WELCOME TO Presentation on New Concepts in Supercritical Turbines - - PowerPoint PPT Presentation

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WELCOME TO

Presentation on New Concepts in Supercritical Turbines

Sanjoy Bhattacharya

• Dy. Genl. Manager, BHEL, Hardwar

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HPT IPT LPT

CROSS SECTIONAL ARRANGEMENT OF 500 MW STEAM TURBINE THREE THREE CY CYLIND LINDER ER TURB TURBIN INE

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 Introduction of New Rating Sets

Major Objectives

• Bring down equipment cost per MW
• Having more Efficient & Reliable product
• Utilize available Steam turbine modules
• Provide Higher competitiveness
• New Rating to compete with Chinese/ New Indian firms

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600MW Steam turbine: Built from proven modules of existing 500 & 250 MW

Orders for 4x600 MW Raigarh-III (Jindal), 2x600 MW Malwa, 2x600 MW each Avantha / Videocon/ Visa Raigarh/ DB Power & 1 x 600 MW Rayalaseema received . Module Combination

• HP: H30-100
• IP : M30-63
• LP : N30-4x6.3

Salient features:

• 4 cylinder turbine (2 LPs)
• HP turbine with Extraction connection for 565 HRH Temp
• IP turbine suitable for 537/565 0C inlet temp.

OPTIONS

• 1. HP Turbine with Extraction & 565 Deg C HRH Temp
• 2. HP Turbine without Extraction & 537 Deg C HRH Temp

Orders for 2 sets - N Chennai, 2 sets –JITPL, 1 set -APGENCO & 2 sets Singareni received. Steam parameters

170 ata / 537 0C/ (537-565) 0C

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600MW Steam Turbine

Design Changes from existing 500 MW sets :

• HP module variant with Extraction
• New Flow path in HP, IP & LP Turbines (with Advanced blading)
• Matching modifications in Rotors & Inner Casings
• New Bearing pedestal between 2 LP cylinders
• New design of Cross Around Pipe & its support
• Enhanced governing characteristics

600 MW Sub critical Sets Steam Turbine

500/ 600 MW SUB CRITICAL CYCLE WITH 2 HP HEATERS, 3 LP HEATERS

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Introduction of Steam Turbine with supercritical parameters

As the fluid pressure increases, Latent Heat (Enthalpy of Steam –Enthalpy of Water) reduces. At Critical point it becomes zero. In physical terms at this pressure water transforms to steam spontaneously.

SUPER CRITICAL STEAM PARAMETERS: PARAMETERS MORE THAN CRITICAL STATE

• STEAM PRESSURE > 221.2 BAR
• STEAM TEMPERATURE > 374.15 Deg C

ULTRA SUPERCRITICAL PRESSURE( 300 BAR) INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg C RESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE

Subcritical 170 ata / 537 °C / 537 °C Super Critical 247 ata / 565 °C / 593 °C

Improvement 4.3 %

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Steam Power plant efficiency increases with increase in steam pressure and temperature. Power plant Cycles operating above critical pressure (221.2 bar) are classified as Supercritical cycles With higher cycle efficiency, the supercritical cycle

• ffers the advantage of ‘burn less

fuel for the same

• utput’ and lower emission.

Supercritical Cycles

Lesser Pollutants – SOX , NOX & CO2

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IMPROVEMENT IN EFFICIENCY WITH INCREASING INLET PARAMETERS FOR STEAM TURBINES

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PARAMETERS UNIT 500 MW 660 MW 800 MW MS PRESSURE ATA 170 247 247 MS TEMPERATURE

• C

537 565 565 MAIN STEAM FLOW T/HR 1500 1919 2380 REHEAT PRESSURE ATA 40.5 56 60 RH TEMPERATURE

• C

537 593 593 FINAL FEED WATER TEMP.

• C

253 290 290

PARAMETERS FOR BHEL STEAM TURBINES

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Typical Supercritical TG Cycle

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REGENERATIVE CYCLE CONFIGURATION

• TWO EXTRACTIONS FROM IPT
• FOUR LP HEATERS
• DEAERATOR
• ONE EXTRATION FROM HPT
• THREE HP HEATERS
• 250% TURBINE DRIVEN BFP
• ONE MOTOR DRIVEN BFP

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STEAM TURBINE MODULE CONFIGURATION

MODULE 500 MW 660 MW 800 MW HP TURBINE H30-100 H30-100 H30-100 IP TURBINE M30-63 M30-100 M30-100 LP TURBINE N30-2 x 10 N30-2 x 12.5 N30-4 x 8 HP VALVES 2 x FV320 2 xFV250A 2 xFV250A IP VALVES 2xAV560 2xAV560A 2xAV560A

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660MW Steam turbine: With Supercritical parameters

Order for 2x660 MW Barh- II/ DB Power & 3 x 660 Bara & Lalitpur TPP Other expected tenders 1 x 660 MW JITPL Angul, Jhabua Seoni, etc Salient Feature:

• New series of HP & IP modules for

supercritical parameters

• Higher size LP module

247 ata Main Steam Pressure 565 0C Main Steam Temperature 593 0C Hot reheat Temperature

• Impulse

tilted blade in HP & IP turbines

• Heat

Shield at the inlet section

• Increase in wall/pipe

thickness

• Material

with improved properties for higher steam temperature

• Optimum flow path

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800MW Steam turbine

Salient features:

• 4 cylinder turbine (2 LP’s)
• New series of HP, IP & LP modules for super critical parameters

Orders for Yermarus (2x800 MW), & Edlapur (1x800 MW), JV between KPCL and BHEL

Order expected for NTPC 2 x 800 MW Gajmara TPP & Udangudi (2x800 MW), JV between

TNEB and BHEL

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800MW Steam turbine: General Arrangement

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CR CROSS OSS SE SECTIO CTIONAL A AL ARR RRAN ANGEME EMENT OF NT OF 80 800 0 MW S MW STE TEAM AM TURB TURBIN INE FOUR FOUR CYLIND CYLINDER ER TURB TURBIN INE

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CON CONST STRUC RUCTIONAL TIONAL FE FEATURES ATURES OF OF HP TUR HP TURBIN BINE E FOR 8 FOR 800 00 MW MW

• SINGLE FLOW, DOUBLE SHELL
• OUTER CASING BARREL TYPE IN TWO PIECES
• INNER CASING AXIALLY SPLIT
• MONO BLOCK DRUM TYPE ROTOR

Barrel in two pieces

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CON CONST STRUCTION UCTIONAL AL FE FEATURE TURES S OF I OF IP TURB P TURBIN INE E FOR 8 FOR 800 00 MW MW

• DOUBLE FLOW, DOUBLE SHELL CASING
• MONO BLOCK DRUM TYPE ROTOR
• STEAM ADMISSION IN L/H FROM BOTH SIDES
• EXTRACTIONS CONNECTIONS IN LOWER HALF ONLY
• VALVES BOLTED TO THE CASING IN LOWER HALF

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HPT FIRST STAGE

Diagonal Impulse Blading

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IP Turbine : HEAT SHIELD WITH VORTEX BORES

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• DOUBLE FLOW, DOUBLE SHELL
• OUTER CASING FABRICATED , INNER CASING CASTINGS
• MONO BLOCK ROTOR

CO CONSTR NSTRUC UCTION TIONAL AL FE FEATURES TURES OF L OF LP P TURB TURBIN INE E FOR 8 FOR 800 00 MW MW

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SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

27 INNER CASING I IS I INDEPENDENT OF O OUTER CASING INNER CASING RESTS O ON OUTER CASING

660 M MW 500 M MW

LP TURBINE LP TURBINE

DIFFERENC NCES IN IN CON ONSTRUCTIO IONAL FEAT ATURES DIFFERENC NCES IN IN CON ONSTRUCTIO IONAL FEAT ATURES 500 MW V/S /S 660 MW 500 MW V/S /S 660 MW

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SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

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PUSH ROD ARRANGEMENT

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LP TURBINE INNER CASING SUPPORT DETAILS FOR 660 / 800 MW

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THROTTLE CONTROLLED GOVERNING WITH HIGH PRESSURE ELECTRO HYDRAULIC COMPACT ACTUATORS (160 BAR)

GO GOVER VERNING NING

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NEW DESIGN(660 MW)

THROTTLE GOVERNING HIGH PRESSURE ELECTRO HYDRAULIC GOVERNING (ACTUATORS WITH PRESSURE OF 160 BAR)

Turbine Governing

EXISTING DESIGN(500 MW)

THROTTLE GOVERNING ELECTRO HYDRAULIC (WITH 32 BAR PRESSURE)

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Turbine Governing

ADVANTAGES OF EHA BASED SYSTEM

• Simplified plant layout due to overall

compact size

• Control oil piping reduced
• Faster response due to state of art

electronic control and protection system

• Better interconnection with other system
• Ease of operation and maintenance
• Valve room is avoided

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Turbine Governing

EHA SYSTEM CONSISTS OF

* HYDRAULIC POWER SUPPLY UNIT * HPSU CONTROL UNIT * VALVES ACTUATORS * CONTROLLERS * PROTECTION SYSTEMS

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OVERHAULING

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SUMMARY

• Proven Supercritical technology in collaboration with M/s Siemens
• Steam Parameters up to 300 bar / 600°C / 620°C
• Modular Turbo set design to fit best customer needs
• High reliability & Availability
• Long Inspection intervals
• High efficiency by using modern CFD tools for flow path & blades

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Thank you for a Patient hearing…………