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Steam TurbinesAl Khobar Roadshow, 24 July 2006
Guido RaimondiHead of Steam Turbine Thermodynamics Design
2
STEAM TURBINES
New New equipmentequipment
Product developmentProduct development
RepoweringRepowering Concept Concept
Retrofit and Retrofit and modernizationmodernization
3
GE USAIMPULSE
Westinghouse USAREACTION
Siemens-KWU DREACTION
BBC CHREACTION
Alsthom FIMPULSE
GEC UKIMPULSE
1970
Siemens AEG SACM Rateau AEI GECBBCSulzer
1) Industrial Turbines2) Impulse on Nuclear Turbines
Mitsubishi JREACTION
GE USAIMPULSE
Toshiba J
ABB-Alstom FREACTION (2)
1999
Siemens Westinghouse DREACTION
1998
Ansaldo IFuji J
2000
Hitachi J
1987
Ansaldo
Hitachi
Doosan
Toshiba
BHEL
Fuji
N. Pignone (1)
Parsons
ASEA STAL
F. Tosi
Ansaldo
Zamech
GEC – Alsthom
1989
CEM
ABB
De Pretto
LMZMitsubishi
ESG
Steam Turbine Technology Evolution
4
STEAM TURBINES
New New equipmentequipment
Product developmentProduct development
RepoweringRepowering Concept Concept
Retrofit and Retrofit and modernizationmodernizationApplication examplesApplication examples
5
0 1000100 200 300
Power output ( MW )
Type and Application
20 100
20 100
70 300
REHEAT TURBINES
MIDDLE SIZE TURBINES
INDUSTRIAL TURBINES
GEOTHERMAL TURBINES
- Geothermal Cycle
- Steam Cycle- Combined Heat and Power- Combined Cycle
- Steam cycle- Combined Cycle
- Steam Cycle- Combined Cyle- Combined Heat and Power
CT, IT
GT
MT, MR (2-cylinders)
RT (3-4cylinders)
Ansaldo Energia Steam TurbinesProduct Range
6
0 300 600 900 1200
Rating ( MVA )
Type and Application
up to 300 MVA
up to 600 MVA
Up to 900 MVA
AIR COOLED
- Steam Turbines- Gas Turbines- Geothermal Turbines
HYDROGEN COOLED
HYDROGEN/WATER COOLED
- Steam Turbines- Gas Turbines
- Steam Turbines
12
34
5
78
9
10 11 12 13
14
15 1616
17
19
20
21
22
23
24
6
18 18
17
Ansaldo EnergiaTurbogenerators – Product Range
7
RT60SMT10C
MT15C
MT25S
RT40S
RT50S
RT20C
RT30C
Frame turbines
Ansaldo Steam Turbines
• Modular concept for single-/multiple-casing ST’s up to 1000MW for combined cycle and conventional fossil-fired power plants for both 50 and 60 Hz.
8RT TURBINES – tandem compound double flow
HP shrink ringsHP shrink rings
Free-standingLSB
Free-standingLSB
Valves directly connectedValves directly connected
No piston cooling steam
No piston cooling steam
One-piece 3D blades
One-piece 3D blades
Welded rotorsWelded rotors
Reaction TechnologyReaction Technology
Ansaldo Energia Steam TurbinesMain Features
9
PERFORMANCE DATA
Output range 100-250 MW
Live steam pressure 70-100 bar
Live steam temperature 540-565 °C
Back pressure 1 - 4 bar
Operation mode Fixed and/or Sliding pressure
MTG20MTG20
Full arc or control stage admission
Single / Double stop/control valve assembly
One controlled extraction solution available for coogeneration application
Downward or upward exhaust for low-profile plant
Shipped assembled for fast installation
DESIGN FEATURES
Back-Pressure Steam Turbinefor Heat and Power
10
Full arc or control stage admission
Single / Double stop/control valve assembly
One controlled extraction solution available for coogeneration application
Downward or upward exhaust for low-profile plant
HP shipped assembled for fast installation
DESIGN FEATURES
Controlled extraction, condensing Steam Turbine for C.C. and Desalination Plant
PERFORMANCE DATA
Output range 100-250 MW
Live steam pressure 70-100 bar
Live steam temperature 540-565 °C
Controlled extrac. pressure 1 - 4 bar
Condenser pressure 0.08-0.2 bar
Operation mode Fixed and/or Sliding pressure
Single flow axial exhaustSingle flow axial exhaust
Controlled extractionControlled extractionMTG20MTG20MTG20-CMTG20-C
11
Full arc admission
One stop / control valves assembly
HP, LP opposite flow configuration
Welded rotor for material optimization
Axial exhaust for low profile plant
Modular LP design for optimizedperformance
- LSB 50 Hz 43”
DESIGN TOPICS
MT10cMT10cPERFORMANCE DATA
Output range 90-160 MW
Live steam pressure 60- 80 bar
Live steam temperature 510-530 °C
Condenser pressure 0.035-0.25 bar
Operation mode: Sliding pressure
1 + 1 ( 50 Hz ) Configuration
2 + 1 ( 50 Hz ) Configuration
No Reheat Steam Turbinefor Combined Cycle
12
PERFORMANCE DATA
Output range: 90-150 MW
Live steam pressure: 100-160 bar
Live steam temperature: 540-565 °C
Reheat steam temperature: 540-565 °C
Condenser pressure: 0.035 - 0.25 bar
Operation mode: Sliding pressure
1 + 1 ( 50 Hz, 60 Hz ) Configuration
( GT 180 / 260 MW )
SINGLE FLOW HP SECTION
Full arc admission for improved operation
Single stop / Control valve assembly
Shipped assembled for fast installation
Axial exhaust for low profile plants
Single combined reheat valve
Welded rotor for material optimization
Modular LP design for optimized performance
LSB 50 Hz 33” - 43”
LSB 60 Hz 36”
COMBINED IP-LP SECTION
Reheat Steam Turbinefor Combined Cycle
MT10cMT10cMT15cMT15c
13
PERFORMANCE DATA
Output range: 250-450 MW
Live steam pressure: 170-280 bar
Live steam temperature: 540-580 °C
Reheat steam temperature: 540-600 °C
Condenser pressure: 0.05 - 0.25 bar
No. of Extractions: 7 - 8
Operation mode: Fixed and/or sliding pressure
Speed: 50 - 60 Hz
LP SECTION
Double flow design
Bearing pedestals connected directly to turbine foundation
Cast inner casing with 360 ° inlet scroll to optimize steam flow
Modular design for optimized performance
- LSB 50 Hz : 33” , 43”- LSB 60 Hz : 36”
IP SECTION
Separated IP section for high efficiency
Double casing design
Two combined reheat valves
Welded rotor solution for materialoptimization
Shipped assembled for fast installation
HP SECTION
Separated HP section for high efficiency
Full arc admission or control stageadmission for high efficiencyat partial load
Welded rotor solution for material optimization
Two stop / control valve assembly
Shipped assembled for fast installation
RT40sRT40s
Reheat Steam Turbinefor Fossil fired Power Plants (1/2)
14
PERFORMANCE DATA
Output range: 400-700 MW
Live steam pressure: 170-250 bar
Live steam temperature: 540-580 °C
Reheat steam temperature: 540-600 °C
Condenser pressure: 0.035 - 0.25 bar
Operation mode: Fixed and/or sliding pressure operation
Speed: 50 - 60 Hz
Four flow design
Bearing pedestals connected directly to turbine foundation
Cast inner casing with 360 ° inlet scroll to optimize steam flow
Modular design for optimized performance
- LSB 50 Hz : 33” , 43”- LSB 60 Hz : 36”
LP SECTIONIP SECTION
Separated IP section for high efficiency
Double casing design
Double flow design
Two combined reheat valves
Welded rotor solution for material optimization
Shipped assembled for fast installation
HP SECTION
Separated HP section for high efficiency
Full arc admission
Two stop / control valve assembly
Welded rotor solution for material optimization
Shipped assembled for fast installation
RT60sRT60s
Reheat Steam Turbinefor Fossil fired Power Plants (2/2)
15
Cooperation and Technology TransferAgreement between ABB/Alstom and AEN
• Validity: 1989-2003• Products
– Steam Turbines > 25 MW– Generators > 10 MVA
(designed according to ABB/Alstom-technology)
• Know-how– Ansaldo had full access to ABB/Alstom technology relating to
Design, Manufacture, Quality Control, R&D, Erection, Commissioning
• After Termination Ansaldo has the right to– Continue to use ABB/Alstom technology on new units and
retrofit/modification of old units, including BBC/ABB fleet
– Subcontract components manufacturing to third parties– Grant licenses to third parties
16
STEAM TURBINES
New New equipmentequipment
Product developmentProduct development
RepoweringRepowering ConceptConcept
Retrofit and Retrofit and modernizationmodernizationApplication examplesApplication examples
17
TEMPERATURE DISTRIBUTIONON BLADING SURFACE
Efficiency ImprovementAdvanced New Blading Design
HP-IP HIGH PERFORMANCE BLADING UPDATING FOR COMBINED CYCLE APPLICATIONS
BLADING DEVELOPMENTFOR ULTRA SUPERCRITICALAPPLICATIONS
18
3-D Navier-Stokes analysis
LL--00 rotating bladerotating blade33--D modelD model
Efficiency Improvement48” Last Stage Bucket Design
Development of a newLast Stage Steel Blade48” length with an annular area of 12 m2
(JRP Ansaldo Energia – Skoda Power)
19
STEAM TURBINES
New New equipmentequipment
Product developmentProduct development
RepoweringRepowering ConceptConcept
Retrofit and Retrofit and modernizationmodernization
20
RepoweringFrom open cycle to Combined Cycle
19%
10%
32.5%
•• In open In open cyclecycle GT GT is is alone, the high temperature alone, the high temperature combustioncombustion gasesgases are are exhausted to atmosphereexhausted to atmosphere; more ; more thanthan 61% of 61% of available energy available energy in the in the fuel is lostfuel is lost..
•• The high The high energy contentenergy contentin in exhaustexhaust gasesgases can can be be used to used to produce high produce high temperature temperature steam by steam by HRSGHRSG
•• and produce more and produce more kW kW in in a newa new SteamSteam TurbineTurbine
•• TransformationTransformation of of ananopen open cyclecycle in a in a combinedcombined cyclecyclereducesreduces the the lost energy lost energy to lessto less thanthan 44 %44 %
•• The Net The Net Efficiency Efficiency of a of a combined cycle is higher thancombined cycle is higher than:: 56 %56 %
21
SteamGenerator
Steam Turbine & Generator
Feedwater cycle
Condenser
Steam Cycle Unit
In a steam cycle unitthe Net Efficiency isabout 39%
mSH=100%
mHRH=80% mLP=75%
mcond=60%
The steam flow
distribution is
22
InIn combined cyclecombined cycle, the Net , the Net EfficiencyEfficiency is higher thanis higher than 56 %56 %
10%
32.5%
Conversion of a conventional unit in C.C. (1+1 configuration)
2 - ST steam path could beoptimized; extraction pipesblanked
4 - Deaerator is new
5 - Piping is new
1 - Steam Generator is replaced byGT and HRSG, Feedwater cycle is removed
3 - Condenser is maintained
RepoweringFrom Steam Cycle to Combined Cycle
mSH=30%
mHRH=40%
mcond=65%
Note (1): Mass flows % refer to original mass flow for each point of a subcritical 350 MW ST
23
STEAM TURBINES
New New equipmentequipment
Product developmentProduct development
RepoweringRepowering ConceptConcept
Retrofit and Retrofit and modernizationmodernizationApplication examplesApplication examples
24
GE USAIMPULSE
Westinghouse USAREACTION
Siemens-KWU DREACTION
BBC CHREACTION
Alsthom FIMPULSE
GEC UKIMPULSE
1970
Siemens AEG SACM Rateau AEI GECBBCSulzer
1) Industrial Turbines2) Impulse on Nuclear Turbines
Mitsubishi JREACTION
GE USAIMPULSE
Toshiba J
ABB-Alstom FREACTION (2)
1999
Siemens Westinghouse DREACTION
1998
Ansaldo IFuji J
2000
Hitachi J
1987
Ansaldo
Hitachi
Doosan
Toshiba
BHEL
Fuji
N. Pignone (1)
Parsons
ASEA STAL
F. Tosi
Ansaldo
Zamech
GEC – Alsthom
1989
CEM
ABB
De Pretto
LMZMitsubishi
ESG
Steam Turbine Technology Evolution
25
AnsaldoEnergiaAnsaldoEnergia
Ansaldo Componenti Franco Tosi
BBC / ABB / AlstomBBC / ABB / Alstom WestinghouseWestinghouseGeneral ElectricGeneral Electric
1949 - 1989 1989 - 2003 1949 - 1988
Ansaldo Steam Turbine Technologies
ESGESG
26
GE USAIMPULSE
Toshiba J
Hitachi J
Westinghouse USAREACTION
Mitsubishi J
ABB-Alstom FREACTION
BBC CH
CEM F
Non-OEM Fleet Market for Ansaldo
Steam Turbines Retrofit and Rehabilitation
27
Retrofit
• The modification/change of the existing turbine hardware intoa new one of updated design in order to improve thermalperformance (IEC Code 60953-3)
• Performance improving is needed when:– The steam turbine has to match the steam parameters of a new
Combined Cycle repowering the original fossil fired one– The steam turbine output power has to suit the capacity of
upgraded boilers– The steam plant heat rate has to be improved, without changing
steam parameters, through the increase of ST efficiency (e.g. by adopting enlarged LP flows to reduce exhaust losses)
• Additionally, the retrofit provides improved reliability and life time
28
Retrofit solutions
• According to the expected effects,the retrofit hardware can include:– Partial replacement of blading
on existing rotor and casing
– Replacement of one or morecomplete inner blocks(steam path, rotor, inner casing)
– Replacement of one or morecomplete turbine sections
29
Original – Impulse type Retrofit – Reaction type (HP-IP section)
Retrofit technologies
• Two technologies– reaction type blading (drum construction)
– impulse type (disc and diaphragm construction)• Ansaldo has developed updates for both technologies and
selected the most cost-effective retrofit solution• This means that machines designed as impulse or reaction
can be totally or partially retrofitted with reaction or impulse
30
Retrofit process
Example of retrofit of non-OEM equipment
Welded rotorWelded rotor
31
Updated retrofit technology
1. Three dimensional blading (3D) on HP-IP section to reduce profile andsecondary losses.
2. Longer last stage blade to reduceexhaust losses and convert them to additional power output.
3. Improved gland seal arrangements to reduce interstage leakageThe application of “brush” tip seals
reduces the amount of steam leakages and improves the stage efficiency
Performance improvements applied through the introduction of updated steam path technology
32
STEAM TURBINES
New New equipmentequipment
Product developmentProduct development
RepoweringRepowering Concept Concept
Retrofit and Retrofit and modernizationmodernizationApplication examplesApplication examples
33
Retrofit Solution
Scope of supplyComplete replacement of the old HP-IP section (impulse
design) with a new HP-IP turbine (reaction design)connected to the existing LP section.
Effects• Nominal rating: 129.5 MW.• High temperature inlet 565°C/565°C.
Reason for retrofitThe existing 250 MW unit, previously operating in steamcycle, operates now in CC, 1 GT + 1 ST configuration.
OEM: Ansaldo (GE technology)1 x 250 MW
Comm. Year: 1966
Chivasso 2
34
Retrofit Solution
Scope of supplyA complete new 33” LP inner block with larger exhaustarea in the existing LP outer casing.
Effects• Nominal rating: 124.5 MW.• Gain of 5.6 MW in power output with reference to the
original design.
Reason for retrofitThe two existing 156 MW units, previously operating inconventional cycle, operate now in CC, 1 GT + 1 STconfiguration.
OEM: F. Tosi (Westingh. tech.)2 x 156 MW
Comm. Year: 1964 - 1966
BB070
Porto Corsini 3 – 4
35
Retrofit Solution
Scope of supplyA complete new 43” LP inner block with larger exhaustarea in the existing LP outer casing.
Effects• Nominal rating: 267 MW.• Gain of 8 MW in power output with reference to the
original deisgn.
Reason for retrofitThe existing 320 MW unit, previously operating inconventional cycle, now operates in CC,2 GT+1 ST configuration.
OEM: Ansaldo (GE technology)1 x 320 MWComm. Year: 1968
2x33.5”
Torre Valdaliga Sud 2
2x43”
36
OEM: F. Tosi (Westingh. Tech.)2 x 329.5 MW Comm. Year: 1973 - 1975BB073
Fusina 3 – 4
Retrofit Solution
Scope of supplyA complete new 43” LP inner block (new steam path,rotor, inner casing) with larger exhaust area in the
existing LP outer casing.
Effects• Upgraded Nominal Rating: 337.5 MW • Gain of 8 MW (+2.4%) in power output with
reference to the original design.• Heat Rate improvement of 42 Kcal/kwh (-2.4%)
Reason for retrofitLP section upgrading in order to improve the heat rateof the unit.
37
1990 1994 Greece LAVRION General Electric 1 x 66.5 - New HP Rotor and diaphragms- New LP Rotor and diaphragms
1990 1994 Argentina COSTANERA British Thompson-Houston 4 x 120 - New HP Rotor and diaphragms- New IP Rotor and diaphragms- New LP Rotor and diaphragms
1990 2002 Italy PIETRAFITTA F.T. / Westinghouse 2 x 60 - New 1°HP nozzle stage
1998 2000 Italy LA SPEZIA 1-2 F.T. / Westinghouse 2 x 120 - New HP-IP section - New LP last stage blading
1999 2001 Italy CASSANO D’ADDA 1 Ansaldo 1 x 80 - New HP-IP rotor and diaphragms- New LP rotor and diaphragms
2000 2001 Italy LA CASELLA 1-4 F.T. / Westinghouse 4 x 120 - New HP blading
2001 2002 Italy PORTO CORSINI F.T. / Westinghouse 2 x 123 - New LP inner block
2002 2003 Italy CHIVASSO 2 Ansaldo 1 x 130 - New HP-IP section
2002 2003 Italy PRIOLO GARGALLO 1-2 F.T. / Westinghouse 2 x 120 - New HP blading
2002 2003 Italy TORREVALDALIGA SUD 2 Ansaldo 1 x 267 - New LP inner block
2006 2007 Italy FUSINA 3-4 F.T. / Westinghouse 2 x 350 New LP inner block
1990 1994 Greece LAVRION General Electric 1 x 66.5 - New HP Rotor and diaphragms- New LP Rotor and diaphragms
1990 1994 Argentina COSTANERA British Thompson-Houston 4 x 120 - New HP Rotor and diaphragms- New IP Rotor and diaphragms- New LP Rotor and diaphragms
1990 2002 Italy PIETRAFITTA F.T. / Westinghouse 2 x 60 - New 1°HP nozzle stage
1998 2000 Italy LA SPEZIA 1-2 F.T. / Westinghouse 2 x 120 - New HP-IP section - New LP last stage blading
1999 2001 Italy CASSANO D’ADDA 1 Ansaldo 1 x 80 - New HP-IP rotor and diaphragms- New LP rotor and diaphragms
2000 2001 Italy LA CASELLA 1-4 F.T. / Westinghouse 4 x 120 - New HP blading
2001 2002 Italy PORTO CORSINI F.T. / Westinghouse 2 x 123 - New LP inner block
2002 2003 Italy CHIVASSO 2 Ansaldo 1 x 130 - New HP-IP section
2002 2003 Italy PRIOLO GARGALLO 1-2 F.T. / Westinghouse 2 x 120 - New HP blading
2002 2003 Italy TORREVALDALIGA SUD 2 Ansaldo 1 x 267 - New LP inner block
2006 2007 Italy FUSINA 3-4 F.T. / Westinghouse 2 x 350 New LP inner block
Order Start-up Country Plant Manifacturer ( OEM ) Units / MW Scope of Supplyyear year
Order Start-up Country Plant Manifacturer ( OEM ) Units / MW Scope of Supplyyear year
Ansaldo Steam Turbine Retrofits Experience List
38
STEAM TURBINES
•• AEN AEN Designs Designs and and Manufactures Steam Turbines fromManufactures Steam Turbines from 20 20 to to 1000 MW1000 MW
ConclusionsConclusions::
•• AENAEN DesignsDesigns andand ManufacturesManufactures GasGas Turbines fromTurbines from 6767 toto 270 MW270 MW
•• AENAEN DesignsDesigns andand Manufactures Generators fromManufactures Generators from 2020 toto 900 MVA900 MVA
•• AENAEN has anhas an intensiveintensive ProductProduct R&D programR&D program
•• AENAEN retrofitsretrofits && repowers its own products includingrepowers its own products including ex F. Tosiex F. Tosi unitsunits
•• AENAEN retrofitsretrofits && repowersrepowers thethe following steam turbines technologiesfollowing steam turbines technologies::–– GE (GE (impulseimpulse),), WestinghouseWestinghouse ((reactionreaction) BBC) BBC--ABBABB--AlstomAlstom ((reactionreaction))
f
Steam TurbinesAl Khobar Roadshow, 24 July 2006
Guido RaimondiHead of ST Thermodynamics Design