline of the evaporator panel........................................................................................... 27
Figure 5: Calculated wall temperatures for T24 ................................................................................. 29
Figure 6: Calculated wall temperatures for HCM12 and Alloy 617B ................................................ 29
Figure 7: Geometry of riffled tubes .................................................................................................... 30
Figure 8: Arrangement of the superheater surface in the host boiler ................................................. 32
Figure 9: Outline of attemperator arrangement .................................................................................. 34
Figure 10: Pressure drop of nozzles vs. flow capacity of attemperator ................................................ 35
Figure 11: Details of spray attemperator 3 ........................................................................................... 35
Figure 12: Flash tank ............................................................................................................................ 36
Figure 13: 3.1A certificate of HCM12 evaporator tube ....................................................................... 41
Figure 14: PMA of Alloy 617B ............................................................................................................ 42
Figure 15: 3.1B certificate of Alloy 617B welding rod ........................................................................ 44
Figure 16: Interim certificate of the Notified Body (RWTV) ........................................................... 46
Figure 17: Cover sheet of WPQR HCM12/Alloy 617B BW ............................................................... 47
Figure 18: Final machining of inner surface of Alloy 617B ................................................................ 48
Figure 19: Alloy 617B. with grain size number G=-3 ......................................................................... 48
Figure 20: Forging of Alloy 617B (OD219.1 x 50mm) ....................................................................... 49
Figure 21: TIG fusion welding without filler metal ............................................................................. 49
Figure 22: TIG welded base material and after PT on the right side .................................................... 50
Figure 23: TIG/SMAW welding of Alloy 617 tube in fixed position .................................................. 50
Figure 24: New heat treatment method for Alloy 617 components ..................................................... 51
Figure 25: Indication of DMV 617 SH-Tube ....................................................................................... 52
Figure 26: Microsection of DMV 617 SH-Tube .................................................................................. 52
Figure 27: Superheater outlet header .................................................................................................... 52
Figure 28: Spray Attemperator ............................................................................................................. 53
Figure 29: Evaporator outlet header (P92) ........................................................................................... 53
Figure 30: Manufactured panel with T24/HCM12/Alloy 617B. .......................................................... 54
Figure 31: Indication found after PT .................................................................................................... 54
Figure 32: PT testing of Alloy 617B V-weld (OD219.1 x WT50mm) and while welding ......................
with TIG/SMAW ................................................................................................................ 56
Figure 33: Cross sectional drawing of gate valves GH 251 and DN125 (KKS no. 26NA76S004) ..... 60
Figure 34: Cross sectional drawing of the globe valves VHA510 and DN50 ..........................................
(KKS no. 26NE22S521) ..................................................................................................... 61
Figure 35: Cross sectional drawing of safety valve SOH (KKS no. 26NA77S094) ............................ 62
Figure 36: Cross sectional drawing of swing check valve KRH400 and DN80 ......................................
(KKS no. 26NA76S508) ..................................................................................................... 63
Figure 37: Cross sectional drawing of check valve VR500 and DN50 (KKS no. 26NE22S522) ........ 63
Figure 38: Left: Cross sections of start-up valve (KKS no. 26NA76S002); Rright: control valve ..........
(KKS no. 26NA76S006) ..................................................................................................... 64
Figure 39: HP-bypass valve (KKS no. 26NA77S003) ......................................................................... 64
Figure 40: Overview of casing neck weld of gate valve. Red arrows show cracks after dye ..................
penetrant testing (KKS no. 26NA76S004-01) .................................................................... 66
Figure 41: Adhesion damage of seat ring (KKS no. 26NA76S004-01) ............................................... 66
Figure 42: Seat of the HP-bypass after 22,000 hours of operation ....................................................... 67
Figure 43: Dissmanteld HP-bypass valve body for detailed investigation ........................................... 68
Figure 44: Cross section of the HP-bypass valve (seam A) with cracks (arrows) and the ....................
appropriate microscopic view on a crack propagated from a thread root ........................... 68
Figure 45: Hardness gradient in valve cross section ............................................................................ 69
166

Figure 46: Outer temperature profile of a thermocouple ...................................................................... 74
Figure 47: Pressure measurement equipment as used for the CTF. First shut-off valves .......................
(see WP3 Valves), impulse pipes and transmitter shut-off valve made of Alloy 617B ...... 75
Figure 48: Design drawing of pressure gauge stop valve tailor-made for the CTF ............................. 76
Figure 49: Pressure gauge stop valve built in for long-term design testing under high temperature .......
conditions (insulation dismantled). The white insulation is high temperature insulation .......
microtherm, the other is a standard insulation material. ..................................................... 76
Figure 50: Flow measuring venture nozzle design as chosen for the CTF ........................................... 77
Figure 51: External view of the installation position of the venture flow nozzle................................. 77
Figure 52: Readings during commissioning of the closed loop control ............................................... 78
Figure 53: Evaporator and superheater temperture control monitor screen shot.................................. 78
Figure 54: Temperature differentials vs. the temperature band ............................................................ 79
Figure 55: Control system architecture ................................................................................................ 80
Figure 56: Old Scholven F control room .............................................................................................. 82
Figure 57: COMTES700 area of the control room ............................................................................... 82
Figure 58: The specific insulation factor of insulation materials at different temperatures ................. 83
Figure 59: The companies involved in the erection phase of the CTF ................................................. 86
Figure 60: Scaffolding in front of the evaporator inside the boiler ...................................................... 88
Figure 61: Left: superheater tubes inside the boiler. Right: marks on superheater .............................. 88
Figure 62: Left: superheater outlet header before dismantling. Right: end of 700C steam pipe ............
at the end of the first dismantling phase ............................................................................. 88
Figure 63: Left: Determination of cutting points. Right: Pipe parts with identification marks after .......
severing ............................................................................................................................... 89
Figure 64: Deposits in a pre-heating pipe detected during the dismantling ......................................... 90
Figure 65: Crack in spray injection nozzle after HP-bypass valve detected during the dismantling ... 90
Figure 66: Left: Superheater tubes in shelves. Right: Evaporator ........................................................ 90
Figure 67: Left: Stored pipes. Right: Stored valves ............................................................................. 91
Figure 68: Hours of operation .............................................................................................................. 92
Figure 69: Number of starts .................................................................................................................. 93
Figure 70: Temperature distribution in the superheater ....................................................................... 93
Figure 71: Main activities and non-availabilities ................................................................................. 94
Figure 72: CTF parts with failures ....................................................................................................... 95
Figure 73: Failure in the superheater .................................................................................................... 96
Figure 74: Intergranular crack at tube 1 ............................................................................................... 96
Figure 75: Left: Inner surface. Right: Outer surface ............................................................................ 97
Figure 76: Location of spray attemperator 2 in the CTF ...................................................................... 98
Figure 77: Spray attemperator 2 ........................................................................................................... 98
Figure 78: Indications at stub welds of the injection nozzle assembly ................................................ 99
Figure 79: Injection nozzle after grinding ............................................................................................ 99
Figure 80: Cracks at the stubs of spray injection nozzle assemblies and extraction of boat-shaped ........
samples.............................................................................................................................. 100
Figure 81: Spray attemperator 2 support construction with bracket .................................................. 101
Figure 82: Indications at bracket of spray attemperator 2 .................................................................. 101
Figure 83: Results of the UT of spray attempeartor at bracket .......................................................... 102
Figure 84: Condition of protective pipe, seen after cutting off crack-affected pipe section .............. 102
Figure 85: Results of the visual inspection, crack of protective pipe in the area of injection ..................
nozzle assembly ................................................................................................................ 103
Figure 86: Different cuttings during the repair works ........................................................................ 103
Figure 87: Damage affected area before and after removal of insulation .......................................... 104
Figure 88: Investigation of the crack .................................................................................................. 105
Figure 89: Location of spray attemperator 3 ...................................................................................... 106
167

Figure 90: Spray attemperator 3 ......................................................................................................... 106
Figure 91: Defective weld at counter bearing of spray injection nozzle assembly ............................ 107
Figure 92: Sample for laboratory investigation .................................................................................. 107
Figure 93: Metallographic investigation ............................................................................................ 108
Figure 94: Crack of spray attemperator 3 inlet weld .......................................................................... 108
Figure 95: Deflection of turbine valve ............................................................................................... 109
Figure 96: Laboratory investigation of crack at spray attemperator 3 inlet weld ............................... 110
Figure 97: Old protective pipe. Left: Pipe broken in 5 segments. Right: deformation at .......................
injection nozzle assembly part of the attemperator ........................................................... 111
Figure 98: crack at circumferential weld and stub weld of the Alloy 617B main pipe ...................... 112
Figure 99: Further indications at stubs ............................................................................................... 113
Figure 100: Indications at stubs after the heat treatment ...................................................................... 114
Figure 101 Indications at circumferential welds after heat treatment ................................................. 114
Figure 102: Cutting of indications ........................................................................................................ 115
Figure 103: Indications at repair weld .................................................................................................. 116
Figure 104: Left: LOM image of SP2. Right: BSE-SEM image of BP1 (arrows: see text). ................ 124
Figure 105: Steam side oxide. Left: BSE-SEM image of H3. Middle: LOM image of SPB2 after ...........
etching. Right: LOM image of BP1 .................................................................................. 125
Figure 106: Shallow pits developed on the steam side of DE1 ............................................................ 126
Figure 107: Left: View from inside header H3 with bore holes after penetrant testing. ............................
Right: Hot crack observed in weld SHHW1 near outer surface ....................................... 126
Figure 108: Hardness measurements performed across dissimilar welds between P92 and ......................
Alloy 617B. r =root layer, t =top layer ........................................................................... 127
Figure 109: Hardness measurements performed across the dissimilar weld between 10CrMo9-10 ..........
and Alloy 617B (DW8). r =root layer, t =top layer ........................................................ 128
Figure 110: Left: The HAZ of P92. Right: Alloy 617B (right) in dissimilar weld, DW7 .................... 128
Figure 111: Left (DW3): SEM images and EDS line scan across the interface between weld metal ........
and P92. Right (DW8): Weld metal and 10CrMo9-10. The contents of Ni, Cr, Fe, and ........
Co at end positions in wt% ............................................................................................... 129
Figure 112: Left (DW4): Steam side oxide at the transition between, P92 and weld metal. .....................
Right (DW8): 10CrMo9-10 and weld metal ..................................................................... 129
Figure 113: Crack that occurred during operation of the CTF. Left: Typical crack path close to .............
a stub. Right: Associated microstructure .......................................................................... 130
Figure 114: Indications that occurred directly after welding of service exposed Alloy 617B in ..............
he area of welds: a) crack in the weld, b) PT-indications during non-destructive testing, .....
c) crack in the heat affected zone ...................................................................................... 131
Figure 115: Left: Indications before operation. Right: Indications after 500 hours of operation......... 132
Figure 116: General test set-up of bending test .................................................................................... 132
Figure 117: Result of the 3-point bending test: a) service exposed sample, b) load-time diagram ............
for sample out of a), c) service exposed +980C for 3h, d) load time diagram for the ..........
sample out of c) ................................................................................................................. 133
Figure 118: Microstructure of service exposed Alloy 617B after different heat treatments ......................
(22,000h at 700C): a) service exposed, b) service exposed +980C for 3h, c) service ........
exposed +1160C for 1h .................................................................................................. 134
Figure 119: Medium size of carbides in service exposed and heat treated Alloy 617B ....................... 134
Figure 120: Test pipe with heating mats and insulation ....................................................................... 135
Figure 121: Arrangement of 18 thermocouples for the 1160C heat treatment test ............................. 136
Figure 122: Heating of the test pipe ..................................................................................................... 136
Figure 123: Measured temperatures during the heat treatment test ...................................................... 136
Figure 124: Rapid cooling down process after the heat treatment with water ..................................... 137
Figure 125: Measured temperatures during cooling in the heat treatment test .................................... 138
168

Figure 126: Comparison between electrode welds and TIG orbital welds ........................................... 138
Figure 127: Metallographic investigation of the six test welds ............................................................ 139
Figure 128: Test set-up for mechanised ultrasonic investigations ....................................................... 140
Figure 129: Cross section of qualification component with reflector positions .........................................
(notches and drilled holes) ................................................................................................ 140
Figure 130: Comparison of mechanised ultrasonic testing (left) and micro-section (right) ................. 141
Figure 131: Microsections with higher magnification ......................................................................... 141
Figure 132: Consumed lifetime in Alloy 617B superheater tubing ...................................................... 142
Figure 133: CAE geometry of spray attemperator ............................................................................... 144
Figure 134: Analysed part positions of spray attemperator 2 ............................................................... 145
Figure 135: Fixed-point thermocouple principle .................................................................................. 146
169

4 GLOSSARY
13CrMo4-5 Ferritic steel: EN 10216-2; W. Nr. 1.7335
10CrMo9-10 Ferritic steel: EN 10216-2; W. Nr. 1.7380
AD2000 German standard of pressure vessels that meet the requirements of PED
Al
2
O
3
Aluminium oxide
Alloy 263 Nickel base alloy: W.-Nr. 2.4650; NiCo20Cr20Mo5Ti2Al
Alloy 617B Nickel base alloy with optimized chemical composition developed from: VdTV
485 NiCr23Co12Mo, W. Nr. 2.4663; ASME Code Cases 1956 and 1982; ISO
NiCr22Co12Mo9; Nicrofer 5520
Alloy 740 Nickel base alloy: INCONELalloy 740
BeO Beryllium monoxide
BM Base metal
BPQR Bending procedure qualification record
BSE-SEM Backscattered electron scanning electron microscopy
CTF Component Test Facility
DCS Digital control system for a computerised automation system for integrated se-
quence, open loop and close loop control
Dissimilar weld Weld between two tubes of dissimilar material quality e.g. HCM12 to Alloy Al-
loy 617B
DMV310N Austenitic steel: European Steel Registration X6CrNiNbN25-20, Steel number
1.4952; VdTV 546 X6CrNiNbN25-20, W.Nr. 1.4952; ASME SA-213
TP310HCbN; ASME Code Case 2115
Duplex oxide layer An oxide layer that consists of an inward and an outward growing layer
ENCIO European network for component integration and optimisation, R&D project
funded by the Research Fund for Coal and Steel, Grant no. RFCP-CT-2011-
00003
Evaporator In the CTF an evaporator panel was implemented operating as superheater and
realized as finned tube wall or membrane wall.
Fireside corrosion Oxide or corrosion layer on the outer periphery of the tubes
Flue gas side The section of the tube periphery in the direction of the burners
HAZ Heat affected zone
HCM12 Ferritic-martensitic steel: VdTV 510 HCM 12
HfO Hafnium oxide
HR3C Austenitic steel: European Steel Registration X6CrNiNbN25-20, Steel number
1.4952; VdTV 546 X6CrNiNbN25-20, W.Nr. 1.4952; ASME SA-213
TP310HCbN; ASME Code Case 2115
HWT II Untersuchung des Betriebs- und Versagensverhaltens dickwandiger Bauteile fr
hocheffiziente Kraftwerke, R&D project funded by the German Federal Ministry
of Economics, funding no. 03ET2017
Inner oxide layer Inner oxide layer in case of duplex layered oxide, in some cases designated as
topotactic
MACPLUS Component Performance-driven Solutions for Long-Term Efficiency Increase in
Ultra Supercritical Power Plants, FP7-ENERGY, Project reference: 249809
MARCKO700 Material-Realisierung CO
2
-armes Kohlekraftwerk, R&D project funded by the
German Federal Ministry of Economics, funding no. 0326894
MgO Magnesium oxide (Magnesia)
Outer oxide layer Outer oxide layer in case of duplex layered oxide, in some cases designated as
epitactic
170

P91 Ferritic-martensitic steel: EN 10216-2; VdTV 552/2 X10CrMoVNb9-1, W. Nr.
1.4903
P92 Ferritic-martensitic steel: EN 10216-2; VdTV 511 X10CrMoVNb9-2, W. Nr.
1.4901;
PGIM Power Generation Information Manager
PMA Particular material appraisal
Provia Commissioning tool for data storage and visualisation based on Excel
prWHT Pre weld heat treatment
PT Penetrant testing
PWHT Post weld heat treatment
Rear side The section of the tube periphery away from the direction of the burners
Rohr2 Pipe stress analysis programme for static and dynamic analysis of complex pip-
ing and skeletal structures
RT Radiographic testing
Sanicro 25 Austenitic steel: VdTV 555 Sanicro25
SAW / SMAW Submerged Arc welding / Shielded metal arc welding
Similar weld Weld between two tubes of similar material quality e.g. HCM12 to HCM12
Steam side oxidation Oxide on the inner periphery of the tubes
T24 Low alloy ferritic steel: EN 10216-2 7CrMoVTiB10-10, Steel number 1.7378;
VdTV 533 7CrMoVTiB10-10, W.Nr. 1.7378; ASTM A-213 T24
TIG Tungsten inert gas welding or Gas tungsten arc welding
TiO
2
Titanium dioxide
TRD German standard of technical rules for steam boiler
TXP Modern DCS system produced by Siemens for modern Power plants with inte-
grated BPS system
Type N Type N (NicrosilNisil) (Nickel-Chromium-Silicon/Nickel-Silicon) thermocou-
ples are suitable for use at high temperatures, exceeding 1.200 C, due to their
stability and ability to resist high temperature oxidation.
Type S Type S thermocouples use platinum or a platinumrhodium alloy for each con-
ductor. These are among the most stable thermocouples, but have lower sensitivi-
ty than other types and are usually used only for high temperature measurements
due to their high cost and low sensitivity.
UT Ultrasonic testing
WM Weld metal
WPQR / WPS Welding procedure qualification record / welding procedure specification
ZeO
3
Zirconium trioxide
'- phase Precipitates in Ni-base alloys consisting of Ni, Al and possibly Ti
- phase Precipitates in Ni-base alloys consisting of Ni and Ti

171
European Commission

EUR 25921 Component test facility for a 700 C power plant (Comtes700)

Luxembourg: Publications Office of the European Union

2013 171 pp. 21 29.7 cm

ISBN 978-92-79-29379-5
doi:10.2777/98172
doi:10.2777/98172
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The objective of Comtes700 was a test of components for the 700 C power
plant technology. A test facility of steam generator components up to a wall
thickness of 50 mm was erected in an existing power plant. A partial steam flow
from the host plant was heated up to 700 C and operated for 22 400 hours.
Compared to ferritic components, machining of nickel-based components lasted
a minimum of four times longer. Maximum grain sizes in semi-finished products
were achieved by a modified heat treatment. After adjustment of testing
technology, overlaps of alloy 617B tubes were avoided.
Evaporator materials functioned satisfactorily during operation. Updated
material properties and reduced mechanical loads restricted the reliability
statement. Superheater materials only failed once in a dissimilar weld. Some
superheater materials may not reach a lifetime of 200 000 hours due to
fireside corrosion. Thick-walled components from 30 to 50 mm in wall thickness
displayed a susceptibility to stress relaxation cracking in welds. Additional
stresses were caused by two-phase flow and insufficient design of spray
attemperator. A solution for the workshop and repair welds was to conduct
different heat treatment procedures. Valves functioned satisfactorily but after
dismantling some internal cracks were found which could be avoided by design
changes. Steam parameter measurements were proved. Non-destructive testing
for initial and periodic inspection was developed during the project, but without
having a relevant acceptance criterion.
The component test was designed, manufactured, erected and operated, but it
revealed challenges which were partly solved. Additional research activities are
necessary before construction and operation of a 700 C power plant in the near
future.
Studies and reports