Ansaldo Service Roadshow - Jeddah - Steam Turbines5

Steam TurbinesJeddah Roadshow, 22 July 2006

Guido RaimondiHead of Steam Turbine Thermodynamics Design

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STEAM TURBINES

New New equipmentequipment

Product developmentProduct development

RepoweringRepowering Concept Concept

Retrofit and Retrofit and modernizationmodernizationApplication examplesApplication examples

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GE USAIMPULSE

Westinghouse USAREACTION

Siemens-KWU DREACTION

BBC CHREACTION

Alsthom FIMPULSE

GEC UKIMPULSE

1970

Siemens AEG SACM Rateau AEI GECBBCSulzer

1) Industrial Turbines2) Impulse on Nuclear Turbines

Mitsubishi JREACTION

GE USAIMPULSE

Toshiba J

ABB-Alstom FREACTION (2)

1999

Siemens Westinghouse DREACTION

1998

Ansaldo IFuji J

2000

Hitachi J

1987

Ansaldo

Hitachi

Doosan

Toshiba

BHEL

Fuji

N. Pignone (1)

Parsons

ASEA STAL

F. Tosi

Ansaldo

Zamech

GEC – Alsthom

1989

CEM

ABB

De Pretto

LMZMitsubishi

ESG

Steam Turbine Technology Evolution

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STEAM TURBINES





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0 1000100 200 300

Power output ( MW )

Type and Application

20 100

20 100

70 300

REHEAT TURBINES

MIDDLE SIZE TURBINES

INDUSTRIAL TURBINES

GEOTHERMAL TURBINES

- Geothermal Cycle

- Steam Cycle- Combined Heat and Power- Combined Cycle

- Steam cycle- Combined Cycle

- Steam Cycle- Combined Cyle- Combined Heat and Power

CT, IT

GT

MT, MR (2-cylinders)

RT (3-4cylinders)

Ansaldo Energia Steam TurbinesProduct Range

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0 300 600 900 1200

Rating ( MVA )

Type and Application

up to 300 MVA

up to 600 MVA

Up to 900 MVA

AIR COOLED

- Steam Turbines- Gas Turbines- Geothermal Turbines

HYDROGEN COOLED

HYDROGEN/WATER COOLED

- Steam Turbines- Gas Turbines

- Steam Turbines

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34

5

78

9

10 11 12 13

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15 1616

17

19

20

21

22

23

24

6

18 18

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Ansaldo EnergiaTurbogenerators – Product Range

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RT60SMT10C

MT15C

MT25S

RT40S

RT50S

RT20C

RT30C

Frame turbines

Ansaldo Steam Turbines

• Modular concept – Ansaldo builds single-/multiple-casing ST’sto match output ranges up to 1000 MW for combined cycle and conventional fossil-fired power plants for both 50 and 60 Hz.

• Also used for steam extraction in co-generation / district heating systems, desalination or chemical processes

8RT TURBINES – tandem compound double flow

HP shrink ringsHP shrink rings

Free-standingLSB

Free-standingLSB

Valves directly connectedValves directly connected

No piston cooling steam

No piston cooling steam

One-piece 3D blades

One-piece 3D blades

Welded rotorsWelded rotors

Reaction TechnologyReaction Technology

Ansaldo Energia Steam TurbinesMain Features

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LP type Speed Exhaust area LSB typeper flow

(1/s) (m2)

23 50 3.2 With lacing wire


33G 50 5.5 Laced

33 50 6.1 Free standing



48 50 11.9 Continuous coupling





Ansaldo Energia Steam TurbinesStandard LP Sections

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PERFORMANCE DATA

Output range 100-250 MW

Live steam pressure 70-100 bar

Live steam temperature 540-565 °C

Back pressure 1 - 4 bar

Operation mode Fixed and/or Sliding pressure

MTG20MTG20

Full arc or control stage admission

Single / Double stop/control valve assembly

One controlled extraction solution available for coogeneration application

Downward or upward exhaust for low-profile plant

Shipped assembled for fast installation

DESIGN FEATURES

Back-Pressure Steam Turbinefor Heat and Power

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PERFORMANCE DATA


Live steam pressure 70-100 bar


Controlled extrac. pressure 1 - 4 bar

Condenser pressure 0.08-0.2 bar

Operation mode Fixed and/or Sliding pressure

Full arc or control stage admission

Single / Double stop/control valve assembly

One controlled extraction solution available for coogeneration application

Downward or upward exhaust for low-profile plant

HP shipped assembled for fast installation

DESIGN FEATURES

Controlled extraction, condensing Steam Turbine for C.C. and Desalination Plant

Single flow axial exhaustSingle flow axial exhaust

Controlled extractionControlled extractionMTG20-CMTG20-C

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Full arc admission

One stop / control valves assembly

HP, LP opposite flow configuration

Welded rotor for material optimization

Axial exhaust for low profile plant

Modular LP design for optimizedperformance

- LSB 50 Hz 43”

DESIGN TOPICS

MT10cMT10cPERFORMANCE DATA


Live steam pressure 60- 80 bar


Condenser pressure 0.035-0.25 bar

Operation mode: Sliding pressure

1 + 1 ( 50 Hz ) Configuration

2 + 1 ( 50 Hz ) Configuration

No Reheat Steam Turbinefor Combined Cycle

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PERFORMANCE DATA

Output range: 90-150 MW

Live steam pressure: 100-160 bar

Live steam temperature: 540-565 °C

Reheat steam temperature: 540-565 °C

Condenser pressure: 0.035 - 0.25 bar

Operation mode: Sliding pressure

1 + 1 ( 50 Hz, 60 Hz ) Configuration

( GT 180 / 260 MW )

SINGLE FLOW HP SECTION

Full arc admission for improved operation

Single stop / Control valve assembly


Axial exhaust for low profile plants

Single combined reheat valve

Welded rotor for material optimization

Modular LP design for optimized performance

LSB 50 Hz 33” - 43”

LSB 60 Hz 36”

COMBINED IP-LP SECTION

Reheat Steam Turbinefor Combined Cycle

MT10cMT10cMT15cMT15c

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PERFORMANCE DATA






No. of Extractions: 7 - 8

Operation mode: Fixed and/or sliding pressure

Speed: 50 - 60 Hz

LP SECTION

Double flow design

Bearing pedestals connected directly to turbine foundation

Cast inner casing with 360 ° inlet scroll to optimize steam flow

Modular design for optimized performance

- LSB 50 Hz : 33” , 43”- LSB 60 Hz : 36”

IP SECTION

Separated IP section for high efficiency

Double casing design

Two combined reheat valves

Welded rotor solution for materialoptimization


HP SECTION

Separated HP section for high efficiency

Full arc admission or control stageadmission for high efficiencyat partial load

Welded rotor solution for material optimization

Two stop / control valve assembly


RT40sRT40s

Reheat Steam Turbinefor Fossil fired Power Plants (1/2)

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PERFORMANCE DATA






Operation mode: Fixed and/or sliding pressure operation

Speed: 50 - 60 Hz

Four flow design

Bearing pedestals connected directly to turbine foundation

Cast inner casing with 360 ° inlet scroll to optimize steam flow

Modular design for optimized performance

- LSB 50 Hz : 33” , 43”- LSB 60 Hz : 36”

LP SECTIONIP SECTION

Separated IP section for high efficiency

Double casing design

Double flow design

Two combined reheat valves



HP SECTION

Separated HP section for high efficiency

Full arc admission

Two stop / control valve assembly



RT60sRT60s

Reheat Steam Turbinefor Fossil fired Power Plants (2/2)

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Ansaldo Steam TurbinesExperience List

5,423581Industrial plants

709589Combined Cycles

40226Waste to Energy power plants

87,1001,176Total

2,118130Geothermal power plants

6,18012Nuclear power plants

65,882344Fossil fueled power plants

Power( MW)UnitsApplication

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Cooperation and Technology TransferAgreement between ABB/Alstom and AEN

• Validity: 1989-2003• Products

– Steam Turbines > 25 MW– Generators > 10 MVA

(designed according to ABB/Alstom-CH technology)• Know-how

– Ansaldo had full access to ABB/Alstom-CH technology relating to Design, Manufacture, Quality Control, R&D, Erection, Commissioning

• After Termination Ansaldo has the right to– Continue to use ABB/Alstom-CH technology on new units and

for retrofit/modification of old units, including BBC/ABB fleet

– Subcontract components manufacturing to third parties– Grant licenses to third parties

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STEAM TURBINES



RepoweringRepowering ConceptConcept


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TEMPERATURE DISTRIBUTIONON BLADING SURFACE

Efficiency ImprovementAdvanced New Blading Design

HP-IP HIGH PERFORMANCE BLADING UPDATING FOR COMBINED CYCLE APPLICATIONS

BLADING DEVELOPMENTFOR ULTRA SUPERCRITICALAPPLICATIONS

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3-D Navier-Stokes analysis

LL--00 rotating bladerotating blade33--D modelD model

Efficiency Improvement48” Last Stage Bucket Design

Development of a newLast Stage Steel Blade48” length with an annular area of 12 m2

(JRP Ansaldo Energia – Skoda Power)

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STEAM TURBINES





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RepoweringFrom open cycle to Combined Cycle

19%

10%

32.5%

•• In open In open cyclecycle GT GT is is alone, the high temperature alone, the high temperature combustioncombustion gasesgases are are exhausted to atmosphereexhausted to atmosphere; more ; more thanthan 61% of 61% of available energy available energy in the in the fuel is lostfuel is lost..

•• The high The high energy contentenergy contentin in exhaustexhaust gasesgases can can be be used to used to produce high produce high temperature temperature steam by steam by HRSGHRSG

•• and produce more and produce more kW kW in in a newa new SteamSteam TurbineTurbine

•• TransformationTransformation of of ananopen open cyclecycle in a in a combinedcombined cyclecyclereducesreduces the the lost energy lost energy to lessto less thanthan 44 %44 %

•• The Net The Net Efficiency Efficiency of a of a combined cycle is higher thancombined cycle is higher than:: 56 %56 %

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SteamGenerator

Steam Turbine & Generator

Feedwatwer cycle

Condenser

Steam Cycle Unit

In a steam cycle unitthe Net Efficiency isabout 39%

mSH=100%

mHRH=90% mLP=80%

mcond=70%

The steam flow

distribution is

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InIn combined cyclecombined cycle, the Net , the Net EfficiencyEfficiency is higher thanis higher than 56 %56 %

10%

32.5%

Conversion of a conventional unit in C.C. (1+1 configuration)

2 - ST steam path could beoptimized; extraction pipesblanked

4 - Deaerator is new

5 - Piping is new

1 - Steam Generator is replaced byGT and HRSG, Feedwater cycle is removed

3 - Condenser is maintained

RepoweringFrom Steam Cycle to Combined Cycle

mSH=40%

mHRH=55%

mcond=65%

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STEAM TURBINES





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GE USAIMPULSE


Siemens-KWU DREACTION

BBC CHREACTION

Alsthom FIMPULSE

GEC UKIMPULSE

1970

Siemens AEG SACM Rateau AEI GECBBCSulzer

1) Industrial Turbines2) Impulse on Nuclear Turbines

Mitsubishi JREACTION

GE USAIMPULSE

Toshiba J

ABB-Alstom FREACTION (2)

1999

Siemens Westinghouse DREACTION

1998

Ansaldo IFuji J

2000

Hitachi J

1987

Ansaldo

Hitachi

Doosan

Toshiba

BHEL

Fuji

N. Pignone (1)

Parsons

ASEA STAL

F. Tosi

Ansaldo

Zamech

GEC – Alsthom

1989

CEM

ABB

De Pretto

LMZMitsubishi

ESG

Steam Turbine Technology Evolution

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AnsaldoEnergiaAnsaldoEnergia

Ansaldo Componenti

BBC / ABB / AlstomBBC / ABB / Alstom WestinghouseWestinghouseGeneral ElectricGeneral Electric

1949 - 1989 1989 - 2003 1949 - 1988

Ansaldo Steam Turbine Technologies

ESGESGFranco TosiFranco Tosi

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GE USAIMPULSE

Toshiba J

Hitachi J


Mitsubishi J

ABB-Alstom FREACTION

BBC CH

CEM F

Non-OEM Fleet Market for Ansaldo

Steam Turbines Retrofit and Rehabilitation

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Retrofit

• The modification/change of the existing turbine hardware intoa new one of updated design in order to improve thermalperformance (IEC Code 60953-3)

• Performance improving is needed when:– The steam turbine has to match the steam parameters of a new

Combined Cycle repowering the original fossil fired one– The steam turbine output power has to suit the capacity of

upgraded boilers– The steam plant heat rate has to be improved, without changing

steam parameters, through the increase of ST efficiency (e.g. by adopting enlarged LP flows to reduce exhaust losses)

• Additionally, the retrofit provides improved reliability and life time

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Retrofit solutions

• According to the expected effects,the retrofit hardware can include:– Partial replacement of blading

on existing rotor and casing

– Replacement of one or morecomplete inner blocks(steam path, rotor, inner casing)

– Replacement of one or morecomplete turbine sections

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Original – Impulse type Retrofit – Reaction type (HP-IP section)

Retrofit technologies

• Two technologies– reaction type blading (drum construction)

– impulse type (disc and diaphragm construction)• Ansaldo has developed updates for both technologies and

selected the most cost-effective retrofit solution• This means that machines originally designed for impulse

operation can be totally or partially retrofitted with impulse orreaction design and viceversa

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Retrofit process

Example of retrofit of non-OEM equipment

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Updated technology

1. Three dimensional blading (3D) on HP-IP section to reduce profile and secondary losses.

2. Longer last stage blade to reduce exhaust losses and convert them to additionalpower output.

3. Improved gland seal arrangements toreduce interstage leakage, particularly important for short HP and IP bladesThe application of “brush” tip seals reduces the amount of steam leakagesand improves the stage efficiency in the HP-IP turbine sections

Performance improvements can be realized through the introduction of updated steam path technology

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STEAM TURBINES





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Retrofit Solution

Scope of supplyComplete replacement of the old HP-IP section (impulse

design) with a new HP-IP turbine (reaction design)connected to the existing LP section.

Effects• Nominal rating: 129.5 MW.• High temperature inlet 565°C/565°C.

Reason for retrofitThe existing 250 MW unit, previously operating in steamcycle, operates now in CC, 1 GT + 1 ST configuration.

OEM: Ansaldo (GE licence)1 x 250 MW

Comm. Year: 1966

Chivasso 2

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Retrofit Solution

Scope of supplyA complete new 33” LP inner block with larger exhaustarea in the existing LP outer casing.

Effects• Nominal rating: 124.5 MW.• Gain of 5.6 MW in power output with reference to the

original design.

Reason for retrofitThe two existing 156 MW units, previously operating inconventional cycle, operate now in CC, 1 GT + 1 STconfiguration.

OEM: F. Tosi (Westingh. lic.)2 x 156 MW

Comm. Year: 1964 - 1966

BB070

Porto Corsini 3 – 4

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Retrofit Solution

Scope of supplyA complete new 43” LP inner block with larger exhaustarea in the existing LP outer casing.

Effects• Nominal rating: 267 MW.• Gain of 8 MW in power output with reference to the

original deisgn.

Reason for retrofitThe existing 320 MW unit, previously operating inconventional cycle, now operates in CC,2 GT+1 ST configuration.

OEM: Ansaldo (GE licence)1 x 320 MWComm. Year: 1968

2x33.5”

Torre Valdaliga Sud 2

2x43”

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Retrofit Solution

Scope of supplyA complete new 43” LP inner block (new steam path,rotor, inner casing) with larger exhaust area in the

existing LP outer casing.

Effects• Nominal rating: 337.5 MW. • Gain of 8 MW in power output with reference to the

original design.

Reason for retrofitLP section upgrading in order to improve the heat rateof the unit.

OEM: F. Tosi (Westingh. lic.)2 x 320 MWComm. Year: 1973 - 1975BB073

Fusina 3 – 4

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1990 1994 Greece LAVRION General Electric 1 x 66.5 - New HP Rotor and diaphragms- New LP Rotor and diaphragms

1990 1994 Argentina COSTANERA British Thompson-Houston 4 x 120 - New HP Rotor and diaphragms- New IP Rotor and diaphragms- New LP Rotor and diaphragms

1990 2002 Italy PIETRAFITTA F.T. / Westinghouse 2 x 60 - New 1°HP nozzle stage

1998 2000 Italy LA SPEZIA 1-2 F.T. / Westinghouse 2 x 120 - New HP-IP section - New LP last stage blading

1999 2001 Italy CASSANO D’ADDA 1 Ansaldo 1 x 80 - New HP-IP rotor and diaphragms- New LP rotor and diaphragms

2000 2001 Italy LA CASELLA 1-4 F.T. / Westinghouse 4 x 120 - New HP blading

2001 2002 Italy PORTO CORSINI F.T. / Westinghouse 2 x 123 - New LP inner block

2002 2003 Italy CHIVASSO 2 Ansaldo 1 x 130 - New HP-IP section

2002 2003 Italy PRIOLO GARGALLO 1-2 F.T. / Westinghouse 2 x 120 - New HP blading

2002 2003 Italy TORREVALDALIGA SUD 2 Ansaldo 1 x 267 - New LP inner block

2006 2007 Italy FUSINA 3-4 F.T. / Westinghouse 2 x 350 New LP inner block

1990 1994 Greece LAVRION General Electric 1 x 66.5 - New HP Rotor and diaphragms- New LP Rotor and diaphragms

1990 1994 Argentina COSTANERA British Thompson-Houston 4 x 120 - New HP Rotor and diaphragms- New IP Rotor and diaphragms- New LP Rotor and diaphragms

1990 2002 Italy PIETRAFITTA F.T. / Westinghouse 2 x 60 - New 1°HP nozzle stage

1998 2000 Italy LA SPEZIA 1-2 F.T. / Westinghouse 2 x 120 - New HP-IP section - New LP last stage blading

1999 2001 Italy CASSANO D’ADDA 1 Ansaldo 1 x 80 - New HP-IP rotor and diaphragms- New LP rotor and diaphragms

2000 2001 Italy LA CASELLA 1-4 F.T. / Westinghouse 4 x 120 - New HP blading

2001 2002 Italy PORTO CORSINI F.T. / Westinghouse 2 x 123 - New LP inner block

2002 2003 Italy CHIVASSO 2 Ansaldo 1 x 130 - New HP-IP section

2002 2003 Italy PRIOLO GARGALLO 1-2 F.T. / Westinghouse 2 x 120 - New HP blading

2002 2003 Italy TORREVALDALIGA SUD 2 Ansaldo 1 x 267 - New LP inner block

2006 2007 Italy FUSINA 3-4 F.T. / Westinghouse 2 x 350 New LP inner block

Order Start-up Country Plant Manifacturer ( OEM ) Units / MW Scope of Supplyyear year

Order Start-up Country Plant Manifacturer ( OEM ) Units / MW Scope of Supplyyear year

Ansaldo Steam Turbine Retrofits Experience List

Steam TurbinesJeddah Roadshow, 22 July 2006

Guido RaimondiHead of ST Thermodynamics Design

Ansaldo Service Roadshow - Jeddah - Steam Turbines5

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