Computational models for residual creep life prediction of power plant components

All high temperature - high pressure power plant components are prone to irreversible visco-plastic deformation by the phenomenon of creep. The steady state creep response as well as the total creep life of a material is related to the operational component temperature through, respectively, the exponential and inverse exponential relationships. Minor increases in the component temperature can thus have serious consequences as far as the creep life and dimensional stability of a plant component are concerned. In high temperature steam tubing in power plants, one mechanism by which a significant temperature rise can occur is by the growth of a thermally insulating oxide film on its steam side surface. In the present paper, an elegantly simple and computationally efficient technique is presented for predicting the residual creep life of steel components subjected to continual steam side oxide film growth. Similarly, fabrication of high temperature power plant components involves extensive use of welding as the fabrication process of choice. Naturally, issues related to the creep life of weldments have to be seriously addressed for safe and continual operation of the welded plant component. Unfortunately, a typical weldment in an engineering structure is a zone of complex microstructural gradation comprising of a number of distinct sub-zones with distinct meso-scale and micro-scale morphology of the phases and (even) chemistry and its creep life prediction presents considerable challenges. The present paper presents a stochastic algorithm, which can be' used for developing experimental creep-cavitation intensity versus residual life correlations for welded structures. Apart from estimates of the residual life in a mean field sense, the model can be used for predicting the reliability of the plant component in a rigorous probabilistic setting. (author)