life assessment as a basis for decision making for future ... klenk wac… · universität...

A, Klenk, G. Wackenhut, K. Metzger MPA-Seminar 2016Universität Stuttgart Stuttgart 05.10.2016 - 1

Life Assessment as a Basis for Decision Making forFuture Flexible Operation ofPlants

A. Klenk, G. Wackenhut, MPA University of StuttgartK. Metzger, GKM Großkraftwerk Mannheim


Background

• New energy concepts are aimed to increasesupply from renewable sources(for example from 20% in 2012 to 35 % in 2020 in Germany by law)

• Due to the special availability characteristics or renewable energy sources (e.g. wind energy) fossile or other plants are needed for backup and net stabilization but will exhibit a far lower usage and higher numbers of start-up and shutdown events

• Estimation of life consumption using conventional and advanced life assessment methods may help to operate components andplants effectively


Lifetime assessment of plant components

Service time h

Num

bero

f com

pone

ntfa

ilure

Failure due to life time expenditure

Additional serviceloading

Loadingaccordingto design

Failures due fabrication, lack of quality

I II III

Life time according to design

Service time h

Num

bero

f com

pone

ntfa

ilure








I


I IIII IIIIII

Life time according to designLife time according to design

LIFE ASSESSMENT IS AFFECTED BY Additional service loadingStart-up / shut down events producing thermal stresses …. Repeated relaxation and higher creep strain accumulation


Monitoring of loading situation:PressureTemperatureDisplacementsStrain, deformationCorrosion, Oxidation Data evaluation and handling:

PlausibilityData management

Calculation:Algorithms forlocal stresseslocal strainsinelastic FE -calculation Damage accumulation rules

Component monitoring:Component and material dependent criteria For repair/replacement Planning of inspection intervals Evaluation of results

Data bank and management:Component dataCharacteristics (general, heat specific)Reference curves (Fatigue)Recorded data storing Documentation of NDT, computation results

Manufacturing quality:Material (appraisals to Codes)Component manufacturing / heat treatmentNDTComponent as built geometry

Life assessment – Current state and possibilities

Structure and advanced methods


Life management GKM Unit 7

From 1993 on ambulant Component testing was applied

2012 – 2016 Introduction of lifeassessment measures for Unit 7


Agenda

• Introduction • Analyses and Evaluations for Life Assessment• Investigations for GKM Unit 7• Consideration of change in loading conditions• Summary and conclusions


Determination of current state

For further service data have to be gathered to ensure safe operation

Initial situation? Data, evaluation of microstrucure, life time estimation

What can be determined?Evaluation based on comparative analysis, extrapolation

Data to be considered:• Evaluation of material state

•Microstructure (Replica), Hardness•NondestructiveTesting

“Kataster” of all investigations carried Strain Measurement at highly loaded components

• Lifetime analysis• Additional calculations to take additional loads into account.


Calculation of exhaustion

Evaluation of total damage (creep AND Fatigue

Linear damage accumulation (creep and fatigue)

Special measures when reaching distinct life consumptionvalues

Uncertainties:• Scatter, uncertainties in material properties• As-built and design geometry is different• Determination of loading parameters (pressure, temperature) and derivation of

stresses by analytical formula.• Local influences from manufacturing history material properties• Total damage accumulation• System- and operation induced additional loading

Life assessment acc. - TRD 301, 508, AD 2000, EN 12952

1eee wz 0.0 0.2 0.4 0.6 0.8 1.0

0.0

0.2

0.4

0.6

0.8

1.0HA10_1.OPJ

TRD 508

21/4Cr1Mo (niedriglegierte Stähle)ASME N47

Ni-Fe-Cr Alloy 800H (Nickelbasislegierungen)ASME N47

304 und 316 SS (austenitische Stähle)ASME N47

Krie

chsc

hädi

gung

Ermüdungsschädigung


Strain measurements

Ltg A, Bogen 12 - Scheitel und Krone

-0,02

0

0,02

0,04

0,06

0,08

0,1

0,12

0,14

0,16

0,18

0 5000 10000 15000 20000 25000 30000

Zeit /h

Deh

nung

/%

AS1 - Umfang AS2 - Axial AK1 - Umfang

Bez. ep /% ep /% ep /%

Messstelle in 30 kh in 100 kh in 250 kh

AS1 - U 0 0 0

AS2 - A 0,06 0,19 0,47

AK1 - U 0,01 0,03 0,09

AG1 - U 0,06 0,19 0,47

AG2 - A 0,04 0,15 0,37

CS1 - U 0,06 0,21 0,53

CS2 - A 0,01 0,03 0,08

CK1 - U 0,03 0,09 0,22

CG1 - U 0,02 0,05 0,13

CG2 - A 0,02 0,07 0,17

Tafel 3: Abschätzung einer resultierenden bleibenden Dehnung bis zu 250.000 Bh

Conclusions of strain measurements obtained 2011 to 2014

• moderate increase of strain during measuring period• Abschätzung von Dehnungen von maximal 0,5% bis zu einer Betriebszeit von

ca. 250.000 h für die untersuchten Bauteile


Microstructural investigations

Replica investigations weredone for highly loadedcomponents (bends, T-piece etc)


Microstructural investigations

Conclusions from metallographicinvestigations:

The martensitic materialX20CrMoV12-1 shows at all positions coarsening of carbidesand dissolution of martensiticlath structure Rating (VGB) : 1

Exemption: Singular postionswith rating 2a (HAZ and in thevicinity of manufacturing defect


As built geometry


Examples for operational dataBezeichnung Kennzeichnung Abschnittsbeschreibung

A-System

P HHD-DAMPF HHD-LTG 71LBA08CP902_XQ50:Amittlerer Abschnitt/

Einzelleitung/DN400/li 380x60

T HHD DAMPF HHD LTG 71LBA08CT002_XQ50:Amittlerer Abschnitt/

Einzelleitung/DN400/li 380x60

P HHD DA V HA LI SAM LTG 71LBA10CP001_XQ50:ARhein-Seite/Abschnitt an Turbine-Eintritt

Leitung A10/Kesselnähe/DN300/li 280x45

T HHD DA V HA LI SAM LTG 71LBA10CT001_XQ50:ARhein-Seite/Abschnitt an Turbine-Eintritt/


T HHD DA V HA RE SAM LT 71LBA09CT001_XQ50:ALandseite/Abschnitt an Turbine-Eintritt/


C-System

P HD DA HZUE 1 LTG 71LBB20CP901_XQ50:Amittlerer Abschnitt/Einzelleitung/

DN600/li 570x37

T HD DA HZUE 1 LTG 71LBB20CT901_XQ50:Amittlerer Abschnitt/Einzelleitung/

DN600/li 570x37

T HD DA V AV HD TURB LI 71LBB21CT002_XQ50:ARhein-Seite/Abschnitt an Turbine-Eintritt/


T HD DA V AV HD TURB RE 71LBB22CT002_XQ50:ALand-Seite/Abschnitt an Turbine-Eintritt/


F-System

P MD-DA HZUE 2 LTG RHS 72LBB03CP011_XQ50:ARhein-Seite/mittlerer Abschnitt/

Doppelleitung/DN800/li 570x37)

P MD DA HZUE 2 LTG LAS 73LBB03CP011_XQ50:ALand-Seite/mittlerer Abschnitt/

Doppelleitung/DN800/li 570x37

T MD-DA.HZUE 2 LTG LAS 73LBB03CT011_XQ50:ALand-Seite/mittlerer Abschnitt/

Doppelleitung/DN800/li 570x37

Analysed data

- pressure- Temperature


Life assessment according to standards

ComponentsMeasuring points used


Component assessments

Bauteilbezeichnung KKS WerkstoffBeurteilungs‐

klasseZeichnung Nr.

Innendurch‐messer

Wand‐dicke

EintrittsammlerSammler / ESA, HHD6 HHD6 X20 CrMoV 12 1 ‐ OM58267 außen / OM58265 innen li 200 48Sammler / ESA, HD3 HD3 13 CrMo 4 4 1 OM58256 außen / OM58257 innen li 300 32Sammler / ESA, MD3 MD3 15Mo3 ‐ OM58470 außen / OM58469 innen li 500 30AustrittsammlerSammler / ASA, HHD6 HHD6 X20 CrMoV 12 1 1 OM59648 außen / OM59647 innen li 200 26Sammler / ASA, HD3 HD3 X20 CrMoV 12 1 1 OM58268 außen / OM58258 innen li 280 20Sammler / ASA, MD3 MD3 10 CrMo 9 10 1 OM58472 außen / OM58471 innen li 478 15,3

Tablesgathering all information areavailable formost of thecomponents

- Replicaresults

- NDT

Comparisonsare helpful


klasseZeichn. Nr.

Innendurch‐messer

Wand‐dicke

Formstücke / A‐SystemY‐Formstück, F1 (A5‐1), F2 (A6‐1) vergleichbar F1 (A5‐1) X20 CrMoV 12 1 2b OM56647 li 200 / li 280 60 / 48Y‐Formstück, F3 (A7‐1) F3 (A7‐1) X20 CrMoV 12 1 2a OM56648 li 280 / li 380 70 / 65T‐Formstück, F4 (A7‐2) F4 (A7‐2) X20 CrMoV 12 1 1 OM56649 li 380 / li 280 90 / 70T‐Formstück, F6 (A101‐1) F6 (A101‐1) X20 CrMoV 12 1 2a OM56650 li 200 / li 280 70 / 50T‐Formstück, F7 (A102‐1) F7 (A102‐1) X20 CrMoV 12 1 1 ‐ li 200 / li 280 70 / 50Formstücke / C‐SytemT‐Formstück, F 5 (C5‐1), mit F6 (C6‐1) vergleichbar F 5 (C5‐1) X20 CrMoV 12 1 1 OM56668 li 450 / li 325 40 / 50 Y‐Formstück, F 7 (C7‐1) F 7 (C7‐1) X20 CrMoV 12 1 1 OM56669 li 450 / li 570 60 / 46T‐Formstück, F 8 (C7‐2) F 8 (C7‐2) X20 CrMoV 12 1 2a OM56670 li 570 7 li 720 65 / 85Y‐Formstück, F 9 (C7‐3) F 9 (C7‐3) X20 CrMoV 12 1 2b OM56671 li 450 / li 720 60 / 70


klasseAußendurch‐

messerWand‐dicke

Unrundheit

A‐SystemGeradrohre / A‐SystemGeradrohr, DN200, li Ø 200x32 A1, A2, A3, A4 X20 CrMoV 12 1 ‐ 264 32 ‐Geradrohr, DN300, li Ø 280x45 A5, A6 X20 CrMoV 12 1 ‐ 370 45 ‐Geradrohr, DN400, li Ø 380x60 A7 X20 CrMoV 12 1 ‐ 500 60 ‐

‐


Extrapolation using existing data

0

5

10

15

20

25

1995 2000 2005 2010 2015

Operational data - Source GKM

Warmstart Kaltstart

a 2000-2008 less startsb 2008-2012 more starts

Extrapolation 1982-2000 mit Regime aExtrapolation 2012- mit Regime b

1982 1983 … 2000 … 2007 2008 … 2012 2013 … 2015 2016 … 2020

Regime 3

Regime a Regime b

Regime 2Regime 1


Ranking acc. to estimated lifetime consumptionTRD Beurteilungs‐ Bewertung mitStelle klasse Ist‐Werten EZ Ew E

CI09 Rohrbogen, Bogen B20, li Ø 450x29 B20 X20 CrMoV 12 1 1 ja 2,18 25,74 27,92CI08 Rohrbogen, Bogen B19, li Ø 450x29 B19 X20 CrMoV 12 1 2b ja 2,73 24,54 27,27CG01 Geradrohr, DN350, li Ø 325x21 C1, C2, C3, C4 X20 CrMoV 12 1 ‐ ‐ 26,60 0,33 26,93CR03 Rohrbogen, DN450, li Ø 450x29 C5, C6 X20 CrMoV 12 1 ‐ ‐ 20,41 6,41 26,82CR02 Rohrbogen, DN400, li Ø 400x26 C10‐1, C10‐2 X20 CrMoV 12 1 ‐ ‐ 20,45 4,17 24,62NRK1 Rohrbogen, B20, li Ø 199 x 37,5 Mwd, A‐System B20 X20 CrMoV 12 1 ‐ ja 22,09 1,84 23,93CG03 Geradrohr, DN450, li Ø 450x29 C5, C6 X20 CrMoV 12 1 ‐ ‐ 19,09 4,34 23,44CI07 Rohrbogen, Bogen B17, li Ø 450x29 B17 X20 CrMoV 12 1 2a ja 3,17 19,93 23,10CI11 Rohrbogen, Bogen B33, li Ø 450x29 B33 X20 CrMoV 12 1 1 ja 3,13 19,54 22,67CI10 Rohrbogen, Bogen B32, li Ø 450x29 B32 X20 CrMoV 12 1 1 ja 4,50 17,51 22,01TRK1 Rohrbogen, DN200, nahtl., li Ø 202 x 8,3 Mwd, R = 305 mm ‐ 13 CrMo 4 4 ‐ ‐ 21,31 0,00 21,31TRK3 Rohrbogen, DN300, nahtl., li Ø 298 x 12,2 Mwd, R = 457 mm ‐ 13 CrMo 4 4 ‐ ‐ 21,22 0,00 21,22TRK6 Rohrbogen, DN500, nahtl., li Ø 467 x 18,8 Mwd, R = 762 mm F203 ‐‐ F208 13 CrMo 4 4 ‐ ‐ 21,07 0,00 21,07TRK2 Rohrbogen, DN250, nahtl., li Ø 252 x 10,4 Mwd, R = 381 mm ‐ 13 CrMo 4 4 ‐ ‐ 21,01 0,00 21,01TRK5 Rohrbogen, DN400, nahtl., li Ø 374 x 15,1 Mwd, R = 609,6 mm F303 ‐‐ F306 13 CrMo 4 4 ‐ ‐ 20,91 0,00 20,91TRK4 Rohrbogen, DN350, nahtl., li Ø 327 x 13,2 Mwd, R = 533,5 mm ‐ 13 CrMo 4 4 ‐ ‐ 20,90 0,00 20,90TRK7 Rohrbogen, DN600, nahtl., li Ø 559 x 22,6 Mwd, R = 914,4 mm F25, F27, F28 13 CrMo 4 4 ‐ ‐ 20,76 0,00 20,76CG02 Geradrohr, DN400, li Ø 400x26 C10‐1, C10‐2 X20 CrMoV 12 1 ‐ ‐ 18,35 2,11 20,47CHD1 Sammler / ASA, HD3 HD3 X20 CrMoV 12 1 1 ja 7,11 13,04 20,15TRK8 Rohrbogen, DN700, geschw., li Ø 657 x 28,0 Mwd, R = 1067 mm F24 13 CrMo 4 4 ‐ ‐ 17,82 0,00 17,82FRK2 Rohrbogen, DN400, li Ø 383x11,2 Mdwd. F22 10 CrMo 9 10 ‐ ‐ 16,76 0,00 16,76TRM1 Rohrbogen, DN400, nahtl., li Ø 383 x 11,2 Mwd, R = 609 mm F22 10 CrMo 9 10 ‐ ‐ 15,73 0,01 15,74TRM2 Rohrbogen, DN500, nahtl., li Ø 478 x 14,0 Mwd, R = 762 mm ‐ 10 CrMo 9 10 ‐ ‐ 15,54 0,01 15,55FRK3 Rohrbogen, DN500, li Ø 478x14 Mdwd. F15, F16, F17, F18 10 CrMo 9 10 ‐ ‐ 15,54 0,00 15,54TRM5 Rohrbogen, DN800, geschw., li Ø 768 x 22,6 Mwd, R = 1219 mm F6, F7 10 CrMo 9 10 ‐ ‐ 15,27 0,01 15,28TRM3 Rohrbogen, DN600, nahtl., li Ø 572 x 16,8 Mwd, R = 914 mm ‐ 10 CrMo 9 10 ‐ ‐ 15,26 0,01 15,27FRK5 Rohrbogen, DN800, li Ø 768x22,6 Mdwd. F6, F7 10 CrMo 9 10 ‐ ‐ 15,27 0,00 15,27FRK4 Rohrbogen, DN600, li Ø 572x16,8 Mdwd. F1, F2, F3, F4 10 CrMo 9 10 ‐ ‐ 15,26 0,00 15,26TRM4 Rohrbogen, DN700, geschw., li Ø 672 x 19,8 Mwd, R = 1067 mm ‐ 10 CrMo 9 10 ‐ ‐ 15,16 0,01 15,17FRM1 Rohrbogen, DN700, li Ø 672x19,8 Mdwd. ‐ 10 CrMo 9 10 ‐ ‐ 15,16 0,00 15,16TGK8 Geradrohr, DN700, geschw., ä Ø 711,2x25,0 ‐ 13 CrMo 4 4 ‐ ‐ 13,12 0,00 13,12TGM5 Geradrohr, DN800, geschw., li Ø 768 x 22,6 Mwd, R = 1219 mm F6, F7 10 CrMo 9 10 ‐ ‐ 12,51 0,02 12,53FGK6 Geradrohr, DN800, ä Ø 812,8x19 Mdwd. F6, F7 10 CrMo 9 10 ‐ ‐ 12,51 0,00 12,51CI01 Rohrbogen, Bogen B2, li Ø 325x21 B2 X20 CrMoV 12 1 1 ja 10,49 1,91 12,41CI02 Rohrbogen, Bogen B3, li Ø 325x21 B3 X20 CrMoV 12 1 1 ja 10,65 1,58 12,23NRK2 Rohrbogen, B7, li Ø 454 x 38 Mwd, C‐System B7 X20 CrMoV 12 1 ‐ ja 11,50 0,71 12,21TGM6 Geradrohr, DN1000, geschw., li Ø 961 x 28,1 Mwd, R = 11524 mm ‐ 10 CrMo 9 10 ‐ ‐ 11,81 0,02 11,83TGK1 Geradrohr, DN200, nahtl., ä Ø 219,1x8,0 ‐ 13 CrMo 4 4 ‐ ‐ 11,58 0,00 11,58TGK2 Geradrohr, DN250, nahtl., ä Ø 273,0x10,0 ‐ 13 CrMo 4 4 ‐ ‐ 11,46 0,00 11,46TGM4 Geradrohr, DN700, geschw., li Ø 672 x 19,8 Mwd, R = 1067 mm ‐ 10 CrMo 9 10 ‐ ‐ 11,07 0,02 11,09FGM1 Geradrohr, DN700, , li Ø 677 x 17 Mwd ‐ 10 CrMo 9 10 ‐ ‐ 11,07 0,00 11,07CI03 Rohrbogen, Bogen B5, li Ø 325x21 B5 X20 CrMoV 12 1 1 ja 7,28 3,40 10,68FGK2 Geradrohr, DN150, ä Ø 168,3x6,3 Mdwd. ‐ 13 CrMo 4 4 ‐ ‐ 10,67 0,00 10,67FRK1 Rohrbogen, DN150, ä Ø 168,3x8 Mdwd. ‐ 15Mo3 ‐ ‐ 10,46 0,00 10,46TGK3 Geradrohr, DN300, nahtl., ä Ø 323,9x12,5 ‐ 13 CrMo 4 4 ‐ ‐ 9,65 0,00 9,65FI03 Rohrbogen, Bogen B18, li Ø 768x22,6 B18 10 CrMo 9 10 1 ja 9,58 0,00 9,58TGK6 Geradrohr, DN500, nahtl., ä Ø 508,0x20,0 ‐ 13 CrMo 4 4 ‐ ‐ 9,04 0,00 9,04TGK5 Geradrohr, DN400, nahtl., ä Ø 406,4x16,0 0 13 CrMo 4 4 ‐ ‐ 9,04 0,00 9,04TGK4 Geradrohr, DN350, nahtl., ä Ø 355,6x14,2 ‐ 13 CrMo 4 4 ‐ ‐ 8,62 0,00 8,62FI04 Rohrbogen, Bogen B23, li Ø 768x22,6 B23 10 CrMo 9 10 1 ja 8,20 0,00 8,20TGK7 Geradrohr, DN600, nahtl., ä Ø 609,6x25,0 F91 13 CrMo 4 4 ‐ ‐ 7,90 0,00 7,90FI01 Rohrbogen, Bogen B7, li Ø 768x22,6 B7 10 CrMo 9 10 1 ja 7,88 0,00 7,88FI02 Rohrbogen, Bogen B8, li Ø 768x22,6 B8 10 CrMo 9 10 1 ja 7,55 0,00 7,55TRM6 Rohrbogen, DN1000, geschw., li Ø 961 x 28,1 Mwd, R = 11524 mm F9 10 CrMo 9 10 ‐ ‐ 5,64 0,01 5,65FRM2 Rohrbogen, DN1000, li Ø 961x28,1 Mdwd. F9 10 CrMo 9 10 ‐ ‐ 5,64 0,00 5,64TGM1 Geradrohr, DN400, nahtl., li Ø 383 x 11,2 Mwd, R = 609 mm F22 10 CrMo 9 10 ‐ ‐ 5,60 0,01 5,61FGK3 Geradrohr, DN400, ä Ø 406,42x11 Mdwd. F22 10 CrMo 9 10 ‐ ‐ 5,60 0,00 5,60AHD2 Sammler / ESA, HHD6 HHD6 X20 CrMoV 12 1 ‐ ja 0,01 5,12 5,13TGM2 Geradrohr, DN500, nahtl., li Ø 478 x 14,0 Mwd, R = 762 mm F15, F16, F17, F18 10 CrMo 9 10 ‐ ‐ 4,69 0,01 4,70FGK4 Geradrohr, DN500, ä Ø 508x14,2 Mdwd. F15, F16, F17, F18 10 CrMo 9 10 ‐ ‐ 4,69 0,00 4,69TGM3 Geradrohr, DN600, nahtl., li Ø 572 x 16,8 Mwd, R = 914 mm F1, F2, F3, F4 10 CrMo 9 10 ‐ ‐ 4,06 0,00 4,06FGK5 Geradrohr, DN600, ä Ø 609,6x17,5 Mdwd. F1, F2, F3, F4 10 CrMo 9 10 ‐ ‐ 4,06 0,00 4,06CHD2 Sammler / ESA, HD3 HD3 13 CrMo 4 4 1 ‐ 1,65 0,00 1,65FMD1 Sammler / ASA, MD3 MD3 10 CrMo 9 10 1 ‐ 0,17 0,00 0,18FMD2 Sammler / ESA, MD3 MD3 15Mo3 ‐ ‐ 0,00 0,00 0,00

Bauteilbezeichnung KKS WerkstoffInbetriebnahme‐2015

28% total lifetime consumption

Many components havecomparatively low lifetimeconsumption


Ranking acc. to estimated lifetime consumptionTRD Beurteilungs‐ Bewertung mitStelle klasse Ist‐Werten EZ Ew E

AR01 Rohrbogen, DN200, li Ø 200x32, R=4*Da A1, A2, A3, A4 X20 CrMoV 12 1 ‐ ‐ 127,60 26,44 154,04AR02 Rohrbogen, DN200, li Ø 200x32, R=5*Da A1, A2, A3, A4 X20 CrMoV 12 1 ‐ ‐ 116,66 26,44 143,11AF3 Y‐Formstück, F3 (A7‐1) F3 (A7‐1) X20 CrMoV 12 1 2a ‐ 4,08 138,76 142,83AI07 Rohrbogen, Bogen B30, li Ø 380x60 B30 X20 CrMoV 12 1 2b ja 17,31 116,80 134,12AF4 T‐Formstück, F4 (A7‐2) F4 (A7‐2) X20 CrMoV 12 1 1 ‐ 45,46 81,66 127,12AI08 Rohrbogen, Bogen B31, li Ø 380x60 B31 X20 CrMoV 12 1 1 ja 19,19 107,35 126,54AF6 T‐Formstück, F6 (A101‐1) F6 (A101‐1) X20 CrMoV 12 1 2a ja 45,48 55,98 101,46AR05 Rohrbogen, DN400, li Ø 380x60, R=5*Da A7 X20 CrMoV 12 1 ‐ ‐ 31,72 62,36 94,08AF7 T‐Formstück, F7 (A102‐1) F7 (A102‐1) X20 CrMoV 12 1 1 ja 32,94 58,22 91,16AG03 Geradrohr, DN400, li Ø 380x60 A7 X20 CrMoV 12 1 ‐ ‐ 24,85 62,36 87,21AR04 Rohrbogen, DN300, li Ø 280x45, R=3,5*Da A5, A6 X20 CrMoV 12 1 ‐ ‐ 32,83 49,76 82,59AR03 Rohrbogen, DN300, li Ø 280x45, R=4*Da A5, A6 X20 CrMoV 12 1 ‐ ‐ 31,26 49,76 81,02CF8 T‐Formstück, F 8 (C7‐2) F 8 (C7‐2) X20 CrMoV 12 1 2a ‐ 20,89 54,12 75,00AG02 Geradrohr, DN300, li Ø 280x45 A5, A6 X20 CrMoV 12 1 ‐ ‐ 22,92 49,76 72,69AI01 Rohrbogen, Bogen B3, li Ø 200x32 B3 X20 CrMoV 12 1 1 ja 24,57 46,60 71,17AF1 Y‐Formstück, F1 (A5‐1), F2 (A6‐1) vergleichbar F1 (A5‐1) X20 CrMoV 12 1 2b ja 4,66 64,43 69,09AI05 Rohrbogen, Bogen B12, li Ø 200x32 B12 X20 CrMoV 12 1 1 ja 21,16 47,51 68,67AHD1 Sammler / ASA, HHD6 HHD6 X20 CrMoV 12 1 1 ‐ 11,25 55,94 67,19AI03 Rohrbogen, Bogen B9, li Ø 200x32 B9 X20 CrMoV 12 1 1 ja 17,91 47,69 65,60AI02 Rohrbogen, Bogen B8, li Ø 200x32 B8 X20 CrMoV 12 1 2a ja 16,89 48,38 65,27AI06 Rohrbogen, Bogen B21, li Ø 200x32 B21 X20 CrMoV 12 1 2a ja 17,31 47,90 65,21AI04 Rohrbogen, Bogen B10, li Ø 200x32 B10 X20 CrMoV 12 1 1 ja 17,09 47,88 64,98CF5 T‐Formstück, F 5 (C5‐1), mit F6 (C6‐1) vergleichbar F 5 (C5‐1) X20 CrMoV 12 1 1 ‐ 32,10 24,32 56,41AG01 Geradrohr, DN200, li Ø 200x32 A1, A2, A3, A4 X20 CrMoV 12 1 ‐ ‐ 23,39 28,34 51,73AI11 Rohrbogen, Bogen B62, li Ø 200x32 B62 X20 CrMoV 12 1 1 ja 16,58 32,18 48,76AI10 Rohrbogen, Bogen B61, li Ø 200x32 B61 X20 CrMoV 12 1 1 ja 15,30 32,30 47,60AI09 Rohrbogen, Bogen B53, li Ø 200x32 B53 X20 CrMoV 12 1 ‐ ja 12,72 32,28 45,00CR04 Rohrbogen, DN600, li Ø 570x37 C7, C7‐3 X20 CrMoV 12 1 ‐ ‐ 20,48 24,32 44,81CF9 Y‐Formstück, F 9 (C7‐3) F 9 (C7‐3) X20 CrMoV 12 1 2b ja 4,59 39,14 43,73CG04 Geradrohr, DN600, li Ø 570x37 C7, C7‐3 X20 CrMoV 12 1 ‐ ‐ 18,47 23,81 42,28FGM2 Geradrohr, DN1000, , li Ø 968 x 24,0 Mwd ‐ 15Mo3 ‐ ‐ 41,50 0,00 41,50FGK1 Geradrohr, DN150, ä Ø 168,3x4 Mdwd. ‐ 15Mo3 ‐ ‐ 40,74 0,00 40,74CI06 Rohrbogen, Bogen B16, li Ø 570x37 B16 X20 CrMoV 12 1 1 ja 7,44 30,71 38,15CI04 Rohrbogen, Bogen B10, li Ø 570x37 B10 X20 CrMoV 12 1 1 ja 7,22 30,83 38,05CI05 Rohrbogen, Bogen B15, li Ø 570x37 B15 X20 CrMoV 12 1 1 ja 6,84 31,16 38,00CF7 Y‐Formstück, F 7 (C7‐1) F 7 (C7‐1) X20 CrMoV 12 1 1 ja 2,66 34,06 36,72CR01 Rohrbogen, DN350, li Ø 325x21 C1, C2, C3, C4 X20 CrMoV 12 1 ‐ ‐ 29,63 0,42 30,05

Bauteilbezeichnung KKS WerkstoffInbetriebnahme‐2015

>50%


Results - Plausibility checks

TRDBauteilbezeichnung

Beurteilungs‐ Bewertung mitRadius

Außendurch‐ Wanddicke Berechnungs‐

Stelle klasse Ist‐Werten messer intrados extrados wanddickeAR01 Rohrbogen, DN200, li Ø 200x32, R=4*Da ‐ ‐ 1056 264 32 32 32AR02 Rohrbogen, DN200, li Ø 200x32, R=5*Da ‐ ‐ 1320 264 32 32 32AI01 Rohrbogen, Bogen B3, li Ø 200x32 1 ja 1056 272,9 37,5 32,6 35,05AI05 Rohrbogen, Bogen B12, li Ø 200x32 1 ja 1056 273,85 38,9 34,9 36,9AI03 Rohrbogen, Bogen B9, li Ø 200x32 1 ja 1320 275,7 39,5 37,5 38,5AI06 Rohrbogen, Bogen B21, li Ø 200x32 2a ja 1320 274,63 39,6 35,3 37,45AI02 Rohrbogen, Bogen B8, li Ø 200x32 2a ja 1056 276,625 40,9 35,7 38,3AI04 Rohrbogen, Bogen B10, li Ø 200x32 1 ja 1320 275,3 39,6 36,5 38,05

TRDBauteilbezeichnung

Beurteilungs‐ 2000 ‐ 2012 Inbetriebnahme‐2015Stelle klasse EZ Ew E EZ Ew E

AR01 Rohrbogen, DN200, li Ø 200x32, R=4*Da ‐ 45,45 8,15 53,60 200,75 27,62 228,37 AR02 Rohrbogen, DN200, li Ø 200x32, R=5*Da ‐ 41,56 8,15 49,71 181,76 27,62 209,38 AI01 Rohrbogen, Bogen B3, li Ø 200x32 1 8,74 14,43 23,17 40,58 47,43 88,01 AI05 Rohrbogen, Bogen B12, li Ø 200x32 1 7,53 14,75 22,27 35,24 48,19 83,43 AI03 Rohrbogen, Bogen B9, li Ø 200x32 1 6,37 14,83 21,20 30,10 48,54 78,64 AI06 Rohrbogen, Bogen B21, li Ø 200x32 2a 6,16 14,89 21,05 29,15 48,60 77,75 AI02 Rohrbogen, Bogen B8, li Ø 200x32 2a 6,01 15,05 21,05 28,48 49,24 77,72 AI04 Rohrbogen, Bogen B10, li Ø 200x32 1 6,08 14,89 20,97 28,80 48,58 77,38

Comparison of results with available as-built geometry and design (if as-built is not available)Influence of consideration of as-built or design geometryDesign geometry with smaller wall thickness results in a reduction of cyclic damage andsignificant increase of creep damageAs built geometry results in small creep damage and higher cyclic damage – total damagehowever is in general smaller.


Scenarios for future operation

Operation time h

Design lifetimeLi

fe c

onsu

mpt

ion

e (t/

t B, n

/NA) %

0

100

2016

Design conditions

dam

age

e.g.

VGB

ratin

g

1

5

Werkstoffschädigung

The estimation of lifetime for different future operation conditions is possible but needs component specific consideration and accurate calculation.

250.000 h 350.000 h320.000 h? 300.000 h

Assumption: Starting at 70% Life consumption


Temperature increase – life time estimation

Temperatureincrease

Based on analysedtime span 2000-2012

Total lifetime consumption

Creep damage


Additional investigation on ex service material

bend 1A-System bend 20

Operation from 09/1981 until 09/2013 Operation hours > 239 000 h Starts: 585 245 bar 530 °C

bend 2C-System bend 7

Operation from 09/1981 - 06/2015 Operation hours > 252 000 h Starts: 614 90 bar 540 °C

DimensionsDaussen = 530 mmDinnen = 454 mm

WD = 38 mmOvalität = 0,89

DimensionsDaussen = 274 mmDinnen = 199 mmWD = 37,5 mm

Ovalität = 0


Investigations on ex-service pipe bends

Creep rupture tests


Investigations on ex-service pipe bends

Creep rupture tests

stre

ss


• NDT-based - analysis of cracks, replica, strains, etc.

• Standard-based as per ISO, European EN Standard, ASME, etc.

• Risk-based for optimizing decision-making related to inspection / maintenance

Remaining life assessments (RLA)

End of life criteria used for RLA has to be linked to the specific damage mechanisms

Material specific problems have to be considered e.g. 9-11%Cr-steels: standard criteria experienced by “conventional” steels could not be used

Calculation:Algorithms forlocal stresseslocal strains

Manufacturing quality:Material (appraisals to Codes)Component manufacturing / heat treatmentNDTComponent as built geometry

Monitoring of loading situation:PressureTemperatureDisplacementsStrain, deformationCorrosion, Oxidation

Ranking of components

considering actual life time expenditure

Summary and Conclusions

Improvement by using inelastic FE-calculationand damage parameters and criterion

Investigations on application of RLA assessment methods under significantlychanged loading conditions are under way (research project within VDEh W 12).


Thank you for your attention!

life assessment as a basis for decision making for future ... klenk wac… · universität...

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