Nuclear Power Plants

The Turbine Island

Philippe Anglaret
VP Business Development , Alstom Nuclear

Paris, 21st October 2013

 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

4 Recent Projects

p.2
 Alstom in Nuclear

Nuclear Island Turbine Island Balance of Plant

Reactor supplier Alstom (including Alstom Grid)

Nuclear Island + Turbine Island + BoP = Nuclear Power Plant

p.3
 Alstom in Nuclear
Turbine Islands based on ARABELLE™ technology

Credits to EDF

p.4
 Alstom in Nuclear
World N°1 supplier of nuclear steam turbine generators

55 years of experience : 136 nuclear units in operation = 113 GW

Europe
North America 90 GW South Korea
8 GW 103 units China 5 GW
8 units 6 units
India
6 GW
6 units
2 GW
11 units

South Africa
< 800 MW
Full-speed 2 GW
24 47
50 2 units 800 - 1200 MW
86 Half-speed 65 > 1200 MW

30% of all the world’s nuclear plants have an Alstom steam turbine

p.5
 EDF French Nuclear Fleet
Various generations of nuclear steam turbines

CP0 – CP1 P4 – P’4

900 MW 1300 MW

N4 – ARABELLE
1550 MW
p.6
 Nuclear Business
Competitive Positioning

• Competitors worldwide experience (50 & 60 Hz grids)

TG supplier Toshiba GE Power Machines Mitsubishi Siemens Alstom

Largest unit in 1100 MWe 1410 MWe 1060 MWe 1180 MWe 1500 MWe 1550 MWe
commercial operation Higashi-Dori 1 Palo Verde 2 Tianwan 1 Genkai 3 Isar 2 Chooz B1
(as of Sept. 2012) (50 Hz) (60 Hz) (50 Hz) (60 Hz) (50 Hz) (50 Hz)

Largest unit under 1400 MWe 1455 MWe 1200 MWe 1370 MWe 1720 MWe 1750 MWe
construction Braka 1-4 Shin-Kori 3 Leningrad II 1 Lungmen 1 Olkiluoto 3 Flamanville 3
(as of Sept. 2012) (50 Hz) (60 Hz) (50 Hz) (60 Hz) (50 Hz) (50 Hz)

• Color code:
Green = currently in Operation
Blue = currently under Construction

p.7
 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

4 Recent Projects

p.8
 Inside a Nuclear Power Plant
Primary, Secondary, Tertiary Loops

• Non-contaminated steam goes to steam turbine

• No turbine island containment needed

The Pressurised Water Reactor (PWR)

p.9
 Inside a Nuclear Power Plant
Primary, Tertiary Loops

• Contaminated steam goes to steam turbine  special gland sealing system

• Turbine island needs some containment (concrete shielding) + specific material choices

The Boiling Water Reactor (BWR)

p.10
 What is specific to Nuclear Power Plants ?
Much larger steam volume flow

80

60
Steam volume flow (m3/s)

Fossil
40 Nuclear
X5
20

0
0 500 1000 1500 2000
Steam turbine generator output (MW)

Nuclear  large volume flows  need for long blades  high centrifugal forces

p.11
 What is specific to Nuclear Power Plants ?
Wet steam conditions

Fossil
Dry
150-300 bar
Steam
540-600°C
H = Enthalpy (kJ/kg)

Saturation line

Nuclear
50-75 bar Wet
265-290°C Steam

S = Entropy (kJ/kg/°K)
p.12
 Steam Expansion Line
Mollier Diagram – N4 Reactor
P : 10.1 bar
T : 268°C

P : 71 bar
T : 287°C “cold” steam at LP inlet :
x : 0.4 % • small LP axial thermal expansion
IP • reduced axial clearances
• possibility to fit a 4th LP
MSR
HP
P : 3.3 bar
T : 148°C

X:0%

P : 10.7 bar
T : 183°C
x : 14.6 %
Enthalpy
H (kJ/kg)
LP

Entropy
S (kJ/kg.K) P : 0.055 bar
x : 12.5 %

p.13
 EPR - Flamanville 3
Simplified steam-water cycle

Steam and water pipes from/to NI Busbars

Generator, exciter
HP IP LP

MSR Condenser,vacuum Circulating water

system, debris filters pumps
100% steam bypass to
condenser Drain tanks

De-aerating
feed-water tank
Condensate
MSR drain pumps extraction
pumps
Core
LP heaters

HP heaters Feed heaters pumps CI auxiliaries cooling

HEX
NSSS PACKAGE

Primary Loop Secondary Loop Tertiary Loop

p.14
 World Nuclear Power Plants
Half-speed dominates the market above 700 MW

• France, U.S.A., Canada, Japan, South Korea, Brazil, Taiwan, South Africa, etc.:
− all nuclear units in operation are half-speed
• China:
− since 2005, all nuclear turbines (with output > 700 MW) ordered are half-speed

26%
Full-speed / Half-speed

Half-speed
66%
91% Full-speed
100%
74%
34%
9%
All sizes < 700 MW > 700 MW > 1200 MW Unit size range

Source: Alstom databases

Above 1200 MW, only half-speed  to keep reasonable stress levels

p.15
 Full Speed vs. Half Speed – what makes the difference ?
Case study : Ling Ao 1 vs. Ling Ao 3
Enthalpy (kJ/kg)
3100

Ling Ao 1
3000 Full speed

2900
Ling Ao 3
IP
Half speed
2800

2700
HP
2600

Half speed
2500
expansion lines
LP
2400
in HP, IP and LP
sections are
2300
much more
efficient
2200

2100
5,8 6 6,2 6,4 6,6 6,8 7 7,2 7,4 7,6
p.16 Entropy (kJ/kg/K)
 A challenge for turbine designers
Covering a wide range of reactors & heat sinks

Typical LP exhaust volumetric flow for a given application: 1 reactor/1 site

Reactors

India Site cooling

water temp. °C
Finland

5
33

32

31

30

28

27

26

24
23

21

19
17

15
p.17
12
 A challenge for turbine designers
Covering a wide range of reactors & heat sinks

Typical LP exhaust area needed for a given application: 1 reactor/1 site

5 000 MWth Reactors
250 m² EPR
ESBWR
4 500 MWth
200 m²
Reactor thermal output in MWth

APWR

4 000 MWth 150 m² ABWR

100 m²
3 500 MWth
AP1000

75 m² VVER1200

3 000 MWth
CPR1000
ATMEA1

2 500 MWth
50 m²
PHWR700
1.5 "Hg
2 000 MWth 2.5 "Hg 1.5 "Hg
100 mbar 90 mbar 80 mbar 70 mbar 60 mbar 50 mbar 40 mbar 30 mbar 20 mbar

Condenser backpressure in mbar

Site cooling
water temp. °C

5
33

32

31

30

28

27

26

24
23

21

19
17

15
p.18
12
 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

4 Recent Projects

p.19
 Integrated Packages
Turbine Island (TI)

p.20
 Integrated Packages
Secondary Loop Package (SLP)

p.21
 Turbine Islands
key components

Steam turbine
Grid equipment

MSR
4-pole generator

Condensate Circulating water Reactor feed-water HP & LP Modular condenser

extraction pumps pumps pumps feed-water heaters

p.22
 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

The steam turbine

4 Recent Projects

p.23
 Turbine Technology
Use of more efficient single flow steam expansion

Moisture Separator
Reheater

71 bar 3 bar

60% of the power output

HP IP LP
BP 1 LP
BP 2 LP
BP 3 comes from single flow
steam expansion

11 bar

Moisture Separator
p.24 Reheater
 ARABELLE™ Steam Turbine
Advanced compared to previous generation

MSR ~10 bar ~3 bar

ARABELLE™
~75 bar Efficient configuration
HP IP LP 1 LP 2 LP 3 Single flow use

MSR
MSR ~10 bar

PREVIOUS GENERATION
~75 bar
LP 1 Traditional configuration
HP LP 2 LP 3
Double flow use

MSR

ARABELLE™ uses more efficient single flow steam expansion

p.25
 ARABELLE™ Steam Turbine
A specific design to maximise single flow steam expansion & efficiency

IP LP
Single Flow Double Flow

HP
ARABELLE™
Single Flow

2 Flows 1 Flow 6 Flows 1 Flow

HP
PREVIOUS GENERATION
Double Flow

LP
Double Flow
p.26
 How to improve turbine efficiency ?

• Efficiency increases with blade aspect ratio

Longer blades have better efficiency

p.27
 ARABELLE™ Characteristics
Combined HP/IP Module, Unique in the Market

• Single flow HP and IP for best efficiency

• Combined HP/IP for maximum power density
• Same footprint for 50 and 60 Hz
• Designed to fit all large commercialised reactors

• HP/IP rotor delivers up to 60% of the overall output

p.28
 ARABELLE 1700 50 Hz
Flamanville 3 HP-IP casing

Flamanville 3 rough machined

HP-IP casing in VOEST ALPINE
foundry

p.29
 ARABELLETM References
Ling Ao 3+4 – 2 x 1080 MW

Ling Ao 3 HP-IP casing in Dong Fang Works

p.30
 ARABELLETM References
Flamanville 3 – 1 x 1750 MW

• HP/IP rotor entering balancing pit, Belfort factory

p.31
 ARABELLETM References
Flamanville 3 – 1 x 1750 MW

• LP2 welded rotor, fully bladed, Belfort factory

p.32
 ARABELLE 1000 for Ling Ao 3
Last Stage Blades : LSB57

Fully bladed LP57 rotor entering Belfort balancing pit (Ling Ao 3)

p.33
 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

The generator

4 Recent Projects

p.34
 GIGATOP 4-pole for Flamanville 3
A highly efficient turbo-generator

• 2000 MVA
• Cos-phi = 0,9
• 1500 rpm
• 4 poles, 3 phases
• 23 kV
• Brush-less exciter
• H2 and H2O cooled
• Stainless steel cooling
tubes
• H2 pressure: 6 bars(g)
• Triple-circuit hydrogen
sealing system
• 99% efficiency

• Flamanville 3 generator final assembly and running tests in Alstom factory

• Validation of manufacturing quality
• Validation of the design, of the electrical performances

p.35
 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

The heat exchangers

4 Recent Projects

p.36
 Key Components
Heat Exchangers for Nuclear Plants

Condenser Auxiliary water/water

coolers
1

5
2
Moisture separator
reheater (MSR)
4 High velocity
2 3 separators (HVS)
1

HP heater
3
Feedwater tank Nuclear purification
LP heater and deaerator system (NPS)

4 5

p.37
 ALSTOM MSR
Moisture Separator Reheaters

ARABELLE N4 - 1550 MW - MSR

p.38
 Nuclear Heat Exchangers
Flamanville 3 deaerating feed-water tank

• When assembled, final dimension is:

47.1 m x 5.9 m x 5.3 m

• Designed by Alstom
- In 3 separate pieces
- 98 t + 90 t + 98 t
- Transported separately
- Welded at site

p.39
 Nuclear Heat Exchangers
A Complete Condensing System

• Single or multiple pressure condensers

• Optimised tube bundle arrangement for high

performances

• Compact arrangement with LP turbines directly

feeding duplex LP1&2 FW heater located in
condenser neck

• Optimised condensate extraction with 3x50%

pumps

• Optimised vacuum hogging / holding system

p.40
 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

The main pumps

4 Recent Projects

p.41
 Key Components
Pumps for Nuclear Plants

Essential
8 service pump
Open/closed loop
7 cooling pump

6 Residual heat
removal pump

6 3
7 2 5
4

1 8

Concrete volute
circulating water Condensate Feedwater pump Intermediate Vacuum pump
pump extraction pump cooling pump
3 5
1 2 4

p.42
 Nuclear Pumps
Concrete Volute Circulating Water Pumps

Flamanville 3 NPP :

• Direct sea-water cooling

of the condenser tubes
• 2 x 50% pumps
arrangement
• 110 000 m3/h each (30,5
m3/s each)
• 15,4 m head A
• Rotate at 151 rpm
A

B
• Civil engineering works on suction ducts (Sept. 2009)

p.43
 Nuclear Pumps
Concrete Volute Circulating Water Pumps

• Flamanville 3 CWP impeller heat treatment (photo credit: Ferry Capitain)

p.44
 The Turbine Island
Agenda

1 Alstom in Nuclear

2 Turbine Island Basics

3 Turbine Island – Key Products & Solutions

4 Recent Projects

p.45
 ARABELLE™ References
Flamanville 3 – 1 x 1750 MW

• Nuclear reactor: EPR (PWR)

• Turbine type, output: ARABELLE 1700, 1 x 1750 MW
• Generator type: GIGATOP 4-pole
• Steam parameters: Live steam: 75 bar / 290°C Unit 3
Exhaust: 46 mbar
• Customer: EDF
• Country: France
• City / region: Normandy

• Schedule: order year 2006

p.46
comm. year 2016
 ARABELLE™ References
Flamanville 3 – 1 x 1750 MW

p.47
 Flamanville 3 – 1750 MWe
ARABELLE™ - Turbine & Generator

• Turbine HP/IP rotor entering balancing pit, Belfort factory, France

p.48
 ARABELLETM References
Flamanville 3 – 1 x 1750 MW

• Generator rotor

p.49
 Flamanville 3 – 1750 MWe
ARABELLE™ - Turbine & Generator

• Generator test, Belfort factory, France

p.50
 Flamanville 3 – 1750 MWe
ARABELLE™ - Turbine & Generator

Site in January 2013

p.51
 ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

• Nuclear reactor: CPR1000 (PWR)

• Turbine type, output: ARABELLE 1000, 2 x 1080 MW
• Generator type: GIGATOP 4-pole
• Steam parameters: Live steam: 64 bar / 280°C
Exhaust: 56 mbar
• Customer: DEC for LDNPC
• Country: China
• City / state: Dapeng / Guang-Dong

• Schedule: order year 2005

comm. year 2010 & 2011
p.52
 ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

p.53
 ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

p.54
 ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

p.55
 ARABELLE™ References
Ling Ao phase II – 2 x 1080 MW

Synchronized in July 2010, ahead of schedule

Measured output level above guarantee

Ling Ao 3, China - 1080 MW

p.56