BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a novel high-strength martensite heat resisting
steel which has superior creep rupture strength at high temperatures of 600 - 630°C
and which is suitable for use as large-sized forged steel, and to a method of producing
the novel steel. Also, the present invention relates to a rotor shaft of a steam turbine,
a method of producing the rotor shaft, a rotor blade and a stator nozzle of the steam
turbine, and a steam turbine power plant.
2. Description of the Related Art
[0002] Materials having superior high-temperature strength are required for various members
of a steam turbine which are exposed to high temperatures. In reply to such requirement,
a practically used material of a steam turbine rotor shaft has been changed from CrMoV
steel to 12Cr steel, i.e., ferrite-base heat resisting steel having superior high-temperature
strength. The steam turbine rotor shaft is required to have not only long-time creep
rupture strength, but also toughness at room temperature to bear against stress abruptly
applied when the steam turbine is started. If the toughness at room temperature is
low, there is a risk that the rotor shaft may cause brittle rupture at the start of
the steam turbine. For that reason, improvements of heat resisting steel have been
progressed in recent years. In particular, ferrite-base 12Cr heat resisting steels
having been developed for use at steam temperature of 600°C or above are disclosed
in Patent Document 1 (
JP,A 62-103345), Patent Document 2 (
JP,A 2-290950), Patent Document 3 (
JP,A 4-147948), Patent Document 4 (
JP,A 7-34202), and Patent Document 5 (
JP,A 2000-54803).
[0003] Meanwhile, steam turbines have recently been improved with intent to realize higher
efficiency and larger capacity, but a thermal power plant operating at steam temperature
of 650°C is not yet realized. The reasons reside in not only the state of the art
that the high-temperature material technology for the entire plant is still insufficient,
but also the problem of reduction in the material cost which is necessitated from
a market trend toward a lower cost. The above-described materials of the turbine rotor
shaft adapted for steam temperature of 600°C or above are relatively high in cost.
A primary one of factors pushing up the cost is poor productivity. Because the materials
of the turbine rotor shaft are susceptible to strengthening of the grain boundary
and enlargement and aggregation of M
23C
6 carbides, B is added to those materials to prevent aggregation into coarser grains.
In producing a large-sized forged product, however, B noticeably reduces productivity
because of increasing forging resistance and narrowing a forgeable temperature range.
Thus, the production cost is increased.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is to provide a high-strength martensite heat
resisting steel which has long-time creep rupture strength required for steam temperature
condition of 600 - 630°C and toughness at room temperature, and which is suitable
for use as a material of a steam turbine rotor shaft and as large-sized forged steel
with an improvement of hot forgeability, and to a method of producing that steel.
Another object of the present invention is to provide a steam turbine rotor shaft
and a method of producing it, a steam turbine rotor blade and a method of producing
it, a steam turbine stator nozzle and a method of producing it, as well as a steam
turbine and a steam turbine power plant, including the method of producing the steam
turbine, in which the turbine blade in a stage using steam to cool the rotor has a
larger height by increasing the high-temperature tensile strength, and higher thermal
efficiency is ensured.
[0005] First, by selecting 620°C as the target temperature in use of heat resisting steel
to be developed, the inventors studied influences of Ni, Mo, W and B upon creep rupture
strength at 620°C and toughness at room temperature. As a result, the inventors found
respective composition ranges of added elements, which satisfied the required creep
rupture strength at 620°C and 10
5 hours and had superior toughness at room temperature, thereby accomplishing the steel
according to one aspect of the present invention. Further, the inventors produced
various kinds of steels while changing the Co content with respect to those composition
ranges, and studied influences upon the creep rupture strength at 620°C, the toughness,
and the tensile strength, thereby accomplishing the steel according to another aspect
of the present invention.
[0006] According to one aspect, the present invention resides in a high-strength martensite
heat resisting steel containing 0.05 - 0.20% by mass of C, 0.1% or less of Si, 0.15
- 0.7% of Mn, 0.15 - 1.0% of Ni, 9.5 - 12.0% of Cr, 0.20 - 0.65% of Mo, 2.0 - 3.0%
of W, 0.1 - 0.3% of V, 0.03 - 0.15% of Nb, and 0.01 - 0.10% of N, (W/Mo) being 4.0
- 10.0, the balance being Fe and unavoidable impurities, and also resides in a steam
turbine rotor shaft, a rotor blade and a stator nozzle each using that steel.
[0007] According to another aspect, the present invention resides in a high-strength martensite
heat resisting steel containing 0.05 - 0.20% by mass of C, 0.1% or less of Si, 0.15
- 0.7% of Mn, 0.15 - 1.0% of Ni, 9.5 - 12.0% of Cr, 0.20 - 0.65% of Mo, 0.1 - 2.0%
of Co, 1.8 - 3.0% of W, 0.1 - 0.3% of V, 0.03 - 0.15% of Nb, and 0.01 - 0.10% of N,
(W/Mo) being 4.0 - 10.0, the balance being Fe and unavoidable impurities, and also
resides in a steam turbine rotor shaft, a rotor blade and a stator nozzle each using
that steel.
[0008] Preferably, the high-strength martensite heat resisting steel of the present invention
contains 0.09 - 0.16% by mass of C, 0.03 - 0.08% of Si, 0.3 - 0.55% of Mn, 0.2 - 0.7%
of Ni, 10 - 11% of Cr, 0.3 - 0.55% of Mo, 2.0 - 2.5% of W, 0.1 - 0.3% of V, 0.04 -
0.10% of Nb, and 0.01 - 0.07% of N, (W/Mo) being 4.0 - 8.0.
[0009] More preferably, the high-strength martensite heat resisting steel of the present
invention further contains at least one of 0.015% or less of B and 0.015% or less
of Al. Also, (Mo + 0.5W) is 1.3 - 1.7 in order to stably ensure satisfactory creep
rupture strength and toughness.
[0010] In particular, with intent to increase productivity and toughness, neither Co nor
B is added. Even when those elements are added, it is preferable that the Co content
is held 2.0% at maximum and the B content is held 0.015% at maximum. Further, the
Al content is preferably held 0.005% or less to increase the long-time creep rupture
strength.
[0011] Further, the present invention resides in a method of producing the high-strength
martensite heat resisting steel having the above-described steel composition and a
method of producing a rotor shaft of any of a high-, an intermediate- and a high-
and intermediate-pressure integral steam turbine using that steel, wherein the method
includes a series of steps of hot plastic working, quenching, primary tempering at
desired temperature, and secondary tempering at higher temperature than that in the
primary tempering.
[0012] The reasons why respective elements of the high-strength heat resisting cast steel
according to the present invention, which can be used for the rotor shafts of the
high-, the intermediate-, and the high- and intermediate-pressure integral steam turbine,
are limited to the above ranges will be described below.
[0013] C is an element necessary for ensuring hardenability. In the tempering process, C
binds with Cr, W, Mo, etc. to form M
23C
6- and M
6C-type carbides at the crystal grain boundary, and also binds with Nb, V, etc. to
form MX-type carbo-nitrides within grains. To obtain those effects, C is required
to be 0.05% at minimum. However, excessive addition of C causes excessive precipitation
of the M
23C
6-type carbides and reduces strength of the matrix (base material); thus decreasing
high-temperature strength. For that reason, an upper limit of the C content is set
to 0.2%. In particular, a preferable range is 0.07 - 0.15% and a more preferable range
is 0.09-0.16%.
[0014] Si is an element that effectively acts as a deoxidizer for molten steel. However,
Si promotes precipitation of the Laves phase and reduces ductility due to segregation
at the grain boundary, etc. For that reason, the Si content is limited to 0.10% or
less. A preferable range is 0.03 - 0.08%.
[0015] Mn is an element that effectively serves as a deoxidizer and a desulfurizer. Also,
Mn improves hardenability. Further, Mn suppresses precipitation of δ-ferrite while
promoting precipitation of M
23C
6-type carbides. Therefore, Mn is required to be added 0.15% at minimum. However, excessive
addition of Mn deteriorates oxidation resistance. For that reason, an upper limit
of the Mn content is set to 0.7%. A preferable range is 0.3 - 0.55%.
[0016] Ni is an element that suppresses precipitation of δ-ferrite, thus providing toughness.
However, excessive addition of Ni reduces the creep rupture strength. For that reason,
the Ni content is limited to 0.15 - 1.0%. A preferable range is 0.2 - 0.7%.
[0017] Cr is an element that is effective in providing oxidation resistance and in precipitating
M
23C
6-type carbides, to thereby increase the high-temperature strength. In order to obtain
those effects, Cr is required to be 9% at minimum. However, excessive addition of
Cr causes precipitation of δ-ferrite and reduces fatigue strength. For that reason,
the Cr content is limited to 9.5 - 12.0%. A preferable range is 10 - 11%.
[0018] Mo improves hardenability and increases temper softening resistance. Also, Mo is
also effective in increasing the high-temperature strength based on the action of
promoting fine precipitation of M
23C
6-type carbides and preventing aggregation. Therefore, Mo is required to be 0.2% or
more. In relation to the W content, however, the Mo content should be held 0.65% or
less. A preferable range is 0.3 - 0.55%.
[0019] W has a more powerful action of suppressing aggregation of M
23C
6-type carbides into coarser grains in comparison with the Mo. Also, W strengthens
the matrix with solid solution. In particular, W is effective in increasing the high-temperature
strength by adding 2.0% or more when Co is not contained, and by adding 1.8% or more
when Co is contained. In relation to the Mo content, however, the W content should
be held 3.0% or less. A preferable range is 2.0 - 2.5%.
[0020] V is effective in precipitating a carbo-nitride of V, to thereby increase the high-temperature
strength. However, if the V content exceeds 0.3%, carbon is excessively fixated and
the amount of precipitated M
23C
6-type carbides is reduced, thus decreasing the high-temperature strength. For that
reason, the V content is limited to 0.10 - 0.30%. A preferable range is 0.13 - 0.25%.
[0021] Co contributes to not only strengthening the matrix with solid solution, but also
suppressing precipitation of δ-ferrite. Addition of 0.1% or more of Co noticeably
increases the high-temperature strength, and one of the reasons why such effect is
developed is presumably attributable to the interaction with W. In other words, that
effect is a specific phenomenon occurred when W is contained 1.8% or more. In creep
causing environment at high temperature and long time, however, excessive addition
of Co causes aggregation of M
23C
6-type carbides into coarser grains at the crystal grain boundary, thus reducing the
creep rupture strength and also reducing the ductility. This results in deteriorating
productivity and increasing the cost. For that reason, an upper limit of the Co content
is set to 2.0%. A preferable range is 0.5 - 1.9%.
[0022] Nb forms NbC and contributes to generating finer crystal grains. Also, a part of
Nb is brought into the solid solution state in the quenching step and forms NbC in
the tempering step, thus increasing the high-temperature strength. Therefore, Nb is
required to be added 0.03% or more. As with V, however, if the Nb content exceeds
0.15%, carbon is excessively fixated and the amount of precipitated M
23C
6-type carbides is reduced, thus decreasing the high-temperature strength. For that
reason, the Nb content is limited to 0.03 - 0.15%. A preferable range is 0.04 - 0.10%.
[0023] N has the actions of precipitating a nitride of V and increasing the high-temperature
strength in the solid solution state based on the IS effect (interaction between an
interstitial solid solution element and a substitutive solid solution element) in
cooperation with Mo and W. Therefore, N is required to be added 0.02% at minimum.
However, addition of N in excess of 0.1% reduces ductility. For that reason, the N
content is limited to 0.02 - 0.1%. A preferable range is 0.04 - 0.07%.
[0024] B has the action of coming into the solid solution state in M
23C
6, thereby suppressing aggregation of M
23C
6-type carbides into coarser grains and increasing the high-temperature strength through
strengthening of the grain boundary. However, addition of B in excess of 0.015% impairs
weldability. Further, addition of B deteriorates productivity and increases the cost.
For that reason, an upper limit of the B content is set to 0.015%. Further, in the
heat resisting steel of the present invention having superior creep rupture strength
in the temperature range of 600 - 630°C, high toughness is obtaining by adding neither
Co nor B. Thus, the electroslag remelting is not required and the production cost
can be reduced. A preferable range is 0.008 - 0.015%.
[0025] Al is added as a deoxidizer and a crystal grain reducing agent (refiner). However,
Al is a nitride-forming element and fixates N, which effectively acts to increase
the creep rupture strength, thereby reducing the long-time creep rupture strength
in a high temperature range. Also, Al promotes precipitation of the Laves phase in
the form of a brittle intermetallic compound made of mainly W, and causes precipitation
of the Laves phase at the crystal grain boundary, thus reducing the long-time creep
rupture strength. In particular, when finer crystal grains are formed, the Laves phase
is continuously precipitated along the crystal grain boundary. Accordingly, an upper
limit of the Al content is set to 0.015%. A preferable range is 0.010% or less and
a more preferable range is 0.0005 - 0.005%.
[0026] Mo and W have the similar effect in point of increasing the high-temperature strength
and are added in a combined manner. With importance focused on the creep rupture strength
in the high temperature range, however, the W content is relatively increased. In
the combined addition of Mo and W, they are added such that (Mo + 0.5W) is preferably
1.3 - 1.7 and more preferably 1.5 ± 0.1 within the above-mentioned respective composition
ranges of Mo and W. Here, (Mo + 0.5W) is defined as the Mo equivalent. Taking into
account the correlation between W and Mo, it is possible to ensure the creep rupture
strength and obtain the toughness by setting a (W/Mo) ratio to be 4.0 - 10.0 within
the above-mentioned range of the Mo equivalent. Although those both characteristics
are increased and decreased depending the added elements, satisfactory characteristics
can be obtained when the (W/Mo) ratio is 4.0 - 8.0 in the same composition system.
[0027] The Cr equivalent expressed by the following formula is preferably 4 - 10.5 and more
preferably 6.5 - 9.5:
[0028] Further, the present invention resides in a rotor shaft for use in a high-pressure
steam turbine, an intermediate-pressure steam turbine, and a high- and intermediate-pressure
integral steam turbine, wherein the rotor shaft is produced by preparing an ingot
by vacuum melting, vacuum carbon deoxidation melting, or as required, electroslag
remelting, and by performing successive steps of hot forging at 850 - 1150°C, heating
at 900 - 1150°C, preferably 1000 - 1100°C, after rough cutting of the ingot surface,
quenching at a cooling rate of 50 - 150°C/hour at a central hole by water spraying,
primary tempering at 500 - 620°C, preferably 550 - 650°C, followed by subsequent furnace
cooling, and secondary tempering at temperature of 630 - 750°C, preferably 660 - 740°C,
higher than that in the primary tempering, followed by subsequent furnace cooling.
[0029] In the steam turbine rotor shaft made of the 12 mass%-Cr martensite steel according
to the present invention, a buildup weld layer is preferably formed on the surface
of a matrix (base material) in a journal portion of the rotor shaft by using a welding
material made of Cr-Mo low-alloy steel that has a high bearing characteristic. It
is preferable that the buildup weld layer is formed in 3 - 10 multi-layers. The Cr
content of the welding material is gradually reduced from the first layer to any of
the second to fourth layers. The fourth and subsequent layers are welded by using
the welding material made of the steel having the same Cr content. Further, the Cr
content of the welding material used for welding the first layer is reduced about
2 - 6% by mass from that of the base material, and the Cr content in the fourth and
subsequent weld layers is set to 0.5 - 3% by mass (preferably 1 - 2.5% by mass).
[0030] The buildup welding is preferable to improve the bearing characteristic of the journal
portion because of having the highest safety, but the journal portion may have a shrink-fitting
or press-fitting structure of a sleeve made of low-alloy steel containing 1 - 3% of
Cr. From the viewpoint of forming many weld layers and gradually reducing the Cr content
in the weld layers, the number of the weld layers is preferably three or more. However,
even if ten or more weld layers are formed, the effect cannot be obtained in excess
of a saturated level. In order to form the weld layers having a required thickness,
at least five buildup weld layers are preferably formed except for an allowance for
final finish by cutting. In addition, preferably, the third and subsequent weld layers
are made of the steel mainly having the tempered martensite structure, and the fourth
and subsequent weld layers are made of the steel containing 0.03 - 0.1% by mass of
C, 0.3 - 1% of Si, and 0.3 - 1.5% of Mn.
[0031] Still further, the present invention resides in a first-stage rotor blade and a first-stage
stator nozzle of the high-pressure steam turbine, the intermediate-pressure steam
turbine, and the high- and intermediate-pressure integral steam turbine, wherein the
first-stage rotor blade and the first-stage stator nozzle are each produced by preparing
an ingot by any of vacuum melting, vacuum carbon deoxidation melting, and electroslag
remelting, and by performing successive steps of hot forging at 850 - 1150°C, heating
at 900 - 1150°C, quenching at a cooling rate of 300 - 600°C/hour by oil cooling, primary
tempering at 500 - 620°C, and secondary tempering at temperature of 630 - 750°C higher
than that in the primary tempering.
[0032] Still further, the present invention resides in a high-pressure steam turbine comprising
a rotor shaft, rotor blades implanted to the rotor shaft, stator nozzles for guiding
inflow of steam toward the rotor blades, and an inner casing for holding the stator
nozzles, wherein the rotor blades are disposed in eight or more stages on one side
with the first stage being of the double-flow type, and the rotor shaft alone or the
rotor shaft and at least a first-stage rotor blade and stator nozzle of the rotor
blades and the stator nozzles are made of the above-described martensite heat resisting
steel.
[0033] Still further, the present invention resides in an intermediate-pressure steam turbine
comprising a rotor shaft, rotor blades implanted to the rotor shaft, stator nozzles
for guiding inflow of steam toward the rotor blades, and an inner casing for holding
the stator nozzles, wherein the rotor blades are disposed in five or more stages on
each of left and right sides in bilaterally symmetrical arrangement and have a double-flow
structure with the first stage implanted to a central portion of the rotor shaft,
and the rotor shaft alone or the rotor shaft and at least a first-stage rotor blade
and stator nozzle of the rotor blades and the stator nozzles are made of the above-described
martensite heat resisting steel.
[0034] Still further, the present invention resides in a high- and intermediate-pressure
integral steam turbine comprising a rotor shaft, rotor blades implanted to the rotor
shaft, stator nozzles for guiding inflow of steam toward the rotor blades, and an
inner casing for holding the stator nozzles, wherein the rotor blades are disposed
in seven or more stages on the high-pressure side and five or more stages on the intermediate-pressure
side, and the rotor shaft alone or the rotor shaft and at least a first-stage rotor
blade and stator nozzle of the rotor blades and the stator nozzles are made of the
above-described martensite heat resisting steel.
[0035] Still further, the present invention resides in a steam turbine power plant including
any of a set of a high-pressure steam turbine, an intermediate-pressure steam turbine,
and two low-pressure steam turbines connected in tandem, and a set of a high- and
intermediate-pressure integral steam turbine and a low-pressure steam turbine, wherein
a rotor shaft alone or a rotor shaft and at least a first-stage rotor blade and stator
nozzle of the rotor blades and the stator nozzles are made of the above-described
martensite heat resisting steel.
[0036] In the steam turbine power plant according to the present invention, preferably,
the low-pressure steam turbine includes the rotor blades disposed in eight or more
stages on each of the left and right sides in bilaterally symmetrical arrangement
and has the double-flow structure with the first stage implanted to the central portion
of the rotor shaft. The last-stage one of the rotor blades is made of martensite steel
containing 0.1 - 0.4% by mass of C, 0.25% or less of Si, 0.90% or less of Mn, 8.0
- 13.0% of Cr, 2 - 3% or less of Ni, 1.5 - 3.0% of Mo, 0.05 - 0.35% of V, 0.02 - 0.20%
of one or more of Nb and Ta in total, and 0.02 - 0.10% of N, and it has tensile strength
at room temperature of 120 kgf/mm
2 or more, preferably 128.5 kgf/mm
2 or more. Further, the blade height is 36 inches or more, and a value of [blade height
(inch) x number of revolutions (rpm)] is 125,000 or more.
[0037] Such a long blade of the steam turbine must have high tensile strength and high cycle
fatigue strength to be endurable against large centrifugal stress and vibration stress
which are caused by high-speed rotation. To that end, the metal structure of a blade
material is formed as the fully tempered martensite structure because the fatigue
strength is reduced if the harmful δ ferrite structure is present. The material composition
is adjusted so as to hold the Cr equivalent at 10 or less and to ensure that the metal
structure of the blade material does not essentially contain the δ ferrite phase.
[0038] Further, in order to obtain the homogeneous and high-strength long blade of the steam
turbine, thermal refining is conducted by performing, after smelting and forging steps,
quenching (preferably oil cooling) through steps of heating to 1000 - 1100°C, i.e.,
temperature sufficient for complete transform to the austenite structure, holding
for preferably 0.5 - 3 hours and subsequent quick cooling to room temperature, and
two or more stages of heat treatment, e.g., primary tempering through steps of heating
to 550 - 570°C, holding for preferably 1 - 6 hours and subsequent cooling to room
temperature, and secondary tempering through steps of heating to 560 - 680°C, holding
for preferably 1 - 6 hours and subsequent cooling to room temperature.
[0039] In an inner casing of the steam turbine which is made of the high-strength heat resisting
steel according to the present invention, preferably, the inner casing is made of
high-strength martensite steel containing 0.06 - 0.16% by mass of C, 0.5% or less
of Si, 1% or less of Mn, 0.2 - 1.0% of Ni, 8 - 12% of Cr, 0.05 - 0.35% of V, 0.01
- 0.15% of Nb, 2% or less of Co, 0.01 - 0.1% of N, 1.5% or less of Mo, 1 - 4% of W,
and 0.0005 - 0.003% of B. Further, the element composition is adjusted to hold the
Cr equivalent in the range of 4 - 10 such that 95% or more of the tempered martensite
structure (i.e., 5% or less of the δ ferrite) is obtained.
[0040] Thus, according to the present invention, it is possible to provide the high-strength
martensite heat resisting steel which has the long-time creep rupture strength required
for the steam temperature condition of 600 - 630°C and toughness at room temperature,
and which is suitable for use as the material of the steam turbine rotor shaft and
as large-sized forged steel with an improvement of hot forgeability, and to the method
of producing the steel. Also, the present invention can provide the steam turbine
rotor shaft and the method of producing it, the steam turbine rotor blade and the
method of producing it, the steam turbine stator nozzle and the method of producing
it, as well as the steam turbine and the steam turbine power plant, including the
method of producing the steam turbine, in which the turbine blade in a stage using
steam to cool the rotor has a larger height by increasing the high-temperature tensile
strength, and higher thermal efficiency is ensured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041]
Fig. 1 is a graph showing the relationship between creep rupture strength at 620°C
and 105 hours and (W/Mo);
Fig. 2 is a graph showing the relationship between impact absorption energy at 25°C
and (W/Mo);
Fig. 3 is a graph showing the relationship between creep rupture strength and impact
absorption energy;
Fig. 4 is a cross-sectional view of a high-pressure steam turbine according to the
present invention;
Fig. 5 is a cross-sectional view of an intermediate-pressure steam turbine according
to the present invention; and
Fig. 6 is a cross-sectional view of a high- and intermediate -pressure integral steam
turbine according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] The best mode for carrying out the present invention will be described in detail
below in connection with exemplary embodiments. It is to be noted that the present
invention is not limited to those embodiments.
(First Embodiment)
[0043] Table 1, given below, shows chemical composition (% by mass) of the steel of the
present invention and comparative steels which are used in this embodiment for comparative
studies. In Table 1, samples No. 1-10 represent the steel of the present invention,
samples No. 11-13 represent the comparative steels, and samples No. 14-19 represent
the known steels (corresponding to Patent Documents 1 and 3). As seen from Table 1,
in the samples No. 1-10 representing the steel of the present invention, the (W/Mo)
ratio is 4.0 - 10.0.
[0044] Each of the steel samples shown in Table 1 was prepared by producing an ingot of
50 kg in a vacuum high-frequency induction melting furnace, and forming a plate of
30 mm (t) × 90 mm (w) × L by hot forging. The hot forging was performed under heating
conditions of temperature 1150°C × 3 hours and at the forging temperature of 1150
- 950°C while the heating was repeated six times.
[0045] Simulating a central portion of a large-sized steam turbine rotor shaft, heat treatment
was conducted by successively performing quenching of 1050°C × 5 hours at a cooling
rate of 100°C/hour, primary tempering through heating and holding of 570°C × 20 hours,
and secondary tempering through heating and holding of 680°C × 20 hours. For each
of the steel samples thus prepared, creep rupture tests were made at various temperatures
and the creep rupture strength at 620°C and 10
5 hours was calculated from the test results by extrapolation. Also, V-notch Charpy
impact tests at room temperature (20°C) were made on each steel sample to obtain absorption
energy.
Table 1
Sample |
Chemical Composition (% by mass) |
C |
Si |
Mn |
Ni |
Cr |
Mo |
W |
V |
Co |
Nb |
B |
N |
Al |
Cr Equivalent |
Mo Equivalent |
W/Mo |
1 |
0.12 |
0.06 |
0.50 |
0.25 |
10.16 |
0.45 |
2.05 |
0.16 |
1.85 |
0.06 |
0.011 |
0.021 |
0.001 |
6.3 |
1.48 |
4.6 |
2 |
0.13 |
0.06 |
0.50 |
0.24 |
10.12 |
0.46 |
2.07 |
0.16 |
1.00 |
0.06 |
0.011 |
0.020 |
0.001 |
7.7 |
1.50 |
4.5 |
3 |
0.12 |
0.06 |
0.52 |
0.27 |
10.16 |
0.44 |
2.08 |
0.16 |
1.00 |
0.06 |
|
0.053 |
0.001 |
7.0 |
1.48 |
4.7 |
4 |
0.12 |
0.07 |
0.51 |
0.24 |
10.13 |
0.45 |
2.06 |
0.16 |
0.54 |
0.06 |
|
0.051 |
0.001 |
8.1 |
1.48 |
4.6 |
5 |
0.13 |
0.06 |
0.53 |
0.25 |
10.22 |
0.47 |
2.04 |
0.16 |
|
0.06 |
|
0.048 |
0.001 |
8.9 |
1.49 |
4.3 |
6 |
0.13 |
0.06 |
0.51 |
0.50 |
10.23 |
0.46 |
2.06 |
0.17 |
|
0.06 |
|
0.049 |
0.001 |
8.0 |
1.49 |
4.5 |
7 |
0.12 |
0.06 |
0.51 |
0.51 |
10.27 |
0.43 |
2.20 |
0.17 |
1.82 |
0.05 |
|
0.051 |
0.002 |
4.7 |
1.53 |
5.1 |
8 |
0.12 |
0.06 |
0.52 |
0.50 |
10.41 |
0.35 |
2.31 |
0.17 |
1.83 |
0.05 |
|
0.048 |
0.002 |
4.8 |
1.51 |
6.6 |
9 |
0.12 |
0.06 |
0.50 |
0.49 |
10.41 |
0.25 |
2.50 |
0.17 |
1.81 |
0.05 |
0.012 |
0.020 |
0.002 |
5.7 |
1.50 |
10.0 |
10 |
0.12 |
0.07 |
0.52 |
0.50 |
10.43 |
0.31 |
2.39 |
0.17 |
1.81 |
0.05 |
|
0.049 |
0.002 |
4.9 |
1.51 |
7.7 |
11 |
0.12 |
0.06 |
0.49 |
0.50 |
10.17 |
0.80 |
1.41 |
0.17 |
|
0.06 |
|
0.048 |
0.001 |
8.8 |
1.51 |
1.8 |
12 |
0.12 |
0.07 |
0.51 |
0.24 |
10.40 |
0.22 |
2.56 |
0.17 |
|
0.05 |
|
0.050 |
0.002 |
9.4 |
1.50 |
11.6 |
13 |
0.12 |
0.07 |
0.06 |
0.20 |
10.00 |
0.60 |
1.80 |
0.20 |
|
0.06 |
0.012 |
0.022 |
0.010 |
11.6 |
1.50 |
3.0 |
14 |
0.12 |
0.06 |
0.04 |
0.05 |
10.20 |
0.70 |
1.70 |
0.20 |
3.30 |
0.06 |
0.002 |
0.022 |
0.010 |
6.1 |
1.55 |
2.4 |
15 |
0.12 |
0.05 |
0.50 |
0.50 |
10.38 |
0.41 |
1.82 |
0.17 |
|
0.05 |
|
0.050 |
0.004 |
7.9 |
1.32 |
4.4 |
16 |
0.11 |
0.06 |
0.46 |
0.25 |
10.20 |
0.20 |
2.60 |
0.20 |
2.54 |
0.07 |
|
0.016 |
0.002 |
5.9 |
1.50 |
13.0 |
17 |
0.11 |
0.06 |
0.46 |
0.25 |
10.20 |
0.20 |
2.60 |
0.20 |
2.52 |
0.07 |
0.013 |
0.017 |
0.002 |
5.9 |
1.50 |
13.0 |
18 |
0.14 |
0.28 |
0.52 |
0.60 |
11.09 |
1.24 |
0.42 |
0.19 |
|
0.09 |
|
0.035 |
0.004 |
10.8 |
1.45 |
0.3 |
19 |
0.12 |
0.08 |
0.06 |
0.20 |
10.00 |
0.60 |
1.80 |
0.20 |
3.02 |
0.06 |
0.012 |
0.021 |
0.010 |
5.7 |
1.50 |
3.0 |
[0046] Table 2, given below, shows the creep rupture strength at 620°C and 10
5 hours and the absorption energy obtained from the results of the Charpy impact tests
at 25°C. As seen from Table 2, in the samples No. 1-10 representing the steel of the
present invention, the creep rupture strength at 620°C and 10
5 hours is relatively high in the range of 10.35 - 13.00 kgf/mm
2 as a whole. The samples No. 11-13 representing the comparative steels and the samples
No. 14-19 representing the known steels have the creep rupture strengths varying in
the range of 7.30 - 13.26 kgf/mm
2. In any type of the steels, steel characteristics are clarified by dividing them
into systems containing Co and B, not containing Co and B, and not containing Co or
B. It is apparent in each of those systems that the steel of the present invention
having the (W/Mo) ratio of 4.0 - 10.0 has higher strength.
Table 2
|
Creep Rupture Strength |
Absorption Energy (20°C) |
kgf/mm2 |
J |
1 |
11.72 |
55 |
2 |
11.79 |
58 |
3 |
11.26 |
130 |
4 |
10.46 |
155 |
5 |
11.03 |
119 |
6 |
11.85 |
139 |
7 |
11.40 |
137 |
8 |
12.00 |
132 |
9 |
13.00 |
42 |
10 |
11.70 |
128 |
11 |
10.17 |
145 |
12 |
12.70 |
110 |
13 |
10.71 |
60 |
14 |
12.03 |
58 |
15 |
11.62 |
135 |
16 |
11.22 |
85 |
17 |
13.26 |
10 |
18 |
7.30 |
45 |
19 |
11.34 |
60 |
[0047] Also, as seen from Table 2, in the samples No. 1-10 representing the steel of the
present invention, the absorption energy obtained from the results of the Charpy impact
tests at room temperature (20°C) is relatively high in the range of 55 - 139 J as
a whole. The samples No. 11-13 representing the comparative steels and the samples
No. 14-19 representing the known steels have the absorption energy varying in the
range of 10 - 145 J. In any type of the steels, steel characteristics are clarified
by dividing them into systems containing Co and B, not containing Co and B, and not
containing Co or B. It is apparent in each of those systems that the steel of the
present invention having the (W/Mo) ratio of 4.0 - 10.0 has higher absorption energy.
[0048] Fig. 1 is a graph showing the relationship between the (W/Mo) ratio and the creep
rupture strength at 620°C and 10
5 hours. As seen from Fig. 1, in any type of the steels, the creep rupture strength
at 620°C and 10
5 hours is noticeably increased by increasing the (W/Mo) ratio in the steel and has
a value higher than 10 kgf/mm
2. Thus, any type of the steels can be satisfactorily used as the material of the rotor
shaft of the steam turbine operated at steam temperature of 600°C or above from the
viewpoint of the creep rupture strength.
[0049] Also, as seen from Fig. 1, in any type of the steels, the steel systems containing
Co and B have higher strength than the steel systems not containing Co and B and not
containing Co or B. Further, it is apparent that, in each of those steel systems,
higher strength is obtained with an increase of the (W/Mo) ratio including the range
of 4.0 - 10.0. In the steel system containing Co, however, the strength is reduced
when the (W/Mo) ratio exceeds 10. Further, higher creep rupture strength is obtained
as the Co content increases.
[0050] Fig. 2 is a graph showing the relationship between the (W/Mo) ratio and the absorption
energy obtained from the results of the Charpy impact tests at room temperature (20°C).
As seen from Fig. 2, comparing all the types of the steels, the energy absorption
is higher in the steel of the present invention in which the (W/Mo) ratio is 4.0 -
10.0, regardless of the steel systems containing Co and B, not containing Co and B,
and not containing Co or B. Further, the absorption energy is at minimum in the steel
system containing Co and B, and is abruptly reduced at the (W/Mo) ratio of 10 or above.
Particularly, in the steel system containing Co, the absorption energy is abruptly
reduced when the (W/Mo) ratio exceeds 10. Thus, it is apparent that, in each of the
steel systems, the steel of the present invention having the (W/Mo) of 4.0 - 10.0
has higher absorption energy.
[0051] Fig. 3 is a graph showing the relationship between the creep rupture strength at
620°C and 10
5 hours and the absorption energy obtained from the results of the Charpy impact tests
at 20°C. The relationship between the creep rupture strength and the absorption energy
differs for each of the steel system not containing Co and B (indicated by marks ▲
and △), the steel system containing Co or B (indicated by marks ■ and □), and the
steel system containing Co and B (indicated by marks ● and ○). As seen from Fig. 3,
the higher the creep rupture strength, the lower is the absorption energy. Comparing
the absorption energy at the same creep rupture strength, the absorption energy is
reduced in the order of the steel system not containing Co and B, the steel system
containing Co, the steel system containing B, and the steel system containing Co and
B.
[0052] In other words, the comparative steels and the known steels are represented by the
samples No. 11 and 15 (containing 0.5% of Ni) which belong to the steel system not
containing Co and B (indicated by mark ▲), the sample No. 12 (containing 0.24% of
Ni) which belongs to the steel system not containing Co and B (indicated by mark
▲), the samples No. 16 and 14 which belong to the steel system containing Co (indicated
by mark ■), the sample No. 13 which belongs to the steel system containing B (indicated
by mark ■), and the samples No. 19 and 17 which belong to the steel system containing
Co and B (indicated by mark ●). From comparison at the same creep rupture strength,
it is apparent that the samples No. 1-10 representing the steel of the present invention
((indicated by marks Δ, □ and ○) have higher absorption energy than the comparative
steels and the known steels belonging to the respective same steel systems. Accordingly,
the steel of the present invention has higher absorption energy than levels given
by characteristic lines representing the comparative steels and the known steels.
Comparing from another aspect, the steel of the present invention has higher creep
rupture strength than the comparative steels and the known steels at the same absorption
energy.
[0053] Thus, the steel of the present invention has the long-time creep rupture strength
required for the steam temperature condition of 600 - 630°C and toughness at room
temperature, and it is suitable for use as the material of the steam turbine rotor
shaft and as the large-sized forged steel with an improvement of hot forgeability.
(Second Embodiment)
[0054] Fig. 4 is a cross-sectional view.of a high-pressure steam turbine (HP) using the
high-strength martensite heat resisting steel according to the present invention as
a rotor shaft material. Fig. 5 is a cross-sectional view of an intermediate-pressure
steam turbine (IP) using the high-strength martensite heat resisting steel according
to the present invention as a rotor shaft material. In this second embodiment, the
HP and the IP are connected in tandem to constitute a steam turbine power plant having
steam temperature of 625°C and output capacity of 1050 MW. A low-pressure steam turbine
is of the cross-compound four-flow exhaust type, and the blade height in the last
stage thereof is 43 inches. More specifically, the steam turbine power plant can be
constituted by a set of (HP) - (IP) - generator and a set of two low-pressure steam
turbines (LP) - generator, each set operating at the rotation speed of 3000 rpm, or
by a set of (HP) - (LP) - generator and a set of (IP) - (LP) - generator, each set
operating at the rotation speed of 3000 rpm. The steam temperature and pressure in
the HP are 625°C and 250 kgf/cm
2. In the IP, the steam temperature is heated to 625°C by a reheater and operation
is performed at pressure of 45 - 65 kgf/cm
2. Steam having temperature of 400°C enters the LP and is sent to a condenser under
vacuum of 722 mmHg at 100°C or below.
[0055] The high-temperature and high-pressure steam turbine power plant according to this
embodiment comprises mainly a coal firing boiler, one HP, one IP, two LPs, a condenser,
a condensing pump, a low-pressure feedwater heater system, a deaerator, a booster
pump, a feedwater pump, and a high-pressure feedwater heater system. More specifically,
ultra high-temperature and high-pressure steam generated in the boiler enters the
HP in which motive power is produced. Then, the steam is reheated by the boiler and
enters the IP in which motive power is produced. The steam exhausted from the IP enters
the LP in which motive power is produced, followed by being condensed in the condenser.
The condensed water is sent to the low-pressure feedwater heater system and the deaerator
by the condensing pump. The feedwater deaerated in the deaerator is sent to the high-pressure
feedwater heater system by the booster pump and the condensing pump. After the water
temperature is raised in the high-pressure feedwater heater system, the feedwater
is returned to the boiler. In the boiler, the feedwater is converted to high-temperature
and high-pressure steam through an economizer, an evaporator and a superheater.
[0056] The HP includes a high-pressure inner compartment (casing) 18, a high-pressure outer
compartment (casing) 19 surrounding the inner compartment 18, and a high-pressure
rotor shaft 20 provided with high-pressure rotor blades 16 implanted to it and disposed
inside those casings. High-temperature and high-pressure steam obtained by a boiler
passes through a main steam pipe and flows into a main steam inlet 28 through a flange
and elbow 25 constituting a main steam section. The steam is then introduced to the
rotor blade in the double-flow first stage through a nozzle box 38. The first stage
has a double-flow structure, and the rotor blades are disposed in eight stages on
one side. Stator nozzles are disposed corresponding to the rotor blades.
[0057] The IP is used to rotate the generator in cooperation with the HP by utilizing steam
obtained by heating the steam, which is exhausted from the HP, to 625°C again by a
reheater. Similarly to the HP, the IP has an intermediate-pressure inner compartment
(casing) 21 and an intermediate-pressure outer compartment (casing) 22, and further
includes stator nozzle corresponding to the intermediate-pressure rotor blades 17.
The intermediate-pressure rotor blades 17 are disposed six stages in each of the left
and right sides in bilaterally symmetric arrangement with a double-flow structure
in which the first-stage rotor blade is implanted to a central portion of the intermediate-pressure
rotor shaft 24.
[0058] According to this embodiment, in each of the HP and IP, the rotor shaft, the first-stage
rotor blade, and the first-stage stator nozzle are made of one sample steel of the
present invention in Table 1 described above, i.e., the 12%-Cr steel containing Co
and B. The rotor shafts of the HP and the IP have similar characteristics to those
in the above-described first embodiment. The first-stage rotor blade and the first-stage
stator nozzle are produced through the steps of quenching by oil cooling after heating
to a temperature level similar to that in the case of the rotor shaft, and tempering
at 650 - 750°C. Thus, the first-stage rotor blade and the first-stage stator nozzle
have slightly higher creep rupture strength and impact values than those of the rotor
shaft.
[0059] The rotor shafts of the high-pressure steam turbine and the intermediate-pressure
steam turbine were produced as follows. First, 30 tons of the heat resisting cast
steel shown in Table 1 was smelted in an electric furnace, and after carbon vacuum
deoxidation, the smelted steel was cast into a mold, followed by forming an electrode
rod with elongation forging. Then, electroslag remelting was performed to smelt the
cast steel from an upper portion toward a lower portion by using the electrode rod,
followed by elongation forging into the rotor shape. The elongation forging was performed
at temperature of 1150°C or below in order to prevent forging cracks.
[0060] After annealing the forged steel, the steel was subjected to steps of heating and
holding to 1050°C while slowly rotating it at speed of 1 (rotation/minute), quenching
(cooling rate of 100°C/hour at a central portion) by water spraying while slowly rotating
it at a similar speed, primary tempering at 570°C, and secondary tempering at 690°C.
The rotor shafts were then obtained by cutting into the respective shapes shown in
Figs. 4 and 5. In this embodiment, each rotor shaft was formed such that the upper
side of the electroslag steel ingot becomes the first-stage blade side and the lower
side becomes the last-stage blade side.
[0061] As a result of examining the central portion of each rotor shaft obtained according
to this embodiment, it was proved that the rotor shaft sufficiently satisfied the
characteristics (i.e., the creep rupture strength at 620°C and 10
5 hours ≥ 10 kgf/mm
2 and the impact absorption energy at 20°C ≥ 1.5 kgf-m) required for the high- and
intermediate-pressure turbine rotors. Thus, it was proved that the steam turbine rotor
capable of being used in steam at 600 - 630°C could be produced.
[0062] Two LPs are connected in tandem and have substantially the same structure. In each
LP, last-stage and other rotor blades are disposed in eight stages in each of the
left and right sides and are arranged in substantially bilateral symmetry. Stator
nozzles are disposed corresponding to the rotor blades. The last-stage rotor blade
has an airfoil height of 43 inches and is produced through a series of steps of smelting
by the electroslag remelting process, forging, and heat treatment. Such a long blade
is made of martensite steel containing 0.08 - 0.18% by mass of C, 0.25% or less of
Si, 0.90% or less of Mn, 8.0 - 13.0% of Cr, 2 - 3% of Ni, 1.5 - 3.0% of Mo, 0.05 -
0.35% of V, 0.02 - 0.20% of one or more of Nb and Ta in total, and 0.02 - 0.10% of
N. Also, the long blade exhibits the tensile strength at room temperature of 120 kgf/mm
2 or more and has the fully tempered martensite structure. More preferably, the tensile
strength is 128.5 kgf/mm
2 or more and the V-notch Charpy impact value at 20°C is 4 kgf-m/cm
2 or more. An airfoil of the long blade having the airfoil height of 43 inches, against
which high-speed steam impinges, is coated with an erosion shield formed by joining
a stellite sheet made of a Co-base alloy by welding in order to prevent erosion caused
by water droplets in the steam.
[0063] A low-pressure rotor shaft is made of forged steel having the fully tempered bainite
structure of a super-clean material containing 3.75% of Ni, 1.75% of Cr, 0.4% of Mo,
0.15% of V, 0.25% of C, 0.05% of Si, and 0.10% of Mn, the balance being Fe. Each of
the rotor blades and the stator nozzles in other stages than the last stage is made
of the 12%-Cr steel containing 0.1% of Mo. Inner and outer casings are each made of
0.25%-C cast steel.
[0064] Further, in this embodiment, a shaft of a generator with output capacity of 1050-MW
class is made of higher-strength steel having the fully tempered bainite structure
and containing 0.15 - 0.30% of C, 0.1 - 0.3% of Si, 0.5% or less of Mn, 3.25 - 4.5%
of Ni, 2.05 - 3.0% of Cr, 0.25 - 0.60% of Mo, and 0.05 - 0.20% of V. Further, the
tensile strength at room temperature is 93 kgf/mm
2 or more, preferably 100 kgf/mm
2 or more, and 50%-FATT (Fracture Appearance Transition Temperature) is 0°C or below,
preferably -20°C or below.
[0065] A central hole is formed in the rotor shaft of each of the HP, IP and LP so that
the presence or absence of defects can be checked through the central hole by ultrasonic
inspection, visual inspection and/or fluorescence flaw detection. Alternatively, the
central hole may be omitted because defects can also be detected by ultrasonic inspection
from an outer surface of the rotor shaft.
[0066] Moreover, in this embodiment, the Cr-Mo low-alloy steel was buildup-welded on a journal
portion of each rotor shaft of the HP and IP to improve bearing characteristics. A
coated arc-welding electrode was used as a welding electrode for the buildup welding.
[0067] The buildup welding was performed to form eight layers. The thickness of each layer
was 3 - 4 mm and the total thickness was about 28 mm with a weld surface cut about
5 mm by grinding. Welding conditions were set such that each of the preheating temperature,
the inter-pass temperature, and the start temperature of stress removing annealing
(SR) was 250 - 350°C and the SR was performed under conditions of heating and holding
of 630°C × 36 hours. First to third layers were formed by using coated arc-welding
electrodes made of 8%-Cr - 0.5%-Mo steel, 5%-Cr - 0.5%-Mo steel, and 2.3%-Cr - 1%-Mo
steel, respectively, and fourth to eighth layers were each formed by using a coated
arc-welding electrode made of 1.3%-Cr - 0.76%-Mo steel. Those welding materials contained
0.03 - 0.07% of C, 0.4 - 0.8% of Si, and 0.5 - 1.0% of Mn.
[0068] The first-stage rotor blade and the first-stage stator nozzle in each of the HP and
IP were also produced by smelting, in a vacuum arc melting furnace, the heat resisting
steel of the present invention containing Co and B, shown in Table 1 described above,
and forming the steel into the blade and nozzle blank shape (with a width of 150 mm,
a height of 50 mm, and a length of 1000 mm) by elongation forging. Further, the forged
steel was subjected to heating to 1050°C, oil quenching, and tempering at 690°C. Thereafter,
the forged steel was cut into the predetermined shape.
[0069] Also, it was confirmed that the first-stage rotor blade of each of the HP and IP
sufficiently satisfied the required characteristics (i.e., the creep rupture strength
at 625°C and 10
5 hours ≥ 15 kgf/mm
2). Thus, it was proved that the steam turbine blade capable of being used in steam
at 620°C or above could be produced.
[0070] Inner casings of high- and intermediate-pressure sections, a casing of a main steam
valve, and a casing of a steam control valve were each produced through the steps
of smelting, in an electric furnace, heat-resisting cast steel of 0.12% C - 9% Cr
- 0.6% Mo - 1.7% W - B, ladle refining, and casting into a sand mold. By sufficiently
performing refining and deoxidation before the casting step, the cast steel could
be obtained which contained no casting defects such as shrinkage.
[0071] Further, as a result of examining characteristics of the inner casings, the casing
of the main steam valve, and the casing of the steam control valve, it was confirmed
that each of those casings satisfied the required characteristics (i.e., the creep
rupture strength at 625°C and 10
5 hours ≥ 10 kgf/mm
2 and the impact absorption energy at 20°C ≥ 1 kgf-m) and could be satisfactorily welded.
Thus, it was proved that the steam turbine casing capable of being used in steam at
620°C or above could be produced.
[0072] According to the second embodiment, it is possible to provide the steam turbine rotor
shaft having the long-time creep rupture strength required for the steam temperature
condition of 600 - 630°C and toughness at room temperature, and the method of producing
the rotor shaft, the steam turbine rotor blade having the required characteristics
and the method of producing it, as well as the steam turbine stator nozzle having
the required characteristics and the method of producing it. Further, it is possible
to provide the steam turbine and the steam turbine power plant, including the method
of producing the steam turbine, in which the turbine blade in the stage using steam
to cool the rotor has a larger height by increasing the high-temperature tensile strength,
and higher thermal efficiency is ensured.
(Third Embodiment)
[0073] Fig. 6 is a cross-sectional view of a high- and intermediate-pressure integral steam
turbine. This third embodiment relates to a steam turbine power plant with steam temperature
of 620°C and output capacity of 600 MW. The power plant of this third embodiment is
of the tandem compound double-flow type, and the last-stage blade height in the LP
is 43 inches. A rotation speed of 3000 rpm is obtained by the high- and intermediate-pressure
integral steam turbine (HP-IP) and one LP (C) or two LPs (D). The steam temperature
and pressure in the high-pressure section (HP) are 600°C and 250 kgf/cm
2. In the intermediate-pressure section (IP), the steam temperature is heated to 600°C
by a reheater and operation is performed at pressure of 45 - 65 kgf/cm
2. The steam temperature in the low-pressure section (LP) is 400°C, and steam in the
LP is sent to a condenser under vacuum of 722 mmHg at 100°C or below.
[0074] The high-pressure side steam turbine (HP) includes an inner compartment (casing)
18 and an outer compartment (casing) 19 surrounding the inner casing 18. The intermediate-pressure
steam turbine (IP) includes an inner compartment (casing) 21 and an outer compartment
(casing) 22 surrounding the inner casing 21. A high- and intermediate-pressure integral
rotor shaft 23 provided with high-pressure rotor blades 16 and intermediate-pressure
rotor blades 17 both implanted to the rotor shaft is disposed inside those casings.
The high-pressure and high-temperature steam obtained by the boiler passes through
a main steam pipe and flows into a main steam inlet 28 through a flange and elbow
25 constituting a main steam section. The steam is then introduced to the high-pressure
rotor blade 16 in the first stage of the high-pressure side steam turbine through
a nozzle box 38. The rotor blades are disposed in eight stages in the HP on the left
side in Fig. 6 and six stages in the IP on the right side in Fig. 6. Stator nozzles
are disposed corresponding to the rotor blades.
[0075] In this third embodiment, each of the rotor shaft, the first-stage rotor blade, and
the first-stage stator nozzle is made of the 12%-Cr steel containing Co and B among
the steel samples of the present invention shown in Table 1 described above.
[0076] The rotor shaft of the high- and intermediate-pressure integral steam turbine was
produced as follows. First, 30 tons of the 12%-Cr steel shown in Table 1 was smelted
in an electric furnace, and after carbon vacuum deoxidation, the smelted steel was
cast into a mold, followed by forming an electrode rod with elongation forging. Then,
electroslag remelting was performed to smelt the cast steel from an upper portion
toward a lower portion by using the electrode rod, followed by elongation forging
into the rotor shape. The elongation forging was performed at temperature of 1150°C
or below in order to prevent forging cracks. After annealing the forged steel, the
steel was subjected to steps of quenching by water spray cooling after heating to
1050°C, two stages of tempering at 570°C and 690°C. The rotor shaft was then obtained
by cutting into the shape shown in Fig. 5. Materials and production conditions for
the other components were the same as those in the second embodiment. Further, buildup
welding was also performed on a bearing journal portion in a similar manner. In addition,
the rotor shaft had the same characteristics as those described above in the first
embodiment.
[0077] The first-stage rotor blade and the first-stage stator nozzle were produced through
the steps of quenching by oil cooling after heating to a temperature level similar
to that in the case of the rotor shaft, and tempering at 650 - 750°C. Thus, the first-stage
rotor blade and the first-stage stator nozzle had slightly higher creep rupture strength
and impact values than those of the rotor shaft.
[0078] The IP heats the steam discharged from the HP again to 600°C by a reheater and rotates
the generator in cooperation with the HP by using the heated steam.
[0079] One LP is connected to the HP-LP. Last-stage and other rotor blades are disposed
in six stages in each of the left and right sides and are arranged in substantially
bilateral symmetry. Stator nozzles are disposed corresponding to the rotor blades.
The last-stage rotor blade has an airfoil height of 43 inches and is made of the 12%-Cr
steel that is similar to that used in the second embodiment. Also, as in the second
embodiment, the last-stage rotor blade in this third embodiment has erosion shields
made of stellite steel, which are welded at two points in the front and rear sides
of the rotor blade by electron beam welding or TIG welding.
[0080] Each of the rotor shaft of the low-pressure steam turbine and the rotor blades and
the stator nozzles in other stages than the last stage is produced in the same manner
as that described above in the second embodiment.
[0081] The concept of this third embodiment can be similarly applied to another type of
power plant, e.g., a large-capacity power plant of 1000-MW class in which the steam
inlet temperature of the high- and intermediate-pressure integral steam turbine is
610°C or above and the steam inlet temperature and the steam outlet temperature of
the low-pressure integral steam turbine are about 400°C and about 60°C, respectively.
[0082] While this third embodiment has been described in connection with the power plant
of the tandem compound double-flow type, it can be modified based on the same concept
to, e.g., a power plant with output capacity of 1050-MW class in which two low-pressure
steam turbines are connected in tandem. In that case, a generator shaft is made of
higher-strength steel having the fully tempered bainite structure, the tensile strength
at room temperature of 93 kgf/mm
2 or more, preferably 100 kgf/mm
2 or more, and 50%-FATT (Fracture Appearance Transition Temperature) of 0°C or below,
preferably -20°C or below, as in the second embodiment.
[0083] According to the third embodiment, it is possible to provide the steam turbine rotor
shaft having the long-time creep rupture strength required for the steam temperature
condition of 600 - 630°C and toughness at room temperature, and the method of producing
the rotor shaft, the steam turbine rotor blade having the required characteristics
and the method of producing it, as well as the steam turbine stator nozzle having
the required characteristics and the method of producing it. Further, it is possible
to provide the steam turbine and the steam turbine power plant, including the method
of producing the steam turbine, in which the turbine blade in the stage using steam
to cool the rotor has a larger height by increasing the high-temperature tensile strength,
and higher thermal efficiency is ensured. Features, components and specific details
of the structures of the above-described embodiments may be exchanged or combined
to form further embodiments optimized for the respective application. As far as those
modifications are readily apparent for an expert skilled in the art they shall be
disclosed implicitly by the above description without specifying explicitly every
possible combination, for the sake of conciseness of the present description.
1. A high-strength martensite heat resisting steel containing 0.05 - 0.20% by mass of
C, 0.1% or less of Si, 0.15 - 0.7% of Mn, 0.15 - 1.0% of Ni, 9.5 - 12.0% of Cr, 0.20
- 0.65% of Mo, 2.0 - 3.0% of W, 0.1 - 0.3% of V, 0.03 - 0.15% of Nb, and 0.01 - 0.10%
of N, (W/Mo) being 4.0 - 10.0, the balance being Fe and unavoidable impurities.
2. A high-strength martensite heat resisting steel containing 0.05 - 0.20% by mass of
C, 0.1% or less of Si, 0.15 - 0.7% of Mn, 0.15 - 1.0% of Ni, 9.5 - 12.0% of Cr, 0.20
- 0.65% of Mo, 1.8 - 3.0% of W, 0.1 - 2.0% of Co, 0.1 - 0.3% of V, 0.03 - 0.15% of
Nb, and 0.01 - 0.10% of N, (W/Mo) being 4.0 - 10.0, the balance being Fe and unavoidable
impurities.
3. The high-strength martensite heat resisting steel according to Claim 1 or 2, wherein
the steel contains 0.09 - 0.16% by mass of C, 0.03 - 0.08% of Si, 0.3 - 0.55% of Mn,
0.2 - 0.7% of Ni, 10 - 11% of Cr, 0.3 - 0.55% of Mo, 2.0 - 2.5% of W, 0.1 - 0.3% of
V, 0.04 - 0.10% of Nb, and 0.01 - 0.07% of N, (W/Mo) being 4.0 - 8.0.
4. The high-strength martensite heat resisting steel according to any one of Claims 1
to 3, wherein the steel further contains at least one of 0.015% or less of B and 0.015%
or less of Al.
5. The high-strength martensite heat resisting steel according to any one of Claims 1
to 4, wherein (Mo + 0.5W) is 1.3 - 1.7.
6. A method of producing a high-strength martensite heat resisting steel containing 0.05
- 0.20% by mass of C, 0.1% or less of Si, 0.15 - 0.7% of Mn, 0.15 - 1.0% of Ni, 9.5
- 12.0% of Cr, 0.20 - 0.65% of Mo, 2.0 - 3.0% of W, 0.1 - 0.3% of V, 0.03 - 0.15%
of Nb, and 0.01 - 0.10% of N, (W/Mo) being 4.0 - 10.0, the balance being Fe and unavoidable
impurities, wherein the method includes a series of steps of hot plastic working,
quenching, primary tempering, and secondary tempering at higher temperature than that
in the primary tempering.
7. A method of producing a high-strength martensite heat resisting steel containing 0.05
- 0.20% by mass of C, 0.1% or less of Si, 0.15 - 0.7% of Mn, 0.15 - 1.0% of Ni, 9.5
- 12.0% of Cr, 0.20 - 0.65% of Mo, 1.8 - 3.0% of W, 0.1 - 2.0% of Co, 0.1 - 0.3% of
V, 0.03 - 0.15% of Nb, and 0.01 - 0.10% of N, (W/Mo) being 4.0 - 10.0, the balance
being Fe and unavoidable impurities, wherein the method includes a series of steps
of hot plastic working, quenching, primary tempering, and secondary tempering at higher
temperature than that in the primary tempering.
8. The method of producing the high-strength martensite heat resisting steel according
to Claim 6 or 7, wherein the steel contains 0.09 - 0.16% by mass of C, 0.03 - 0.08%
of Si, 0.3 - 0.55% of Mn, 0.2 - 0.7% of Ni, 10 - 11% of Cr, 0.3 - 0.55% of Mo, 2.0
- 2.5% of W, 0.1 - 0.3% of V, 0.04 - 0.10% of Nb, and 0.01 - 0.07% of N, (W/Mo) being
4.0 - 8.0.
9. The method of producing the high-strength martensite heat resisting steel according
to any one of Claims 6 to 8, wherein the steel further contains at least one of 0.015%
or less of B and 0.015% or less of Al.
10. The method of producing the high-strength martensite heat resisting steel according
to any one of Claims 6 to 9, wherein (Mo + 0.5W) is 1.3 - 1.7.
11. A steam turbine rotor shaft made of the high-strength martensite heat resisting steel
according to any one of Claims 1 to 5.
12. A method of producing a steam turbine rotor shaft, wherein the method includes a step
of obtaining a rotor shaft material by the method of producing the high-strength martensite
heat resisting steel according to any one of Claims 6 to 10.
13. The method of producing the steam turbine rotor shaft according to Claim 12, wherein
the method includes a step of producing an ingot of the martensite heat resisting
steel by any of vacuum melting, vacuum carbon deoxidation melting and electroslag
remelting, and performs successive steps of hot forging at 850 - 1150°C, heating at
900 - 1150°C, quenching at a cooling rate of 50 - 150°C/hour at a central hole, primary
tempering at 500 - 620°C, and secondary tempering at temperature of 630 - 750°C higher
than that in the primary tempering.
14. A steam turbine rotor blade made of the high-strength martensite heat resisting steel
according to any one of Claims 1 to 5.
15. A steam turbine stator nozzle made of the high-strength martensite heat resisting
steel according to any one of Claims 1 to 5.
16. A steam turbine comprising a rotor shaft, rotor blades implanted to said rotor shaft,
stator nozzles for guiding inflow of steam toward said rotor blades, and an inner
casing for holding said stator nozzles, wherein said rotor blades are disposed in
seven or more stages on the high pressure side and in five or more stages on the intermediate
pressure side, and said rotor shaft alone or said rotor shaft and at least a first-stage
rotor blade and stator nozzle of said rotor blades and said stator nozzles are constituted
respectively by the rotor shaft according to Claim 11, the rotor blade according to
Claim 14, and the stator nozzle according to Claim 15.
17. The steam turbine according to Claim 16, wherein said steam turbine is any of a high-pressure
steam turbine, an intermediate-pressure steam turbine, and a high- and intermediate-pressure
integral steam turbine.
18. A method of producing a steam turbine comprising a rotor shaft, rotor blades implanted
to said rotor shaft, stator nozzles for guiding inflow of steam toward said rotor
blades, and an inner casing for holding said stator nozzles, said rotor blades being
disposed in seven or more stages on the high pressure side and in five or more stages
on the intermediate pressure side, wherein the method includes a step of producing
said rotor shaft by the method according to Claim 12 or 13.
19. A steam turbine power plant including any of a set of a high-pressure steam turbine,
an intermediate-pressure steam turbine, and two low-pressure steam turbines connected
in tandem, and a set of a high- and intermediate-pressure integral steam turbine and
a low-pressure steam turbine, wherein at least one of said high-pressure steam turbine,
said intermediate-pressure steam turbine, and said high- and intermediate-pressure
integral steam turbine is constituted by the high-pressure steam turbine, the intermediate-pressure
steam turbine, and the high- and intermediate-pressure integral steam turbine according
to Claim 17.