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REPORT TITLE: BOILER MATERIALS FORULTRASUPERCRITICAL COAL POWER PLANTS

Type of Report: Quarterly

Reporting Period Start Date: January 1, 2002Reporting Period End Date: March 31, 2002

Principal Author: R. Viswanathan

EPRI

Date Report Issued: April 15, 2002

DOE Award Number: DE-FG26-01NT41175OCDO Grant Number: D-00-20

Submitting Organization: The Energy Industries of Ohio, Inc.Park Center One, Suite 2006100 Oak Tree BoulevardIndependence, Ohio 44131

Participating Organizations:

Alstom Power, Inc.2000 Day Hill Road

Windsor, CT 06095

Babcock Borsig Power, Inc.5 Neponset Street

Worcester, MA 0615

Foster Wheeler Development Corp.12 Peach Tree Hill Road

Livingston, NJ 07039McDermott Technology, Inc./Babcock & Wilcox Company1562 Beeson St.

Alliance, OH 44601

Electric Power Research Institute(EPRI)3412 Hillview AvenuePalo Alto, CA 94303

Oak Ridge National Laboratory1 Bethel Valley Road Bldg. 4500SOak Ridge, NY 37831-6156

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USC Materials Quarterly Report Jan-Mar, 2002 April 15, 2002

U.S. Department of Energy Disclaimer

This report was prepared as an account of work sponsored by an agency of the United StatesGovernment. Neither the United States Government nor any agency thereof, nor any of theiremployees, makes any warranty, express or implied, or assumes any legal liability or responsibility forthe accuracy, completeness, or usefulness of any information, apparatus, product, or processdisclosed, or represents that its use would not infringe privately owned rights. Reference herein to anyspecific commercial product, process, or service by trade name, trademark, manufacturer, or otherwisedoes not necessarily constitute or imply its endorsement, recommendation, or favoring by the UnitedStates Government or any agency thereof. The views and opinions of authors expressed herein do nonecessarily state or reflect those of the United States Government or any agency thereof.

Project Consortium Legal Notice/Disclaimer

This report was prepared by the Energy Industries of Ohio in consortium with theElectric Power Research Institute, Inc. (EPRI); Alstom Power, Inc; Babcock BorsigPower, Inc.; Babcock & Wilcox/McDermott Technology, Inc.; and Foster WheelerDevelopment Corporation pursuant to a Grant partially funded by the U.S. Department ofEnergy (DOE) under Instrument Number DE-FG26-01NT41175 and the Ohio CoalDevelopment Office/Ohio Department of Development (OCDO/ODOD) under Grant

Agreement Number CDO/D-00-20. NO WARRANTY OR REPRESENTATION,EXPRESS OR IMPLIED, IS MADE WITH RESPECT TO THE ACCURACY,

COMPLETENESS, AND/OR USEFULNESS OF INFORMATION CONTAINED IN THISREPORT. FURTHER, NO WARRANTY OR REPRESENTATION, EXPRESS ORIMPLIED, IS MADE THAT THE USE OF ANY INFORMATION, APPARATUS, METHOD,OR PROCESS DISCLOSED IN THIS REPORT WILL NOT INFRINGE UPONPRIVATELY OWNED RIGHTS. FINALLY, NO LIABILITY IS ASSUMED WITHRESPECT TO THE USE OF, OR FOR DAMAGES RESULTING FROM THE USE OF,

ANY INFORMATION, APPARATUS, METHOD OR PROCESS DISCLOSED IN THISREPORT.

Reference herein to any specific commercial product, process, or service by trade name,trademark, manufacturer, or otherwise, does not necessarily constitute or imply its

endorsement, recommendation, or favoring by the Department of Energy and/or the Stateof Ohio; nor do the views and opinions of authors expressed herein necessarily state orreflect those of said governmental entities.

NOTICE TO JOURNALISTS AND PUBLISHERS: Please feel free to quote and borrowfrom this report, however, please include a statement noting that the U.S. Departmentof Energy and the Ohio Coal Development Office provided support for this project.

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1.0 Executive Summary

A. Project Objective

The principal objective of this project is to develop materials technology for use in ultrasupercritical(USC) plant boilers capable of operating with 760C (1400F), and up to 5500 psi with emphasis upon35 MPa (5000 psi) steam.

B. Background and Relevance

In the 21st century, the world faces the critical challenge of providing abundant, cheap electricity tomeet the needs of a growing global population while at the same time preserving environmentalvalues. Most studies of this issue conclude that a robust portfolio of generation technologies and fuelsshould be developed to assure that the United States will have adequate electricity supplies in a varietyof possible future scenarios.

The use of coal for electricity generation poses a unique set of challenges. On the one hand, coal isplentiful and available at low cost in much of the world, notably in the U.S., China, and India. Countrieswith large coal reserves will want to develop them to foster economic growth and energy security. Onthe other hand, traditional methods of coal combustion emit pollutants and CO2 at high levels relativeto other generation options. Maintaining coal as a generation option in the 21st century will requiremethods for addressing these environmental issues.

This project has established a government/industry consortium to undertake a five-year effort toevaluate and develop advanced materials that allow the use of advanced steam cycles in coal-basedpower plants. These advanced cycles, with steam temperatures up to 760C, will increase the

efficiency of coal-fired boilers from an average of 35% efficiency (current domestic fleet) to 47% (HHV).This efficiency increase will enable coal-fired power plants to generate electricity at competitive rates(irrespective of fuel costs) while reducing CO2 and other fuel-related emissions by as much as 29%.

Success in achieving these objectives will support a number of broader goals. First, from a nationalprospective, the program will identify advanced materials that will make it possible to maintain a cost-competitive, environmentally-acceptable coal-based electric generation option. High sulfur coals willspecifically benefit in this respect by having these advanced materials evaluated in high-sulfur coalfiring conditions and from the significant reductions in waste generation inherent in the increasedoperational efficiency. Second, from a national perspective, the results of this program will enabledomestic boiler manufacturers to successfully compete in world markets for building high-efficiency

coal-fired power plants.

The project is based on an R&D plan developed by the Electric Power Research Institute (EPRI) thatsupplements the recommendations of several DOE workshops on the subject of advanced materials,and DOEs Vision 21. In view of the variety of skills and expertise required for the successfulcompletion of the proposed work, a consortium that includes EPRI, McDermott Technology Inc. (MTI)and the major domestic boiler manufacturers (Alstom Power, Babcock and Wilcox, Foster Wheeler andBabcock Borsig Power) has been developed.

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C. Project Tasks

The project objective is expected to be achieved through 9 tasks as listed below:

Task 1. Conceptual Design and Economic AnalysisTask 2. Mechanical Properties of Advanced AlloysTask 3. Oxidation ResistanceTask 4. Fireside Corrosion ResistanceTask 5. Welding ReviewTask 6. FabricabilityTask 7: CoatingsTask 8: Design Data and RulesTask 9: Project Integration and Management

D. Major Accomplishments During the Quarter

Preliminary conceptual design work is nearly complete at both Alstom Power Co. and Babcock &Wilcox. It was determined that although the optimum plant efficiencies for 1400F main steamwould be achieved at a steam pressure of 6500 psi, the stresses would be excessive to permituse of any existing materials and the impact of the higher pressure on material costs would not beeconomically justifiable. Therefore, 1400F/1400F/-5000 psi was established as the project goal.Under these conditions only one alloy (i.e. IN 740) was found to be applicable for bothsuperheater (SH) outlet headers and finishing SH tubes. Selecting the steam conditions to be1350F/1400F/5000 psi, rendered many more alloys applicable and at lower wall thicknesses,permitting plant cycling. The latter condition was therefore established as an initial first step toexplore.

Achievable plant efficiencies were estimated to be about 47% on a High Heating Value (HHV)basis compared to 35% for state-of-the-art (SOA) supercritical plants. Efficiency values reportedfor European plants are generally on a Low Heating Value (LHV) basis and are not comparable toU.S. plants due to variety of differences. This issue will be further examined and reported underTask 1.

For the highest temperature headers and superheater conditions alloy IN 740 was found to beclearly the most suitable followed by Nimonic 230. For intermediate temperature headers Super304 or HR120, and for SH tubing Marko Alloy 617, IN 617, Super 304, HR120 and HR6W may besuitable. For waterwall tubes alloy T23 (HCM2S) is deemed adequate and will be evaluated.

Other ferritic steels such as P92 and P122 have already been investigated extensively by EPRIand others and hence will be evaluated only to a limited degree in this project.

Responsibilities for specifying, qualifying and procuring the above materials have been assignedto the appropriate consortium members. Each company will coordinate purchasing anddistributing the alloy/alloys assigned, including distribution to ORNL. Some information regardingavailability of the materials has already been generated by contacts with vendors. It is anticipatedthat orders will be placed by the end of April with a delivery time of 18-24 weeks.

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In addition to the above alloys, small samples of alloy 188, RA 333, 310 CbN, RA 253, SAVE 12,P92, and P1222 will also be included in the corrosion studies.

Summary reports regarding alloy selection have been prepared by B&W, MTI and ORNL. Thesewill be issued in the course of the next few months.

Economic analysis of plant break even costs for USC plants, for various heat rates, capacityfactors, fuel costs and many other variables has been completed and a report will be issuedduring this year.

Detailed test program for the mechanical tests has been laid out.

Review of literature relating to steamside oxidation has been completed and several usefulconclusions have been reached. Test conditions and facilities have been established. It is

anticipated that test facilities will be completed by August 2002 and that tests will be started byJanuary 2003.

Test loop designs for fireside corrosion are being modified for USC conditions. Candidate alloyshave been identified. The Reliants Niles Plant at Niles, Ohio has been confirmed as a field testsite.

Review of literature on coatings is completed and the task report is expected to be issued in thenext few months.

A meeting of the steering committee and task group leaders was held on March 7 and 8, 2002. In

addition, a conference call with all the team members were held on February 18 and April 3, 2002(see Attachments 1-3 for Minutes). The committee structure established by the consortium isfunctioning very smoothly.

E. Plans for the Next Quarter

It is anticipated that the following work will be completed during the next quarter:

Issue of draft reports on alloy selection (by B&W, MTI and ORNL) coating technology (by Alstom)and steamside oxidation (B&W).

Completion of work on Task 1 conceptual design and on the economic analysis. Assemble report

and ready for issue.

Finalization of material needs and issuing purchase order(s).

Start of construction of test facility for steamside oxidation testing at McDermott Technology Inc.

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Definition of tube dimensions of probes and identification of host sides for fireside corrosion byFoster Wheeler Development Corporation.

Selection of welding process to be evaluated.

Location of filler materials and sources.

Technical efforts will continue.

F. Issues

Reduction in FY 02 funding has resulted in deferring some of the tasks. The rescheduling andreorganization of the milestones was done at considerable expense of time. FY 03 fundingsufficient to maintain planned work is required to sustain the project effort into next year. DOEFY 03 budgeting considerations should be addressed.

Consortium members have indicated that the cost of materials is expected to substantially exceedtheir anticipated (allocated) costs and that adjustment to the budget or scope may be needed.

Availability of alloy Marko 617 is still uncertain. Final selection of alloys still awaits moreinformation.

Timely input and feedback to the project manager by the consortium members continues to be aconcern.

Delivery lead time of 18-24 weeks for materials can turn out to be a schedule problem ifprocurement is not initiated on time.

Some large utilities such as Southern Company, NRECA and AEP have expressed a desire to actin advisory roles and attend project meetings. The Steering Committee has agreed to approvethis on a case-by-case basis. EPRI would like to seek their participation and to expand suchparticipation by other stakeholders on a more consistent basis with the approval of the sponsorsand the Steering Committee.

The lead role for Task 8 (codes and design) has been transferred to John Fishburn of AlstomPower from Mike Gold of B&W.

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2.0 Taskwise Status

Task 1: Conceptual Design and Economic Analysis (Task lead EPRI)

The objective of Task 1 is to specify the temperature/pressure distribution for 760C/35 MPa(1400F/5000 psi). Steam inlet conditions will be determined so that the data needs and therange of test parameters can be identified and the economics of material selection established.

Task 1A: Alstom Approach (Alstom Power Co.)

Objectives: The primary objectives of this subtask are:

- Develop a conceptual boiler design for a high efficiency ultra supercritical cycle designed for1400F steam temperature.

- Identify tubing and piping materials needed for high temperature surface construction.

- Estimate gas and steam temperature profiles so that appropriate mechanical, corrosion andmanufacturing tests of materials can be designed and conducted to prove the suitability of theselected alloys.

Progress for the Quarter:

Initial efforts focused on selecting appropriate boiler design parameters. Since steam turbineheat balance for 1400F/1400F temperatures was not available, existing steam turbine heat

balances for lower steam conditions were reviewed. Optimum efficiencies are achieved whenoperating temperatures are matched with specific operating pressures. However determination ofthe optimum steam cycle efficiency for a given operating temperature requires detailed analysesof a steam turbine design and performance which is outside the scope of this project. Inestablishing the operating pressure for a 1400F cycle, a single reheat Thermie cycle designed for1292F/1328F/5292psi was considered. Information from the Thermie steam turbine wasextrapolated for the higher steam temperature. The resulting steam turbine throttle pressure of6500 psi was selected for the initial boiler analyses.

Conceptual boiler design work has been carried out for a plant rated at 700MW electrical outputfiring Ohio type coal. A number of boiler surface arrangements were considered and a

conventional panel type architecture was selected. Heat transfer surfaces were selected, boilerperformance was determined; and gas and steam temperature profiles were calculated.

High strength alloys for high temperature applications were reviewed and candidate alloys foradvanced steam conditions were identified. All of the promising candidate materials such asIN740, IN 230, IN 617, and HR6W are not typically used by the boiler industry. Analysis of thesteam outlet headers and piping indicated that IN740 is the only material that has adequatestrength. However, the outlet headers fabricated from this alloy would have very thick walls that

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may not be adequate for cycling duty. In general it is desirable to have cycling capabilities and allrecent designs appear to have it. However, by virtue of the high efficiency and materialslimitations and it is believed that these high temperature designs need to be base loaded.Lowering design conditions reduced the wall thicknesses and enabled the application of otheralloys beside IN 740. When the operating pressure was decreased to 5500psi/1400F/1400F,application of IN230 became feasible. However, the wall thickness was also very large and theengineering solution required increasing the number of main steam lines from 2 (IN 740) to 4 (IN230). Lowering the main steam temperature to 1350F made the use of IN617 possible.However, again, headers and piping wall thickness was judged to be too thick and four mainsteam lines were required. HR6W and IN617 have similar strength, therefore, application ofthese alloys is limited to similar operating conditions. All other available alloys do not appear tobe suitable for very high temperature application. Fabrication concerns, if any, of headers andpiping made of IN740 and IN230 need to be more fully examined.

Metal temperatures were checked for the SH finishing surface applying IN 617. Allowable metaltemperatures of tubing were exceeded by a substantial amount for design conditions at6500psi/1400F. Suitability of IN740 was also checked. The wall thickness of some tubing was

judged to be too thick. Based on the preliminary assessment of the pressure parts, it wasrecommended that operating conditions be lowered to boiler outlet conditions of1350F/1400F/5500psi and that these conditions be explored as initial targets. INCO 740 is anexcellent alloy for this application.

The boiler was resurfaced for lower steam conditions. A metal temperature program was set-upto select appropriate tubing materials. Superheater finishing section was analyzed. The analysisindicated that the entire finishing section would need to be constructed of IN740 alloy. All otheralloys, because of smaller allowable stresses at high temperatures, produce unacceptably thickwalls. Metal temperature analyses of superheater panels and platens are in progress. Apreliminary conclusion leads one to believe that IN740 and IN230 are crucial to the developmentof the advanced steam cycle.

Concerns: Budget shortfall is a concern.

Plans for the Next Quarter: Design investigations will be continued. Analyses of the superheatersections will be completed. Material requirements for the waterwalls and reheater finishingsection will be determined. Draft report will be issued by July.

Task 1B: B&W Approach (Babcock & Wilcox Co.)

Objective: The objectives of this subtask are the same as in Subtask 1A..


- Prepared a final Draft white paper summarizing ferritic and austinetic superalloy materialsthat are best candidates for USC boilers.

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- Attended Pittsburgh meeting to discuss and review results with the steering committee.

- Several turbine cycles were studied to assess the impact of pressure on efficiency as well asboiler and piping materials and thicknesses leading to the selection of a 5000 psi for designpressure. Turbine heat balances for various loads were provided for the 5500 psi/ 1400F /1400F case and the 5000 psi / 1350F /1400F case. Ohio coal from the Pittsburgh 8 seamwas used for the calculations. The impact of single and double reheat was assessed and asingle reheat cycle was used for the design studies.

- Main steam temperature is being studied to determine cost/benefit. Reducing main steam to1350F results in a significant impact on materials. Consideration is being given to this costreduction versus the impact on efficiency.

- Initiated work to develop a conceptual boiler design.

- The lower furnace tube material was evaluated for 5000 and 6500 psi steam conditionsconsidering a higher enclosure inlet temperature. At 5500 psi or lower turbine inlet pressure,T-23 material is suitable to achieve reasonable thicknesses. Above that pressure moreexpensive T-92 would be required.

- Due to excessive economizer surface and potentially high temperatures to the furnace inletfrom the economizer, an alternative low-pressure heat exchanger system is being investigatedto take more heat out of the flue gas at the FGD and between the economizer and theairheater. This energy displaces steam turbine extraction and reduces the heat rate (increaseefficiency).

- A preliminary 750 MWe boiler proposal side view drawing was completed.

Concerns: No concerns at this time.

Plans for the Next quarter:

- Complete investigation of flue gas feedwater heating to lower heat rate and fluid inlettemperature to the furnace enclosure.

- Determine the efficiency of the selected cycle based on both U.S. and European assumptionsand relate the results to the program goal.

- Report on the process of selecting the design pressure and discuss cycle efficiency.

- Initiate economic analysis.

- The subtask will be completed and a subtask report issued by July 31, 2002.

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Task 1C: Economic Analysis

Objective: The objective of this task is to determine relative economics of the USC plant.

Progress for the Quarter: A net heat rate of 7,570 Btu/kWh (45.8%) HHV was assumed basedon heat balance for a 1350F/1400F/5000 psi single reheat plant. For a condenser pressure of2.0 in HgA, the USC total plant cost that would give the same 20 year levelized cost of electricityas a conventional subcritical PC plant, assuming 80% capacity factor and $1.50/MMBtu cost forOhio coal were calculated. Salient conclusions are as follows:

- The USC total plant cost can be 11.5% higher at the same cost of electricity as a conventionalsubcritical PC Plant.

- Improved efficiency leads to 13% lower USC Balance of Plant (BOP) cost. Smaller coalhandling, pollution control, and other BOP costs for the same net plant output are estimated.

- USC Boiler/Steam Turbine costs can be 40% higher than a conventional subcritical plant.Note that the same percentage was assumed for Indirects, Engineering, and Contingency forthe two types of plants.

Concerns: None

Plans for the Next Quarter: The model will be refined and extra case run based on any commentsreceived from the Steering Committee. The subtask will be completed and a report issued beforeSeptember 30, 2002.

Task 2. Mechanical Properties of Advanced Alloys

The objective of Task 2 is to produce the database needed to design a boiler to operate at the steamconditions within the scope of the project. In the near term, the target steam conditions are 760C(1400F) and 35 MPa (5000 psig). To attain this objective, eight subtasks have been identified thatrelate to material selection, test plan development, and data collection to meet the needs of a state-of-the-art design methodology consistent with internationally accepted power boiler construction codes.

Subtask 2A: Assessment of the Alloy Performance Requirements:

This assessment will focus on performance needed for boiler service in the temperature range of1200F (649C) to 1600F (871C) and will provide justification for the materials selected for thepressure retention components of the boiler.

Consortium participants provided recommendations and assistance in the down-selection of materialsfor evaluation. To achieve the 760C steam condition, the alloys of choice were two martensitic steelsfor tubing and piping (NF12 and SAVE 12), two austenitic alloys for tubing (310HCbN and HR6W),

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and four nickel-base alloys for tubing and some heavy section usage (alloy 230, alloy 617, Inconel 740and modified alloy 617).

The report that provides background and details of the assessment is still being written. The sectionon low alloy steels and 9-12% chromium steels has been completed and is in review. The fullassessment report is not expected until May.

Task 2B: Detailed Test Plan:

The mechanical properties test plan is being reviewed in light of the materials selected for the initialthrust of the project. The data available for each of the candidate materials will be reviewed andsupplementary testing needs identified when applicable. Data needed to characterize the specificheats and product forms will be identified in the test plan.

Data are being collected for each of the eight alloys identified in Subtask 2A. Three of the materials(310HCbN, alloy 230, and alloy 617) have very extensive databases. Here, the mechanical testing

plan will include characterization testing and those supplementary tests needed to address issuesidentified in Task 8 on codes and standards.

Task 2C: Long Term Creep Strength:

The objective of the long-term creep testing is to identify the general characteristics of the creep anddamage accumulation in the candidate alloys.

Currently, 40 creep machines have been assigned to Task 2C. Of these, 20 are in use but will be re-assigned when testing materials become available. An additional 20 machines are being refurbishedand will have improved extension sensors and temperature control systems for testing of the nickel

base alloys to 871C (1600F).

Task 2D: Microstructural Analysis:

The objective of the microstructural analysis is to identify the microstructural changes that significantlylead to strengthening, weakening, and internal damage characteristic of each material and to explorehow these characteristics relate to the exposure conditions of the testing.

June, 2002 is the target date for the start of a university subcontract to perform microstructural analysisof the austenitic alloys. Emphasis will be placed on the aging response of Inconel 740 and modifiedalloy 617.

Time-temperature-precipitation diagrams are being collected for other alloys identified in Task 2A.

Task 2E: Assessment of Creep-Fatigue Properties:

The objective of the creep-fatigue studies is to develop a database that will lead to a practical yetconservative method to address the issue of creep-fatigue damage in the boiler materials. Specific

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fatigue conditions including thermal-mechanical fatigue and thermal shock will be addressed for thosematerials used in components that could encounter such loading conditions.

Two resistance furnaces were obtained for the creep fatigue testing of the martensitic steels. A designfor an improved gripping designs was completed. Several fatigue specimens of HT9 steel wereordered to enable checkout testing to be performed on 12% chromium steels. Several fatiguespecimens of alloy 120 were ordered to enable checkout testing of austenitic alloys.

A thermal shock loading system for heavy wall tubes was located and steps needed to re-commissionthe system are being identified.

Task 2F: Modeling of Weld Joints:

The objective of Task 2F is to produce the experimental data needed model dissimilar metal and thicksection weld joints.

Two large capacity creep frames (50,000 and 100,000 pounds force) were set aside for testing thick-section weldments. Several 20,000 pound force machines were designated for use. Conceptualdesigns for specimens were started.

Task 2G: Study of Accelerated Testing Methods:

The objective of the accelerated testing is to provide a method to rapidly characterize changes in thestrength of the candidate materials. Such changes could occur as a result of fabrication strains,thermal or mechanical overloads, or simply thermal exposure.

Relaxation testing and indentation creep testing are two methods that have been used as means of

accelerated testing.

A relaxation system was re-commissioned and Inconel 740 specimens were obtained for checkouttesting.

Task 2H: Model Validation:

The objective of the model validation testing is to produce a database that can be used to confirm orvalidate the design rules that are developed in Task 8.

Efforts to develop the model validation subtask have not progressed beyond the preliminary test matrix

identified in the test plan.

Task B: Steamside Corrosion Resistance

A liaison meeting with McDermott Technologies was held in March. Also, a visit was made to CCTechnologies to inspect their pressurized steam exposure facilities.

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Task 3: Steamside Oxidation Resistance (Task lead MTI)

The objective of this task is to evaluate the relative oxidation resistance of various advanced alloys and

to identify the temperature limits for each.

Task 3A; Autoclave Testing

Objective: To perform steamside oxidation tests on commercially available and developmentalmaterials at temperatures between 650C and 900C (1202F - 1652F).

Progress for the Quarter: The steam oxidation test facility was evaluated in greater detail duringthe quarter ended March, 2002. The furnace in which the test will be performed was identified,along with a retort (in which the specimens will be placed) that fits inside the furnace. The retort,shown in Figure 1, is composed of 310SS, and is felt to be inadequate for the temperatures that

will be evaluated during this program. Thus, it appears that either a new vessel will have to beconstructed from different material, or that the current retort will have to be coated.

~ 6

FIGURE 1 310SS RETORT AT MTI

The retort is configured to permit steam to enter at one end of the vessel, and exit at the otherend of the vessel. The anticipated testing configuration is shown in Figure 2.

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To Drain

Cooling CoilBPR

Furnace

Pump

Feedtank

Preheater

Test Vessel with Coupons

FIGURE 2 ANTICIPATED STEAM OXIDATION TEST CONFIGURATION

During the evaluation of the test facility, it became obvious that the MTI test facility is not configured toperform high pressure testing. Modifying the MTI facility to accommodate high pressure conditionswould be cost prohibitive. Thus, an alternate facility will be sought to perform any high pressure tests.

A meeting was held at MTI on February 18, 2002 with representatives of MTI, Oak Ridge NationalLaboratory (ORNL), and B&W to discuss the steam oxidation programs that were to be performed at

MTI and ORNL. During this meeting, it was learned that Ian Wright (ORNL) was going to visit CCTechnologies in Columbus, Ohio regarding high pressure steam oxidation testing. The results of Iansinitial visit to CC Technologies was positive, but test plans have not yet been finalized.

From the February 18 meeting, it appears that both MTI and ORNL will be testing commercial ferriticand austenitic alloys. In addition, MTI will be testing coated materials and ORNL will be testing modelFe-Cr and Fe-Cr-Ni alloys. Differences in the test materials and test conditions will make the resultsfrom the test programs at MTI and ORNL both complete and complimentary.

Discussions with B&W and ORNL, along with consideration of MTIs test facility size and capabilitieshave lead to the following description of the anticipated steam oxidation tests that will be performed at

MTI:

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Anticipated MTI Steam Oxidation Test

Test Conditions Steam produced from OWT water (~100 ppb O2)

Tests run at 650, 800 and 900C (1202, 1472 and 1652

F)

Low steam flow velocity Test pressure at near atmospheric

Test Specimens Specimen dimensions of 1 x 1 x thickness (~0.25) Specimens to have rounded corners Specimens will be vertically oriented parallel to steam flow Triplicate specimens of each test material 20 materials tested per run, a total of 60 specimens per run Specimens visually examined after 1000, 2000 and 4000 hours One specimen from each material weighed and destructively examined to

determine scale thickness after 1000, 2000 and 4000 hours

Test Materials A group of ~10 Baseline alloys will be included in all three test runs Up to 6 coated materials will be included in each test run Commercial ferritic materials will be emphasized at the lower temperatures Commercial austenitic materials will be emphasized at the higher

temperatures Materials included in the tests will depend upon availability Anticipated Baseline alloys:

Ferritic T23, P92 and SAVE12Austenitic 230, HR-120, 188, 617, IN-740, Super 304H and HR6W

B&W provided MTI with plates of materials that they received from Haynes for this project. Thematerials were 230 Alloy, HR-120, 617 Alloy and 188 Alloy. MTI cut sufficient material from theseplates to meet the needs of the steam oxidation tests at MTI. The remainder of these plates arecurrently at MTI and have been offered to ORNL for their steam oxidation tests, and to Foster Wheelerfor their fireside tests.

Contacts have been made with Foster Wheeler and Alstom to coordinate obtaining materials for steamoxidation testing, fireside testing and coating tests.

Concerns: None

Plans for Next Quarter: Between April and June, 2002, MTI will begin constructing the test facilityand will determine if a new retort must be constructed. Test materials will be collected and the listof materials that will be included in each test run will be modified to reflect availability of thematerials. Additional contacts will be made with ORNL to finalize plans for a high pressure testrun, possibly at CC Technologies.

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Task 3B: Coating Tests

Objective: To evaluate coated specimens for steamside oxidation resistance in conjunction withTask 7.

Progress for the Quarter: Information was disseminated to Task 7 personnel regarding thespecimen size and approximate number of materials that could be accommodated in each steamoxidation test run. MTI initiated a dialogue between the Task 7 leader and Integran (a companylocated in Canada) regarding inclusion of Integran material in the USC program. Integranproduces grain boundary engineered (GBE) materials which may provide improved corrosionbehavior and mechanical properties for some of the materials being considered.

Concerns: None

Plans for the Next Quarter: Communications will be maintained with Task 7 personnel tocoordinate delivery of coated materials for the first steam oxidation test run.

Task 3C: Assessment of Temperature

Objective: To determine the practical temperature limits for the materials based on the steamsideoxidation test results.

Progress for the Quarter: None

Concerns: None

Plans for the Next Quarter: None

Task 3D: Review of Available Information & Reporting

Objective: To review available steamside oxidation literature pertaining to materials andenvironmental conditions of interest. Project status updates will be prepared and status meetingswill be attended as required.

Progress for the Quarter: The literature review for ferritic/martensitic materials is nearly complete.Preliminary results from this review are as follows:

- At ~550C, 9-12% Cr and 2-3% Cr alloys oxidize at about the same rate.

- At ~700C, alloys with >10-11% Cr display much lower oxidation rates than lower Cr alloys

- Below 700C oxidation follows a parabolic rate law

- Two studies reported linear oxidation for Fe-Cr alloys with up to 15% Cr at 700-1200 C

- 11-12% Cr alloys display inhomogeneous scales; 9% Cr alloys display uniform scales

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- Cr and Si are effective in controlling oxidation, however, Si concentrations >0.4% aredetrimental to toughness properties

- Oxide scales consist of an outer magnetite layer and an inner Fe-Cr oxide spinel; for high Cralloys, a Cr-rich layer was observed at the metal/scale interface

- Preliminary findings from literature are that ferritic materials will have unacceptable steamoxidation rates at temperatures above ~650C

Steam oxidation literature for austenitic materials has been ordered. A draft of the literaturereview should be available by the end of April, 2002.

Monthly status reports were prepared for January and February, 2001. The information in thisreport was presented at the DOE/OCDO Project Review Meeting in Pittsburgh, PA on March 7,2002.

Concerns: None

Plans for the Next Quarter: The literature review will be completed and issued. Monthly statusreports will be written for April and May 2002.

Task 3E: Conduct Experimental Exposures

Objective: To evaluate the steam oxidation behavior of model Fe-Cr alloys.

Progress for the Quarter: Since ORNL has some model Fe-Cr and Fe-Ni-Cr alloys available,

there appears to be no need for MTI to fabricate any additional model alloys. Current plans arefor ORNL to perform the testing of these model alloys. MTI will remain cognizant of the ORNLtest results on these model alloys.

Concerns: None

Plans for the Next Quarter: MTI will maintain cognizance of ORNL activities pertaining to modelalloy test results.

Task 3F: Characterization

Objective: To characterize samples of the model Fe-Cr alloys fabricated in Task 3E before and aftersteamside oxidation testing using metallographic and electron optic techniques.

Progress for the Quarter: None

Concerns: None

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Plans for the Next Quarter: MTI will maintain cognizance of ORNL activities pertaining to modelalloy characterization.

Task 3G: Data Analysis and Coordination

Objective: To evaluate the steamside oxidation results and to determine the effects of materialproperties and environmental factors on oxidation behavior.

Progress for the Quarter: No progress will be possible until the steamside oxidation tests havebeen completed (GFY2006).

Concerns: None

Plans for the Next Quarter: None

Task 4: Fireside Corrosion (Task lead Foster wheeler)

The objective of the task is to evaluate the relative resistance of various advanced alloys to firesidecorrosion over the full temperature range expected for the USC plant.

Task 4A Laboratory Testing

Objective: To perform laboratory tests on candidate alloys exposed to various depositsrepresentative of the three coals at the range of temperatures expected for the USC plant.

Progress for the Quarter: The materials to test have not been finalized and therefore the

laboratory tests have not begun. The apparatus and test plan are being reviewed to beginmaterial procurement.

Concerns: None

Plans for Next Quarter: Finalize materials and procure test materials. Candidate materials needto be identified and procured.

Task 4B Corrosion Probe Testing in Utility Boilers

Objective: To install corrosion probes of various alloys at three coal fired power plants and

control them at the temperature ranges expected for the USC plant.

Progress for the Quarter: Previous corrosion probe designs are being reviewed in light of thehigher test temperatures to determine the required probe dimensions. This information will beutilized for probe material procurement.

Concerns: Identification of correct tubing diameters is crucial before procurement can bespecified.

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Plans for Next Quarter: Foster Wheeler will define tube dimensions for probes and begin locatingHost Power Plants.

Task 4C Steam Loop Testing

Objective: To install steam loops at two power stations and evaluate candidate alloys in boilersfor fireside corrosion.

Progress for the Quarter: Material needs for this task were defined and supplied to EPRI.

- A list of preferred choices of materials for the test loop is being developed.- Design of the test loop was initiated is underway.- Haynes International was contacted regarding availability of several material grades for

inclusion in the test loop.- Detailed design of the test loop continues. It was determined that 2 OD tubes could be used

to conform to the wishes of other consortium members in need of test tubing.- Haynes International has responded to our request for availability of several materials by only

supply round bar and plate so ID machining will be necessary.

Concerns: Availability of raw materials in the proper sizes is still a concern.

Plans for Next Quarter:- Continue determination of Host Site Location.- Continue detailed design of the test loop.- Continue to pursue materials.

Task 5: Welding Development (Task lead Alstom Power)

The objectives of the task are:

- To define weld metal choices for candidate materials.

- To evaluate weldability issues.

- To establish acceptable welding procedures and practices.

- To evaluate the effects of manufacturing heat treatments and preheat and post weld heattreatments on weldment integrity and properties.

- To produce samples needed to determine the properties of candidate ultrasupercritical alloywelds and weldments, including the dissimilar metal weld joint between the various types ofmaterial (actual mechanical and property testing will be performed under Task 2).


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The Task 5 efforts were concentrated on identifying the materials that will be used in the programand taking the initial steps toward material procurement. These were more preliminary activitiesrather than being associated with any specific subtask item and included:

- Candidate materials were identified and investigation responsibilities were assigned to thethree organizations participating in this task. Because the high temperature areas in the boilerconfiguration being studied had the greatest level of concern, the materials selected fell intothe higher alloy categories. The assignments, which included procurement responsibility,were as follows:

- McDermott Technology (B&W): Inconel 740 and Haynes 230.

- Babcock Borsig Power: HR6W and SAVE 12 with AC66 and NF12 as alternates.

- Alstom Power: Marco and Super 304H with Inconel 617 as an alternate.

- Initial contacts with suppliers of the materials listed above were made and pricing, productform, and availability information was requested. Some information was received for Inconel740, Inconel 617, and Haynes 230 and complete details for all of the alloys are expected bylate May. The initial data indicate that the nickel base materials will be expensive and,because they are not stocked, will have relatively long lead times.

- Weld filler metal procurement efforts and literature surveys were started for Inconel 740 andHaynes 230. Preliminary information indicates that there have been difficulties weldingHaynes 230 with a submerged arc process, which is often the method of choice for joiningthick sections.

Concerns:

- The actual costs of the nickel base alloys selected for the program might be considerablyhigher than those used for estimating purposes during the proposal development phase andcould have a significant impact on the workscope. For example, the scope of the thick sectioninvestigation efforts might have to be reduced if the material costs cannot be offset.

- The initial investigation regarding joining thick sections of Haynes 230, one of the alloysselected for study, indicates that difficulties will be encountered, at least if a submerged arcwelding process is used.

Plans for the Next Quarter:

- Ordering the materials to be used in the program.

- Selecting the welding processes to be studied.

- Locating sources for filler metals capable of joining the base materials and appropriate for thewelding processes.

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TASK 6: FABRICABILITY (Task lead Babcock and Wilcox)

The objective of the task is establish fabrication guidelines for the alloys needed for boiler componentsin the USC Plant. To establish the affect fabrication operations have on the properties of thesematerials of construction, and the remedial actions needed to return the materials to their originalcondition.

Subtask 6A.3: Superheater Components: Metallurgical Testing and Evaluation

Subtask 6B.4: Thick-Walled Components

Objective: Conduct preliminary processing trials to scale up processes for applying protectivecoatings and claddings.


Material needs for this task were defined and supplied to EPRI.

Preliminary contact with Haynes International and Sumitomo Metals was made regardingproduct forms and sizes needed for this task.

As reported in Task 4C, Haynes International has responded to our request for availability ofseveral materials by indicating they will provide costs of materials they have in stock in thenext week or so. They can only supply round bar and plate.

A meeting has been arranged in April to discuss material availability with Sumitomo.

Concerns: Availability of the proper size of the desired materials is a concern.

Plans for the Next Quarter: Little activity is planned on this task in the way of initiating fabricabilitytests except for activity to collect all material needs of all task participants and continue contactswith raw material suppliers.

Task 7: Coatings (Task lead Alstom Power Co.)

The major objectives for Task 7 Coatings are:

- Review state-of-the-art of coating technology and identify development needs.- Develop coating manufacturing techniques, which can provide corrosion/erosion protection for

components in USC boilers, cost effectively.- Establish manufacturing techniques for application of internal coatings for oxidation protection,

cost effectively.- Provide coated samples for corrosion and oxidation testing in the laboratory and in the field.

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These objectives will be accomplished through execution of eight sub-tasks. Progress on these sub-tasks during the reporting period is described below.

Task 7A Detailed Study of Current State of the Art

Objective: To review the state of the art.


- Efforts continued on examining the state of the art. In addition to continuing review oftechnical literature, contacts were established with several organizations:

- UniqueCoat Technologies offers a patented thermal spray technique that generates a densewell-adhered metallic or cermet type of coating. The coating is applied in powder form andrepresents a combination of HVOF and cold spray process with a shroud of reducingcombustion gases.

- Integran Technologies offers a patented process for Grain Boundary Engineering (GBE)aimed at enhanced corrosion resistance. The surface layer of the material is modified via athermo-mechanical process to enhance the population of special grain boundaries.

- Applied Thin Films, Inc has developed a sol-gel coating process termed CerablakTMTechnology targeted for high temperature oxidation and corrosion protection.

- Energy Research Company has developed a ceramic coating technology for corrosionprotection of high temperature waste-heat recuperators. This technology may be transferableto boiler components.

Concerns: None


- Attend 16Th Annual Conference on Fossil Energy Materials; conference has relevant sessionon coatings.

- Finish draft state of the art report and circulate for comments.

Task 7E: Process Scale Up Preliminary Trials

Objective: To evaluate process scale up.


- Examined surface characteristics of sample laser clad tubes produced by Praxair SurfaceTechnologies.

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- Assessed potential laser cladding compositions for use in the USC project.

- Examined surface characteristics and microstructures of swaged laser clad tubes.

- Conducted preliminary trials to roll swaged laser clad tubes into header block assemblies.

- Attended the DOE/OCDO USC Project Review Meeting in Pittsburgh.

- Based on joint selection of 6 alloys, assessed potential coatings for compatibility.

Concerns: Lead times to procure some candidate alloys may exceed project schedule.


- Task 7B:- Task 7B - Coating Feasibility (Internal Coating) will begin execution with initial planning and

organization activity.

- Task 7E:- Procure samples of IN 740 and Haynes 230 for coatings evaluation

- Complete the evaluation of laser clad tubes.

- Assess the properties, characteristics and application methods of 50Ni-50Cr and 70Ni-30Ccoatings

- Assess plasma transferred arc as a a means to apply Ni-Cr coatings

- Prepare chromized samples for oxidation testing under Task 3.

Task 8: Design Data and Rules (Task lead Alstom Power Co.)

The objective of the task is to explore application of advanced mathematical models for pressure-partsto boiler and pressure parts industry for reducing product costs in new designs. There is anopportunity to reduce pressure part costs through:

- Standardized design rules and restricted component configurations based on more

sophisticated analyses that will provide consistent safety margins and reliability.

- Advanced design life tools to reduce ignorance factors in safety margins based on the levelsand details of analysis and available material behavior information.

- ASME Code approval of these tools.

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Progress for the Quarter: Collection and consolidation of material property data for use inpreliminary design has been started.

Concerns: None

Plans for the Next Quarter: Material property data collection will continue.

Task 9: Program Management and Integration (Task lead EIO, EPRI)

Objective: The objective of the task is to provide technical and administrative managementsupport.


- OCDO royalty payment agreement has been reviewed and signed by all consortium members.

- All subcontracts between EIO and consortium members have been signed.

- Monthly reports were submitted for January, February, and March 2002.

- A meeting of the Steering committee and the Task Leaders was held on March 7 and 8 inPittsburgh. All logistical arrangements were made. In addition, conference calls between allthe members were held on February 18 and April 3, 2002. All meetings and conferences wereminuted and the minutes were distributed.

- Task 1 work was managed and coordinated as part of this task.

- Copies of recent literature updates continued to be sent to consortium members.

- A paper describing the DOE project was prepared and presented at a DOE Conference inMarch, held in Clearwater, Florida. The paper was published in the conference proceedings.

- Considerable time was initially spent collecting information on material requirements andconsolidating it. Since this procedure turned out to be ineffective, responsibilities for eachalloy was assigned to a team members.

- Communication and the coordination with the team members was continuously maintained via

phone calls and e-mail.

Concerns: Timely follow-up on action items agreed upon by consortium members continues to bea challenge.

Plans for the Next Quarter:- Project management and integration activities will continue.

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- Material requirements will be finalized and procurement orders placed.

- Issue state-of-the-art reports on alloy selection, coatings and steamside oxidation. AssembleTask 1 report and ready to issue.

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Attachment 1

2/18/02 Teleconference Minutes on DOE/USC Project

A teleconference was held on February 18, 12-2 PM

The following team members participated:

R. Viswanathan EPRIK. Coleman EPRIS. Gehl EPRIR. Purgert EIOS. Goodstine Alstom Power

J. Borden Alstom PowerM. Palkes Alstom PowerJ. Blough F-WB. Vitalis BBPJ. Tanzosh B&WB. Swindeman ORNL

1Alloy Selection/Procurement

Consensus was reached that for Tasks 5 and 6, 6 to 8 alloys will be evaluated, each OEM taking responsibility for2 alloys. Since only 3 OEMs are involved in Task 5, it was recognized that some stretching of scope may be

needed to cover 8 alloys. Considerable discussion took place regarding alloy procurement. After muchdiscussion of the issues such as commercial availability, product form, etc. it was resolved that contacting thevendors was the best way to resolve the uncertainties. It was stated that all information regarding Marco alloywas confidential. Inco 740 was not available commercially although small lengths could be procured. It was notclear at all if any of the four Ni base alloys of interest are available as pipes. The action item identified was thateach boiler OEM will take responsibility for obtaining more information on one alloy. The responsibilitiesassigned were as follows:

Inco 740 and Inco 617 - Jeff BoughHaynes 230 - Jim TanzoshMarco Alloy(modified 617) - Brian Vitalis

The following information will be sought:

Availability of the alloy and the product form in which it is available

Tube size available, length, diameter and wall (preferred 2 diameter0.4 to 0.5 wall thickness)

Availability of filler metal

Supply terms (schedule, free vs at a price, etc.)

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Each OEM will report the results at the March meeting in Pittsburgh.

For heavy section components, other alloys will be considered in addition to the 4 alloys above. (If available inthick section). In 602A, HR120, 347HFG, 800HT and HR3C, HCM12A(P122), , NF12, HR6W, 310HCBM,and SAVE12 were mentioned as possible candidates. Final selection will be made based on Task 1 reports andthe Swindeman report at the March 7 meeting.

For waterwall tubes, HCM2S(T23) was clearly the candidate and lot of information is already available. (It wasstated that P91 does not need to be looked at because enough information is available. I believe that T23 and P91need to be looked at for DMW weldability.)

Other Issues

Choice of 1400F/6500 psi was discussed. Although these conditions are severe, Alstom felt that withoutthe high pressure, desired plant efficiency will not be achieved. For conceptual design purposes, it was

agreed that Alstom will evaluate 1400F/6500 psi steam plant, while B&W will evaluate 1400F/5000 psi

plant. B&W will also run calculations on the effect of varying the pressure on the wall thickness.

Weld reduction factors were discussed. In some cases the factor could be large. There was no agreementon whether to take them into account in design. It seems that the ASME Code procedures only will befollowed.

Task 8 leadership will be shifted from Mike Gold to John Fishburn. Since there was no financialimplication, no formal paperwork was deemed necessary.

The pros and cons of utility attendance at project review meetings was discussed. It was agreed that weshould permit it on a case by case basis. Southern Company attendance at the Pittsburgh/March meeting onThursday afternoon and Friday morning was unanimously approved.

Bob Swindeman will look into possible mechanisms for interacting with THERMIE and other Europeanprograms and report to the committee in March.

The current status of the draft language for royalty payment to OCDO was discussed. One major definitionthat has been settled on was what technology was subject to repayment. The definition of what repaymentis need on is patentable new technology.

Summary of Action Items:

Each OEM to ascertain status of one Ni-base alloy (assigned) and report to the steering Committee inMarch.

Recommendations for additional candidate alloys to be reported by Task 1 participants and ORNL to theSteering Committee in March.

ORNL to report to the Steering Committee on channels for interaction with European programs.

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Attachment 2

Boiler Materials for Ultrasupercritical Coal Power Plants

Project Review Meeting

Pittsburgh, Pa. March 7 & 8, 2002

Meeting Minutes

The morning of March 7, 2001 was spent with the individual task groups meeting to discuss progress andplanning. After lunch, all attendees were brought together in a general session to review the status of the overallproject and each task. The agenda for the Steering committee is included in Attachment 1. Those in attendanceincluded:

Name CompanyR. Viswanathan (Vis) EPRIM. Borden Alstom PowerB. Vitalis Babcock Borsig Power

B. Swindeman ORNLP. Masziasz ORNLM. Mathur NETLB. Hulm B&WB. Purgert EIOU. Rao NETLS. Goodstine Alstom PowerJ. Henry Alstom PowerJ. Fishburn Alstom PowerH. Johnson OCDOG. Booras EPRI

G. Stanko Foster WheelerP. Weitzel B&WW. Mohn MTIJ. Tanzosh B&WJ. Sarver MTIJ. Blough Foster WheelerM. Palkes Alstom PowerK. Coleman EPRI

R. Viswanathan (Vis) opened the meeting and discussed the conference call that occurred on Feb. 18, 2002. Theminutes were reviewed and approved. Recent documents sent to the members by R. Viswanathan (Vis) werereviewed including Task 1 statement of work, project milestone table, and material selection and procurement.The goals of the project were reviewed. The primary goals were to develop a power plant with operatingconditions of 5000 psi steam at 1400F and an efficiencies much higher than SOA Supercritical Plants. Followingis a summary of each of the tasks that were presented.

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Task 1

G. Booras from EPRI presented information on the cost analysis for a power plant operating at the above statedconditions. The numbers in the presentation were preliminary with many assumptions being made. Discussionsduring the presentation will help Mr. Booras narrow down the analysis to some thing that will benefit the project.The coal mixtures and prices used in the analysis did not include Ohio coal. Another analysis will be completedusing properties of a typical Ohio coal. The back pressure used was also viewed to not be realistic and was raisedto the 2.0 1.5 Hg range for calculation of the thermal cycle. The presentation slides for the cost analysis areshown in Attachment 3.

M. Palkes presented information on the feasibility of raising the temperature and pressure from that originallyproposed in the project description. Looking at the strength of the material at the elevated temperatures andpressures, the pressure for investigation was agreed upon to be 5000 psi with reheat temperature of 1400F andinitial superheat temperature of 3500F with final superheat temperature targeted at 1400F. Pressure drop of about6% in the reheater was thought to be about right for this design which would allow for about a 1000 psi reheatpressure. The 5000 psi/1400F operating conditions were reaffirmed by the voting members of the steering

committee.

P. Weitzel discussed design considerations for a 750 MW reference plant. He indicated that INCO 740 wassubstantially better than Nimonic 230. Thickness of header drops substantially when temperature is lowered

from 1400F to 1350F. Steam-line and header thicknesses are reasonable at 1350F mainsteam and 1400Freheat steam temperatures. Both Alstom and B&W agreed to issue Task 1 report by July 2002.

Task 2

B. Swindeman reviewed the materials testing being completed under Task 2. The available materials were

broken down into three groups; Primary, Secondary, and Developmental. The primary materials will be thosematerials studied in the program. The secondary group includes materials that might be added if some of theprimary group materials are found to not be acceptable in the program. The developmental materials arematerials that would probably be useful in the program but are not far enough along in the development to beincluded at this time. The high temperature ultra-fine precipitate strengthened (HT-UPS) materials may needinvestigated for service. One problem with many of the materials being brought into the codes lately is that notmuch high temperature creep data is included. On materials that do not have Code acceptance, a literature searchor testing will be performed to get info to the Codes. ORNL has a CREDA with Inco Alloys (Specialty Metals)to perform bend tests on Inconel 740.

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Task 3

J. Sarver presented the task summary for corrosion. Work is ongoing with I. Wright of ORNL for this task.Materials and test schedules are being reviewed. How to handle exfoliation of test coupons was discussed.Coated specimens need to be available by Dec 2002. Please see Attachment 4.

Task 4

J. Blough presented information on fireside corrosion. Test temperatures for waterwall overlays will be 900F,1000F, and 1150F. Test duration will be up to 1000 hours with samples measured at different intervals. Coalsevaluated will be western, eastern, and mid-west (Ohio).

Corrosion test probes will be installed at three utilities. Tests will run for 8000 and 16,000 hours. Testtemperatures for the probes will be around 1300F, 1400F, and 1700F.

Steam loops will be built by McDermott and Babcock Borsig. The McDermott loop will be installed at the Niles

plant around the end of the year. The alloys for superheat tubes were broken down into A and B list. TheA list contains 740, 230, 617, HR120, and HR6W. The B list included 625, 214, 188, 347H, super 304, and310 HCBN. Coefficient of thermal expansion will be a concern. May also look at co extruded 50 Cr 50 Ni(Inconel 72).

Dr. Mathur provided an update on the DOE Combustion and Environmental Research Facility. Testing costsaround $2000/sample. The variables that can be studied include fuel handling, combustion, flame stability,materials heat transfer, ash slagging/fouling, and flue gas emissions. The equipment has the ability to burn multifuels.

Task 5

W. Mohn discussed welding development. This task includes Alstom, Babcock Borsig, and McDermott. FosterWheeler is not participating in this task. Edison Welding institute will be utilized for some of the evaluation.Areas of concern include filler metal evaluation and heat treatment. Six materials will be evaluated. Two eachby each participating company. Two section sizes for each material will be evaluated. Appropriate weldingprocess will be evaluated and dissimilar metal welds will be evaluated. Each boiler manufacturer will evaluatefive material/section /process combinations and one dissimilar weld for a total of six evaluations.

Material assignments for welding include the following.

Material Company

Haynes 230, In 740 McDermott617, Super 304H Alstom

HR6W, Save 12 Babcock Borsig

Availability of thin section, thick section, and filler metal are a concern. Specimen size will try to bestandardized but may depend on material availability. Welding process to be evaluated includes GTAW,SMAW, and SAW. Schedules depend a lot on material availability. If welding has to be performed on drops leftover from the fabricability testing, the schedule will be impacted.

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Testing will include standard ASME tests. Testing of Weld properties will be performed under Task 2. Sampleswill be provided from this task to Task 2 for this purpose. Task 2 will develop a method to accelerate Type IVcracking so this can be evaluated.

Task 6

J. Tanzosh updated the group on fabrication progress. For thin walled tubing, several different alloys will beevaluated for superheat service. Because of the project goal of 5000 psi, 1400F; we need to focus on high-endmaterials. These include Inconel 740, Alloy 230, Inconel 617 (or Marco if available), and HR6W. Testing willinclude bending, swaging, and welding. The Marco alloy is listed as having 100,000 creep rupture strength of12.3 ksi @ 1400F. This is about 1.2 KSI better than the 617. Material for tubing will probably be ordered assolid bar stock as this is available. The material will then be machined to the correct size for testing. This shouldsubstantially speed up the material procurement issue.

For thick walled testing we need some pipe forms to simulate header fabrication. Materials of concern in this

area are primarily the advanced ferritics and traditional austenitics like Super 304H. Fabricability tests can bemade on thick plate (about 2 thick). This will also help speed up the project if thick walled pipe is not available.The thick plate will allow for all testing except pipe bending. Materials will probably include P122 or Save 12for advanced ferritics, Super 304H for austenitics, and 740 or 230 for the upper end.

Material assignments were made for participating companies. The following table lists material and assignments

Material Company

In 740 Foster Wheeler

Haynes 230 McDermott

617 Alstom

HR6W Babcock Borsig

Thermal conductivity for these materials needs to be evaluated. ASME Section IID will be checked first to seewhat is available. If no data is available, ORNL will perform testing in Task 2. Some early testing has shownthat T122 may be worse than T91 or T92. Strain limits also need to be evaluated. Because of the materialquantity available, small punch creep tests may be utilized.

Task 7

Task 7 was presented by S. Goodstine. Testing will be performed for internal and external coating evaluation.The primary areas of concern are oxidation on the internal coatings and coal ash erosion/corrosion on the externalsurface. To evaluate this, we first need to determine where in the boiler the different materials will be installed.This will be determined in Task 1. Thermal barrier coatings may need to be evaluated for use inside headers andother possible uses. External coating may include metallic and ceramic. The target for sample completion is toallow for Task 3 and Task 4 testing by the end of 2002. Materials of most concern will be the ferritics.Presentation slides are included in Attachment 5.

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Task 8

The steering committee officially voted to replace M. Gold with J. Fishburn as the lead for Task 8. J. Fishburnindicated that thermal fatigue will be an issue at the design conditions sought by this project. The Code currentlydoes not have thermal fatigue or life in the current calculations. There is a tentative agreement for a fatigueassessment in a non-mandatory appendix to Section 1. This task needs information from Task 1 before muchdevelopment work can start. A goal of having the Task 1 report completed was set for July.

General

Materials have been summarized for each task above. Below is compilation of the material assignments for eachcompany.

NF12 (SAVE12) Babcock Borsig Plate

INCO 740 Foster Wheeler P&T

Haynes 230 B&W P&T

Marco (Mod 617) Alstom T

High end NI Alloys

INCO 617 (backupsfor Marco)

Alstom T

HR6W (made bySumitomo)

Babcock Borsig T

Super 304 Alstom P&T

IntermediateAustenitic

HR120 (backup toSuper 314)

Alstom P&T

Preferred size .04 wall 2 OD.

P= PipeT=TubePlate=Plate

A goal was set to have some material available by the first of April 2002 so material dependent work can start.

We have had some utilities indicate interest in joining the program and helping to fund the project. The steeringcommittee voted to allow utilities to join and attend the task meetings. They will not be allowed to vote at thesteering committee level. This may be a good way to develop support for program with utilities and possiblyobtain a site for a demonstration plant.

U. Rao will prepare a sanitized statement of work for submission to utilities interested in joining the program. B.Purgert will put together a non-disclosure statement for the project.

A review of the reporting requirements was provided. The Quarterly report will be sent out by R. Viswanathan(Vis). To allow for on time completion, when companies send their updates to V. Viswanathan, copies need togo to all team members for review. This should be completed by the 10

thof the month after the Quarter ends.

Comments must be sent to V. Viswanathan by the 25th of the month. On the 25th, the report will be sent to EIO

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(B. Purgert). The report must be sent by 4 PM on the 28th

to DOE. Reports should be completed according to theinstruction sent to each member by V. Viswanathan.

Monthly updates are due to K. Coleman by the 5th

of each month.

Invoices should be submitted to OCDO by the 5 th of the month. Invoices should be sent to DOE by the 15th ofthe month.

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Materials for USC Boilers

DOE/OCDO Project Review Meeting

Proposed Agenda

March 7, 2002

9:00AM-12:00PM Task Group Meetings12:00 PM-1:00 PM Lunch (Dutch)1:00 PM-1:30PM Introductions and Welcome (R. Purgert, Vis)1:30 PM-2:00 PM Task 1, Conceptual Design (Vis, J. Tanzosh, M. Palkes)2:00 PM-2:30 PM Task 1, Economic Studies (G. Booras)2:30 PM-3:00 PM Task 2, Mechanical Properties (R. Swindeman)3:00 PM-3:15 PM Break3:15 PM-3:45 PM Task 3, Steamside Oxidation (J. Sarver, I. Wright)

3:45 PM-4:15 PM Task 4, Fireside Corrosion (J. Blough, J. Tanzosh, B. Vitalis)4:15 PM-4:45 PM EPRI Work on Weldability (K. Coleman)4:45 PM Adjourn

March 8, 2002

8:30 AM-9:00 AM Task 5, Weldability (M. Borden, E. Robitz, K. Coleman)9:00 AM-9:30 AM Task 6, Fabricability (J. Tanzosh, J. Henry, G. Stanko)9:30 AM-10:00 AM Task 7, Coatings (S. Goodstine, W. Mohn)10:00 AM-10:30 AM Task 8, Design Rules (M. Gold, A.R. Ahluwalia, J. Fishburn,

R. Swindeman)

10:30 AM-11:00 AM Sponsors Guidance DOE (Udaya Rao, R. Romanosky)

OCDO (H. Johnson)11:00 AM-12:00 PM Technical Issues (Group)

Material Selection

Material Procurement

Conferences/Papers

Thermie

Other Issues12:00 PM-12:30 PM Administrative Issues (R. Purgert)

12:30 PM Adjourn

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Attachment 3

A telephone conference was held on April 3,2002, 1 to 2PM PST. Following attended:

Udaya RaoBelinda HulmJeff SarverWalt MohnBrian VitalisJeff BloughGreg StankoJeff HenryMike BordenSteve Goodstine

Tom Masiasz

John Sanders of B&W could not attend meeting as he was injured in a car accident. His recovery isexpected to be short. The Group conveyed their regards and best wishes to John

Belinda described the following materials in hand

Haynes 230 1/4"x9"x14"HR 120 3/8"x9"x14"188 alloy 1/4"x9"x14"617 alloy 3/16"/12"/12"

Inco740 .59"x4.5"x.59"(Expected shortlyRA 333,RA353, RA 253,and602Ca (In hand)

The properties of the Rolled alloys are expected to be between HR 6W and HR 120.

The above materials cover the samples needed for steamside corrosion and partly for firesidecorrosion. For the latter, tube samples will also be needed later.P92,SAVE 12,HR 6W,Super 304 and310HCBN are also to be obtained by B&W for Steamside and fireside corrosion tests.

For tasks 5 and 6, alloys will be procured by the respective company assigned after consolidatingevery ones need. Costs will be prorated by quantity used by each and charged accordingly. This

scheme was acceptable to all. FW(Greg Stanko) is waiting for quotes on IN 740. No problem expected Haynes 230, quote is awaited by B&W. Jeff Henry reported that the Marko alloy may actually become available, He is talking to D.C

Agarwall re terms.IN617 is proving to be very expensive, but Bob Swindeman reported that verysmall amounts only be needed as lot of data was already available. Alstom to determine quantityneeded and get quotes. Alstom is also getting quotes on Super 304. HR 120 is only an alternate to304 and hence not needed.

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Brian Vitalis thinks that HR 6W may not be available. He is considering alloy AC66 (Similar to IN800, per Bob.Swindeman) as an alternative. Will get more info on this as well as on NF 12.

In determining quantities needed, ORNL requirements are included. Swindeman to estimate andinform every one. He thinks that he could mostly use leftovers from Task 5 and 6.

The cost of materials is turning out to be considerably more than was expected. Task 5 and 6leaders will coordinate strategy to share materials to reduce costs. Increased funding may also beneeded. Alternately scope reduction may be needed.

Lead times for delivery was in the range 18 to 24 weeks. Group agreed that this was anticipatedand therefore will not affect schedules.

The need for organizing a steering comm meeting was not expected at this time. The immediate action for each organization is to consolidate total project needs and get quotes

from vendors for the alloy for which they are responsible. This will be completed in 1 month (ByMay1,2002). At that time we will need to discuss budget adjustments with Bob Purgert. Then,orders will be placed.

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