Experimental and Numerical Investigations on the Relaxation Behavior of Power Plant Flange Connections Under Steady State and Transient Conditions

Abstract

An essential part of today's power plants are flanges, for example, as connection between turbine housings and pipes. They allow for revisions, inspections, and maintenance measures. Ongoing changes toward higher amounts of renewable energy sources leading to higher demands in flexibility to counterbalance weather-related fluctuations. This flexibility leads to changing load types with more frequent warm and hot starts, causing uncertainties for the design and the determination of maintenance intervals of bolted flange connections. In this context, results of a recently finished research project and ongoing numerical investigations are presented. Tests were conducted on a model of an IP turbine flange under near-to-service loads, such as internal pressure and temperature, using a test rig allowing heating on the flange's inner surface. Concerning different influences on the stress relaxation behavior, results are shown for tests with martensitic and nickel-based bolted joints. The total test time of 5000 h for each bolted joint consist of 2000 h under steady-state conditions and 3000 h under transient conditions. Comparisons of the results with the martensitic and nickel-based bolted joint show an opposite creep strain distribution in the bolt and flange. In addition, a significant influence of the already existing creep deformation from previous load periods can be observed. Comparative simulations with a modified Graham–Walles creep model are carried out. The results confirm the differences in creep behavior with both bolted joints and reproduce the observed influence of the previous creep deformation.