Power Plant Life Management and Performance Improvement

Power Plant Life Management and Performance Improvement

1st Edition - September 28, 2011

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  • Editor: John Oakey
  • Hardcover ISBN: 9781845697266
  • eBook ISBN: 9780857093806

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Description

Coal- and gas-based power plants currently supply the largest proportion of the world’s power generation capacity, and are required to operate to increasingly stringent environmental standards. Higher temperature combustion is therefore being adopted to improve plant efficiency and to maintain net power output given the energy penalty that integration of advanced emissions control systems cause. However, such operating regimes also serve to intensify degradation mechanisms within power plant systems, potentially affecting their reliability and lifespan.Power plant life management and performance improvement critically reviews the fundamental degradation mechanisms that affect conventional power plant systems and components, as well as examining the operation and maintenance approaches and advanced plant rejuvenation and retrofit options that the industry are applying to ensure overall plant performance improvement and life management.Part one initially reviews plant operation issues, including fuel flexibility, condition monitoring and performance assessment. Parts two, three and four focus on coal boiler plant, gas turbine plant, and steam boiler and turbine plant respectively, reviewing environmental degradation mechanisms affecting plant components and their mitigation via advances in materials selection and life management approaches, such as repair, refurbishment and upgrade. Finally, part five reviews issues relevant to the performance management and improvement of advanced heat exchangers and power plant welds.With its distinguished editor and international team of contributors, Power plant life management and performance improvement is an essential reference for power plant operators, industrial engineers and metallurgists, and researchers interested in this important field.

Key Features

  • Provides an overview of the improvements to plant efficiency in coal- and gas-based power plants
  • Critically reviews the fundamental degradation mechanisms that affect conventional power plant systems and components, noting mitigation routes alongside monitoring and assessment methods
  • Addresses plant operation issues including fuel flexibility, condition monitoring and performance assessment

Readership

Power plant operators, industrial engineers and metallurgists, and researchers interested in this important field.

Table of Contents

  • Contributor contact details

    Woodhead Publishing Series in Energy

    Foreword

    Part I: Power plant fuel flexibility, condition monitoring and performance assessment

    Chapter 1: Solid fuel composition and power plant fuel flexibility

    Abstract:

    1.1 Introduction

    1.2 Fuel chemistry and characterisation

    1.3 Use of alternative fuels in combustion power plants and application of technology to improve fuel flexibility

    1.4 Future trends

    1.5 Sources of further information and advice

    Chapter 2: Condition monitoring and assessment of power plant components

    Abstract:

    2.1 Introduction

    2.2 Monitoring boiler and heat recovery steam generator

    2.3 Steam turbines and generators

    2.4 Condition monitoring of gas turbines

    2.5 In situ assessment of gas turbine hot parts by non- destructive techniques

    2.6 Remote monitoring solutions

    2.7 Future trends

    Chapter 3: Availability analysis of integrated gasification combined cycle (IGCC) power plants

    Abstract:

    3.1 Introduction

    3.2 Basic structure of integrated gasification

    3.3 Availability issues of the ASU

    3.4 Availability issues of the gasification unit

    3.5 Availability issues of acid gas removal (AGR) and sulfur recovery

    3.6 Availability issues of the combined cycle

    3.7 Summary of existing plants

    3.8 Forecast based on RAM modeling

    3.9 Future trends

    Part II: Coal boiler plant: materials degradation, plant life management and performance improvement

    Chapter 4: Environmental degradation of boiler components

    Abstract:

    4.1 Introduction

    4.2 Component operating environments

    4.3 Degradation mechanisms and modeling

    4.4 Quantification of damage and protective measures

    4.5 Future trends

    4.6 Sources of further information and advice

    Chapter 5: Creep in boiler materials: mechanisms, measurement and modelling

    Abstract:

    5.1 Introduction

    5.2 Creep deformation and damage mechanisms in boiler materials

    5.3 Measurement methods

    5.4 Effect of operating environment

    5.5 Predictive modelling

    Chapter 6: Microstructural degradation in boiler steels: materials developments, properties and assessment

    Abstract:

    6.1 Introduction

    6.2 The development of steel for power engineering

    6.3 Methodology for assessing the state of a material and determining the residual durability of the operational elements under creep conditions

    6.4 Characteristics of microstructure and property degradation processes

    6.5 Preparation of a classification system for material after operation

    6.6 Modeling degradation processes and their use

    6.7 Conclusion

    Chapter 7: Boiler steels, damage mechanisms, inspection and life assessment

    Abstract:

    7.1 Introduction

    7.2 Boiler materials, metallurgy and microstructure

    7.3 Damage mechanisms and component failure

    7.4 Inspection and monitoring of damage and integrity/life assessment issues in high chromium martensitic steels

    Part III: Gas turbine plant: materials degradation, plant life management and performance improvement

    Chapter 8: Creep, fatigue and microstructural degradation in gas turbine superalloys

    Abstract:

    8.1. Introduction

    8.2. Creep

    8.3. Fatigue

    8.4. Combined creep and fatigue

    8.5. Microstructural degradation

    8.6. Future trends

    8.7. Conclusion

    Chapter 9: Gas turbine materials selection, life management and performance improvement

    Abstract:

    9.1 Introduction

    9.2 Superalloys

    9.3 Protective coatings

    9.4 Material applications

    9.5 Advanced materials and coatings

    9.6 Life management and diagnostic

    9.7 Future trends

    9.8 Sources of further information and advice

    9.10 Appendix 1: nomenclature

    9.11 Appendix 2: key definitions

    Chapter 10: Gas turbine maintenance, refurbishment and repair

    Abstract:

    10.1 Introduction

    10.2 Field service overhaul and maintenance

    10.3 Parts refurbishment: incoming inspection

    10.4 Parts repair

    10.5 Coating and finishing technology

    10.6 Final repair operations

    10.7 Quality control and first article inspection

    10.8 Part life extension and optimisation

    10.9 Future trends

    10.10 Conclusion

    Part IV: Steam boiler and turbine plant: materials degradation, plant life management and performance improvement

    Chapter 11: Steam oxidation in steam boiler and turbine environments

    Abstract:

    11.1 Introduction

    11.2 Steam boiler and turbine environments

    11.3 Oxidation thermodynamics and kinetics

    11.4 Scale morphology and spallation

    11.5 Steam oxidation management

    11.6 Future trends

    11.7 Conclusion

    11.8 Sources of further information and advice

    11.10 Appendix: nominal alloy composition for alloys of interest.

    Chapter 12: Steam boiler component loading, monitoring and life assessment

    Abstract:

    12.1 Introduction

    12.2 Analysis of different ways of conducting start-up and shut-down operations and their influence on thermal and total stress loads in critical pressure components

    12.3 Monitoring of remnant lifetime of pressure components

    12.4 Conclusions

    Chapter 13: Steam turbine materials selection, life management and performance improvement

    Abstract:

    13.1 Introduction

    13.2 High temperature cylinders

    13.3 Low temperature cylinders

    13.4 Conclusion

    Chapter 14: Steam turbine upgrades for power plant life management and performance improvement

    Abstract:

    14.1 Introduction

    14.2 Drivers

    14.3 Product selection and specification

    14.4 Performance improvement

    14.5 Mechanical design

    14.6 Installation

    14.7 Conclusion

    14.9 Appendix: glossary

    Part V: Heat exchangers and power plant welds: materials management and performance improvement

    Chapter 15: High-temperature heat exchangers in indirectly fired combined cycle (IFCC) systems: materials management and performance improvement

    Abstract:

    15.1 Introduction

    15.2 High-temperature heat exchanger (HTHX) construction

    15.3 Pilot-scale HTHX testing

    15.4 Conclusions

    15.5 Acknowledgments

    Chapter 16: Heat recovery steam generators: performance management and improvement

    Abstract:

    16.1 Introduction

    16.2 Gas turbine heat recovery steam generators (HRSGs)

    16.3 How pinch and approach points affect HRSG size and steam generation

    16.4 HRSG simulation

    16.5 Improving HRSG efficiency

    16.6 Conclusion

    16.9 Appendix: nomenclature

    Chapter 17: Power plant welds and joints: materials management and performance improvement

    Abstract:

    17.1 Introduction

    17.2 Materials selection and development

    17.3 Weld/joint degradation

    17.4 Application of degradation-protection technologies

    17.5 Impact on power plant performance/life management

    17.6 Dissimilar joints

    17.7 Inspection and hardness testing

    17.8 Repair

    17.9 Future trends

    17.10 Sources of further information and advice

    17.11 Acknowledgements

    Index

Product details

  • No. of pages: 704
  • Language: English
  • Copyright: © Woodhead Publishing 2011
  • Published: September 28, 2011
  • Imprint: Woodhead Publishing
  • Hardcover ISBN: 9781845697266
  • eBook ISBN: 9780857093806

About the Editor

John Oakey

Professor John E. Oakey is Head of the Energy Technology Centre at Cranfield University, UK, and is renowned for his work on advanced materials and technologies for energy systems and plant life extension.

Affiliations and Expertise

Cranfield University, UK

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