David W. Gandy Technical Executive, Nuclear Electric Power Research Institute Valve and Actuator Trends for the Power Industry March 7, 2013 Power Generation Technologies, Trends, and Influences
David W. Gandy
Technical Executive, Nuclear
Electric Power Research Institute
Valve and Actuator Trends
for the Power Industry
March 7, 2013
Power Generation Technologies,
Trends, and Influences
2 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Presentation Outline
• Current Electricity Generation Trends
• Transformation of the Electricity System
• Scenarios Impacting the Electricity Portfolio thru 2050
• Materials Requirements & Needs
• Research in Materials Technologies at EPRI
• Materials Research for Valves at EPRI
3 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Electricity Generation
--Coal
• 38% of electricity generated in USA
uses coal as fuel source (down from 50%)
• Abundant domestic energy resource
– 25% of world’s total coal reserves (275 billion tons)
• Expected to comprise 35% of the national fuel mix in 2040
• Significant improvements realized in pre- and post-
combustion emission reduction technology
Major Challenges: Uncertainty associated with
environmental regulations & future CO2 emission limits;
CO2 capture & storage technologies
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Electricity Generation
--Natural Gas
• 29% of total current generation
is NG-based
• Expected to comprise 30% of national fuel mix in 2040
• Low emissions
• Low capital costs and regulatory barriers for other fuels
make natural gas-based generation easier to site and build
• New sources of natural gas—such as shale gas—are
transforming the market
• Low prices currently
Major Challenges: Environmental concerns with
shale fracking & gas distribution
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Electricity Generation
--Nuclear
• 104 nuclear power plants in the
USA provide 20% of the nation’s electricity
• Expected to comprise 17% of national fuel mix in 2040
• Largest non-emitting generation source
• Uranium is plentiful and efficient.
• Nuclear power plant performance continues to improve
Major Challenges: High construction costs and used fuel
disposal; safety concerns following Fukushima accident
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Electricity Generation
--Renewables (including Hydro)
• Hydro comprises 7% of USA generation
• Wind makes up 3%, while solar and biomass
make up only a fraction of the generation
• Wind -- Tremendous growth in last few years –
~52 GW installed through 2012
• Wind generation can change rapidly,
presenting challenges to the power system
• Renewables projected at 16% by 2040
Major Challenges: Storage & integration of
variable generation.
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Where Does Our Electricity Come From?
Source: U.S. Energy Information Administration Power Monthly
Nov 2011-Oct 2012 Electric Sector Generation
38.3%
29.2%
20.0%
7.1%
4.7% 0.5% 0.2%
Coal
Gas
Nuclear
Hydro
Renewables
Oil
Other
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Which Plants are Used the Most Today?
2010
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Different Fuel Mixes Used Across US
Source: US DOE Information Administration (EIA-923)--2010
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How Many Plants Does it Take to Power a City?
Nuclear
1 2 Solar
Photovoltaic Wind Turbines Geothermal Biomass
Natural Gas Coal
1.6 Million 2,000 30 20
3
= =
= = =
Annual electricity consumption for 1 million homes (based on average
annual household consumption of 12,000 kilowatt hours)
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Transformation of Electricity System
• Transformation will take time!!!
– Existing infrastructure built over several decades
• Significant uncertainty
– Lack of coherent Energy Policy in USA…..
– Environmental regulations?
– Climate policy?
– Renewable energy standards?
– Fuel prices?
– Investment in new plants?
• Challenge: Providing clean, reliable, & affordable energy.
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National Generation Mix:
Portfolios Examined
Limited Portfolio
• Nuclear generation does not
expand
• No CO2 capture and storage
(CCS)
• Natural Gas based on AEO 2010
Full Portfolio
• New Nuclear, plus 80% of
existing capacity can extend to
80 years
• Coal w/ 90% Carbon Capture &
Storage
• Natural Gas based on AEO 2010
• Inter-Regional Transmission new
builds
• Renewables costs decline faster
& improved performance
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0
1000
2000
3000
4000
5000
6000
7000
2010 2020 2030 2040 2050
0
1000
2000
3000
4000
5000
6000
7000
2010 2020 2030 2040 2050
Limited Portfolio Full Portfolio
National Generation Mix:
Reference Scenario (Today’s policy)
TW
h
Existing Coal
New Coal
Gas
Existing Nuclear
Hydro+
Wind
Solar Energy Efficiency
& Price Response*
Geothermal
Biomass
New Nuclear
AEO 2010
Baseline
* Above the black line reflects embedded EE in the AEO 2010 Reference Case
Gas
Existing Nuclear
New Coal
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0
1000
2000
3000
4000
5000
6000
7000
2010 2020 2030 2040 2050
0
1000
2000
3000
4000
5000
6000
7000
2010 2020 2030 2040 2050
National Generation Mix:
CO2 Controls (80% CO2 Reduction by 2050)
Limited Portfolio Full Portfolio
TW
h
Existing Coal
New Coal
Gas
Existing Nuclear
Hydro+
Wind
Solar
Energy Efficiency
& Price Response*
Biomass
Gas w/CCS
New Nuclear
New Coal w/CCS
CCS Retrofit
Geothermal
AEO 2010
Baseline
* Above the black line reflects embedded EE in the AEO 2010 Reference Case
15 © 2012 Electric Power Research Institute, Inc. All rights reserved.
0
1000
2000
3000
4000
5000
6000
7000
2010 2020 2030 2040 2050
0
1000
2000
3000
4000
5000
6000
7000
2010 2020 2030 2040 2050
National Generation Mix:
Clean Energy Standard
Limited Portfolio Full Portfolio
TW
h
Existing Coal
New Coal
Gas
Existing Nuclear
Hydro+
Wind
Solar
Energy Efficiency
& Price Response*
Biomass
New Nuclear
New Coal
w/CCS
CCS Retrofit
Geothermal
AEO 2010
Baseline
* Above the black line reflects embedded EE in the AEO 2010 Reference Case
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How Do We Achieve the Full Portfolio?
Advanced Materials Technologies
will certainly be an integral part of it!
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Materials Requirements & Needs
--Ultra-Supercritical Coal Technologies
Increased Efficiency Reduced Emissions
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A progressive increase in steam conditions
has been taking place worldwide
2400/1005/1005
Imp
rove
me
nt
in E
ne
rgy E
ffic
ien
cy
Mature technology
Cu
rre
nt
Ma
rke
t
intr
od
ucti
on
US
Cu
rre
nt
Ma
rke
t
intr
od
ucti
on
by J
ap
an
an
d E
uro
pe (
Ste
el R
&D
)
R&D ongoing
Europe, Japan,
U.S.
(Ni-based
Materials)
US A-USC Goal
1950’s 1960’s 1970’s 1980’s 1990’s 2000’s 2010’s
Original Illustration:
Courtesy of ALSTOM Power
3480 psi / 1005oF / 1050oF
3600/1050/1085
4000/1085/1100
4000/1100/1130
4000/1165/1200
5400/1300/1325/1325
Cost Effective Materials Have Been Critical
to Achieving Increased Efficiency
5400/1350/1400
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U.S. DOE/OCDO: A-Ultra-Supercritical Steam Boiler Consortium—Phase I
2: Material Properties
3: Steamside Oxidation
4: Fireside Corrosion
5: Welding
6: Fabricability
7: Coatings
8: Design Data & Rules
(including Code
interface)
1: Conceptual Design
Develop the materials technology to fabricate and operate an A-USC steam boiler with
steam parameters up to 1400°F (760°C)
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DOE/OCDO A-USC Steam Turbine Consortium
--Phase II
Tasks
1.Rotor/Disc Testing (near full-size forgings)
2.Blade/Airfoil Alloy Testing
3.Valve Internals Alloy Testing
4.Rotor Alloy Welding and Characterization
5.Cast Casing Alloy Testing
6.Casing Welding and Repair
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Materials Research at EPRI
-- Ultra-Supercritical Coal Technologies
Powder Metallurgy to
Produce Valves, Pump
Housings, Elbows, etc
Advanced Austenitic Alloys Improved Life
Prediction Technologies
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Ultra-Supercritical Coal Technologies
--Materials Needs
• Large castings
– Nickel-based turbine shells
– Stop & control valves
– Other valve bodies & pump housings
• Large forgings
– Nickel-based rotors & discs (large diameter)
• Austenitic extruded pipe & headers
– Nickel-based (eg., IN740 & 282)
– Creep resistant stainless steels
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South Texas Project, NINA/NRG
2-ABWR (2,700 MW)
Alternate Energy Holdings
1-USEPR (1,600 MW)
Blue Castle, TP
1-Unspecified Technology
Amarillo, UNE
2-USEPR (3,200 MW)
Callaway, AEE
1-USEPR (1,600 MW)
Fermi, DTE
1-ESBWR (1,550 MW)
Comanche Peak, LUM/TXU
2-USAPWR (3,400 MW)
Victoria, EXE
2-ABWR (2,700 MW) *
Grand Gulf, NS/ETR
1-Unspecified Technology
River Bend, ETR
1-Unspecified Technology
Turkey Point, FPL
2-AP1000 (2,200 MW)
Levy County, PGN
2-AP1000 (2,200 MW)
Alvin W. Vogtle, SO
2-AP1000 (2,200 MW)
Summer, SCG
2-AP1000 (2,200 MW)
Lee Station, DUK
2-AP1000 (2,200 MW)
Harris, PGN
2-AP1000 (2,200 MW)
Nine Mile Point, UNE
1-USEPR (1,600 MW)
Bell Bend/PPL, UNE
1-USEPR (1,600 MW)
North Anna, D
1-Unspecified Technology
Calvert Cliffs, UNE
1-USEPR (1,600 MW)
Bellefonte, NS/TVA
2-AP1000 (2,200 MW)
Source: NRC Expected New Nuclear Power Plant Applications (July 2009) / U.S DOE Nuclear Power Deployment Scorecard * COLA Amended to ESP
Announced Intentions to File COLA
Filed COLA/ESP
COLA Review Suspended / Partially Suspended
PSE&G
1-Unspecified Technology
New Nuclear Plants Under Consideration in U.S.
COLA approved for issuance
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Materials Research at EPRI
-- Nuclear
• Improved SCC-resistant alloys over
Alloy 52 and 690
• Co-free hardfacing alloys for valves &
blades (reduced radiation exposure)
• Powder metallurgy/HIP – improved
chemistries & inspection
• Joining for large sections
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Nuclear
--Materials Needs
• Large Forgings
– Reactor pressure vessel plate &
nozzles (w/ controlled segregation)
– Improved forging quality-Boiling
Water Reactor (BWR) Core
Shrouds
– Nickel-based rotors & discs (large
diameter)
– Small Modular Reactors
• Large Extruded Pipe w/ improved
corrosion resistance
Courtesy: Omaha Public Power District
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Valves
• Fossil Valve Issues
– Grade 91 – lack of controls on both repairs & heat treatment of castings
– Hard-facing delamination due to cycling
• Ultra-supercritical Valve Issues
– No air-casting methods for large turbine shells & stop/control valves
• Nuclear Valve Issues
– Inspection of castings (porosity, segregation, grain size variance, etc)
– No definitive inspection method
– NRC pushing to improve inspection of cast components
27 © 2012 Electric Power Research Institute, Inc. All rights reserved.
316L Stainless Steel
--Powder Metallurgy/HIP
2011
2010
2011
500X
• Good tensile/yield properties
• Charpy Impact: >122 ft-lbs (3 orientations)
• No Porosity, homogenous microstructures
• Good Fatigue properties
• Inspection, near forging quality
ASME Code Case & NRC
Review—submitted 11/2011
courtesy Rolls-Royce
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Grade 91 (9Cr-1Mo steel)
--Powder Metallurgy/HIP
• Good tensile/yield/creep properties
• Charpy Impact: >78 ft-lbs (3 orientations)
• No Porosity, homogenous microstructures
• Inspection, near forging quality
ASME Code Case & Data Pkg—
submitted 11/2012
2011
500X
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Erosion-Resistant Hard-facing
Alloy Development
P/M-HIP parts and
tests specimens
Alloy modeling &
development
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Summary
• No one technology, fuel or resource is the “right choice.”
• A range of generation options produces the least cost and impact on economy.
• Existing generation will take time and significant investment to replace & upgrade.
• Advances in technologies will require new alloys, improved materials processes, re-investment in forging capabilities.
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Together…Shaping the Future of Electricity