PowerGen Asia 2011 KualaLumpur SST6000 Wechsung.

SST6000 steam turbine for future coal-based power generation
Prof Peng Zeying Shanghai Turbine Plant, China Michael Wechsung Siemens AG, Germany
PowerGen-Asia 2011, Kuala Lumpur, Malaysia Siemens AG 2011. All rights reserved. Copyright
Energy Sector
Agenda
Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat Outlook - 700C Summary
Page 2
Copyright Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector
Shanghai Turbine Plant - STP

the worlds biggest steam turbine manufacturer
1953 Shanghai Turbine Plant founded 1981 Westinghouse design and manufacturing license 300MW & 600MW 1995 STP and Westinghouse Joint Venture Shanghai Turbine Co., LTD. (68% STP and 32% Westinghouse) 1999 Siemens took over Westinghouse Chinese / German Joint Venture 2003 Licensee for several Siemens Steam Turbines in China
Page 3
Siemens Steam Turbine History

More than 80 Years
1996 1985 1970 1954
First super critical steam turbo set worldwide Start delivery of all German nuclear power plants 3DS technology: Efficiency SPP > 48%
2008
Delivery worlds largest ST for NPP Olkiluoto3
Isar 2 is today the most powerful steam turbo set
2010 2004
Opening expansion of new office building
2001
Hafen site new office facilities
Official opening of new heavy machinery workshop
1996-1998 1927
Purchase of Thyssen machinery plant in Mlheim
1970
Ground breaking ceremony for Hafen site
Merge Westinghouse, Parsons ALSTOM (Industrial turbine)
For internalCopyright Siemens AG 2011. All All rights reserved. use only. Copyright Siemens AG 2008. rights reserved.
Page 4
PowerGen Asia 2011 - Kuala Lumpur, Sep 2011
Energy Sector Energy Sector
Product Portfolio Steam Turbine Series

SST-3000 for Combined Cycle Power Plants
CCPP
single-flow LP axial exhaust
max. 177bar/ 565C/565C

90-250 MW
SST-5000 for sub critical SPP and CCPP

SPP CCPP CSP
with down, double-side or single-side exhaust with two, four or six-flow LP turbines with shrunk-on disc rotor design
max. 177bar/ 600C/600C

150-700 MW
SST-6000 for Steam Power Plants

SPP
max. 280bar/ 600C/610C

300-1200 MW
SST-9000 for Nuclear Power Plants

NPP
max. 80bar/ 300C

1500 rpm 1000-1900 MW
90 1900 MW (50 Hz and 60 Hz) Page 5 Copyright Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector
Agenda
Shanghai Turbine Plant & Siemens
State of the Art - USC

Next step - Double Reheat Outlook - 700C Summary
Page 6
SST 6000 series turbine

Bypass cooling for minimum wall thickness Advanced sealing technologies Barrel type: minimum radial clearances fast thermal loading capability Symmetrical casing design for minimum radial clearances High-performance LP blading for different sizes of exhaust area
high performance 3DVTM blading
Push rod arrangement for reduced axial clearances IP-admission blade ring with integral cooling Power range: 600..1200 MW
Page 7
Design Principle Modular Concept example: HP Turbine

T, p main steam conditions
H50
material change
H60
H70 V4
V3 V2 V1
scaling of modules power output/mass flow MW

Page 8 Copyright Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector
Design Principle Modular Concept example: HP Turbine
Page 9
USC references
Plant Isogo Yuhuan Wai Gao Qiao 3 Westfalen Eemshafen Lnen Mainz Country Japan China China Germany Netherlands Germany Germany Power output 1 x 600 MW 4 x 1000 MW 2 x 1000 MW 2 x 800 MW 2 x 800 MW 1 x 800 MW 1 x 800 MW Main steam 251 bar / 600C 262 bar / 600C 270 bar / 600C 275 bar / 600C 275 bar / 600C 270 bar / 600C 273 bar / 600C Reheat steam 610C 600C 600C 610C 610C 610C 610C Commercial operation 2001 2007 2008 2011 2012 2012 2013
Page 10
Operating Experience - Isogo, 48000 EOH
Power Output: Main Steam: Reheat Steam: Condenser: Type of cooling: Fuel type:
600 MWel 251 bar/600C 610C 0,0507bar once through, sea water hard coal
comm. operation: 2002
martensitic 13% chrome seal strips
Page 11
References Wai Gao Qiao 3, China
Max. proven power output: 1112 MW !
Power Output: 1040 MWel Main Steam: 270 bar/600C Reheat Steam: 600C Condenser: 0.053/0.042 bar With Stage Bypass (Overload) Fuel type: hard coal Comm. Operation: 2008
Asian Power Plant of the Year
Page 12
Steam Power Plant Development Roadmap Covers Double Reheat and 700C
Steam Cycle Efficiency (net)
Single reheat
55% 50% 45% 40% 35% 30% 1950
Double reheat
Nickel Alloys (350 bar, 700C)
Ferrites / Martensites (240 bar, <~620C)
Higher parameter Larger size Improved cycle

1970 1990 2010 2030
Page 13
Agenda
Shanghai Turbine Plant & Siemens State of the Art - USC
Next step - Double Reheat

Outlook - 700C Summary
Page 14
DRH studies at Siemens Steam Turbines
1. Danish Customer 900MW; 50Hz; 590/604/604; Master Cycle 2. Wai Gao Qiao Unit 9 1350MW; 50Hz; Cross Compound; 600/620/610 Variants: SRH, DRH & adv. DRH 3. Japanese Customer 600MW; 60Hz; 600/610/610 (625) Variants: SRH, DRH & adv. DRH 4. Siemens Plant concept 900MW; 50Hz; Design for CCS; 600/610/610 Variants: SRH, DRH, 1-RH
Page 15
1350 MW double-reheat with Siemens components example WGQ 9 Cross over pipe: 31.2 m
m.st.
RH1
RH2
RH2
50 m 71 m
Thrust Rotor dynamics Axial expansion
Too long rotor train and challenging generator size Cross compound
1350 MW double-reheat cross-compound with Siemens components 1350MW WGQ9
540 t w/o Generator 990 t with Generator 27 m
55.6 m
1350MW DRH Steam turbine arrangement and systems of 1st train
HRH piping 1 Hydraulic Supply Unit
Lubricating Oil Module
Weight of turbine deck + turbine train: ~3500 t

MS piping CRH piping 2 Gland Steam Condenser Evacuated Stand Pipes Seal Steam Header CRH piping 1 Page 18 Copyright Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector
1350MW DRH Steam turbine arrangement and systems of 2nd train
IP turbine 2b IP turbine 2a
Hydraulic Supply Unit for turbine valves
Lubricating Oil Module Page 19 Copyright Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector
Overall plant efficiency development

48.8 46.0 43.5 46.3
Overall plant net efficiency in %
2.5
2.5
2.8
43.5
43.5
46.3
Heat Rate / kJ/kWh Station Power Rate Boiler efficiency
7320 4.5% 93.6%
7140 3.5% 95.5%
6947 4.0% 94.0%
6765 3.0% 95.5%
Typical CHN 1000 MW unit
State-of-the-art single reheat
DRH 1350 MW at design conditions
DRH 1350 MW with state-of-theart technology
Page 20
Agenda
Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat
Outlook - 700C
Summary
Page 21
700C Steam Power Plant Affected Components
Flue gas train

Cleaned flue gas
7 6
Boiler Boiler house superheater Flue gas

2 1
Turbine building
Power distribution grid
Ammonia Lime emulsion

5 3 4 4 12 9 10 11
Main steam Feed water
Live & reheat steam piping

8
Electric power
13 14
Gypsum Fly ash

1 2 3 4 5 6 7 Steam generator DeNOx plant Air preheater Fan Electrostatic precipitator Desulfurization plant Stack 8 9 10 11 12 13 14
AIR Ash Coal

Steam turbine Condenser Pump Feedwater heater Feedwater tank Generator Transformer
HP & IP turbines 11 and valves 10

Condensate
Circulating 10 water
Cooling tower
Steam conditions: 700C / 350 bar 720C / 70 bar
Cooling air
Fresh water
Page 22
700C Steam Turbine Technology Challenges Requirements Increased temperature and pressure Qualification of available Nickel alloys for very heavy and thick-walled parts (forgings and castings > 10 tons) Drawback Material costs and machining effort (time)
Steam/Gas Parameters Pressure
350 bar 700C 700C Steam Turbine USC Steam Turbine Gas Turbine
250 bar 600C 25 bar 1400C
Temperature
Development Focus Production procedures (large forgings & castings, welding, machining) Material properties for steam environment, thick-walled components Non-destructive evaluation Blade and seal technologies Design concepts, including cooling
700C Steam Turbine Development Project Status Large Nickel alloy forging and casting demonstrated Welding of dissimilar materials (Nickel alloys / steel) Machining tests on Nickel alloy performed Design concepts available
Source: AD700
Page 24
Source: AD700
700C Steam Turbine Principle of Construction for HP Turbine Design

Cooling Steam Live Steam 350bar 700C
HP
Characteristics
Proven basic concept (Siemens barrel-type) Solid rotor shaft Welded rotor and inner casing Cooled outer casing with full pressure load Inner casing with low pressure load at inlet Flanged valve attachment
Ni-based alloys Exhaust Steam Weld Seams of different materials
Principle of Construction
Page 25
Agenda
Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat Outlook - 700C
Summary
Page 26
Further increase of efficiency with different technology

52.0 Overall plant net efficiency in %
49.2 1)
3.2
48.8
3.2
46.0
48.8 46.0
1000 MW SRH with state-of-theart technology
700 C SRH
DRH 1350 MW with state-of-theart technology
700C DRH
1) 50.1% with open circuit cooling @ North Sea
Page 27
Steam Turbine Technology

Development 700C as final step ~ 2010 ~ 2010 State of the art State of the art
USC single reheat (280 bar / 600C / 620C) in tandem compound configuration up to 1200 MW power output
b D hu hai. l R& a ba/ 600C ng o h / 610C / 620C) USC double reheat (310 lbar ~ 2015 ~ 2015 ns g ded in S e Pilot WaiGaoQiao IV linncross compound configuration up to Siem lly a Next step Next step the icia ns st,powerfoutput 1 1350 tMW s of eme us Si Aug turbine C& e E Sinc steam en S e PP 700C single ion betw S t reheat (350 bar / 700C / 720C) in tandem ~ 2020for ~ 2020 pera o e co a configuration up to 550 MW power output Future steptive: dcompound pe Future step th c obje exten road m pilot project Wilhelmshaven postponed German Key ther that r fu work an to Increase power output of 700C (350 bar / 720C) in Beyond 2020 Beyond 2020 tandem compound configuration to 900+ MW Operational experience of 550 MW mandatory
* Ultra super critical / Hyper super critical
Thank you for your attention!
Michael Wechsung Head of ST Product Strategy Siemens Energy Rheinstr. 100 45478 Muelheim an der Ruhr Phone: +49 (208) 456-3644
E-mail: michael.wechsung@siemens.com
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SST6000 steam turbine for future coal-based power generation

Shanghai Turbine Plant - STP

Siemens Steam Turbine History

Isar 2 is today the most powerful steam turbo set

Official opening of new heavy machinery workshop

Merge Westinghouse, Parsons ALSTOM (Industrial turbine)

PowerGen Asia 2011 - Kuala Lumpur, Sep 2011

Energy Sector Energy Sector

Product Portfolio Steam Turbine Series

single-flow LP axial exhaust

max. 177bar/ 565C/565C

SST-5000 for sub critical SPP and CCPP

max. 177bar/ 600C/600C

SST-6000 for Steam Power Plants

max. 280bar/ 600C/610C

SST-9000 for Nuclear Power Plants

max. 80bar/ 300C

Shanghai Turbine Plant & Siemens

State of the Art - USC

SST 6000 series turbine

high performance 3DVTM blading

Design Principle Modular Concept example: HP Turbine

scaling of modules power output/mass flow MW

Design Principle Modular Concept example: HP Turbine

Operating Experience - Isogo, 48000 EOH

comm. operation: 2002

martensitic 13% chrome seal strips

References Wai Gao Qiao 3, China

Max. proven power output: 1112 MW !

Asian Power Plant of the Year

Steam Cycle Efficiency (net)

55% 50% 45% 40% 35% 30% 1950

Nickel Alloys (350 bar, 700C)

Ferrites / Martensites (240 bar, <~620C)

Higher parameter Larger size Improved cycle

Shanghai Turbine Plant & Siemens State of the Art - USC

Next step - Double Reheat

DRH studies at Siemens Steam Turbines

Thrust Rotor dynamics Axial expansion

1350 MW double-reheat cross-compound with Siemens components 1350MW WGQ9

540 t w/o Generator 990 t with Generator 27 m

1350MW DRH Steam turbine arrangement and systems of 1st train

HRH piping 1 Hydraulic Supply Unit

Lubricating Oil Module

Weight of turbine deck + turbine train: ~3500 t

1350MW DRH Steam turbine arrangement and systems of 2nd train

Hydraulic Supply Unit for turbine valves

Overall plant efficiency development

Overall plant net efficiency in %

Heat Rate / kJ/kWh Station Power Rate Boiler efficiency

7320 4.5% 93.6%

7140 3.5% 95.5%

6947 4.0% 94.0%

6765 3.0% 95.5%

Typical CHN 1000 MW unit

State-of-the-art single reheat

DRH 1350 MW at design conditions

DRH 1350 MW with state-of-theart technology

700C Steam Power Plant Affected Components