Large capacity supercritical sets

Over all Efficiency can be improved by:

Improving internal efficiency
Adoption of advance steam parameters
Improving thermal efficiency
Improvement in efficiency with Increasing inlet
parameters for Steam turbines
Parameters for Critical State
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 SO
X
, NO
X
& CO
2
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
I
m
p
r
o
v
e
m
e
n
t

4.3 %
Entropy
T
e
m
p
e
r
a
t
u
r
e

Supercritical Cycles
Details of Super-Critical Units in 10
th
, 11
th
, 12
th
&13
th
5 Year Plans
Sub Critical
(MW)
660
MW
(No.)
800
MW
(No.)
Super Critical
(MW)
TOTAL
MW
10
th
Plan 9620 0 0 0 9620
11
th
Plan 45470 7 1 5420 50890
12th Plan 18270 25 33 42,900 61,170
13
th
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)
Introduction of large capacity super critical
Steam Turbines with power output 660MW
HPT IPT LPT
Cross sectional arrangement of
500 mw Steam turbine

Cross sectional arrangement of
660 mw Steam turbine
Cross sectional arrangement of
800 mw Steam turbine
Module 500MW 660MW 800MW
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
PARAMETERS UNIT
SUBCRITICAL SUPERCRITICAL
500 MW 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
Overview of a Large capacity set with
super critical parameters
Constructional details of
HP turbine
Inner Casing
Inlet
Outer Casing-Barrel type
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
HP Turbine
HP Turbine
HP Turbine
For Over load valve
Extraction Chamber
Overload valve
HP Turbine
Section through HP admission 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
HP Turbine Additional Features
Outer Casing (rear)
G17CrMo5-10
HW 19582
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
HP Turbine with Breech-Nut connection
Breech Nut
Constructional details of
IP turbine
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
IP Turbine Inlet Ring
Reduction in wall temperature of
the Rotor
Reduction in Creep damage
Reduction of Cracking
Increase of Life cycle time
IP Turbine Inlet Ring
Outer Casing
GGG 40.3
HW 19793
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
IP Turbine with Casing mounted valves
Constructional details of
LP turbine
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
HPT IPT LPT
LP Turbine - 500MW LP Turbine - 660 MW
LP Turbine
EXHAUST
DIFFUSER
ROTOR
LP INNER
INNER CASING
LP INNER OUTER
CASING
GUIDE BLADE
CARRIERS
LP LONGITUDINAL
GIRDER
LP FRONT WALL
ATMOSPHERIC RELIEF
DIAPHRAGM
LP Turbine - 500MW
LP Turbine 660MW
EXHAUST
DIFFUSER
ROTOR
LP INNER OUTER
CASING
LP SIDE WALL
LP END WALL
ATMOSPHERIC RELIEF
DIAPHRAGM
CASING UPPER
PART
LP Turbine 660MW
Arrangement of thrust bolt for minimizing
axial clearances
26NiCrMoV14-5
HW 19373
X20Cr13
HW 10786
Rotor
Inner Casing
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
Arrangement of thrust bolt for minimizing axial
clearances
Banana type guide blade
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
Fabricated bearing pedestals Cast bearing pedestals
GGG-40.3 Nodular Casting
Bearing Pedestals
Governing System
660 MW steam
turbine equipped
with high pressure
electro-hydraulic
governing system
Advantage:
Compact design
Less control fluid piping
Less erection and commissioning
time
Characteristics 500 MW
(Low Pressure 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
Advantages of high pressure 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
Additional features
Less noise 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
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
Lub oil system in 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
LUB OIL MODULE
el. temperature
control valve,
T
oil
=50C
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 9
s-1
oil vapor
demister,
acc. to german
regulations
(TA-Luft)
main throttle,
min. flow
lube oil
double filter
(2x100%, 25m)
return line
2x100%
plate heat exchanger,
controlled by oil side
2x100%
lifting oil filter 25m,
pressure control valve
tank
module design exemplary
Off-line-filter
OLF60, 3m
Lub Oil Module in 660 MW
OIL MODULE
example
Lub Oil Module in 660 MW
Turbine driven main 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
Electric actuators of 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
Steam Strainers
Steam strainers in 660
MW unit are located
inside turbine valves
(ESV & IV) and hence
separate strainer
housings in MS & HRH
lines are eliminated.
Thanks
STEAM TURBINE Unit 1 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
660 MW TG SETS


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 10
th
July 2009.
- Documents for HP module shall be available from Siemens after
signing of TCAE3.
660 MW TG SETS


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.