Steam Turbines Al Khob Khobar ar Ro Roads adsho how, w, 24 24 Ju July ly 200 2006 6
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STEAM TURBINES
New equipment Product development Repowering Concept Retrofit and modernization
2
STEAM TURBINES
New equipment Product development Repowering Concept Retrofit and modernization
2
Stea St eam m Tu Turb rbin ine e Te Tech chno nolog logy y Ev Evol olut ution ion Siemens
GE USA IMPULSE
AEG
Siemens-KWU
Westinghouse
D
REACTION
N. Pignone (1)
Ansaldo
Sulzer
BBC
USA
REACTION
BHEL
BBC
SACM
Rat eau
Alsthom
CH
REACTION
AEI
GEC
GEC
F
IMPULSE
UK
IMPULSE
1970
ASEA STAL CEM
Toshiba
Parsons
F. Tosi
1987
Doosan
LMZ
ABB
Mitsubishi
De Pretto
Fuji Hitachi
1989
GEC – Alsth Alsthom om
Zamech
Ansaldo
1998
GE
USA
Siemens Westinghouse
IMPULSE
Hitachi
Toshiba J
REACTION J
D
1999
Mitsubishi
ABB-Alstom
J
REACTION
REACTION
F
2000
(2)
ESG
Fuji
J
Ansaldo I 1) Industria Industriall Turbines Turbines 2) Imp Impul ulse se on Nucle Nuclear ar Turb Turbine ines s
3
STEAM TURBINES
New equipment Product development Repowering Concept Retrofit and modernization Application examples
4
Ansaldo Energia Steam Turbines Product Range Type and Application GEOTHERMAL TURBINES GT
- Geothermal Cycle
100
20 INDUSTRIAL TURBINES CT, IT
- Steam Cycle - Combined Heat and Power - Combined Cycle
20
100
MIDDLE SIZE TURBINES - Steam cycle - Combined Cycle
MT, MR (2-cylinders)
300
70 REHEAT TURBINES
RT (3-4cylinders)
- Steam Cycle - Combined Cyle - Combined Heat and Power
0
100
200
300
1000
Power output ( MW ) 5
Ansaldo Energia Turbogenerators – Product Range Type and Application
AIR COOLED - Steam Turbines - Gas Turbines - Geothermal Turbines
up to 300 MVA
HYDROGEN COOLED 14 10
21
13
12
11
6
9
up to 600 MVA
5 4
- Steam Turbines - Gas Turbines
1
3
7
2
22
8
15
16
16 23
17
17
18
18
24
20 19
HYDROGEN/WATER COOLED - Steam Turbines
Up to 900 MVA 0
300
600
900
1200
Rating ( MVA ) 6
Ansaldo Steam Turbines
Modular concept for single-/multiple-casing ST’s up to 1000 MW for combined cycle and conventional fossil-fired power plants for both 50 and 60 Hz. Frame turbines
MT10C
RT20C
MT25S
RT60S
RT50S RT40S RT30C MT15C
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Ansaldo Energia Steam Turbines Main Features Reaction ReactionTechnology Technology No Nopiston piston cooling coolingsteam steam
Free-standing Free-standing LSB LSB
HP HPshrink shrinkrings rings
Welded Weldedrotors rotors Valves Valvesdirectly directlyconnected connected
One-piece One-piece 3D 3Dblades blades
RT TURBINES – tandem compound double flow
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Back-Pressure Steam Turbine for Heat and Power MTG20
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
DESIGN FEATURES 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
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Controlled extraction, condensing Steam Turbine for C.C. and Desalination Plant MTG20-C MTG20
Controlled Controlledextraction extraction Single Singleflow flowaxial axialexhaust exhaust PERFORMANCE DATA Output range
100-250 MW
Live steam pressure
70-100 bar
Live steam temperature
540-565 °C
Controlled extrac. pressure
1-4
Condenser pressure
0.08-0.2 bar
bar
Operation mode Fixed and/or Sliding pressure
DESIGN FEATURES 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
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No Reheat Steam Turbine for Combined Cycle MT10c
PERFORMANCE 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
DESIGN TOPICS Full arc admission
Axial exhaust for low profile plant
One stop / control valves assembly
Modular LP design for optimized performance
HP, LP opposite flow configuration - LSB 50 Hz 43” Welded rotor for material optimization
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Reheat Steam Turbine for Combined Cycle MT15c MT10c
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
COMBINED IP-LP SECTION
Full arc admission for improved operation
Axial exhaust for low profile plants
Single stop / Control valve assembly
Single combined reheat valve
Shipped assembled for fast installation
Welded rotor for material optimization Modular LP design for optimized performance LSB 50 Hz 33” - 43” LSB 60 Hz 36”
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Reheat Steam Turbine for Fossil fired Power Plants (1/2) PERFORMANCE DATA
RT40s
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:
HP SECTION
IP SECTION
50 - 60 Hz
LP SECTION
Separated HP section for high efficiency
Separated IP section for high efficiency
Double flow design
Full arc admission or control stage admission for high efficiency at partial load
Double casing design
Bearing pedestals connected directly to turbine foundation
Two combined reheat valves
Cast inner casing with 360 °inlet scroll to optimize steam flow
Welded rotor solution for material optimization
Modular design for optimized performance
Welded rotor solution for material optimization Two stop / control valve assembly
Shipped assembled for fast installation
- LSB 50 Hz : 33” , 43” - LSB 60 Hz : 36”
Shipped assembled for fast installation
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Reheat Steam Turbine for Fossil fired Power Plants (2/2) PERFORMANCE DATA
RT60s
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
HP SECTION Separated HP section for high efficiency Full arc admission Two stop / control valve assembly
IP SECTION
LP SECTION
Separated IP section for high efficiency
Four flow design
Double casing design
Bearing pedestals connected directly to turbine foundation
Double flow design
Cast inner casing with 360 °inlet scroll to optimize steam flow
Two combined reheat valves
Welded rotor solution for material optimization
Welded rotor solution for material optimization
Modular design for optimized performance
Shipped assembled for fast installation
Shipped assembled for fast installation
- LSB 50 Hz : 33” , 43” - LSB 60 Hz : 36”
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Cooperation and Technology Transfer Agreement 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 15
STEAM TURBINES
New equipment Product development Repowering Concept Retrofit and modernization Application examples
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Efficiency Improvement Advanced New Blading Design
HP-IP HIGH PERFORMANCE BLADING UPDATING FOR COMBINED CYCLE APPLICATIONS
TEMPERATURE DISTRIBUTION ON BLADING SURFACE
BLADING DEVELOPMENT FOR ULTRA SUPERCRITICAL APPLICATIONS
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Efficiency Improvement 48” Last Stage Bucket Design L-0 rotating blade 3-D model
Development of a new Last Stage Steel Blade 48” length with an annular area of 12 m2 (JRP Ansaldo Energia – Skoda Power)
3-D Navier-Stokes analysis
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STEAM TURBINES
New equipment Product development Repowering Concept Retrofit and modernization
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Repowering From open cycle to Combined Cycle • In open cycle GT is alone, the high temperature combustion gases are exhausted to atmosphere; more than 61% of available energy in the fuel is lost. • The high energy content in exhaust gases can be used to produce high temperature steam by 19% HRSG • and produce more kW in a new Steam Turbine • Transformation of an open cycle in a combined cycle reduces the lost energy to less than 44 % • The Net Efficiency of a combined cycle is higher than:
32.5%
56 % 10%
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Steam Cycle Unit In a steam cycle unit the Net Efficiency is about 39%
Steam Turbine & Generator mHRH=80%
The steam flow distribution is
mLP=75%
mSH=100%
mcond=60%
Condenser Steam Generator
Feedwater cycle
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Repowering From Steam Cycle to Combined Cycle Conversion of a conventional unit in C.C. (1+1 configuration) mHRH=40% 1 - Steam Generator is replaced by GT and HRSG, Feedwater mSH=30% cycle is removed
2 - ST steam path could be optimized; extraction pipes blanked
mcond=65% 32.5%
3 - Condenser is maintained 4 - Deaerator is new 5 - Piping is new
10%
In combined cycle, the Net Efficiency is higher than
56 %
Note (1): Mass flows % refer to original mass flow for each point of a subcritical 350 MW ST
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STEAM TURBINES
New equipment Product development Repowering Concept Retrofit and modernization Application examples
23
Steam Turbine Technology Evolution Siemens
GE USA IMPULSE
AEG
Siemens-KWU
Westinghouse
D
REACTION
N. Pignone (1)
Ansaldo
Sulzer
BBC
USA
REACTION
BHEL
BBC
SACM
Rateau
Alsthom
CH
REACTION
AEI
GEC
GEC
F
IMPULSE
UK
IMPULSE
1970
ASEA STAL CEM
Toshiba
Parsons
F. Tosi
1987
Doosan
LMZ
ABB
Mitsubishi
De Pretto
Fuji Hitachi
1989
GEC – Alsthom
Zamech
Ansaldo
1998
GE
USA
Siemens Westinghouse
IMPULSE
Hitachi
Toshiba J
REACTION J
D
1999
Mitsubishi
ABB-Alstom
J
REACTION
REACTION
F
2000
(2)
ESG
Fuji
J
Ansaldo I 1) Industrial Turbines 2) Impulse on Nuclear Turbines
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Ansaldo Steam Turbine Technologies
General GeneralElectric Electric 1949 - 1989
Ansaldo Componenti
BBC BBC //ABB ABB//Alstom Alstom 1989 - 2003
ESG ESG
Westinghouse Westinghouse 1949 - 1988
Franco Tosi
AnsaldoEnergia AnsaldoEnergia
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Steam Turbines Retrofit and Rehabilitation Non-OEM Fleet Market for Ansaldo GE
USA
IMPULSE
Toshiba
J
Hitachi
J
Westinghouse
USA
REACTION
Mitsubishi
J
ABB-Alstom
F
REACTION
BBC
CH
CEM
F
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Retrofit •
•
•
The modification/change of the existing turbine hardware into a new one of updated design in order to improve thermal performance (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
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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 more complete inner blocks (steam path, rotor, inner casing)
– Replacement of one or more complete turbine sections
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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
Original – Impulse type
Retrofit – Reaction type (HP-IP section)
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Retrofit process
Example of retrofit of non-OEM equipment
Welded rotor
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Updated retrofit technology Performance improvements applied through the introduction of updated steam path technology 1.
Three dimensional blading (3D) on HP-IP section to reduce profile and secondary losses.
2.
Longer last stage blade to reduce exhaust losses and convert them to additional power output.
3.
Improved gland seal arrangements to reduce interstage leakage The application of “brush” tip seals reduces the amount of steam leakages and improves the stage efficiency
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STEAM TURBINES
New equipment Product development Repowering Concept Retrofit and modernization Application examples
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Chivasso 2 OEM: Ansaldo (GE technology) 1 x 250 MW Comm. Year: 1966
Retrofit Solution
Reason for retrofit The existing 250 MW unit, previously operating in steam cycle, operates now in CC, 1 GT + 1 ST configuration.
Scope of supply Complete 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.
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Porto Corsini 3 – 4 OEM: F. Tosi (Westingh. tech.) 2 x 156 MW Comm. Year: 1964 - 1966
BB070
Retrofit Solution
Reason for retrofit The two existing 156 MW units, previously operating in conventional cycle, operate now in CC, 1 GT + 1 ST configuration.
Scope of supply A complete new 33” LP inner block with larger exhaust area 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.
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Torre Valdaliga Sud 2 2x33.5”
OEM: Ansaldo (GE technology) 1 x 320 MW Comm. Year: 1968
Retrofit Solution
Reason for retrofit 2x43”
The existing 320 MW unit, previously operating in conventional cycle, now operates in CC, 2 GT+1 ST configuration.
Scope of supply A complete new 43” LP inner block with larger exhaust area in the existing LP outer casing.
Effects • Nominal rating: 267 MW. • Gain of 8 MW in power output with reference to the original deisgn.
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Fusina 3 – 4 OEM: F. Tosi (Westingh. Tech.) 2 x 329.5 MW BB073
Retrofit Solution
Comm. Year: 1973 - 1975
Reason for retrofit LP section upgrading in order to improve the heat rate of the unit.
Scope of supply A 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%)
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Ansaldo Steam Turbine Retrofits Experience List Order Order year year
Start-up Start-up year year
Country Country
Plant Plant
Manifacturer Manifacturer( (OEM OEM) )
1990 1990
1994 1994
Greece Greece
LAVRION LAVRION
General GeneralElectric Electric
11 xx 66.5 66.5 - -New New HP HPRotor Rotorand and diaphragms diaphragms --New LP Rotor and diaphragms New LP Rotor and diaphragms
1990 1990
1994 1994
Argentina Argentina
COSTANERA COSTANERA
British BritishThompson-Houston Thompson-Houston
44 xx 120 120
--New New HP HPRotor Rotorand and diaphragms diaphragms --New IP Rotor and diaphragms New IP Rotor and diaphragms --New New LP LPRotor Rotorand and diaphragms diaphragms
1990 1990
2002 2002
Italy Italy
PIETRAFITTA PIETRAFITTA
F.T. F.T./ /Westinghouse Westinghouse
22 xx 60 60
--New New1°HP 1°HPnozzle nozzlestage stage
1998 1998
2000 2000
Italy Italy
LA LASPEZIA SPEZIA1-2 1-2
F.T. F.T./ /Westinghouse Westinghouse
22 xx 120 120
--New NewHP-IP HP-IPsection section --New LP New LPlast laststage stageblading blading
1999 1999
2001 2001
Italy Italy
CASSANO CASSANOD’ADDA D’ADDA11
Ansaldo Ansaldo
11 xx 80 80
--New NewHP-IP HP-IProtor rotorand anddiaphragms diaphragms --New NewLP LProtor rotorand anddiaphragms diaphragms
2000 2000
2001 2001
Italy Italy
LA LACASELLA CASELLA1-4 1-4
F.T. F.T./ /Westinghouse Westinghouse
44 xx 120 120
--New NewHP HPblading blading
2001 2001
2002 2002
Italy Italy
PORTO PORTOCORSINI CORSINI
F.T. F.T./ /Westinghouse Westinghouse
22 xx 123 123
--New NewLP LPinner innerblock block
2002 2002
2003 2003
Italy Italy
CHIVASSO CHIVASSO22
Ansaldo Ansaldo
11 xx 130 130
--New NewHP-IP HP-IPsection section
2002 2002
2003 2003
Italy Italy
PRIOLO PRIOLOGARGALLO GARGALLO1-2 1-2
F.T. F.T./ /Westinghouse Westinghouse
22 xx 120 120
--New NewHP HPblading blading
2002 2002
2003 2003
Italy Italy
TORREVALDALIGA TORREVALDALIGASUD SUD22 Ansaldo Ansaldo
11 xx 267 267
--New NewLP LPinner innerblock block
2006 2006
2007 2007
Italy Italy
FUSINA FUSINA3-4 3-4
22xx350 350
New NewLP LPinner innerblock block
F.T. F.T./ /Westinghouse Westinghouse
Units Units/ /MW MW
Scope ScopeofofSupply Supply
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STEAM TURBINES Conclusions: •
AEN Designs and Manufactures Steam Turbines from 20 to 1000 MW
•
AEN Designs and Manufactures Gas Turbines from 67 to 270 MW
•
AEN Designs and Manufactures Generators from 20 to 900 MVA
•
AEN has an intensive Product R&D program
•
AEN retrofits & repowers its own products including ex F. Tosi units
•
AEN retrofits & repowers the following steam turbines technologies: – GE (impulse), Westinghouse (reaction) BBC-ABB-Alstom (reaction)
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