Nuclear Power Plants
The Turbine Island
Philippe Anglaret
VP Business Development , Alstom Nuclear
Paris, 21st October 201...
The Turbine Island
Agenda

1
2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

4

p.2

Alstom in Nuc...
Alstom in Nuclear

Nuclear Island

Turbine Island

Balance of Plant

Reactor supplier

Alstom

(including Alstom Grid)

Nu...
Alstom in Nuclear
Turbine Islands based on ARABELLE™ technology

Credits to EDF

p.4
Alstom in Nuclear
World N°1 supplier of nuclear steam turbine generators
55 years of experience : 136 nuclear units in ope...
EDF French Nuclear Fleet
Various generations of nuclear steam turbines

CP0 – CP1

P4 – P’4

900 MW

1300 MW

N4 – ARABELL...
Nuclear Business
Competitive Positioning

• Competitors worldwide experience (50 & 60 Hz grids)
TG supplier

Toshiba

Larg...
The Turbine Island
Agenda

1
2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

4

p.8

Alstom in Nuc...
Inside a Nuclear Power Plant
Primary, Secondary, Tertiary Loops

•
•

Non-contaminated steam goes to steam turbine
No turb...
Inside a Nuclear Power Plant
Primary, Tertiary Loops

•
•

Contaminated steam goes to steam turbine  special gland sealin...
What is specific to Nuclear Power Plants ?
Much larger steam volume flow

Steam volume flow (m3/s)

80
60

Fossil
Nuclear
...
What is specific to Nuclear Power Plants ?
Wet steam conditions

Fossil

Dry
Steam

H = Enthalpy (kJ/kg)

150-300 bar
540-...
Steam Expansion Line
Mollier Diagram – N4 Reactor
P : 10.1 bar
T : 268°C
P : 71 bar
T : 287°C
x : 0.4 %

“cold” steam at L...
EPR - Flamanville 3
Simplified steam-water cycle
Steam and water pipes from/to NI

Busbars

HP

IP

MSR
100% steam bypass ...
World Nuclear Power Plants
Half-speed dominates the market above 700 MW
•

France, U.S.A., Canada, Japan, South Korea, Bra...
Full Speed vs. Half Speed – what makes the difference ?
Case study : Ling Ao 1 vs. Ling Ao 3
Enthalpy (kJ/kg)
3100

Ling A...
A challenge for turbine designers
Covering a wide range of reactors & heat sinks
Typical LP exhaust volumetric flow for a ...
A challenge for turbine designers
Covering a wide range of reactors & heat sinks
Typical LP exhaust area needed for a give...
The Turbine Island
Agenda

1
2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

4

p.19

Alstom in Nu...
Integrated Packages
Turbine Island (TI)

p.20
Integrated Packages
Secondary Loop Package (SLP)

p.21
Turbine Islands
key components

Steam turbine

Grid equipment

MSR

4-pole generator

Condensate
extraction pumps

p.22

C...
The Turbine Island
Agenda

1

Alstom in Nuclear

2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

T...
Turbine Technology
Use of more efficient single flow steam expansion

Moisture Separator
Reheater

71 bar

3 bar

HP

IP

...
ARABELLE™ Steam Turbine
Advanced compared to previous generation
MSR

~75 bar

HP

~10 bar

IP

LP 1

LP 2

~3 bar

ARABEL...
ARABELLE™ Steam Turbine
A specific design to maximise single flow steam expansion & efficiency
IP
Single Flow

LP
Double F...
How to improve turbine efficiency ?
• Efficiency increases with blade aspect ratio

Longer blades have better efficiency
p...
ARABELLE™ Characteristics
Combined HP/IP Module, Unique in the Market

• Single flow HP and IP for best efficiency
• Combi...
ARABELLE 1700 50 Hz
Flamanville 3 HP-IP casing

Flamanville 3 rough machined
HP-IP casing in VOEST ALPINE
foundry

p.29
ARABELLETM References
Ling Ao 3+4 – 2 x 1080 MW

Ling Ao 3 HP-IP casing in Dong Fang Works
p.30
ARABELLETM References
Flamanville 3 – 1 x 1750 MW

• HP/IP rotor entering balancing pit, Belfort factory
p.31
ARABELLETM References
Flamanville 3 – 1 x 1750 MW

• LP2 welded rotor, fully bladed, Belfort factory
p.32
ARABELLE 1000 for Ling Ao 3
Last Stage Blades : LSB57

Fully bladed LP57 rotor entering Belfort balancing pit (Ling Ao 3)
...
The Turbine Island
Agenda

1

Alstom in Nuclear

2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

T...
GIGATOP 4-pole for Flamanville 3
A highly efficient turbo-generator
•
•
•
•
•
•
•
•

2000 MVA
Cos-phi = 0,9
1500 rpm
4 pol...
The Turbine Island
Agenda

1

Alstom in Nuclear

2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

T...
Key Components
Heat Exchangers for Nuclear Plants
Condenser

Auxiliary water/water
coolers

1

5

2
Moisture separator
reh...
ALSTOM MSR
Moisture Separator Reheaters

ARABELLE N4 - 1550 MW - MSR
p.38
Nuclear Heat Exchangers
Flamanville 3 deaerating feed-water tank
• When assembled, final dimension is:
47.1 m x 5.9 m x 5....
Nuclear Heat Exchangers
A Complete Condensing System
• Single or multiple pressure condensers
• Optimised tube bundle arra...
The Turbine Island
Agenda

1

Alstom in Nuclear

2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

T...
Key Components
Pumps for Nuclear Plants
Essential
8 service pump
Open/closed loop
7 cooling pump
6 Residual heat
removal p...
Nuclear Pumps
Concrete Volute Circulating Water Pumps
Flamanville 3 NPP :
• Direct sea-water cooling
of the condenser tube...
Nuclear Pumps
Concrete Volute Circulating Water Pumps

• Flamanville 3 CWP impeller heat treatment (photo credit: Ferry Ca...
The Turbine Island
Agenda

1
2

Turbine Island Basics

3

Turbine Island – Key Products & Solutions

4

p.45

Alstom in Nu...
ARABELLE™ References
Flamanville 3 – 1 x 1750 MW
• Nuclear reactor:

EPR (PWR)

• Turbine type, output:

ARABELLE 1700, 1 ...
ARABELLE™ References
Flamanville 3 – 1 x 1750 MW

p.47
Flamanville 3 – 1750 MWe
ARABELLE™ - Turbine & Generator

• Turbine HP/IP rotor entering balancing pit, Belfort factory, F...
ARABELLETM References
Flamanville 3 – 1 x 1750 MW

• Generator rotor
p.49
Flamanville 3 – 1750 MWe
ARABELLE™ - Turbine & Generator

• Generator test, Belfort factory, France
p.50
Flamanville 3 – 1750 MWe
ARABELLE™ - Turbine & Generator

Site in January 2013

p.51
ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW
• Nuclear reactor:

CPR1000 (PWR)

• Turbine type, output:

ARABELLE 1...
ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

p.53
ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

p.54
ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

p.55
ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW
Synchronized in July 2010, ahead of schedule
Measured output level abo...
Philippe Anglaret the VP Business Development for Alstom Nuclear (Atoms for the Future 2013)
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Philippe Anglaret the VP Business Development for Alstom Nuclear (Atoms for the Future 2013)

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Philippe ANGLARET, the VP Business Development for Alstom Nuclear, presented the Turbine Island with its different characteristics and very impressive pictures.

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Philippe Anglaret the VP Business Development for Alstom Nuclear (Atoms for the Future 2013)

  1. 1. Nuclear Power Plants The Turbine Island Philippe Anglaret VP Business Development , Alstom Nuclear Paris, 21st October 2013
  2. 2. The Turbine Island Agenda 1 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions 4 p.2 Alstom in Nuclear Recent Projects
  3. 3. Alstom in Nuclear Nuclear Island Turbine Island Balance of Plant Reactor supplier Alstom (including Alstom Grid) Nuclear Island + Turbine Island + BoP = Nuclear Power Plant p.3
  4. 4. Alstom in Nuclear Turbine Islands based on ARABELLE™ technology Credits to EDF p.4
  5. 5. Alstom in Nuclear World N°1 supplier of nuclear steam turbine generators 55 years of experience : 136 nuclear units in operation = 113 GW Europe North America 8 GW 8 units 90 GW 103 units China India South Korea 5 GW 6 units 6 GW 6 units 2 GW 11 units 50 86 Full-speed Half-speed South Africa 2 GW 2 units < 800 MW 24 47 65 30% of all the world’s nuclear plants have an Alstom steam turbine p.5 800 - 1200 MW > 1200 MW
  6. 6. EDF French Nuclear Fleet Various generations of nuclear steam turbines CP0 – CP1 P4 – P’4 900 MW 1300 MW N4 – ARABELLE 1550 MW p.6
  7. 7. Nuclear Business Competitive Positioning • Competitors worldwide experience (50 & 60 Hz grids) TG supplier Toshiba Largest unit in commercial operation (as of Sept. 2012) Largest unit under construction (as of Sept. 2012) GE 1100 MWe 1410 MWe Higashi-Dori 1 Palo Verde 2 (50 Hz) (60 Hz) 1400 MWe Braka 1-4 (50 Hz) 1455 MWe Shin-Kori 3 (60 Hz) Power Machines Mitsubishi Siemens Alstom 1060 MWe Tianwan 1 (50 Hz) 1180 MWe Genkai 3 (60 Hz) 1500 MWe Isar 2 (50 Hz) 1550 MWe Chooz B1 (50 Hz) 1200 MWe Leningrad II 1 (50 Hz) 1370 MWe Lungmen 1 (60 Hz) 1720 MWe Olkiluoto 3 (50 Hz) 1750 MWe Flamanville 3 (50 Hz) • Color code: Green = currently in Operation Blue = currently under Construction p.7
  8. 8. The Turbine Island Agenda 1 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions 4 p.8 Alstom in Nuclear Recent Projects
  9. 9. Inside a Nuclear Power Plant Primary, Secondary, Tertiary Loops • • Non-contaminated steam goes to steam turbine No turbine island containment needed The Pressurised Water Reactor (PWR) p.9
  10. 10. Inside a Nuclear Power Plant Primary, Tertiary Loops • • Contaminated steam goes to steam turbine  special gland sealing system Turbine island needs some containment (concrete shielding) + specific material choices The Boiling Water Reactor (BWR) p.10
  11. 11. What is specific to Nuclear Power Plants ? Much larger steam volume flow Steam volume flow (m3/s) 80 60 Fossil Nuclear 40 X5 20 0 0 500 1000 1500 2000 Steam turbine generator output (MW) Nuclear  large volume flows  need for long blades  high centrifugal forces p.11
  12. 12. What is specific to Nuclear Power Plants ? Wet steam conditions Fossil Dry Steam H = Enthalpy (kJ/kg) 150-300 bar 540-600°C Saturation line Nuclear Wet Steam 50-75 bar 265-290°C S = Entropy (kJ/kg/°K) p.12
  13. 13. Steam Expansion Line Mollier Diagram – N4 Reactor P : 10.1 bar T : 268°C P : 71 bar T : 287°C x : 0.4 % “cold” steam at LP inlet : • small LP axial thermal expansion • reduced axial clearances • possibility to fit a 4th LP IP HP MSR P : 3.3 bar T : 148°C X:0% P : 10.7 bar T : 183°C x : 14.6 % Enthalpy H (kJ/kg) Entropy S (kJ/kg.K) p.13 LP P : 0.055 bar x : 12.5 %
  14. 14. EPR - Flamanville 3 Simplified steam-water cycle Steam and water pipes from/to NI Busbars HP IP MSR 100% steam bypass to condenser Generator, exciter LP Circulating water pumps Condenser,vacuum system, debris filters Drain tanks De-aerating feed-water tank MSR drain pumps Core Condensate extraction pumps LP heaters HP heaters Feed heaters pumps NSSS PACKAGE Primary Loop p.14 Secondary Loop CI auxiliaries cooling HEX Tertiary Loop
  15. 15. World Nuclear Power Plants Half-speed dominates the market above 700 MW • France, U.S.A., Canada, Japan, South Korea, Brazil, Taiwan, South Africa, etc.: − • all nuclear units in operation are half-speed China: since 2005, all nuclear turbines (with output > 700 MW) ordered are half-speed Full-speed / Half-speed − 26% 66% Half-speed 91% 100% Full-speed 74% 34% 9% All sizes < 700 MW > 700 MW > 1200 MW Unit size range Source: Alstom databases Above 1200 MW, only half-speed  to keep reasonable stress levels p.15
  16. 16. Full Speed vs. Half Speed – what makes the difference ? Case study : Ling Ao 1 vs. Ling Ao 3 Enthalpy (kJ/kg) 3100 Ling Ao 1 Full speed 3000 2900 Ling Ao 3 Half speed IP 2800 2700 HP 2600 Half speed expansion lines in HP, IP and LP sections are much more efficient 2500 LP 2400 2300 2200 2100 5,8 p.16 6 6,2 6,4 6,6 6,8 7 7,2 7,4 7,6 Entropy (kJ/kg/K)
  17. 17. A challenge for turbine designers Covering a wide range of reactors & heat sinks Typical LP exhaust volumetric flow for a given application: 1 reactor/1 site Reactors p.17 5 9 12 15 17 19 21 23 24 26 27 28 30 31 32 Finland 33 India Site cooling water temp. °C
  18. 18. A challenge for turbine designers Covering a wide range of reactors & heat sinks Typical LP exhaust area needed for a given application: 1 reactor/1 site Reactor thermal output in MWth 5 000 MWth 250 m² 200 m² 150 m² 4 500 MWth 4 000 MWth EPR ESBWR APWR ABWR 100 m² 3 500 MWth AP1000 75 m² VVER1200 3 000 MWth CPR1000 ATMEA1 50 m² 2 500 MWth 2 000 MWth 100 mbar 90 mbar PHWR700 1.5 "Hg 2.5 "Hg 80 mbar 70 mbar 60 mbar 1.5 "Hg 50 mbar 40 mbar 30 mbar 20 mbar 5 9 12 15 17 19 21 23 24 26 27 28 30 31 32 33 Condenser backpressure in mbar p.18 Reactors Site cooling water temp. °C
  19. 19. The Turbine Island Agenda 1 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions 4 p.19 Alstom in Nuclear Recent Projects
  20. 20. Integrated Packages Turbine Island (TI) p.20
  21. 21. Integrated Packages Secondary Loop Package (SLP) p.21
  22. 22. Turbine Islands key components Steam turbine Grid equipment MSR 4-pole generator Condensate extraction pumps p.22 Circulating water pumps Reactor feed-water pumps HP & LP feed-water heaters Modular condenser
  23. 23. The Turbine Island Agenda 1 Alstom in Nuclear 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions The steam turbine 4 p.23 Recent Projects
  24. 24. Turbine Technology Use of more efficient single flow steam expansion Moisture Separator Reheater 71 bar 3 bar HP IP 11 bar p.24 Moisture Separator Reheater LP 1 BP LP 2 BP LP 3 BP 60% of the power output comes from single flow steam expansion
  25. 25. ARABELLE™ Steam Turbine Advanced compared to previous generation MSR ~75 bar HP ~10 bar IP LP 1 LP 2 ~3 bar ARABELLE™ Efficient configuration Single flow use LP 3 MSR MSR ~75 bar HP LP 1 ~10 bar LP 2 LP 3 PREVIOUS GENERATION Traditional configuration Double flow use MSR ARABELLE™ uses more efficient single flow steam expansion p.25
  26. 26. ARABELLE™ Steam Turbine A specific design to maximise single flow steam expansion & efficiency IP Single Flow LP Double Flow HP Single Flow 2 Flows 1 Flow ARABELLE™ 6 Flows 1 Flow HP Double Flow PREVIOUS GENERATION LP Double Flow p.26
  27. 27. How to improve turbine efficiency ? • Efficiency increases with blade aspect ratio Longer blades have better efficiency p.27
  28. 28. ARABELLE™ Characteristics Combined HP/IP Module, Unique in the Market • Single flow HP and IP for best efficiency • Combined HP/IP for maximum power density • Same footprint for 50 and 60 Hz • Designed to fit all large commercialised reactors • HP/IP rotor delivers up to 60% of the overall output p.28
  29. 29. ARABELLE 1700 50 Hz Flamanville 3 HP-IP casing Flamanville 3 rough machined HP-IP casing in VOEST ALPINE foundry p.29
  30. 30. ARABELLETM References Ling Ao 3+4 – 2 x 1080 MW Ling Ao 3 HP-IP casing in Dong Fang Works p.30
  31. 31. ARABELLETM References Flamanville 3 – 1 x 1750 MW • HP/IP rotor entering balancing pit, Belfort factory p.31
  32. 32. ARABELLETM References Flamanville 3 – 1 x 1750 MW • LP2 welded rotor, fully bladed, Belfort factory p.32
  33. 33. ARABELLE 1000 for Ling Ao 3 Last Stage Blades : LSB57 Fully bladed LP57 rotor entering Belfort balancing pit (Ling Ao 3) p.33
  34. 34. The Turbine Island Agenda 1 Alstom in Nuclear 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions The generator 4 p.34 Recent Projects
  35. 35. GIGATOP 4-pole for Flamanville 3 A highly efficient turbo-generator • • • • • • • • 2000 MVA Cos-phi = 0,9 1500 rpm 4 poles, 3 phases 23 kV Brush-less exciter H2 and H2O cooled Stainless steel cooling tubes • H2 pressure: 6 bars(g) • Triple-circuit hydrogen sealing system • 99% efficiency • Flamanville 3 generator final assembly and running tests in Alstom factory • Validation of manufacturing quality • Validation of the design, of the electrical performances p.35
  36. 36. The Turbine Island Agenda 1 Alstom in Nuclear 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions The heat exchangers 4 p.36 Recent Projects
  37. 37. Key Components Heat Exchangers for Nuclear Plants Condenser Auxiliary water/water coolers 1 5 2 Moisture separator reheater (MSR) 2 3 High velocity separators (HVS) 4 1 HP heater 3 LP heater 4 p.37 Feedwater tank and deaerator 5 Nuclear purification system (NPS)
  38. 38. ALSTOM MSR Moisture Separator Reheaters ARABELLE N4 - 1550 MW - MSR p.38
  39. 39. Nuclear Heat Exchangers Flamanville 3 deaerating feed-water tank • When assembled, final dimension is: 47.1 m x 5.9 m x 5.3 m • Designed by Alstom - In 3 separate pieces - 98 t + 90 t + 98 t - Transported separately - Welded at site p.39
  40. 40. Nuclear Heat Exchangers A Complete Condensing System • Single or multiple pressure condensers • Optimised tube bundle arrangement for high performances • Compact arrangement with LP turbines directly feeding duplex LP1&2 FW heater located in condenser neck • Optimised condensate extraction with 3x50% pumps • Optimised vacuum hogging / holding system p.40
  41. 41. The Turbine Island Agenda 1 Alstom in Nuclear 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions The main pumps 4 p.41 Recent Projects
  42. 42. Key Components Pumps for Nuclear Plants Essential 8 service pump Open/closed loop 7 cooling pump 6 Residual heat removal pump 3 6 2 5 7 4 1 Concrete volute circulating water pump 1 p.42 Condensate extraction pump 2 Feedwater pump 3 Intermediate cooling pump 8 Vacuum pump 5 4
  43. 43. Nuclear Pumps Concrete Volute Circulating Water Pumps Flamanville 3 NPP : • Direct sea-water cooling of the condenser tubes • 2 x 50% pumps arrangement • 110 000 m3/h each (30,5 m3/s each) • 15,4 m head • Rotate at 151 rpm A A B • Civil engineering works on suction ducts (Sept. 2009) p.43
  44. 44. Nuclear Pumps Concrete Volute Circulating Water Pumps • Flamanville 3 CWP impeller heat treatment (photo credit: Ferry Capitain) p.44
  45. 45. The Turbine Island Agenda 1 2 Turbine Island Basics 3 Turbine Island – Key Products & Solutions 4 p.45 Alstom in Nuclear Recent Projects
  46. 46. ARABELLE™ References Flamanville 3 – 1 x 1750 MW • Nuclear reactor: EPR (PWR) • Turbine type, output: ARABELLE 1700, 1 x 1750 MW • Generator type: GIGATOP 4-pole • Steam parameters: Live steam: 75 bar / 290°C Exhaust: 46 mbar • Customer: EDF • Country: France • City / region: Normandy • Schedule: p.46 order year comm. year 2006 2016 Unit 3
  47. 47. ARABELLE™ References Flamanville 3 – 1 x 1750 MW p.47
  48. 48. Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator • Turbine HP/IP rotor entering balancing pit, Belfort factory, France p.48
  49. 49. ARABELLETM References Flamanville 3 – 1 x 1750 MW • Generator rotor p.49
  50. 50. Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator • Generator test, Belfort factory, France p.50
  51. 51. Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator Site in January 2013 p.51
  52. 52. ARABELLE™ References Ling Ao phase II – 2 x 1080 MW • Nuclear reactor: CPR1000 (PWR) • Turbine type, output: ARABELLE 1000, 2 x 1080 MW • Generator type: GIGATOP 4-pole • Steam parameters: Live steam: 64 bar / 280°C Exhaust: 56 mbar • Customer: DEC for LDNPC • Country: China • City / state: Dapeng / Guang-Dong • Schedule: p.52 order year comm. year 2005 2010 & 2011
  53. 53. ARABELLE™ References Ling Ao phase II – 2 x 1080 MW p.53
  54. 54. ARABELLE™ References Ling Ao phase II – 2 x 1080 MW p.54
  55. 55. ARABELLE™ References Ling Ao phase II – 2 x 1080 MW p.55
  56. 56. ARABELLE™ References Ling Ao phase II – 2 x 1080 MW Synchronized in July 2010, ahead of schedule Measured output level above guarantee Ling Ao 3, China - 1080 MW p.56

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