Steam Turbines

Al Khobar Roadshow, 24 July 2006

Guido Raimondi Head of Steam Turbine Thermodynamics Design

STEAM TURBINES

New equipment Product development Repowering Concept Retrofit and modernization

Steam Turbine Technology Evolution

Siemens AEG Sulzer BBC SACM Rateau AEI GEC

GE USA IMPULSE

Siemens-KWU
REACTION

Westinghouse
REACTION

USA

BBC
REACTION

CH

Alsthom
IMPULSE

GEC
IMPULSE

UK

1970

Ansaldo Toshiba Doosan

N. Pignone (1)

BHEL

ASEA STAL CEM

F. Tosi

Parsons

1987

1989 LMZ

Mitsubishi

ABB
De Pretto Ansaldo

GEC Alsthom

Fuji Hitachi

Zamech

1998

1999

GE
IMPULSE

USA

Siemens Westinghouse
REACTION

Mitsubishi
REACTION

ABB-Alstom
REACTION

F
(2)

2000

Hitachi

Toshiba
J

ESG

Fuji

Ansaldo I
1) Industrial Turbines 2) Impulse on Nuclear Turbines

STEAM TURBINES

New equipment Product development Repowering Concept Retrofit and modernization

Application examples

Ansaldo Energia Steam Turbines Product Range

Type and Application
GEOTHERMAL TURBINES
- Geothermal Cycle

GT

20
INDUSTRIAL TURBINES
- Steam Cycle - Combined Heat and Power - Combined Cycle

100

CT, IT

20

100

MIDDLE SIZE TURBINES

- Steam cycle - Combined Cycle

MT, MR (2-cylinders)

70
REHEAT TURBINES
- Steam Cycle - Combined Cyle - Combined Heat and Power

300

RT (3-4cylinders)

100 200 Power output ( MW )

300

1000
5

Ansaldo Energia Turbogenerators Product Range

Type and Application

AIR COOLED
- Steam Turbines - Gas Turbines - Geothermal Turbines

up to 300 MVA

HYDROGEN COOLED
14 6 10 11 12 13 21 9 5 4 3 2

- Steam Turbines - Gas Turbines

7 8 16 15 16

22 23 17 17

up to 600 MVA
24

18 20 19

18

HYDROGEN/WATER COOLED
- Steam Turbines

Up to 900 MVA 0 300 600 900 1200

Rating ( MVA )
6

Ansaldo Steam Turbines

Modular concept for single-/multiple-casing STs up to 1000 MW for combined cycle and conventional fossil-fired power plants for both 50 and 60 Hz.
Frame turbines MT10C RT20C MT25S RT60S

RT50S RT40S RT30C MT15C

Ansaldo Energia Steam Turbines Main Features

Reaction Technology Reaction Technology No piston No piston cooling steam cooling steam Free-standing Free-standing LSB LSB

HP shrink rings HP shrink rings

Welded rotors Welded rotors Valves directly connected Valves directly connected

One-piece One-piece 3D blades 3D blades

8

RT TURBINES tandem compound double flow

Back-Pressure Steam Turbine for Heat and Power

MTG20

PERFORMANCE DATA
Output range Live steam pressure Live steam temperature Back pressure 100-250 MW 70-100 bar 540-565 C 1-4 bar

Operation mode Fixed and/or Sliding pressure

DESIGN FEATURES
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

Controlled extraction, condensing Steam Turbine for C.C. and Desalination Plant
MTG20-C MTG20
Controlled extraction Controlled extraction Single flow axial exhaust Single flow axial exhaust
PERFORMANCE DATA
Output range Live steam pressure Live steam temperature Controlled extrac. pressure Condenser pressure 100-250 MW 70-100 bar 540-565 C 1-4 bar

0.08-0.2 bar

Operation mode Fixed and/or Sliding pressure

DESIGN FEATURES
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

10

No Reheat Steam Turbine for Combined Cycle

MT10c
PERFORMANCE DATA
Output range Live steam pressure Live steam temperature Condenser pressure 90-160 MW 60- 80 bar 510-530 C 0.035-0.25 bar

Operation mode: Sliding pressure 1 + 1 ( 50 Hz ) Configuration 2 + 1 ( 50 Hz ) Configuration

DESIGN TOPICS
Full arc admission One stop / control valves assembly HP, LP opposite flow configuration - LSB 50 Hz 43 Welded rotor for material optimization Axial exhaust for low profile plant Modular LP design for optimized performance

11

Reheat Steam Turbine for Combined Cycle

MT15c MT10c
PERFORMANCE DATA
Output range: Live steam pressure: Live steam temperature: Reheat steam temperature: Condenser pressure: Operation mode: 90-150 MW 100-160 540-565 540-565 bar C C

0.035 - 0.25 bar 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 Shipped assembled for fast installation

COMBINED IP-LP SECTION

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

12

Reheat Steam Turbine for Fossil fired Power Plants (1/2)

RT40s
PERFORMANCE DATA
Output range: Live steam pressure: Live steam temperature: Reheat steam temperature: Condenser pressure: No. of Extractions: 250-450 MW 170-280 540-580 540-600 bar C C

0.05 - 0.25 bar 7-8

Operation mode: Fixed and/or sliding pressure Speed: 50 - 60 Hz

HP SECTION
Separated HP section for high efficiency Full arc admission or control stage admission for high efficiency at partial load Welded rotor solution for material optimization Two stop / control valve assembly Shipped assembled for fast installation

IP SECTION
Separated IP section for high efficiency Double casing design Two combined reheat valves Welded rotor solution for material optimization Shipped assembled for fast installation

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

13

Reheat Steam Turbine for Fossil fired Power Plants (2/2)

RT60s
PERFORMANCE DATA
Output range: Live steam pressure: Live steam temperature: Reheat steam temperature: Condenser pressure: 400-700 170-250 540-580 540-600 MW bar C C

0.035 - 0.25 bar

Operation mode: Fixed and/or sliding pressure operation Speed: 50 - 60 Hz

HP SECTION
Separated HP section for high efficiency Full arc admission Two stop / control valve assembly Welded rotor solution for material optimization Shipped assembled for fast installation

IP SECTION
Separated IP section for high efficiency Double casing design Double flow design Two combined reheat valves Welded rotor solution for material optimization Shipped assembled for fast installation

LP SECTION
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

14

Cooperation and Technology Transfer Agreement between ABB/Alstom and AEN

Validity: 1989-2003 Products Steam Turbines > 25 MW Generators > 10 MVA (designed according to ABB/Alstom-technology) Know-how Ansaldo had full access to ABB/Alstom technology relating to Design, Manufacture, Quality Control, R&D, Erection, Commissioning

After Termination Ansaldo has the right to

Continue to use ABB/Alstom technology on new units and retrofit/modification of old units, including BBC/ABB fleet Subcontract components manufacturing to third parties Grant licenses to third parties
15

STEAM TURBINES

New equipment Product development Repowering Concept Retrofit and modernization

Application examples

16

Efficiency Improvement Advanced New Blading Design

HP-IP HIGH PERFORMANCE BLADING UPDATING FOR COMBINED CYCLE APPLICATIONS

TEMPERATURE DISTRIBUTION ON BLADING SURFACE

BLADING DEVELOPMENT FOR ULTRA SUPERCRITICAL APPLICATIONS

17

Efficiency Improvement 48 Last Stage Bucket Design

L-0 rotating blade 3-D model

Development of a new Last Stage Steel Blade 48 length with an annular area of 12 m2
(JRP Ansaldo Energia Skoda Power)

3-D Navier-Stokes analysis

18

STEAM TURBINES

New equipment Product development Repowering Concept Retrofit and modernization

19

Repowering From open cycle to Combined Cycle

In open cycle GT is alone, the high temperature combustion gases are exhausted to atmosphere; more than 61% of available energy in the fuel is lost. atmosphere; lost. The high energy content in exhaust gases can be used to produce high temperature steam by 19% HRSG and produce more kW in a new Steam Turbine Transformation of an open cycle in a combined cycle reduces the lost energy to less than 44 % The Net Efficiency of a combined cycle is higher than: than:
32.5%

56 %

10%

20

Steam Cycle Unit

In a steam cycle unit the Net Efficiency is about 39%
The steam flow distribution is
mSH=100%

Steam Turbine & Generator mHRH=80% mLP=75%

mcond=60%

Condenser Steam Generator

Feedwater cycle

21

Repowering From Steam Cycle to Combined Cycle

Conversion of a conventional unit in C.C. (1+1 configuration) mHRH=40% 1 - Steam Generator is replaced by
GT and HRSG, Feedwater cycle is removed 2 - ST steam path could be optimized; extraction pipes blanked 3 - Condenser is maintained 4 - Deaerator is new 5 - Piping is new
10%

mSH=30%

mcond=65%
32.5%

In combined cycle, the Net Efficiency is higher than cycle,

56 %
22

Note (1): Mass flows % refer to original mass flow for each point of a subcritical 350 MW ST

STEAM TURBINES

New equipment Product development Repowering Concept Retrofit and modernization

Application examples

23

Steam Turbine Technology Evolution

Siemens AEG Sulzer BBC SACM Rateau AEI GEC

GE USA IMPULSE

Siemens-KWU
REACTION

Westinghouse
REACTION

USA

BBC
REACTION

CH

Alsthom
IMPULSE

GEC
IMPULSE

UK

1970

Ansaldo Toshiba Doosan

N. Pignone (1)

BHEL

ASEA STAL CEM

F. Tosi

Parsons

1987

1989 LMZ

Mitsubishi

ABB
De Pretto Ansaldo

GEC Alsthom

Fuji Hitachi

Zamech

1998

1999

GE
IMPULSE

USA

Siemens Westinghouse
REACTION

Mitsubishi
REACTION

ABB-Alstom
REACTION

F
(2)

2000

Hitachi

Toshiba
J

ESG

Fuji

Ansaldo I
1) Industrial Turbines 2) Impulse on Nuclear Turbines

24

Ansaldo Steam Turbine Technologies

General Electric General Electric

1949 - 1989

BBC //ABB //Alstom BBC ABB Alstom

1989 - 2003

Westinghouse Westinghouse
1949 - 1988

Ansaldo Componenti

ESG ESG

Franco Tosi

AnsaldoEnergia AnsaldoEnergia

25

Steam Turbines Retrofit and Rehabilitation

Non-OEM Fleet Market for Ansaldo
GE
IMPULSE

USA

Toshiba Hitachi

J J

Westinghouse
REACTION

USA

Mitsubishi

ABB-Alstom
REACTION

BBC CEM

CH F

26

Retrofit
The modification/change of the existing turbine hardware into a new one of updated design in order to improve thermal performance (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

27

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 more complete inner blocks (steam path, rotor, inner casing)

Replacement of one or more complete turbine sections

28

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 designed as impulse or reaction can be totally or partially retrofitted with reaction or impulse

Original Impulse type

Retrofit Reaction type (HP-IP section) 29

Retrofit process

Example of retrofit of non-OEM equipment

Welded rotor

30

Updated retrofit technology

Performance improvements applied through the introduction of updated steam path technology
1. Three dimensional blading (3D) on HP-IP section to reduce profile and secondary losses. Longer last stage blade to reduce exhaust losses and convert them to additional power output. Improved gland seal arrangements to reduce interstage leakage The application of brush tip seals reduces the amount of steam leakages and improves the stage efficiency

2.

3.

31

STEAM TURBINES

New equipment Product development Repowering Concept Retrofit and modernization

Application examples

32

Chivasso 2
OEM: Ansaldo (GE technology) 1 x 250 MW Comm. Year: 1966

Retrofit Solution

Reason for retrofit

The existing 250 MW unit, previously operating in steam cycle, operates now in CC, 1 GT + 1 ST configuration.

Scope of supply
Complete 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 565C/565C.

33

Porto Corsini 3 4
OEM: F. Tosi (Westingh. tech.) 2 x 156 MW Comm. Year: 1964 - 1966 BB070

Retrofit Solution

Reason for retrofit

The two existing 156 MW units, previously operating in conventional cycle, operate now in CC, 1 GT + 1 ST configuration.

Scope of supply
A complete new 33 LP inner block with larger exhaust area 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.

34

Torre Valdaliga Sud 2

2x33.5

OEM: Ansaldo (GE technology) 1 x 320 MW Comm. Year: 1968

Retrofit Solution
2x43

Reason for retrofit

The existing 320 MW unit, previously operating in conventional cycle, now operates in CC, 2 GT+1 ST configuration.

Scope of supply
A complete new 43 LP inner block with larger exhaust area in the existing LP outer casing.

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

35

Fusina 3 4
OEM: F. Tosi (Westingh. Tech.) 2 x 329.5 MW Comm. Year: 1973 - 1975

BB073

Retrofit Solution

Reason for retrofit

LP section upgrading in order to improve the heat rate of the unit.

Scope of supply
A complete new 43 LP inner block (new steam path, rotor, inner casing) with larger exhaust area in the existing LP outer casing.

Effects
Upgraded Nominal Rating: 337.5 MW Gain of 8 MW (+2.4%) in power output with reference to the original design. Heat Rate improvement of 42 Kcal/kwh (-2.4%)

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Ansaldo Steam Turbine Retrofits Experience List

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

1990 1990

1994 1994

Greece Greece

LAVRION LAVRION

General Electric General Electric

1 x 66.5 --New HP Rotor and diaphragms 1 x 66.5 New HP Rotor and diaphragms --New LP Rotor and diaphragms New LP Rotor and diaphragms 4 x 120 4 x 120 --New HP Rotor and diaphragms New HP Rotor and diaphragms --New IP Rotor and diaphragms New IP Rotor and diaphragms --New LP Rotor and diaphragms New LP Rotor and diaphragms --New 1HP nozzle stage New 1HP nozzle stage --New HP-IP section New HP-IP section --New LP last stage blading New LP last stage blading --New HP-IP rotor and diaphragms New HP-IP rotor and diaphragms --New LP rotor and diaphragms New LP rotor and diaphragms --New HP blading New HP blading --New LP inner block New LP inner block --New HP-IP section New HP-IP section --New HP blading New HP blading --New LP inner block New LP inner block New LP inner block New LP inner block

1990 1990

1994 1994

Argentina Argentina

COSTANERA COSTANERA

British Thompson-Houston British Thompson-Houston

1990 1990 1998 1998

2002 2002 2000 2000

Italy Italy Italy Italy

PIETRAFITTA PIETRAFITTA LA SPEZIA 1-2 LA SPEZIA 1-2

F.T. / /Westinghouse F.T. Westinghouse F.T. //Westinghouse F.T. Westinghouse

2 x 60 2 x 60 2 x 120 2 x 120

1999 1999

2001 2001

Italy Italy

CASSANO DADDA 1 CASSANO DADDA 1

Ansaldo Ansaldo

1 x 80 1 x 80

2000 2000 2001 2001 2002 2002 2002 2002 2002 2002 2006 2006

2001 2001 2002 2002 2003 2003 2003 2003 2003 2003 2007 2007

Italy Italy Italy Italy Italy Italy Italy Italy Italy Italy Italy Italy

LA CASELLA 1-4 LA CASELLA 1-4 PORTO CORSINI PORTO CORSINI CHIVASSO 2 CHIVASSO 2 PRIOLO GARGALLO 1-2 PRIOLO GARGALLO 1-2

F.T. / /Westinghouse F.T. Westinghouse F.T. / /Westinghouse F.T. Westinghouse Ansaldo Ansaldo F.T. / /Westinghouse F.T. Westinghouse

4 x 120 4 x 120 2 x 123 2 x 123 1 x 130 1 x 130 2 x 120 2 x 120 1 x 267 1 x 267 2 x 350 2 x 350

TORREVALDALIGA SUD 2 Ansaldo TORREVALDALIGA SUD 2 Ansaldo FUSINA 3-4 FUSINA 3-4 F.T. / /Westinghouse F.T. Westinghouse

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STEAM TURBINES
Conclusions:
AEN Designs and Manufactures Steam Turbines from 20 to 1000 MW AEN Designs and Manufactures Gas Turbines from 67 to 270 MW AEN Designs and Manufactures Generators from 20 to 900 MVA AEN has an intensive Product R&D program AEN retrofits & repowers its own products including ex F. Tosi units AEN retrofits & repowers the following steam turbines technologies:
GE (impulse), Westinghouse (reaction) BBC-ABB-Alstom (reaction) (impulse), reaction) BBC- ABBreaction)

f
38

Steam Turbines
Al Khobar Roadshow, 24 July 2006

Guido Raimondi Head of ST Thermodynamics Design