POWER ENGINEERING ae ee Power plant valve: Cast versus forged production soon016 ‘ns but exon lege rococo dave gh uve. ens cvs ih ase bes cae Parma atf ppeatonsn power my, tes Ave Ela “The cast vere forged debate has been around fr year inthe valve manufacturing nous, ‘Anos ea srodition stil dominates, changing operating envionment inthe power indus, suchas the shit towards nner pressure and temperature appleatons, have eign the debate an which technique Is Driven bythe everneeasing demand for eneray, operational lemperatures in superttealand urasupereriial powerplants 2s wal as in combined-cycle power plants hava climbed signicartyin the ast |wo decades. Testngin Europe i cureny at 700°C/1282 for blr systoms and plants iste US wil soon be operating above 600°C/112"F While mull thermal eels and higher temperatures alow operator to increase plant efciency, they alo put an immense amount of tess on system componente. Degradation of ‘matfal caused by cep and carson fatigue are now being decid more often in room CCPPS and heat covery alaam generators (HRSG), lading to Ngher mantanance levels and pant downline. AS resul, mary valve manufacturer have started fo retnk tei material specfcatons and producion techniques, in particular when dealing wit component or eiical and severe sence applications, {changes inthe operating parameters of madem pow plans, and in particular the move fom salto ‘éynamic leads trough combinad-cyle operation, afl vale marl behavior. Irereats in plant eyeing impact on lemperature an pressure diferent, alfecting the ba placed on valves and ppeine components within the stesm crc Fluctuations in tomperature crate sess and elongaton asthe valve expands and contacts under diferentDeformation of re vale i cased once siestes paced onthe valve excees this yl strength by affecting fae, Material considerations In genera, al vane mata, whether ferged or east, have ofthe demands for onsesranath and ‘orosion resistance that canbe found in many etical process envionment “The stronger he vate, the Bator is abit ras aur when put under possi, resulting in higher actly and utimataly longer product Mets However, a Key applcation feature ote power ganaraion Indust 1s the potontal or vale fluro othe increase in plant cycling to meet ereray supply neods “The impact ofhigh eyelng duty on steam temperature and pressure paces greater svesses on valve ‘components, ana equres the material fo endure thee fctuatans and ferential throughout the atime of the valve, Cast matte tend to requ oss mass than forged produc - rare mass can led o kgor thermal ‘radents which can result in geateretreses, The relationship cf castng and poral vods needs tobe taken info account, with consceraton given to determing the sloly factor and allowable stress lve Anobar important aspect iat needs to be considered ete metas ably owihstnd he pressures of corosion. Causes by the combined actons of anygon, eter meas and sa, coroson is sil a major problem inthe power industry, after resulting in costly rapa ar excessive downtime. Dngradaton of valve mata 's thr accelerates when under pressure om high operating temparatures. The higher he temperature, ne Softer ne maleral wil coms increasing the risk of thermal atgue. Design codes an standards om the American Saclay of Mechanical Engineers (ASME) low or the use of both forged ana cast mater wthin the prmary cicut,dapending on te baler design and operational parameter. Ths chemical composton of those components, paricular the Ivelof come, athe Ianutactuing method ae key actors lo determine a vale'sereep strength and metrical stably. For ‘example, NCO grade alloys, containing 2.25 per cant f chrome, can retain thir strength in temperauss of upto 550°C whe higher grades, suchas C12-A wih 8 per cont chrome, ar abot withstand tomperatres of up store. ‘To.cope withthe charges in powerplant operations, to stuaton fr forging grades is beginning to evoho White towor grades, suchas F2, containing 225 percent of chrome, can be suitable fr up to 380°C, Ft raters wih 9 per con chrome are abl to wihtand temperatures of upto 850°C Ineeased elency targets for modem powar plans are pushing operating temperatures above 600°C. To meet tess requirements, plant engineer and valve manulackcors are moving a F92 grade alloys, for which here it no ‘cast equivalent wth the ASHE standard. The diference in perfomance over Ft gfade alloys also dear For example, an F2 cats 2500 valve a 60°C delivers a specal class rating of 2.4 bar compared wih 203.1 bar for F9, A1575°C, the ratinge ae the same Batwoon the two males, However, a 625°C, the ‘ference ls 190 bar for FB2 compared wits 152.1 bar for Ft [Alnough chorical composon i an important consideration ast hasan impact onthe mechanical properties ‘ofthe mater, the neat veatment of the rater san exsental parameter that determines the overall strength ofthe valve when apeata in gh-amparaure environments and under intense mechanical tes, ‘hater fring or cating each valv will neo fo be heated o a normals temperature - sual around 1000" - and needs abe coled down in las tan 4000 seconds to achieve a highly durable end produ mle smal vals canbe cooled down elaively quickly valves with higher mass, ypicaly wih a large Meeting quality standards ‘hte the majo of nlamatonal standards proside guidance onthe expected quaranaed ite of the mater In ambient tomperature, there's curently no oficial data avaliable fo tests high temperatures. However, te ‘changing operating environments inthe power indy, n paul te stresses caused by higher cycling and regular shutdowns, ae calig for ehangosn testing procedures. As result, ts that take ilo corsderation ‘scitonal parameters, such a operating nous, numberof shutdowns and tomperaure range, are becoming incrasingly important in ordr to acuratoly evaluate to Ifosoan of the pros ‘With changes to materi guidetnes and egulaons imminent many engineers have sready stated to specty ‘atari that go beyond tne current equred apeclfeatonin order io secure future comlianes In ac. ome ‘governing bodes, sch as the American Sociely of Testing and Maras (ASTM) and ASME, have aady State to clude deta manutatring process requltement no tel specticatons in response tothe ‘changes nthe operating envconment Basis fling ssingant ertaria In terms ofthe cnemical composton, testing procedures and physical properies ofthe mateal, mary valves now aso have tebe ether castor ‘oxged, dopending onthe Indust end applcaton, Ura supercritical coaltes plan, fr example, capable of eperating above 600°C, making thse applications ial sued to F92 forged grace materials In the coming yeas, the combined-cycle market wil move towards these emperatre ranges and re use of F52 Is expectd to become more prvalantin these applestonsSuitability of valve casting Casting sil eprasents large share of the valve manufacturing indus, Infact. mos tel components stat ‘3 casts, a process in wrich maton matali poured into a customized mould andthe soldfed. There ae a numberof advantages to ths procedure: + Fledity indesign as valves canbe casto-snpe (reser vary and comply of shape 9 processed in Bui for, + Greater mata choice (custom loys) as fundies have fl contol over the chemical metal composition rast ungue equraments at anaforcabe cost Can engure vale ara madd o mest exact epecfeatone crak cating rai: Pentair Valves & Controls Micro graph of typiealF91 Credit: Pentair Valves & Controls + Reduced machining cots (requ lass machining than forgings io achieve more complex shapes) “Castings are more wisely avaiable, making replacements easier: + Cast vas havea conoured shape unde edges), ‘Altough casings romain an intspal par ofthe val manufacuring industry, ho shit towards higher prssuraoperalion in he las fw yars has exposed a number of shortcomings+ The soleation process can produce small mpurs, suchas voids and eracks that canlead slower ‘mechanical propares, requng costy a tins-ntonsive wel rep ‘much lower hardness This requres ngourus inspections of te va to ensureithas mainained the proper strongh and coop resitancs + Higher specfeatone In ¢chrome materia can only be achlaved afer extensive hea! teatment, esting in longer celvery tes which canbe cause by many fcr incising NDE and testing requrements. Hwover, ner have boon significant improvement inthe mouk’-and core-nakng recesses, reducing the ‘appearance detects on castes vales For example, lw pressure ae casing tachniqus ae adopted by an inerasing numberof fountis te improve the overall mechanical inopiy ofthe fal product The rise of forged valves “The past fow years have seen 2 shit towards the use of forged seo, in parcular or valves used inertial and severe service appations, Tiss rected inthe ue af higher perfomance aloysin temperature ‘pplcatlons above S00°C/"112"F. Al orging procesea stan wih 2 sl pace of metal ong thats forged ino shape with harsmersoposses,Anough wek-inonse, ths process has a numberof bares 1 a os r.woring is necessary (valve fforgedinto shape ou one Sol pacalngot + Forging process reduces surface poco and class up intemal caves and voids due tothe immanse pressures involved inthe manufackinng process, Ths enables forged valves to rlain thi srctral ntogny, Teauling na mecharicaly stronger and more durable produt (igh dctiy nd lense strength) + Flew of he forges material belng manufactured ota Intermediate rating This has loss wall hicknoss Tor enhanced performance due to thermal cyl aigue wth 9Cr-1Mo material -lss wall hickress has a sealer emperatire gradient which requests tne for melerathikness to reach equlorum, and is ‘arafre less 2rane to thermal faigue. This oes a robust solution fr pow plants which cyte rough startup and phase-down ona daly bass + Forged material can be machined a meet specie desgn condone using intermedia ratings. Ths ors ‘end users and asset owners another akemative and can be used in both vale cating and forgings. Win the he ightar weight ve sable to recuoe the heainglcocling stresses asthe uns eyle on and ft parulaty as thinner wall components can heat an cool more quickly, rsuhing in fewer thermal sestes, okMolten stool hte ferging produces a vary strong pace of equipment hore are some consequences and imtations tobe + Cost and energy-intensive (eques extensive work in aero refne he procuct and achive the requ shape an fish + Limitations on sie, shape and thickness (processed in sd late); + Larger forgings need tobe produces trom wa or more places and welded ogee, Right valve, right application High manufacturing standards and atten to deal are paramount to ensure that each valve, whether as ‘or forged, meets he required design and perfomance eer, Whi forged materi wl atin sar to omnate Netvpreseue and hightemperature apelcations in some industie, easing wl continue o prove sllrnatve and remain an important ase othe valve manufacturing induc | cotetfectve and rai ‘void ina valve the: wil eee many tmos a day? A sluton to mitgato thas risks sto work wth an “expocanced valve manufacturer which ofers engineering expertise in bol cast and forged valves, an can ‘26v onthe mos appropiate ASME-complantpreduet whieh meets specte lant an applieton needs. ‘Arvo Ellauis Marketing Manager fr Gas Power at Partai Valves & ContosToPIcs ABOUT US RESOURCES SUPPORT World Regions SmartGridTAD About Us Ccurentiesue Se Map re OlFrad Bush Advertsing RSS Fe PENNWELL POWER SITES. ydrowerla Power Engineering