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Report RSE 17000277

Numerical simulation to support the flexibility of thermoelectric power plants andcharacterization of materials

It reports the damaage law for 1CrMoV steel worked out from TMF tests. Its use in thermomechanical analysis (numerically) of a steam turbine undergoing a cold startup, full power operation, weekend shutdown and restart. the outcome of the functioning test of a combined cycle simulator to be used for the study of operating modes in accordance with the "flexibility" requirements of the power grid.

The characteristic transients of the "flexible" operation of thermoelectric plants, required by grid ancillary services, on one hand require plant modifications and different operating modes, on the other hand lead to a machinery life consumption increase not fully quantifiable up to date. RSE has proposed a methodology for the analysis of the lifetime consumption of fossil fired plants, based on the synergy among the results of experimental tests for thermomechanical characterization of materials, finite element dynamic modelling of specific plant components, and dynamic simulators of the entire plant, including automation and control systems modelling.

This document shows the achievements concerning activities related to all the components of the methodology, which are the base for specific applications. Specifically, the document summarizes the results of TMF tests on specimens subjected to "service like" cycles: these results have been used to work out the Coffin-Manson damage law for 1CrMoV steel. It confirms the validity of the finite element model of 320 MWe steam turbine, built by RSE in a COMSOL environment. Furthermore, the synergy between experimental evidence and numerical modelling is highlighted by showing the calculation of the lifetime consumption figured out from the damage law for 1CrMoV steel, in case of a steam turbine subjected to the operational sequence: cold startup, full power steady, weekend shutdown, warm restart. Finally, the report shows the outcome of the preliminary test of the integration of process models and automation and control models designed to build a 375 MWe combined cycle simulator.

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