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Research Papers: Design and Analysis

Component Testing and Numerical Calculation of a Bolted High Temperature Power Plant Pipe Flange Under Complex, Near-Service Loads

[+] Author and Article Information
Benjamin Leibing

Materials Testing Institute (MPA),
University of Stuttgart,
Pfaffenwaldring 32,
Stuttgart 70569, Germany
e-mail: benjamin.leibing@mpa.uni-stuttgart.de

Andreas Klenk

Materials Testing Institute (MPA),
University of Stuttgart,
Pfaffenwaldring 32,
Stuttgart 70569, Germany
e-mail: andreas.klenk@mpa.uni-stuttgart.de

Michael Seidenfuss

Institute for Materials Testing,
Materials Science and Strength of
Materials (IMWF),
University of Stuttgart,
Pfaffenwaldring 32,
Stuttgart 70569, Germany
e-mail: michael.seidenfuss@imwf.uni-stuttgart.de

1Corresponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received November 18, 2017; final manuscript received June 8, 2019; published online August 2, 2019. Assoc. Editor: Sayed Nassar.

J. Pressure Vessel Technol 141(6), 061201 (Aug 02, 2019) (11 pages) Paper No: PVT-17-1235; doi: 10.1115/1.4043996 History: Received November 18, 2017; Revised June 08, 2019

To ensure a reliable power supply with a minimum environmental impact in the future, further increases in efficiency and flexibility of fossil-fired power plants are major challenges to address in recent R&D activities. In order to counterbalance substantial fluctuations in the electricity grid due to the rising share of renewable resources, frequent start-ups and shut-downs of turbomachinery will be claimed by the market. Hence, along with the development of advanced materials for elevated steam parameters, contemplations with respect to altered boundary conditions of established materials, e.g., for bolted pipe flange connections, are required. In this paper, a selection of results from a recently finished research work on stress relaxation will be presented. Together with European power plant component manufacturers, a newly developed test rig comprising a scaled intermediate pressure (IP) steam turbine pipe flange now allows investigations under near-service conditions. Before, throughout, and after performance of the experiments, an extensive measurement setup enables the examination of effects that cannot be studied in standardized relaxation tests. Within this work, a loss in bolt pretension of up to almost 50% over a comparatively short period of experimental time was observed. By means of numerical calculations, creep deformation in the transition areas between pipe and flange plate sections was identified to be a major originator of these pretension drops. Particularly, good correlations between experiments and finite element method (FEM) simulations could be achieved through the implementation of enhancements concerning the fitting strategy of the Graham–Walles-type creep model which was used.

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References

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Figures

Grahic Jump Location
Fig. 1

Temperature/pressure load cycle (schematic)

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Fig. 2

Basic concept of the flange testing setup

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Fig. 3

Main dimensions (in mm), parts, and materials of the test flange design

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Fig. 4

Final setup of the flange test rig (computer-aided engineering model and reality) [18,19]

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Fig. 5

Bolt elongation after tightening of the bolts (before the start of the experimental phases)

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Fig. 6

Flange gap closure due to tightening of the bolts

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Fig. 7

Flange gap measurements during phase I (start of the experiment until revision 1)

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Fig. 8

Bolt elongation drop until revision 1 (phase I)

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Fig. 9

Flange gap measurements during phase I (revision 1 until revision 2)

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Fig. 10

Bolt elongation drop until revision 2 (phase I)

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Fig. 11

Permanent flange gap deformation after completion of experimental phases I–III

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Fig. 12

Permanent elongation of the bolts after completion of experimental phases I–III

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Fig. 13

Exemplary model comparison for creep and relaxation data (1% CrMoV-steel) [20]

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Fig. 14

Overview on the CreepRelax-fitting tool

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Fig. 15

Improved GWD-model for a 1% CrMoV-steel by means of a combined fit [20]

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Fig. 16

Global FEM model including the mesh (11.25 deg-segmentof the whole geometry) [18,19]

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Fig. 17

FEM model details of the bolting

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Fig. 18

Contour plots of von Mises equivalent stress after fastening of the bolts at RT

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Fig. 19

Contour plot of von Mises equivalent stress after heating of the assembly to 625 °C and indication of nodes used for detailed analyses

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