WELCOME TO Presentation on New Concepts in Supercritical Turbines Sanjoy Bhattacharya Dy. Genl. Manager, BHEL, Hardwar 1
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CROSS SECTIONAL ARRANGEMENT OF 500 MW STEAM TURBINE HPT IPT LPT THREE THREE CY CYLIND LINDER ER TURB TURBIN INE 3
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 4
600MW Steam turbine: Built from proven modules of existing 500 & 250 MW OPTIONS Module Combination 1. HP Turbine with Extraction & 565 Deg C HRH Temp • HP: H30-100 • IP : M30-63 2. HP Turbine without Extraction & 537 Deg C HRH Temp • LP : N30-4x6.3 Salient features: • 4 cylinder turbine (2 LPs) Steam parameters • HP turbine with Extraction connection for 565 HRH Temp 170 ata / 537 0 C/ (537-565) 0 C • IP turbine suitable for 537/565 0 C inlet temp. Orders for 2 sets - N Chennai, 2 sets – JITPL, 1 set -APGENCO & 2 sets Singareni received. 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 . 5
600 MW Sub critical Sets Steam Turbine Design Changes from existing 500 MW sets : • HP module variant with Extraction 600MW Steam Turbine • 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 6
500/ 600 MW SUB CRITICAL CYCLE WITH 2 HP HEATERS, 3 LP HEATERS
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. 4.3 % SUPER CRITICAL STEAM PARAMETERS: Improvement 45 40 35 PARAMETERS MORE THAN CRITICAL STATE 30 25 • STEAM PRESSURE > 221.2 BAR 20 15 • STEAM TEMPERATURE > 374.15 Deg C 10 5 ULTRA SUPERCRITICAL PRESSURE( 300 BAR) 0 500 MW 800 MW Super Critical Subcritical 247 ata / 565 °C / 170 ata / 537 °C / 537 °C 593 °C INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg C RESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE 8
Supercritical Cycles 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 offers the advantage of ‘burn less fuel for the same output’ and lower emission. Lesser Pollutants – SOX , NOX & CO2 9
IMPROVEMENT IN EFFICIENCY WITH INCREASING INLET PARAMETERS FOR STEAM TURBINES 10
PARAMETERS FOR BHEL STEAM TURBINES PARAMETERS UNIT 500 MW 660 MW 800 MW MS PRESSURE ATA 170 247 247 o C MS TEMPERATURE 537 565 565 MAIN STEAM FLOW T/HR 1500 1919 2380 REHEAT PRESSURE ATA 40.5 56 60 o C RH TEMPERATURE 537 593 593 FINAL FEED WATER o C 253 290 290 TEMP. 11
Typical Supercritical TG Cycle 12
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 13
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 14
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660MW Steam turbine: With Supercritical parameters • 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 Salient Feature: 247 ata Main Steam Pressure • New series of HP & IP modules for 565 0 C Main Steam Temperature supercritical parameters 593 0 C Hot reheat Temperature • Higher size LP module 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 16
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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 18
800MW Steam turbine: General Arrangement 19
CR CROSS OSS SE SECTIO CTIONAL A AL ARR RRAN ANGEME EMENT OF NT OF 800 80 0 MW S MW STE TEAM AM TURB TURBIN INE FOUR FOUR CYLIND CYLINDER ER TURB TURBIN INE 20
CON CONST STRUC RUCTIONAL TIONAL FE FEATURES ATURES OF OF HP TUR HP TURBIN BINE E FOR 8 FOR 800 00 MW MW Barrel in two pieces • SINGLE FLOW, DOUBLE SHELL • OUTER CASING BARREL TYPE IN TWO PIECES • INNER CASING AXIALLY SPLIT • MONO BLOCK DRUM TYPE ROTOR 21
CON CONST STRUCTION UCTIONAL AL FE FEATURE TURES S OF IP TURB OF I 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 22
Diagonal Impulse Blading HPT FIRST STAGE 23
IP Turbine : HEAT SHIELD WITH VORTEX BORES 24
CO CONSTR NSTRUC UCTION TIONAL AL FE FEATURES TURES OF L OF LP P TURB TURBIN INE E FOR 800 FOR 8 00 MW MW • DOUBLE FLOW, DOUBLE SHELL • OUTER CASING FABRICATED , INNER CASING CASTINGS • MONO BLOCK ROTOR 25
SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW 26
LP TURBINE LP TURBINE DIFFERENC DIFFERENC NCES IN NCES IN IN CON IN CON ONSTRUCTIO ONSTRUCTIO IONAL FEAT IONAL FEAT ATURES ATURES 500 MW V/S 500 MW V/S /S 660 MW /S 660 MW 500 M MW 660 M MW INNER CASING RESTS O ON INNER CASING I IS I INDEPENDENT OUTER CASING OF O OUTER CASING 27
SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW 28
PUSH ROD ARRANGEMENT 29
LP TURBINE INNER CASING SUPPORT DETAILS FOR 660 / 800 MW 30
GOVER GO VERNING NING THROTTLE CONTROLLED GOVERNING WITH HIGH PRESSURE ELECTRO HYDRAULIC COMPACT ACTUATORS (160 BAR) 31
Turbine Governing EXISTING DESIGN(500 MW) NEW DESIGN(660 MW) THROTTLE GOVERNING THROTTLE GOVERNING ELECTRO HYDRAULIC HIGH PRESSURE ELECTRO (WITH 32 BAR PRESSURE) HYDRAULIC GOVERNING (ACTUATORS WITH PRESSURE OF 160 BAR) 32
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 33
Turbine Governing EHA SYSTEM CONSISTS OF * HYDRAULIC POWER SUPPLY UNIT * HPSU CONTROL UNIT * VALVES ACTUATORS * CONTROLLERS * PROTECTION SYSTEMS 34
OVERHAULING 35
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 36
Thank you for a Patient hearing………… 37
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