SupercriticalTurbineGenerators IntegratingAdvancementsExperience GRSivaprasad MHITurbineGenerators

L&T MHI TURBINE GENERATORS PRIVATE LIMITEDINDIA SUPERCRITICAL TURBINE GENERATORS – INTEGRATING ADVANCEMENTS AND EXPERIENCES G.R. Sivaprasad Date : July 20, 2011 Turbine Generators 1 Presentation Flow 1. Brief on Supercritical Technology 2.L&T MHI TURBINE GENERATORS Overview 3.Features of L&T MHI Turbine Generator 4.Projects Under Execution 5.Future Trend – Ultra Supercritical Turbine Generators 2 Brief On Super-Critical Technology INDIA Turbine Generators 3 Super-Critical Parameters Turbine Generators 4 Latest Project in India (%) Heat rate difference of turbine (relative) 0.3 0.3 1.3 0.8 0.9 MPa x degC 25.1x600/620 25.1x600/610 24.5x600/600 566/593 USC 566/566 538/566 SC 0.8 1.7 538/538 BASE Note: The values in diagram are typical HR differences respect to steam pressure and temperature. Actual heat rate may differ and shall be determined based on a given design condition. 5 16.7 24.2 Steam pressure (MPa abs.) Turbine Generators Steam Condition & Efficiency Net Efficiency (%LHV) 46 45 44 43 42 41 Net Efficiency CO2 Reduction 0 CO2 Reduction (%) 6 -1 -2 -3 -4 -5 Main Reheat 538 538 566 600 625 566 593 593 600 625 (Base) Inlet Steam Temperature Steam Temperature (oC) Turbine Generators . Benefits of Super-Critical Large Size Units  Higher cycle efficiency means primarily  Less fuel consumption  Less per MW infrastructure investments  Less emission  Less auxiliary power consumption  Less water consumption Large size units mean  Rapid Capacity addition  Reduced land requirement  Reduced manpower requirement Operational flexibility  Shorter start-up time. Suitable for variable pressure operation  Better temp. control and load change flexibility   Turbine Generators 7 . L&T MHI TURBINE GENERATORS -OVERVIEW Turbine Generators 8 . L&T MHI TURBINE GENERAORS PRIVATE LIMITED Turbine Generators 9 . JV STRUCTURE L&TMHI TURBINE GENERATORS PVT LIMITED JV established on Nov.5th. 2007 Turbine Generators 10 . ARIEL VIEW OF L&T MHI TURBINE GENERATOR WORKS AT HAZIRA .SURAT . 2007 Lock-in Period 7 years Product Range Supercritical TG set 500 MW& above 150 MW & 300 MW ST for CCPP Technology licence term 20 years Governing law As per Republic of India Turbine Generators 12 .JV DETAILS JV Agreement Signed on Nov 05 . JV DETAILS Project Cost 1257 Cr Investment 1164 Cr Capacity 4000 MW / annum Manpower 900 Location Vadodara / Hazira Turbine Generators 13 . JV DETAILS Total Area 283279 sq. 12 MW Turbine Generators 14 . mtr Power Reqd. mtr Main factory Building 250*30*42Sq. mtr 70 acres Factory buildup Area 57700 Sq. State of Art Facility    Major Machine Tools Heavy Machines Medium Machines 46 Nos 38 Nos 59 Nos  Major Equipments (CNC Cutting. Furnace ..) o Generator Test Bed (1000 MW) o High Speed Balancing ( 4500 rpm) o Blade Manufacturing 15 Turbine Generators . 200T Press.Shot Blast etc. Assembly shop Turbine Generators 16 . Blade Shop Internal View Turbine Generators 17 . Generator Test Facility GENERATOR TESTING APPDCL PROJECT Generator Test Facility 18 Turbine Generators . LMTG Inauguration Jan’11 Turbine Generators 19 . Features of L&T MHI Turbine Generator INDIA Turbine Generators 20 . MHI Steam Turbine – C/S View Turbine Generators 21 . History of MHI Large Steam Turbines DEVELOPMENT OF TURBINE CAPACITY MW 1175 MW 1000 MW 1371 MW 1180 MW 1050 MW 1000 SUPERCRITICAL 600 MW NUCLEAR SUPERCRITICAL 1000 MW SUPERCRITICAL 1050MW 500 75 MW REHEAT STEAM TURBINE 156 MW NUCLEAR 340 MW FOSSIL 0 1950 1960 1970 1980 OPERATION YEAR 1990 2000 22 Turbine Generators . History of MHI Large Steam Turbines Development of Steam Pressure & Temperature ℃ 650 600 400 350 550 300 500 250 200 450 150 510 ℃ 480 ℃ 538 ℃ 190 169 WAKAMATSU STEP2 (649/593℃) MATSUURA #2 50MW (593/593℃) 1000MW WAKAMATSU STEP1 (593/593℃) 50MW MISUMI #1 (600/600℃) 1000MW kg/cm2g OSAKA #3 (566/538℃ ) 156.25MW GOI #5 SHIN-TOKYO #4 (566/566℃ (538/538℃) ) 350MW 75MW TACHIBANAWAN #2 (600/610℃) 1050MW 566 ℃ TEMPERATURE 246 PRESSURE HEKINAN #3 (538/593℃) 700MW 250 255 127 102 88 100 400 59 60 50 42 350 0 1950 1960 1970 1980 1990 2000 2010 23 OPERATION YEAR Turbine Generators . 1 538/566 538/552/566 24.1 24.1 24.1 538/552/566 538/538 538/552/566 538/566 538/566 538/538 538/566 538/566 538/566 538/566 538/566 Commercia l Operation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Kansai EPCO Himeji #4 Kansai EPCO Takasago Tokyo EPCO Kashima Kansai EPCO Himeji #5 Kansai EPCO Kainan #3 Kyusyu EPCO Sendai #1 Kansai EPCO Tanagawa II #1 Tokyo EPCO Sodegaura #4 Chugoku EPCO Iwakuni #3 Kansai EPCO Gobo #1 Kyusyu EPCO Sendai #2 Kansai EPCO Ako #1 Kansai EPCO Miyazu #1 Kansai EPCO Nanko #1 EPDC Matsuura #1 450 450×2 600×2 600 600 500 600 1000 500 600 500 600 375 600 1000 1967 1971 1971 1973 1974 1974 1977 1979 1981 1984 1985 1987 1989 1990 1990 24 Turbine Generators .1 24.1 538/552/566 24.1 24.1 538/552/566 24.1 24. Unit MW Steam Condition (Turbine Inlet) Press (MPa) Temp (℃C) 24.1 24.1 24.1 24.1 24.1 24.1 24.MHI SC Steam Turbines – operating installations N o. 1 24.5 24.5 24.1 24.5 24.1 24. Unit MW Steam Condition (Turbine Inlet) Press Temp (MPa) (℃C) 24.1 538/566 24.5 24.5 24.MHI SC Steam Turbines – operating installations No.1 24.5 25.1 538/593 566/593 24.7 593/593 600/600 600/610 538/566 538/566 538/566 538/566 538/566 595/595 600/600 600/610 566/593 Commerci al Operation 16 Tokyo EPCO Higashi-Ogishima 17 Chubu EPCO Hekinan #3 18 Hokuriku EPCO Nana-Ota #1 19 EPDC Matsuura #2 20 Chugoku EPCO Misumi #1 21 EPDC Tachibanawan #2 22 23 24 25 26 27 28 29 30 Thailand EGAT Ratchaburi Taiwan FPCC UP-1 China CP-1 KOBE STEEL Kobe #1 Taiwan FPCC FP-1 #5 (UP-C) Kansai EPCO Maizuru #1 Tokyo EPCO Hirono #5 ENEL Torrevaldaliga Nord XCEL Comanche #3 1000 700 500 1000 1000 1050 751×2 600×2 600×6 700 600 900 600 686×3 830 1991 1993 1995 1997 1998 2000 2000 2000 2000 2002 2004 2004 2004 (2008) (2009) 25 Turbine Generators .1 24.0 24. 0% Toshiba 22.2% Hitachi 17.World No.6% Alstom 11.0% GE 3.2% Siemens 13.3% Siemens 12.1 Share Among Leading Players(Except for Chinese Manufactures and Co-production) Hitachi 16.1% Alstom 12.7% Toshiba 22.MHI LARGE FOSSIL STEAM TURBINE .6% Mitsubishi 26.6% Mitsubishi 28.4% Fuji 4.1% GE 4.4% Fuji 5.8% World Market Share Over 600MW / Fossil Unit Turbine Generators 26 . A.655 (26) Algeria 29 (3) Italy 2.711 (38) Vietnam 721 (2) Brunei 10 (1) Singapore 660 (8) Guatemala 181 (2) El Salvador 124(5) Costa Rica 34 (2) Ecuador 146 (2) Peru 27 (1) Indonesia 7.062(28) Tunisia 510 (3) Qatar264 (6) Egypt 1.800 (16) U.417 (35) Bangladesh 51 (4) Myanmar Kenya 340 (5) 115 (5) Thailand 8.987 units) Unit : MW ( ) : Number of Units Iceland 1.165 (16) Macao 46 (2) Philippines 2.863 (39) Pakistan 1.943 (59) Hong Kong 3.E 433 (8) Saudi Arabia 9.559(13) New Zealand 492 (5) Argentina 947 (5) Turbine Generators 27 . 8.062 (13) India 642 (9) Korea 4.443 (60) Australia 905 (18) Malaysia 2.322 (28) Taiwan 10.297 (15) 9.156 (7) Netherlands 58 (1) Portugal 3 (1) Spain 5.040 (3) Yugoslavia 64 (3) Greece 2 (1) Ukraine 110 (3) Turkey 3.073 (92) Japan 66.939 MW (1.120 (12) Ireland United 187 (1) Kingdom 1.274 (12) Azerbaidjan 175 (3) Iraq 811 (7) Canada 563 (12) China Iran 2.721 (20) Syria 2.079 (750) Mexico 12.217 (5) Jordan 97 (1) Kuwait 4.MHI STEAM TURBINE WORLD WIDE Total : 182.A.566 (57) U.S.753 (73) Bahama 50 (2) Dominica 198 (3) Curacao 125 (5) Venezuela 12 (1) Surinam 30 (1) Colombia 670(8) Brazil 1.424 (23) Chile 1. of LP Casing No. of HP-IP Casing Max.MHI Turbine Configurations No. of Generator Design Constraints 50 Hz 60 Hz 2-Cylinder 1 1 (HP-IP Combined) 1 (HP-IP Combined) 2 HP&IP (Double Flow) 2 HP&IP (Double Flow) 1 LP exhaust area HP-IP blade strength  Control stage blade (HP)  IP last stage blade Generator capacity 750 MW* 750 MW* 3-Cylinder 2 1 1000 MW 1000 MW 4-Cylinder 2 1 1100 MW 1100 MW 4-Cylinder 2 (Cross (1500/1800 Compound) rpm) 2 (The efficiency is higher than that of Tandem-Compound 4-cylinder design) － － Turbine Generators 28 . Unit Capacity No. MHI Turbine Configurations 4 Casings 1200 (Cross Compound) Application Range (MW) 1100 1000 900 800 2 Casings 1LP+HIP 700 600 4 Casings 3 Casings 2LP+HP+IP 500 400 2LP+HIP Turbine Generators 29 . HP-IP Combined Turbine F3D ISB Reaction Blade IP Inlet Cooling Advanced 12Cr Rotor Forging Turbine Generators 30 . Features of HP-IP Combined Turbine Shorter longitudinal span Smaller differential expansion Easy maintenance Turbine Generators 31 . 5IN 48IN 54IN Titanium 49IN 54IN 3000rpm 1500rpm 32 Turbine Generators .ISB RANGE FOR LAST BLADE (For 50Hz) 30IN 35.4IN 40. ADVANTAGES OF ISB LP END BLADES Larger damping is generated by the contact at the shrouds and snubbers. which is caused by the twist-back deformation due to centrifugal force. ISB Reduction in Vibration Stress Conventional Grouped Blade Turbine Generators 33 . ADVANTAGES OF ISB LP END BLADES Lower centrifugal stress by a large blade root and groove. Enhancement of Reliability for Corrosive Environments Turbine Generators ISB Conventional Grouped Blade 34 . 5 DEVELOP 1990 1992 1993 MENT FIRST APPLICATION (60Hz) 1991 1995 1995 (50Hz) 1998 1997 1997 40 48 1998 1999 2004 45 54 2000 2003 Turbine Generators 35 35 .5 33 (50Hz) 30 Ht 35.4 40.MHI ISB DESIGN BECAME WORLD STANDARD ISB Design Since 1990 in MHI BLADE (60Hz) 25 29. Operating Experience of the HIRONO #5 Date in commercial operation: July 12. 2004 HP-IP LP GEN #1 LP Turbine HIP Turbine #2 #3 #4 #5 #6 Turbine Entire View Vibrational value (Peak-Peak μm） Brg Metal Temp. #4 #5 #6 Bearing No. (°C) 150 100 50 0 #1 #2 #3 ANN at 100% Load 300 200 100 0 #1 #2 #3 at 100% Load ANN #4 #5 #6 Bearing No. 36 Turbine Generators . New Heat-Resistant Alloy for Turbine Steam Temp Turbine Parts ≦ 566℃ CrMoV ≦ 610℃ 12CrMoVNb (TMK-1) 12CrMoVNb (MJC-12) 12CrMoWVNb (10705MBU) Super 9Cr (T91) ≦ 630℃ 3Co12CrMoWVNbB (MTR10A) 3Co12CrMoWVNbB (MTC10A) 3Co12CrMoWVNbB (MTB10A) 3Co12CrMoWVNbB (MTV10A) ≦ 650℃ Modified A286 HP/IP Rotor Inner Casing Nozzle Box Blade Valve 2.25CrMo W545 Type 316H The materials in Green column are developed by MHI. Turbine Generators 37 .25CrMo Type 316H 12CrMoWV (Type 422) 2. having supplied more than 1900 units worldwide. Having state of the art R&D facility and through its experience and developmental efforts MHI is continuously improving steam turbine design for better performance & reliability.     MHI ISB Blade Design became world standard Turbine Generators 38 . Integral Shroud Blades of LP end blades results in better vibrational characteristics. Highly reliable control stage.  More than 30 large sized units with supercritical parameters. Developed high heat resistant alloys for ultra supercritical steam parameters (630o C).MHI’s Steam Turbines  Over 35 years of experience in Steam turbine manufacturing. FEATURES OF MITSUBISHI/LMTG GENERATORS  HIGH RELIABILITY PROVEN THROUGH EXTENSIVE EXPERIENCE (OVER 80 YEARS / OVER 1800 UNITS)  WIDE OUTPUT RANGE (UP TO 2000 MVA) ■ BEST APPLICATION OF COOLING SYSTEM (AIR / HYDROGEN / WATER) 3 9 Turbine Generators 39 . Supply Record For Thermal Power Plant Total:1934 Units 639 Units (H2 Cooled) 1295 Units (Air Cooled) AS of Aug. 2010 80 70 60 50 50 80 GR EE NL AN D 70 60 60 50 P RO E Mid-East 100 Units 86 Units 70 80 ND LA EN RE G Asia 186 Units 179 Units 80 70 60 50 40 NO RTH AM ERICA EU 40 40 ASI A TR O PIC O FC AN CER 40 30 TR O PIC O FC AN CER 20 A T LA 30 30 20 P A C IFIC O C E A N 30 20 N T 10 PACI F I C EQ UATO R IC 10 A F RI CA O C 10 10 OC E A N TR O PIC O F CAPRICO R N 30 10 SO UTH AM ERICA 30 10 E I NDI A N OC E A N A 10 EQ UATO R 10 N 20 TR O PO FC APRIC O RN 20 20 20 20 A U S TR A LIA 30 30 30 30 30 30 40 40 40 40 40 40 40 40 50 60 70 80 80 70 60 50 50 60 70 80 80 70 60 50 50 60 70 80 70 60 50 50 60 60 50 ANTA RCTICA 80 70 80 80 70 North/South America 99 Units 170 Units 4 0 Europe 16 Units 23 Units Other (Pacific/Africa) 6 Units 39 Units Japan 232 Units 798 Units 40 Turbine Generators . APPLICATION OF COOLING SYSTEM TYPE OF GENERATOR COOLING (STATOR) AIR COOLED HYDROGEN COOLED HYDROGEN INNER COOLED GENERATOR CAPACITY (MVA) 200 2 pole 400 600 800 1000 1200～ 2 pole 2 pole WATER COOLED 4 1 2 pole 41 Turbine Generators . 600MVA (NUCLEAR) MAX.MITSUBISHI EXPERIENCE OF LARGE CAPACITY WATER COOLED GENERATOR ■ LARGE CAPACITY : ■ LONG TERM OPERATION : MAX.008MVA 2007** *Commercial operation Year. 1. ALL UNITS IN SERVICE) WATER LEAKAGE NEVER EXPERIENCED ■ HIGH RELIABILITY : ■ EXPERIENCE : TOTAL 22 UNITS (INCLUDING NUCLEAR) (TYPICAL UNIT FOR THERMAL POWER PLANTS) NANKO #1 670MVA 1990* HEKINAN #3 800MVA 1993* RATCHABURI #1 990MV 2000* COMANCHE #3 1. **Year of manufacture Turbine Generators 42 .008MVA (COAL-FIRED) MORE THAN 30 YEARS (SINCE 1979 OF FIRST 1.300MVA UNIT FOR NUCLEAR. 1. 990MVA 3.000rpm WATER COOLED GENERATOR FOR THERMAL POWER PLANT IN THAILAND Commercial operation .1999 Turbine Generators 43 . PROJECT UNDER EXECUTION INDIA Turbine Generators 44 . Pressure – 242 Bar M.s.PROJECT UNDER EXECUTION APPDCL 2 x 800 MW STG JAYPEE 2 x 660 MW MAHAGENCO 3 x660 MW RAJPURA 2 x 660 MW Jaypee Karchana 3 x 660 MW STG STG BTG EPC Steam parameters – M. Temp – 565 Deg C Reheat Temp – 593 Deg C L&T MHI Turbine Generators 45 .S. 21 July 2011 STATOR CORE FABRICATION BLADE ASSEMBLY Turbine Generators 46 . JAYPEE PROJECT PROGRESS Turbine Generators 47 . ROTOR WINDING Turbine Generators 48 . Rotor insertion at MELCO Turbine Generators 49 . ROTOR AT LMTG SHOP Turbine Generators 50 .21 July 2011 APPDCL PROJECT . FUTURE TREND.ULTRASUPERCRITICAL INDIA Turbine Generators 51 . 1.3 % Compare to Supercritical 1.3 % 52 Turbine Generators .7 M pa Temperature: 538/538 Deg-C or 538/560 Deg-C Supercritical : Pressure : 24.1 M pa Temperature: 538/560 Deg-C to 566/593 Deg-C Ultra Supercritical(USC) Pressure : 24.ULTRASUPERCRITICAL IN MHI TERMINOLOGY Subcritical : Pressure : 16.1 to 31.c HEAT RATE improvement by approx.0 M pa Temperature: 593/593 Deg-C to 600/620 deg.21 July 2011 FUTURE TREND IN INDIA. 21 July 2011  MHI has adequate experience for over 600/600 steam turbines Steam Condition (0C) 600/600 600/610 600/600 600/600 600/600 600/600 600/610 Customer Station Chugoku EPCO Misumi #1 EPDC Tachibanawan #2 Tokyo EPCO Hirono #5 China Yingkou (2 units) Licenser China Kanshan (2 units) Licenser China Heyuan (2 units) Licenser MW 1.050 600 600 600 600 678 Fuel Coal Coal Coal Coal Coal Coal Coal C/O 1998 2000 2004 2007 2008 2009 2009 ENEL Torrevaldaliga Nord (3 units) Tokyo EPCO Hirono #6 Korea EWP Danjin (2 units) 600 1000 600/600 600/600 Coal Coal (2013) (2015/6) Turbine Generators 53 .000 1. 2000 54 .EPDC Tachibanawan #2 1050MW Turbine Largest Capacity Steam Turbine with the Highest Steam Condition Turbine Type Steam Condition In Operation since Turbine Generators : CC4F-46 : 25.1MPa×600/610℃ : DEC. 6MPa×600/600℃ : Jul.2004 55 Turbine Generators .Tokyo EPCO Hirono #5 600MW Turbine 600 MW Two Cylinder Steam Turbine with 48-inch Blade 2 pad journal bearing 12Cr HIP Rotor Advanced flow guide Advanced direct support LP frame 600℃ class advanced HP-IP combined frame 3000 rpm 48inch Steel ISB TURBINE TYPE STEAM CONDITON IN OPERATION SINCE : TC2F-48 : 24. THANK YOU Turbine Generators 56 .