This document is a profile for the project titled 'Advanced Modelling And Testing Of Thick Section Welded Hcm2s'.
The principal aim of the project is to use advanced modelling and testing to extend the size range in which the HCM2S steel can be fabricated with and without post weld heat treatment (PWHT). The specific objectives of the project are:
To optimise the fabrication of thick section HCM2S utilising practical and efficient welding processes (MMA,FCAW).
To investigate thoroughly the welding of HCM2S without PWHT.
To model the weld and cross-weld mechanical properties of HCM2S with, and without, PWHT.
To demonstrate acceptable weldment mechanical properties.
To produce fabrication guidelines for thick section HCM2S with, and without, PWHT.
This profile contains information on the project's:
Author(s): Barrie, M, Maskell, RV, Brown, TB & Dauda, T
Published: 2005
Publisher: Department of Trade and Industry
This document is a report for the project titled 'Advanced Modelling and Testing – Thick Sectioned Welded Alloy HCM2S (P23)'.
The principal aim of the project was to use advanced modelling and testing to extend the size range for which the HCM2S (P23) steel can be fabricated both with and without PWHT. The specific objectives were:
To optimise the fabrication of thick section HCM2S utilising practical and efficient welding processes (MMA, FCAW).
To thoroughly investigate the welding of HCM2S without PWHT.
To model the weld and cross weld mechanical properties of HCM2S both with and without PWHT in order to define cross weld properties.
To demonstrate acceptable weldment mechanical properties.
Consequently to produce fabrication guidelines for thick section HCM2S both with and without PWHT.
This report is divided into the following sections:
To reduce the capital and through life cost of steam turbines generating with clean coal technologies at steam temperatures above 570°C.
To develop the materials and welding technology necessary to provide a fabricated steam turbine rotor to operate with elevated steam temperatures in the high temperature part and long, high strength, turbine blades in the low temperature part of the rotor.
To fully characterise the microstructures and properties of such steam turbine rotors to enable the development of lifeing methodologies.
An investigation has been made into the possibility of welding together 10%Cr and 3.5%NiCrMoV rotor steels, a combination which would allow manufacture of large turbine rotors with inlet steam temperatures in excess of 570°C.
Following a comprehensive modelling programme by the University of Cambridge and complementary testing and examination by Siemens Power Generation (SPG), a welding procedure was developed and successful narrow gap TIG welds were made between 380mm diameter, 50mm thick material. This was accomplished using the established Tungsten Inert Gas (TIG) filler wire.
Author(s): Hutchinson, J., Conroy, R. & Stalker, R.
Published: 2004
Publisher: Department of Trade and Industry
This document is a report for the project titled 'Fabricated Turbine Rotors - Advanced Steam Turbines'.
An investigation has been made into the possibility of welding together 10%Cr and 3.5%NiCrMoV rotor material in order to produce the next generation steam turbines operating above 570°C.
Following a comprehensive modelling programme and complementary testing and examination by Siemens Power Generation (SPG) and the University of Cambridge, a welding procedure was developed and successful plate and small diameter welds were made between sections of 3.5%NiCrMoV and 10Cr material. Mechanical and metallurgical assessment of these welds showed that the weldment properties matched the requirements of the original parent material.
Following the success of the initial welds, a large-scale weld has been manufactured using the established materials and procedures to fully validate the developed welding procedure. This weld has been subjected to non-destructive examination (NDE) followed by extensive mechanical and metallurgical testing. The results confirm that the large scale weldment properties matched the requirements of the original parent materials and thereby satisfy the objectives of the project.
This report is divided into the following sections:
Steels for advanced steam turbines operating within super-critical steam conditions have been developed within the COST
501 collaborative programmes and are continuing to be developed within the COST 522 programme. The data generated
has already been used to develop and design high temperature
turbines which are now in operation or at an advanced stage
of construction.
New cleaner coal power generation technologies such as air blown gasification combined cycle (ABGC), integral gasification combined cycle (IGCC) and fluidised bed combustion will be looking to utilise these new steels in steam turbines but costs will need to be reduced to improve their competitiveness. The objectives of the project are:
To reduce the capital and through life cost of steam turbines generating in combined cycles with clean coal technologies
To develop the materials and welding technology to provide a fabricated steam turbine rotor to operate with supercritical steam temperatures in the high temperature part and long, high strength turbine blades in the low temperature part of the rotor
To characterise fully the microstructures and properties of such steam turbine rotors to enable the development of lifing methodologies
These combined cycle plants will generate in the region of 350 MW to 400 MW and will utilise steam turbines with an output in the range of 120 MW to 250 MW. The cost of the steam turbine can be reduced considerably if the number of turbine cylinders is reduced. A single cylinder reheat turbine would be adopted for smaller outputs and a two cylinder turbine with an HP turbine and a combined IP/LP turbine for the larger outputs. The requirement for a single rotor forging steel that has good creep properties at temperatures of 570°C and greater combined with high strength and toughness to carry long turbine blades at the low pressure end cannot be met by the COST steels alone.
This profile contains information on the project's:
The principal aim of the project was to use advanced modelling and testing to extend the size range for which the HCM2S (P23) steel can be fabricated both with and without Pre-Weld Heat Treatment (PWHT). The specific objectives were:
To optimise the fabrication of thick section HCM2S utilising practical and efficient welding processes - Manual Metal Arc (MMA) and Flux Cored Arc Welding (FCAW).
To thoroughly investigate the welding of HCM2S without PWHT.
To model the weld and cross weld mechanical properties of HCM2S both with and without PWHT in order to define cross weld properties.
To demonstrate acceptable weldment mechanical properties.
Consequently to produce fabrication guidelines for thick section HCM2S both with and without PWHT.
This project involved the manufacture of a number of pipe butt welds between HCM2S (P23) and itself - both with and without PWHT, and also dissimilar joints with BS 3064 660 (CMV) and ASTM A 335 P91 respectively, both these alloys representing materials with which there has been identified a potential desirability to join with thick section P23.
It was concluded that acceptable strains were developed during the life of the thick P23 weld for the non-PWHT'd condition to make it a viable option.
This summary provides information on:
Objectives
Summary
Background
Experimental Work
Results
Conclusions
Potential for Future Development
Cost
Duration
Contractor
Collaborators
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