Assessment of Resource Parameters of the Extended Operation High-Pressure Rotor of the K-1000-60/3000 Turbine

Authors

Olha Yu. Chernousenko, National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” (37, Peremohy Ave., Kyiv, 03056, Ukraine), e-mail: chernousenko20a@gmail.com, ORCID: 0000-0002-1427-8068

Vitalii A. Peshko, National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” (37, Peremohy Ave., Kyiv, 03056, Ukraine), e-mail: vapeshko@gmail.com, ORCID: 0000-0003-0610-1403

Abstract

The reliable operation of nuclear power plants (NPPs) is a prerequisite for the constant development of Ukraine’s energy sector. At the current stage of development, a considerable part of the NPP steam turbine equipment is reaching its end-of-design-life value. The continuation of the operation of NPPs beyond original design life requires that the remaining useful life of its main components be verified. A model for the estimation of the resource parameters of the high-pressure (HP) rotor of a K-1000-60/3000 steam turbine has been developed. On the basis of the three-dimensional spatial analogue, the calculation of the thermal and stress-strain states of the HP rotor has been performed for all typical operating modes. It has been established that the stress concentration zones are the fillets and relief holes in the first stages, as well as the axial relief holes in the fourth and fifth stages. The calculation of the rate of cyclic damage accumulation in the base metal has been performed using correlational low-cycle fatigue dependencies, since there are no experimental data on the resistance of steel grade 30KhN3M1FA, from which the rotor is made, in the literature. Permissible values of the number of startup cycles from different thermal states and the permissible operating time under steady-state operating modes have been calculated. The level of the accumulated cyclic and static damage has been estimated for the HP rotor of Rivne NPP (RNPP) Unit 3. The loss of long-term steel strength, as a mechanism of destruction, has been found to have a dominant influence on the resource performance of the rotor under study, compared to low-cycle fatigue. The static component, D_st, of the accumulated damage of the HP rotor of the K-1000-60/3000 turbine of RNPP Unit 3 is 77%, the cyclic one D_cy is 11%. The individual remaining useful life is 26,287 hours, which allows extending the HP rotor life by additional 25 thousand hours.

Keywords: nuclear power plant, continued operation, residual life, steam turbine, low-cycle fatigue, long-term strength, design life.

Full text: Download in PDF

References

1. Dobrovolskyi, V. Ye., Novychenok, L. M., Zavodnyi, M. A., Mukhopad, H. V., Pasternak, V. P., Horieshnik, A. D., … & Veksler, Ye. Ya. (2005). Kontrol metalu i prodovzhennia terminu ekspluatatsii osnovnykh elementiv kotliv, turbin i truboprovodiv teplovykh elektrostantsii [Metal control and extension of service life of the main elements of boilers, turbines and pipelines of thermal power plants]. Regulatory document of the Ministry of Fuel and Energy of Ukraine. Typical instruction SOU-N MPE 40.17.401:2004. Kyiv: HRIFRE, Ministry of Fuel and Energy of Ukraine, 76 p. (in Ukrainian).
2. Shulzhenko, M. H., Hontarovskyi, P. P., Matiukhin, Yu. I., Melezhyk, I. I., & Pozhydaiev, O. V. (2011). Vyznachennia rozrakhunkovoho resursu ta otsinka zhyvuchosti rotoriv i korpusnykh detalei turbin. [Determination of estimated resource and evaluation of rotor life and body parts of turbines: Methodological guidelines. Regulatory document SOU-N MEV 0.1–21677681–52:2011: approved by the Ministry of Energy and Coal Mining of Ukraine: effective as of 07.07.11. Kyiv: Ministry of Energy and Coal Mining of Ukraine (in Ukrainian).
3. (1983). Raschet temperaturnykh poley rotorov i korpusov parovykh turbin [Calculation of temperature fields of rotors and steam turbine bodies]. Technical Guidance RTM no. 108.020.16-83, introduced 29.11.1983, instead of RTM 24.020.16-73. Leningrad: NPO CKTI, 112 p. (in Russian).
4. (1985). Detali parovykh statsionarnykh turbin. Raschot na malotsiklovuyu ustalost [Details of steam stationary turbines. Calculation of low-cycle fatigue]. Technical Guidance RTM no. 108.021.103-85, approved and implemented at the direction of the Ministry of Power Engineering of 13.09.85, no. AZ-002/7382. Moscow, 49 p. (in Russian).
5. Metodicheskiye ukazaniya o poryadke provedeniya rabot pri otsenke individual’nogo resursa parovykh turbin i prodlenii sroka ikh ekspluatatsii sverkh parkovogo resursa [Procedural Guidelines for Assessment of Individual Service Life of Steam Turbines and Prolongation of Their Operational Life Beyond the Individual Service Life of Steam Turbines and Extending Their Operational Life Beyond The Equipment Service Life]: Industry Guidance Document RD 34.17.440-96. Moscow, 1996, 98 p. (in Russian).
6. Chernousenko, O. Yu., Ryndiuk, D. V., & Peshko, V. A. (2019). Napruzheno-deformovanyi stan rotora turbiny K-1000-60/3000 pry typovykh rezhymakh ekspluatatsii [Stress-strain state of the K-1000-60 / 3000 turbine rotor at typical operating modes]. Visnyk NTU «KhPI». Ser. Enerhetychni ta teplotekhnichni protsesy y ustatkuvannia – NTU “KhPI” Bulletin: Power and heat engineering processes and equipment, no. 3 (1328), pp. 4–10 (in Ukrainian). https://doi.org/10.20998/2078-774X.2019.03.01
7. Peshko, V., Chernousenko, O., Nikulenkova, T., & Nikulenkov, A. (2016). Comprehensive rotor service life study for high & intermediate pressure cylinders of high power steam turbines. Propulsion and Power Research, vol. 5, iss. 4, pp. 302–309. https://doi.org/10.1016/j.jppr.2016.11.008
8. Chernousenko, O., Butovsky, L., Rindyuk, D., Granovska, O., & Moroz, O. (2017). Analysis of residual operational resource of high-temperature elements in power and industrial equipment. Eastern-European Journal of Enterprise Technologies, vol. 1, no. 8 (85), pp. 20–26. https://doi.org/10.15587/1729-4061.2017.92459

Received 06 November 2019

Published 30 December 2019