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
4 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
5 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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.
7 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
8 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Which Plants are Used the Most Today?
2010
9 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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)
11 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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.
12 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
13 © 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
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
14 © 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:
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
16 © 2012 Electric Power Research Institute, Inc. All rights reserved.
How Do We Achieve the Full Portfolio?
Advanced Materials Technologies
will certainly be an integral part of it!
17 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Materials Requirements & Needs
--Ultra-Supercritical Coal Technologies
Increased Efficiency Reduced Emissions
18 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
19 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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)
20 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
21 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Materials Research at EPRI
-- Ultra-Supercritical Coal Technologies
Powder Metallurgy to
Produce Valves, Pump
Housings, Elbows, etc
Advanced Austenitic Alloys Improved Life
Prediction Technologies
22 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
23 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
25 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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
26 © 2012 Electric Power Research Institute, Inc. All rights reserved.
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.
31 © 2012 Electric Power Research Institute, Inc. All rights reserved.
Together…Shaping the Future of Electricity