W.Herzog Life Time assessment-Kairo-May2009

Life time assessment
of Steam Turbines
Wilhelm Herzog
Energy Sector
Energy Service Division / Oil & Gas and Industrial Applications Services
© Siemens AG 2009. All rights reserved.

Life time assessment of Steam Turbines
Content
Why life time assessment?

What is life time?
Yield and creep strength
Life time consuming factors
How is a life time study performed?
Life time calculation
Taking replica
Results and possible measures
Measures as a result of study
Conclusion

Page 2 May 2009 W. Herzog Siemens Energy; E S SO PLS EN NBG 2
Why life time assessment of older steam turbines?
To assess the present status and detect weak points

As life of components is limited, failure risk increases
Unit operation beyond design life
Maintaining the availability and reliability
Determining the optimum time and scope of preventive repair
measures
Capital-intensive retrofits and modernizations of plant components

Increased forced outages
Forced
8
outage rate [%]
0
0 10 20 30 40 Years
Operating time

What is life time?
Lifetime is the time period of a component
where an adequate safety margin for further operation exists

where a component can be operated economical

Creep Strain Curve and Microstructure
Creep strain
Build-up of porosity
No cracking just elongation Fast crack propagation
Primary creep Secondary creep Tertiary creep
Design limit Time

Yield and creep strength
> 350°C turbine components are

dimensioned with a safety factor against
creep strength depending on time
Creep strength depending on time
Yield strength
105 hours

Lower creep strength scatter band
For the lifetime evaluation lower scatter band values have to be used
Stress
Scatterband
of strength
Actual stress
min. max.
Rupture time
Rotor operational stresses
Blade centrifugal load Steam pressure
Thermal stresses
Stresses due to steam pressure
Temperature during start-up

Loading due to centrifugal forces

Operational casing stresses
Typical casing element Stresses due to steam pressure
Insulation
Start-up
Shut-down
Thermal stresses
Casing wall
temperature profile
Not shown: Stresses caused by prevented expansion, pipe forces, etc.

Life time consuming factors
Creep fatigue Low cycle Erosion / Mechanical

damage (>450°C) fatigue damage corrosion damage
Caused by:
Casing internal Start/shutdown Wet steam Rubbing

pressure
Load cycles Poor steam Foreign particles
Rotor centrifugal quality
Temp. - variation Fracture
forces
Insufficient
Water carry- over Normal wear
standstill
precautions

How is a life time study performed?
Lifetime calculation Metallography Inspection/crack Service history

testing
Creep & LCF, Replica examination Inspection for:

based on: • EoH, number of starts
• actual operating data • at selected most highly • Erosion, corrosion • Load changes, actual
stressed areas, • Foreign particle temp./ pressures
• state-of-the art • Rubbing
cracked zones or • Typical start-up and
calculation methods
known weak points shut-down curves
• latest material
• Unusual occurrences
properties Hardness measurement Crack testing: (overspeed, short
• actual wall thickness • Dye penetrant circuits, temp.
• Magnetic particle excursion)
inspection
• Ultrasonic • Previous
failures, overhaul
Wall thickness: reports, replaced parts
• By means of ultrasonic
Comprehensive report including recommended actions

Creep and low cycle-fatigue (LCF)
Lower scatter band

creep values
strength
Operating time
Creep
Time to rupture
Number of cycles to
crack initiation
T1 T2 TB1 TB2 N1 N2 NA1 NA2 Load-cycle N

Operating time (h)
Creep fatigue Low-cycle fatigue
Damage due to creep Et = T1 / TB1 + T2 / TB2 +...... Damage due LCF EN = N1 / NA1 + N2 / NA2 +......
Total Damage E = Et + EN

Casing stresses calculated by FE-method
FE-model of casing FE-calculated stress

wheel-chamber section distribution

Metallographic inspection by means of replicas
Replica on a polished and

etched specimen point
Carbide Cavity or
Carbide Cavity or crack Carbide
crack
Surface imaging with replica
Cross-section Taking the replica Replica after removal

Taking replicas at selected high-stressed points
Replica locations
Valve chest
ESV
Measurement of wall
thickness
Nozzle group line
Replicas to be taken
at high stressed
zones, cracks,
weldings or known
weak points

Replica locations
Rotor control-wheel disc Emergency-stop valve casing

Creep damage evolution as function of time
Pore chains on
grain boundaries
Isolated cavities
Numbers 1 - 5 designate the microstructure classification according to TRD 508

Microstructure with cavities on grain boundaries
Creep damage with chains

of cavities & micro-cracks
Isolated cavities
(Magnification approx. 500x)

Weldíng crack valve / nozzle chest
Material: GS17CrMoV5 11
Steam temperatures: 530°C
Operating hours: 170.000

Results & possible measures of life time assessment
Life time calculation result
Total available life time

Accumulated
damage
Allowable life time

consumption
Consumed life time

Results & possible measures of life time assessment
Life time extension
Design lifetime
Available
lifetime Retrofitting
Reduction of
stresses
Time
Life extending measures New expiry date
Measures as a result of study
Preventive measures after the study can be:
Repeated checks of the concerned components

Reconditioning/repair, such as re-touching of sharp transitions,
grinding/welding of defective areas
Replacement by original or improved design
Retrofitting of improved monitoring equipment
Operating mode changes to reduce stresses

Conclusion
In order to ensure operational safety, reliability and availability life time

assessment should be performed:
After 100.000 h at inlet steam temperatures > 450°C

OEM has service history of your turbine and entire fleet with
similar components
Current standards for analysis, calculation and material
knowledge are applied

Thanks
for your attention


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Life time assessment

© Siemens AG 2009. All rights reserved.

 Why life time assessment?

© Siemens AG 2009. All rights reserved.

 To assess the present status and detect weak points

© Siemens AG 2009. All rights reserved.

© Siemens AG 2009. All rights reserved.

Lifetime is the time period of a component

 where an adequate safety margin for further operation exists

© Siemens AG 2009. All rights reserved.

Primary creep Secondary creep Tertiary creep

Design limit Time

© Siemens AG 2009. All rights reserved.

> 350°C turbine components are

Creep strength depending on time

© Siemens AG 2009. All rights reserved.

Blade centrifugal load Steam pressure

Stresses due to steam pressure

Temperature during start-up

© Siemens AG 2009. All rights reserved.

Typical casing element Stresses due to steam pressure

Not shown: Stresses caused by prevented expansion, pipe forces, etc.

© Siemens AG 2009. All rights reserved.

Creep fatigue Low cycle Erosion / Mechanical

 Casing internal  Start/shutdown  Wet steam  Rubbing

© Siemens AG 2009. All rights reserved.

Lifetime calculation Metallography Inspection/crack Service history

Creep & LCF, Replica examination Inspection for:

Comprehensive report including recommended actions

Lower scatter band

T1 T2 TB1 TB2 N1 N2 NA1 NA2 Load-cycle N

Creep fatigue Low-cycle fatigue

© Siemens AG 2009. All rights reserved.

FE-model of casing FE-calculated stress

© Siemens AG 2009. All rights reserved.

Replica on a polished and

Surface imaging with replica

Cross-section Taking the replica Replica after removal

© Siemens AG 2009. All rights reserved.

Nozzle group line

© Siemens AG 2009. All rights reserved.

Rotor control-wheel disc Emergency-stop valve casing

© Siemens AG 2009. All rights reserved.

Numbers 1 - 5 designate the microstructure classification according to TRD 508

© Siemens AG 2009. All rights reserved.

Creep damage with chains

(Magnification approx. 500x)

© Siemens AG 2009. All rights reserved.

© Siemens AG 2009. All rights reserved.

Life time calculation result

Total available life time

Allowable life time

Consumed life time

© Siemens AG 2009. All rights reserved.

Life time extension

Preventive measures after the study can be:

 Repeated checks of the concerned components

© Siemens AG 2009. All rights reserved.

In order to ensure operational safety, reliability and availability life time

 After 100.000 h at inlet steam temperatures > 450°C

© Siemens AG 2009. All rights reserved.

© Siemens AG 2009. All rights reserved.

Why life time assessment?

To assess the present status and detect weak points

where an adequate safety margin for further operation exists

Casing internal Start/shutdown Wet steam Rubbing

Repeated checks of the concerned components

After 100.000 h at inlet steam temperatures > 450°C