WELCOME TO

Presentation on New Concepts in Supercritical Turbines

Sanjoy Bhattacharya Dy. Genl. Manager, BHEL, Hardwar

1

2

CROSS SECTIONAL ARRANGEMENT OF 500 MW STEAM TURBINE HPT IPT LPT THREE CYLINDER TURBINE 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 1. HP Turbine with Extraction & 565 Deg C HRH Temp 2. HP Turbine without Extraction & 537 Deg C HRH Temp

• • •

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

• • •

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

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

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 :

• •

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: PARAMETERS MORE THAN CRITICAL STATE

•

STEAM PRESSURE > 221.2 BAR

•

STEAM TEMPERATURE > 374.15 Deg C ULTRA SUPERCRITICAL PRESSURE(



300 BAR) 25 20 15 10 5 0 45 40 35 30 170 ata / 537 °C / 537 °C 800 MW Super Critical 247 ata / 565 °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 MS PRESSURE MS TEMPERATURE MAIN STEAM FLOW REHEAT PRESSURE RH TEMPERATURE FINAL FEED WATER TEMP.

UNIT ATA o C T/HR ATA o C o C 500 MW 660 MW 800 MW 170 537 1500 40.5

537 253 247 565 1919 56 593 290 247 565 2380 60 593 290 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 HP TURBINE IP TURBINE LP TURBINE HP VALVES IP VALVES 500 MW H30-100 M30-63 N30-2 x 10 2 x FV320 2xAV560 660 MW H30-100 M30-100 N30-2 x 12.5

2 xFV250A 2xAV560A 800 MW H30-100 M30-100 N30-4 x 8 2 xFV250A 2xAV560A 14

15

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 for higher properties steam

•

temperature Optimum flow path Salient Feature:

•

New series of HP & IP modules for supercritical parameters

•

Higher size LP module 247 ata Main Steam Pressure 565 0 C Main Steam Temperature 593 0 C Hot reheat Temperature 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

17

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

CROSS SECTIONAL ARRANGEMENT OF 800 MW STEAM TURBINE FOUR CYLINDER TURBINE 20

CONSTRUCTIONAL FEATURES OF HP TURBINE FOR 800 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

CONSTRUCTIONAL FEATURES OF IP TURBINE FOR 800 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

CONSTRUCTIONAL FEATURES OF LP TURBINE FOR 800 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 DIFFERENCES IN CONSTRUCTIONAL FEATURES 500 MW V/S 660 MW 500 MW INNER CASING RESTS ON OUTER CASING 660 MW INNER CASING IS INDEPENDENT OF 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

GOVERNING THROTTLE CONTROLLED GOVERNING WITH HIGH PRESSURE ELECTRO HYDRAULIC COMPACT ACTUATORS (160 BAR) 31

Turbine Governing

EXISTING DESIGN(500 MW) THROTTLE GOVERNING ELECTRO HYDRAULIC (WITH 32 BAR PRESSURE) NEW DESIGN(660 MW) THROTTLE GOVERNING HIGH PRESSURE ELECTRO 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