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supercritical MW Turbinebasic concept.ppt
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- 2. • Over allEfficiency can be improved by: Improving internal efficiency Adoption of advance steam parameters Improving thermal efficiency
- 3. Improvement in efficiencywith Increasing inlet parameters for Steam turbines
- 4. Parameters for CriticalState • Steam Pressure > 221.2 Bar • Steam Temperature > 374.15 Deg C Ultra Supercritical Pressure 300 BAR Increase in steam parameters results in significant improvement in efficiency With higher cycle efficiency, the supercritical cycle offers lower emission & lesser pollutants – SOX , NOX & CO2 0 5 10 15 20 25 30 35 40 45 500 MW 660 MW Sub critical 170 ata / 537 °C / 537 °C Super Critical 247 ata / 565 °C / 593 °C Improvement 4.3 % Entropy Temperature Supercritical Cycles
- 5. Details of Super-CriticalUnits in 10th , 11th , 12th &13th 5 Year Plans Sub Critical (MW) 660 MW (No.) 800 MW (No.) Super Critical (MW) TOTAL MW 10th Plan 9620 0 0 0 9620 11th Plan 45470 7 1 5420 50890 12th Plan 18270 25 33 42,900 61,170 13th Plan 4000 36 36 52,560 56,560 Power Projections Comparison between SubCritical & SuperCritical (MW) 9620 45470 18270 4000 0 5420 42,900 52,560 0 10000 20000 30000 40000 50000 60000 10th Plan 11th Plan 12th Plan 13th Plan Total Subcritical (MW) Total Super critical (MW)
- 6. Introduction of largecapacity super critical Steam Turbines with power output 660MW
- 7. Cross sectional arrangementof 500 mw Steam turbine
- 8. Cross sectional arrangementof 660 mw Steam turbine
- 9. Cross sectional arrangementof 800 mw Steam turbine
- 10. Module 500MW 660MW800MW HP Turbine H30-100 H30-100 (H70-V4) H30-100 (H70-V4) IP Turbine M30-63 M30-63 (I50-V2) M30-100 (I60-V2) LP Turbine N30-2x10 N30-2x12.5 (L2x12.5) N30-4x8 (L4x8) HP Valves 2xFV320 2xFV250 2xFV250 IP Valves 2xAV560 2xAV560 2xAV560 Steam Turbine module configuration
- 11. PARAMETERS UNIT SUBCRITICAL SUPERCRITICAL 500MW 660 MW 800 MW MS PRESSURE ATA 170 247 247 MS TEMPERATURE o C 537 565 565 MAIN STEAM FLOW T/HR 1500 2000 2425 REHEAT PRESSURE ATA 40.5 54 54 RH TEMPERATURE o C 537 593 593 REHEAT FLOW T/HR 1335 1740 2090 FINAL FEED WATER TEMP. o C 253 271 290 CONDENSATE FLOW T/HR 1180 1515 1860 Comparison of parameters
- 12. Overview of aLarge capacity set with super critical parameters
- 13. Constructional details of HPturbine
- 14. Inner Casing Inlet Outer Casing-Barreltype Exhaust Shaft Seal-Front Shaft Seal-Rear • Single flow • Double shell casing – Inner casing axially split – Outer casing barrel type & axially divided – Single exhaust in L/H • Mono block rotor • First stage diagonal blading • Provision for extraction • Over load valve • Casing mounted valves • Transported as single unit • Single flow • Double shell casing – Inner casing : axially split – Outer casing: Barrel type – Single exhaust in L/H • Mono block rotor • Reaction blading with Integral shroud • Casing mounted valves • Transported as single unit HP Turbine 500 MW 660 MW
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- 17. HP Turbine For Overload valve Extraction Chamber
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- 20. Section through HPadmission with sealing between HP inner and outer shell Section through HP admission without sealing between HP inner and outer shell 500 MW 660 MW HP Turbine
- 21. HP Turbine AdditionalFeatures
- 22. Outer Casing (rear) G17CrMo5-10 HW19582 G-X12CrMoVNbN9-1 X22CrMoV12-1 HW 10687 Rotor Inner Casing HP Moving & Guide Blades (rear) X12CrMoWVNbN10-1-1 HW19488 G-X12CrMoVNbN9-1 Outer Casing (front) X12CrMoWVNbN10-1-1 HP Moving & Guide Blades (front) Materials of HP turbine
- 23. HP Turbine withBreech-Nut connection Breech Nut
- 24. Constructional details of IPturbine
- 25. • Double flow •Double casing design with horizontal split • Inlet from Lower half • Single Exhaust from upper half • Extraction connections from lower half • Admission blade ring with cooling Inner Casing Inlet Exhaust Outer Casing Extraction Inlet Rotor • Double flow • Double shell casing with horizontal split • Mono block rotor • Reaction blading • Inlet from Upper & Lower halves • Two exhaust in L/H • Extraction connections from Upper & lower half IP Turbine Inlet Exhaust 500 MW 660 MW
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- 27. •Reduction in walltemperature of the Rotor •Reduction in Creep damage •Reduction of Cracking •Increase of Life cycle time IP Turbine –Inlet Ring
- 28. Outer Casing GGG 40.3 HW19793 G-X12CrMoVNbN9-1 Rotor Inner Casing X12CrMoWVNbN1011 HW19488 HW19688 Guide Blades: X19CrMoVNbN111 IP Moving (initial stg.) : NiCr20TiAl Materials of IP turbine Guide Blades: X19CrMoVNbN111 IP Moving (rear stg.) : NiCr20TiAl
- 29. IP Turbine withCasing mounted valves
- 30. Constructional details of LPturbine
- 31. • Double flow •Three shell casing • Horizontally split • Mono block rotor • Reaction blading • Rigid coupling • Double flow • Double shell casing • Single admission from top half • Outer Casing & condenser rigidly connected • Push rod arrangement to minimize axial clearances • Mono block rotor • Inner / Outer casing fabricated LP Turbine
- 32. LP Turbine -500MW LP Turbine - 660 MW LP Turbine
- 33. EXHAUST DIFFUSER ROTOR LP INNER INNER CASING LPINNER OUTER CASING GUIDE BLADE CARRIERS LP LONGITUDINAL GIRDER LP FRONT WALL ATMOSPHERIC RELIEF DIAPHRAGM LP Turbine - 500MW
- 34. LP Turbine –660MW EXHAUST DIFFUSER ROTOR LP INNER OUTER CASING LP SIDE WALL LP END WALL ATMOSPHERIC RELIEF DIAPHRAGM CASING UPPER PART
- 35. LP Turbine –660MW
- 36. Arrangement of thrustbolt for minimizing axial clearances
- 37. 26NiCrMoV14-5 HW 19373 X20Cr13 HW 10786 Rotor InnerCasing LP Moving & Guide Blades Drum Stages X10CrNiMoV 12-2-2 HW 19392 Last Stage Moving Blade X2CrNi12 HW 18802 Hollow Guide Blades Fabricated ST 37-II AA10401/10119 Outer Casing Materials for LP turbine Fabricated ST 37-II AA10401/10119
- 38. Arrangement of thrustbolt for minimizing axial clearances
- 39. Banana type guideblade Last stages of LPT Improved cylindrical profile blade (TX) HPT / IPT middle & LPT initial stages Twisted profile blade (F) HPT / IPT rear stages 3 Dimensional blade (3 DS) HPT / IPT initial stages Turbine Blading
- 40. Fabricated bearing pedestalsCast bearing pedestals GGG-40.3 Nodular Casting Bearing Pedestals
- 41. Governing System 660 MWsteam turbine equipped with high pressure electro-hydraulic governing system Advantage: • Compact design • Less control fluid piping • Less erection and commissioning time
- 42. Characteristics 500 MW (LowPressure Gov.) 660 MW (High Pressure Gov.) Operating Pressure 8/32 Bar 160 Bar IP valves Suspended Casing mounted Control signal to Actuator Hydraulic Electronic Size of Actuators Bulky Compact Control & Protection Elements Hydraulic / Electro- hydraulic Electronic Governing System
- 43. Advantages of highpressure EHA based governing system • Bulky servomotors replaced with compact actuators leading to compact layout in TG hall • Governing & protection racks replaced by electronic systems • Faster response due to state of art electronic control and protection systems • Reduced manufacturing time at shop • Turbine driven MOP replaced with motor driven pump • Mechanical Emergency governor replaced by electronic protection system, eliminating actual over speeding at site
- 44. Additional features • Lessnoise because of latest features hence no cleading up to 85 db • Hydraulic turning wheel for barring replaced by Hydraulic turning motor at front bearing pedestal similar to 250 MW • Steam strainer elements built in the valves resulting in elimination of strainer housings
- 45. LP Bypass valve Advantages: 1.Considerable reduction in overall space 2. Use of just one actuator, lower control fluid consumption and simplified C&I. Small sized HPSU 3. Overall weight of valve assembly will be less 4. Less number of O&M Spares needed 5. Procurement and O&M cost will be much less In 500 MW LP Bypass, combined stop & control valve is used For 660 MW, single stem LP Bypass valve having both stop & control function will be used
- 46. Lub oil systemin 500 MW set consists of • Main Oil Tank • Main Oil Pump (Turbine Driven) • Auxiliary Oil Pump (2X100%) • Emergency Oil Pump • Jacking Oil Pump (2X100%) • Oil Vapour Exhausters (2X100%) • Oil Coolers (2X100%) • Duplex Oil Filters (Lub Oil & Jacking Oil) • Seal Oil Storage Tank • Temp control valve, butterfly, pressure limit valves
- 47. LUB OIL MODULE el.temperature control valve, Toil=50°C 2x100% lube oil pumps, centrifugal pumps, 6 bar Emergency oil pump, 220V battery voltage 2x100% lifting oil pumps, vane pumps, max. 175bar, switch off at 9s-1 oil vapor demister, acc. to german regulations (TA-Luft) main throttle, min. flow lube oil double filter (2x100%, 25µm) return line 2x100% plate heat exchanger, controlled by oil side 2x100% lifting oil filter 25µm, pressure control valve tank module design exemplary Off-line-filter OLF60, 3µm Lub Oil Module in 660 MW
- 48. OIL MODULE example Lub OilModule in 660 MW
- 49. • Turbine drivenmain oil pump in 500 MW set is replaced by motor driven lub oil pump in 660 MW Advantage: 1. Injectors in system are avoided 2. Interconnecting pipe between injectors & MOP is no more required 3. Smaller main oil tank Main Oil Pump
- 50. • Electric actuatorsof angle drain valves replaced by pneumatic actuators Advantage: In case of loss of control air, valves move immediately in the defined fail safe position. A motorised valve remains in the actual position in case of power loss and need to be operated manually Drain Valves
- 51. Steam Strainers Steam strainersin 660 MW unit are located inside turbine valves (ESV & IV) and hence separate strainer housings in MS & HRH lines are eliminated.
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- 53. STEAM TURBINE Unit1 Unit 2 1 H. P. Turbine SAG SAG 2 I. P. Turbine SAG BHEL 3 L. P. Rotor SAG BHEL 4 L. P. Inner casing SAG BHEL 5 L. P. Outer casing BHEL BHEL 6 Cross Around Piping SAG BHEL 7 FB Pedestal SAG BHEL 8 HP Pedestal SAG BHEL 9 IP Pedestal SAG BHEL 10 LP Pedestal SAG BHEL 11 ESV & CV SAG BHEL 12 IVCV SAG BHEL 13 LPBP Valve BHEL BHEL 14 Governing Control Rack NA NA 15 LPBP Control Rack NA NA 16 Valves (CRH NRV, EXTRACTION NRVS, OVERLOAD VALVES) SAG BHEL 17 Instruments & Rack SAG SAG 18 Tools & Tackles SAG NA 19 TG Dec Embedments BHEL BHEL 20 Oil Module BHEL BHEL 21 Piping and Mounting Accessories (Turbine Integral Piping System) BHEL BHEL 25 Base Plate Assembly BHEL BHEL 800 MW TG SETS 660 MW BARH TG SETS Division of Work
- 54. 660 MW TGSETS AVAILABILITY OF DOCUMENTS: -The schedule given by Siemens indicates documents flow starting Oct’ 2009 up to end of 2010. -This does not suit BHEL e.g. – LP outer casing is to be supplied by BHEL by February 2011 while Siemens’ date of supply of document is Oct’ 2010. Similar case exists for other assemblies for set no.-2 (in BHEL scope). - Preponment of 6-12 months required. - Detailed letter being sent to Siemens by 10th July 2009. - Documents for HP module shall be available from Siemens after signing of TCAE3.
- 55. 660 MW TGSETS MANUFACTURING FACILITIES FOR TURBINES: • Facility planned for weld overlay for HP / IP rotors. • No other special facility is required for manufacture of these turbines. • Machining facilities had been evaluated on the basis of 660 MW documentation received for Swarzpumpe project. • Documentation for Barh project is yet to be received. It is envisaged that being a modular design, major changes necessitating new machines are not expected.