Ust

1
Mitsubishi Reheat Boiler

1. General
In the UST, improvement of fuel consumption will be planned to apply reheat cycle in conventional marine steam turbine plant. In case of applying Reheat cycle, the Reheater will be applied for main boiler additionally. And exhaust steam of High Pressure Turbine (HP Turbine) is led to Intermediate Pressure Turbine (IP Turbine) through the Reheater for reheating steam up to Boiler Superheater outlet steam temperature. (Refer to Fig.1)
HP
BOILER TURBINE
AST LP R/G
M/C
REHEATE
HP
IP
BOILER TURBINE
AST LP R/G
M/C
Fig.1 Comparison of Plant Configuration
plant. Consequently, the Reheater tubes must be avoided tube failure by excessive tube metal temperatures. Even if tube failure occurs as worst case, continuous operation of the ship is desired. As for marine reheat boiler, it would appear that there are following three kind of type mainly. Dual Furnace Type Gas By-pass Type Individual Type Dual Furnace Type has main furnace and reheat furnace in one boiler. These furnaces are divided by Divided Water Wall or Divided Water Tube. Gas By-pass Type is divided two ~ three flow paths of combustion gas. One of path is installed Superheater and Reheater. The other paths are installed Superheater only. Also, outlet damper is arranged in outlet of each path. Individual Type is that boiler for Reheater is completely separated from Main Boiler. And exhaust steam of HP turbine is led to this separated Reheat Boiler for reheating. Each type of reheat boiler has both advantages and disadvantages (Refer to attached table). However, separated Reheater in the Dual Furnace type is selected for UST considering protection and reliability of the Reheater. In this type of boiler, Reheater and reheat furnace are located flow path outlet of combustion gas which is low gas temperature. Then, continuous operation can be done with Reheat Burner stop only when no steam flow or extremely low steam flow conditions.
2. Basic Design Concept of Reheat Boiler

Generally, main boiler for marine propulsion system is required following items; High reliability and redundancy Compact and light weight considering engine room arrangement Easy maintenance and operation due to simple system Also, there is case of no steam flow or extremely low steam flow conditions in frequent load changes or astern / loading / stand-by of the ship which is the major difference points with on-shore
Economizer
Reheater
Reheat Burner Fig.2 Overview of Reheat Boiler
MITSUBISHI HEAVY INDUSTRIES, LTD.

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3. Features of Reheat Boiler
1) Basic Construction of Boiler Basic Construction of Boiler and Economizer are applied MHI MB type main boiler which is used for conventional steam turbine plant. Therefore, its pressure parts by themselves can offer the adequate rigidity and yet absorbed the thermal expansion without difficulty. Reheat furnace which has reheat burner at lower position, is added at flow path outlet of combustion gas. Both main furnace and reheat furnace are of completely water cooled welded wall construction which assures complete sealing against combustion gas leakage. Also, high strength carbon steel plate is applied for steam drum and water drum to comply with high pressure application.
Similar construction as conventional non-reheat boiler
Accordingly, increasing of heating surface area for the Superheater and improvement of thermal resistance are required. For increasing of heating surface area, secondary Superheater is added behind of primary Superheater in parallel. This construction is still remained futures of MB type main boiler, drainable and easy maintenance construction. As for improvement of thermal resistance of Superheater tubes, secondary Superheater which is higher steam temperature compare with that of primary Superheater, is not exposed from furnace radiation directory to locate downstream of flow path. Secondary Superheater Primary Superheater
Superheater Header
Fig.4 Construction of Superheater Furthermore, combustion gas temperature will be down due to heat absorption of primary Superheater. Therefore, metal temperature of Superheater tubes can be kept similar with that of conventional main boiler even if steam temperature is higher than conventional. This kind of construction for Superheater, called Twin Superheater, has been manufactured in large capacity main boilers and proven technology.
Fig.3 Basic construction of Reheat Boiler
2) Construction of Superheater For improvement of plant efficiency in UST, high pressure and temperature for main steam is applied compare with conventional steam turbine plant. Table 1 Comparison between conventional and reheat boiler Conventional Boiler
Reheat Boiler
Construction
Design Pressure Material of Drum Material of Header Material of Tube
7.65 MPa LR Grade 490 Carbon Steel Plate LR Grade 410 Carbon Steel Pipe LR Grade 360 Carbon Steel Tube
12.0 MPa ASTM A299 Gr.A LR Grade 460 Carbon Steel Pipe LR Grade 410 Carbon Steel Tube


The material of primary Superheater Header is applied as same as conventional main boiler and those of secondary Superheater header is applied high strength characteristic material, ANSI A335 Code case 2199, in high temperature. In addition, connection method between Superheater header and Stainless steel tubes is applied as same as method for On-shore boiler shown in Fig.6.
Allowable Stress Curve
180
Furnace Radiation
160
140 ASME SA335 Cade Case 2199 Allowable Stress (N/mm ) 120
2
Fig.5 Conceptual image of furnace radiation
100
LR Gr.440 Steel Pipe
80
60
Reheat Boiler Superheater Metal Temp Calculation (Non RH, Oil Firing)
40
650
Metal Temp.
600
20 CST: 515 0 100 200 300 400 500 Metal Temperature () UST: 560 600 700
550 Steam / Metal Temperature ()
500
Furnace Radiation Max. Metal Temp for Conventional Boiler 18Cr Stainless Steel
Steam Temp.
Fig.8 Allowable Stress Curves
450
400
350
18Cr Stainless Steel

6 pass 7 pass 8 pass 9 pass Secondary Superheater
300
250
1 pass
2 pass
3 pass
4 pass
5 pass
Primary Superheater
18Cr Stainless steel tube
Superheater Tube
Fig.6 Metal Temp of Superheater Tubes For material of Superheater Tubes, Chrome-Molybdenum alloy steel, ANSI A213-T22 equivalent, is applied for relatively low metal temperature region as same as conventional main boiler and Stainless steel, ANSI A213-TP347H equivalent, which has already proven material for On/Off-shore application is applied for high metal temperature region. This stainless steel material, contained much Chrome, excels at anti high temperature corrosion by Vanadium etc. Therefore, it can prevent corrosion from progressing by bad fuel.
1 0.9
2.25Cr-Mo-W alloy steel header Fig.9 Detail of Superheater Header 3) Reliability of Reheater Reheater is designed to achieve specified steam temperature by using Reheat Burner which is located bottom of Reheat furnace. However, as mentioned former, there is case of no steam flow or extremely low flow condition in frequent load changes or astern / loading / stand-by of the ship which is the major difference points with On-shore plant. In this situation, there is possibility to burn Reheater tubes by excessive tube metal temperature due to reduction of steam cooling effect. To solve above problems, Reheater and Reheat furnace are located flow path outlet of combustion
Corrosion Rate (mm/yr)
0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 540
Composition of Test Soot : 80%V2O5 - 20%Na2SO4
Estimated Max Metal Temp. 2.25Cr-1Mo Alloy Steel
18Cr Stainless Steel
560
580
600
620
640
660
Metal Temperature ( )
Fig.7 Characteristics of 18Cr Stainless Steel


gas which is low gas temperature. Then, Reheater Tubes are not exposed high temperature combustion gas so that Reheat Burner is stop. Therefore, Reheater is thoroughly protected due to low temperature combustion gas from main furnace.
160
In addition, combustion gas at Reheater inlet during Reheat Burner operation will be high. However, construction of Reheater casing is applied inner insulation method which is proven construction of On-shore Heat Recovery System. Then, these constructions are protected against thermal expansion etc.
11MPa x 138
420 2.2MPa x 360
Reheater
2.0MPa x 560
6 Main Burner
Fig.12 Construction of Reheater 4) Environmental Issue Fig.12 shows exhaust gas emission for each propulsion plant during normal operation and using boil off gas as fuel. Content of carbon oxide for steam turbine plant is lower than other plant because of source of exhaust gas coming from main boiler. And fuel consumption for UST plant will be reduced compare with conventional steam turbine plant due to high plant efficiency. Therefore, further reduction can be expected. Fig.13 shows exhaust gas emission during port operating condition. During port condition, steam turbine plants have dual fuel burning modes. However, a diesel electric plant is restricted to diesel mode only, because gas mode cannot be used at low load condition. Therefore the NOx and SOx emissions from steam turbine plant will be lower than other plants.
300
Superheater Furnace
Reheat BNR
10MPa x 565
Fig.10 Normal Operating Condition
155
11MPa x 138
365 2.2MPa x 335
Reheater
2.0MPa x 450
530 Main Burner
250 200 150
CO2 NOx
Superheater Furnace
STOP
100 50 0
10MPa x 565
Under Sea C ST Normal UST DFEGoing G TC(Gas C G mode) TSC Fig.11 Reheat Burner Stop Condition Fig.13 Emission during normal operation


800 700 600 500 400 300 200 100 0 CST UST DFE*1 GTCC NOx SOx CO2
Fig.14 Emission during port operation
4. Boiler Control System

For reheat boiler, Automatic Boiler Control System has also been developed suitable control for additional Reheater and Reheat Burner. Basic function of conventional boiler control system is as follows. - Automatic Combustion Control (ACC) - Feed Water Control (FWC) - Steam Temperature Control (STC) - Steam Dump Control (SDC) - Burner Management System (BMS)
1) ACC for Reheat Burner Basically, total fuel quantity and combustion air quantity is controlled according to steam demand. And fuel distribution to main burner and reheat burner is shared with constant rate at steady operating condition. 2) Reheat Steam Temperature Control The reheated steam temperature is naturally varied according to boiler load. And rapid temperature variation or excessive high temperature is compensated the fuel quantity of reheat burner by detecting reheat steam temperature. Also, the superheated steam temperature is controlled to avoid excessive temperature difference between superheated steam temperature and reheated steam temperature at low load. 3) Reheater Protection System As mentioned former, there is case of no steam flow or extremely low flow condition in frequent load changes or astern / loading / stand-by of the ship. In this situation, there is possibility to burn Reheater tubes by excessive tube metal temperature. Therefore, automatic reheat burner operation at low load etc. is performed by this system.
600.0 Oil Firing (Non Bleed Condition)
SH Temp (RHB off)
160.0
140.0
550.0
Non Control SH - RH
120.0 500.0 Temp Difference () 100.0 Steam Temp ()
450.0
RH Temp (RHB off) Control SH - RH
80.0
Fig.15 Local operation panel for Main Boiler In case of Reheat Boiler Control, following functions are required additionally. And above additional functions are confirmed by using UST plant simulator. (Fig.16)
60.0
400.0
Allowable Temp Diff
40.0 350.0 20.0
300.0 0 10 20 30 40 50 Turbine load (%) 60 70 80 90
0.0 100
Fig.17 Characteristics of Steam Temperature
5. Conclusion
Generally, propulsion plant for LNGC requires reliability and safety concern. MHI Reheat Boiler designed considering these requirements mainly. Even if new technology is applied in this boiler, we carried out several confirmation not only numerical analysis but also scale model test, firing test etc. As a result of our investigation, we are confident about the design of Reheat Boiler and believe that our customers will be satisfied for applying UST plant for new LNGC.
Fig.16 Example of Simulator Output

Mitsubishi Reheat Turbine

1. General
Steam turbine plant has so many records as marine propulsion system and it is sufficiently attractive even at present because of maintenance - free and low NOx Emission for the environment except for a weak point that fuel efficiency in the plant is relatively low. In recent years, diesel propulsion such as DFE/DRL become conspicuous in LNG market due to a sudden rise of crude oil and their high engine performance, which surpasses steam propulsion by far. It is obvious that a supreme proposition to achieve the restoration of the steam turbine plant is to make the plant efficiency improved remarkably. In the latest reheat turbine plant called UST Plant which has been proposed by MHI (See Fig.1), fuel efficiency in the plant is improved by about 15% as compared with that in the conventional steam turbine plant (CST) without the present convenience and it can rival DFE/DRL plant in a total cost including initial, running and maintenance one. Main points of difference between UST and CST are as follows. 1) Application of reheat plant (Addition of Reheater and Intermediate turbine) 2) Application of higher pressure and higher temperature steam 3) Introduction of the latest technologies to improve turbine internal efficiency
Economizer Generator Turbine Aux. Steam Line Reheater
pressure turbine, one (1) intermediate pressure turbine and one (1) low pressure turbine with an astern turbine incorporated in the low pressure turbine casing, and shall be arranged for driving a propeller through a reduction gear and shafting.
Reheat Steam Main Steam (AHD) HP/T Exh. to Reheater HP/T IP/T R/G Main Steam Reheat Steam : abt. 9.8MPa x 555 : abt. 2.0MPa x 555
AST/T Main Steam (AST) M/C
LP/T
Fig.2 Components of the UST Turbine
2. Basic Specification of UST Turbine

The basic specification is shown in Table 1. Main frame of the UST turbine is called MR types (Mitsubishi marine propulsion Reheat turbine), and they are classified into MR36-II (26MW), MR40-II (30MW), MR45-II (33MW) and MR50-II (37MW) in accordance with the shaft output power and revolution specified (See Table 2). For over 37MW reheat turbine, MHI is now diligently in developing and also the next generation UST for huge LNG carrier (over 200Km3) with twin-screw system will be sooner released to you. Table 1 Basic Specification of UST Turbine (25MW base)
CST UST MR36-II 9.8MPaG x 555 2.0MPaG x 555 728mmHgv. x 24 Applied 23.5MW x 76rpm 1.5MW 25MW x 76rpm 3 2-stage F.W. system
Type Main Steam Reheat Steam
HP/T
IP/T
LP/T Main Condenser
MS36-2 5.68MPa x 520 722mmHgv. x 27 N/A 25MW x 78rpm 25MW x 78rpm 3 3-stage F.W. system
Main Boile
Air H
Gland Condenser
Exhaust Steam Shaft Generator Turbine Output Thrust Electric
Dearator
LP F.W.Heater Drain Tank
Feed Water Pump
Total No. of Extraction Feed Water Heater
Fig.1 UST Plant (MHI) Success of the UST plant certainly depends on main propulsion reheat-steam turbine (UST turbine) for the plant (See Fig.2). The UST turbine shall consist of one (1) high
CST: Conventional Steam Turbine (Non-Reheat) UST: Ultra Steam Turbine (MHI Reheat)


Table 2 Major Frame of MHI UST Turbine
Frame MR36-II MR40-II MR45-II MR50-II MR60-II Base Power Abt. 36,000ps (26MW) Abt. 40,000ps (30MW) Abt. 45,000ps (33MW) Abt. 50,000ps (37MW) Abt. 60,000ps (44MW) HP/IP Frame HR-22 HR-22 HR-26 HR-28 Now developing LP Frame LR-18 LR-18 LR-20 LR-23 Now developing
Our advanced SAH system adopting the shaft generator, dual economizer and so on has equal efficiency of the plant to or higher than GAH with easy operation and maintenance-free.
3. Introduction of UST Turbine

Major points of difference from CST are as follows. 1) Intermediate pressure turbine integrated with high pressure turbine for the reheat plant 2) Turbine rotor and single cylindrical turbine casing for higher temperature use (560) with the latest materials and construction proven by land use turbines 3) Introduce of the latest technology to improve the turbine performance (3-D Rateau Nozzle, Unsteady Loss Reduced Blade and ISB etc.) 4) Application of the latest curtis stage with much higher efficiency, 3-diemnsional stationary blade for reaction stages and optimized construction of exhaust steam guide etc 5) 2-stage with 2-line Astern turbine for high pressure and high temperature use MHI UST turbine can improve the performance of about 22 23% by comparison with CST due to the above-mentioned items to get higher turbine internal efficiency, the application of the reheat cycle and the adoption of main steam with higher pressure and temperature. Cross sections of the UST turbine (HR-22 and LR-18) are shown in Fig.3. The UST turbine is based on some small-medium sided land use reheat turbines proven.
AHD Nozzle Valve (Bar-Lift Type) Main Steam Inlet HP/T Exhaust
The main steam and reheat steam condition at turbine inlet is designed as below. Main Steam: 9.8MPaG x 555 Reheat Steam: 2.0MPaG x 555 In a case that the reheat plant is equipped with the shaft generator held in the intermediate shaft, the main turbine has to develop a total output power including the electric power generation. In general, the electric power expected at the guaranteed point in the plant is about 1.2 1.3MW. Therefore, the plant can gain much higher efficiency by developing the electric power with using rather the main turbine than the alternator turbine (Specified output power: 3.5MW), which is of lower performance at the partial load. However, it should be decided as to whether the shaft generator is adopted in consideration of an effect-to-cost including an initial cost, installation and a complexity of PMS (power management system) etc. Meanwhile the plant is a typical SAH (Steam Air Heater) system composed of two (2)-stage feed water heating system with three (3)-stage extraction and no high pressure heater is installed. It is because a simplicity and easy maintenance in the plant is regarded as important. Theoretically GAH (Gas Air Heater) system with multi-stage high pressure heater and multi-stage extraction has a little higher efficiency (about 2 3% in terms of FOC) as compared with normal SAH system; however, GAH system is extremely complex and strictly inferior to SAH system in operativeness and maintenance.
Thermal Shield Integrated with Multi-Stage Diaphragm Ring
IP/T Exhaust
Reheated Steam Inlet IP/T Part
Dummy Ring integrated with Nozzle Block
HP/T Part
Fig.3-1 Cross Section of UST Turbine (HR-22)


Reaction Stages Rateau Stages Flow Guide & Bearing Cone
d) Ahead stop valve and maneuvering valve There is no big constructional change from the existing system except for valve body and bolt material. The detailed structural analysis in steady/unsteady condition has been performed in accordance with the UST plant condition. The comparison of turbine components between CST and UST is shown in Table 4. Table 4 Comparison of Turbine Components between CST and UST
CST UST MR36-II 25MW x 76rpm HR-22 LR-18 1-Curtis 2 lines + 5 Rateau 6 Rateau 6 Rateau + 4 Reaction 2-Curtis with 2 lines Unit Type Power x rpm HP/IPT Type LP/T Type HP IP LP AST MS36-2 25MW x 78rpm H-22 L-18 1-Curtis 2 lines + 7 Rateau 4 Rateau + 4 Reaction 2-Curtis with 2 lines
LP/T Inlet
LP/T Exhaust To Main Condenser
Astern Turbine
Fig.3-2 Cross Section of UST turbine (LR-18) In consideration of a spare-saving, regular maintenance and overhauling each docking, it is needed to reduce a number of parts composing the UST turbine and to make it simplified for some unique requirements to marine use.
4. Major Parts in UST Turbine

Major parts composing the UST turbine are as follows. a) High-Intermediate Pressure Turbine (HR-22) Main and reheat steam flow into the turbine in the middle of the turbine and each exhaust steam goes out from the end of the turbine. HR-22 turbine has basically followed similar size and specification of land use turbine. The detailed structural analysis in steady/unsteady condition has been performed in accordance with UST plant condition. b) Low Pressure Turbine (LR-18) In LR-18 turbine, there is no big constructional change from the existing low pressure turbine except for the turbine casing and rotor material. c) Astern turbine Astern turbine element is incorporated in the low pressure turbine and arranged on the forward end of the turbine as well as CST turbine. The blade and steam chamber material are selected as the high temperature use in accordance with the UST plant condition.
In order to improve the turbine efficiency, HR-22 type of high-Intermediate pressure turbine is composed of 12 stages (1 Curtis with 2 lines and 11 Rateau Stages) in total and LR-18 type of low pressure turbine is composed of 10 stages (6 Rateau Stages and 4 Reaction Stages) in total. UST Astern turbine is of 2 Curtis with 2 lines as well as CST, however; it is refined in accordance with the UST steam condition.
5. Major Materials in UST Turbine

MHI have so many experiences and records of reheat turbine applying the steam condition with high pressure and high temperature in commercial land use power plants and for marine use also, our know-how of the latest reheat turbine technologies and special materials of course is applicable. Major materials (Casing, valve body, turbine blades, diaphragm etc.) have suitably referred to those applied to our land use reheat turbines. It is understood that the reheat turbines for the land use cannot be applied to the UST turbine as it is

Stage

because there are some differences in size and/or output power between the UST turbine and land use ones. MHI UST turbine is just a marine use reheat one for state-of-the-art that takes the latest technology of our land use reheat turbines while succeeding peculiar structural, functional concept for. The major materials applied for the UST turbine are shown in Table 5 with comparing to those for CST turbine. Table 5-1 Materials for Casing/Body
Part AHD Stop Valve AHD Maneuving Valve AST Maneuving Valve HR(HP) Turbine Casing Steam Chest at AST Turbine 1.25Cr.0.5Mo. Cast Steel or 2.5Cr.1Mo. Cast Steel MJC-12 12Cr.Cast Steel CST UST
Table 5-2 Materials for Bolt

Part Main Steam Line AHD Stop Valve M8B AHD Maneuving Valve AST Maneuving Valve HR(HP) Turbine Casing 12Cr.Mo. MTB10A M8B CST UST
Table 5-3 Moving Blades/Nozzle & Diaphragm/Rotor Materials for UST Turbine
Part HR(HP) Turbine Moving Blades HR(HP) Turbine Nozzle & Diaphragm HR(HP) Turbine Rotor CST 12Cr.Mo. S 13Cr.Mo. S 12Cr.Mo. S 13Cr.Mo. S Ni.Cr.Mo.V. S UST 12Cr.Mo. S 13Cr.Mo. S SA 182 F91 12Cr.Mo. S Cr.Mo.V. S 2.5Ni.Cr. Mo.V. S
LR(LP) Turbine Rotor
Cr.Mo. S
For the UST turbine casing, High-Cr. Casting Steel (MJC-12 casing steel), which was developed for land use reheat turbines as a special material used under high pressure and high temperature condition, is applied as specified in Table 5-1. Consequently it has been succeeded to make strength of the casing high enough to endure the UST steam condition. And also MTB10A, which has almost similar coefficient of linear expansion to that the material of the casing has, is applied as the material of the casing bolt (See Table 5-2). In the UST turbine, it has been confirmed by the detailed turbine condition analysis using 3-demensional FEM (Steady/Unsteady) that no fatal steam leakage from flange at casing/valve bodies occurs at all considerable operating cases such as turbine starting, running-in, steady powering and long-term operation for creep strength and the turbine condition at all the cases is sufficiently satisfactory for the criteria of MHI turbine design. Meanwhile M8B, which has a special quality of high creep strength in high temperature condition, is applied as the material of holding bolts at AHD stop valve and AHD/AST maneuvering valve cover giving because these valves are always under high temperature condition. For turbine blades, the existing materials are well applicable in the UST steam condition in consideration of application records of land and/or marine use (See Table 5-3). For nozzle and diaphragm being in high temperature steam, SA 182 F91 (Super 9Cr.) developed for power plant is applied. The materials of HR turbine rotor and LR turbine rotor are properly selected from application records of land use turbines based on metal temperature of each rotor in working condition. In addition, HR turbine is equipped with the rotor cooling system in the structure (See below for further details) and it can be expected to prevent a drop in the creep strength caused by the long-term operation and to make a lifetime of the rotor elongated even more.


6. Remarkable Features of UST Turbine
The most significant feature in the UST turbine is that the remarkable improvement of turbine performance can be achieved with sufficient safety at all considerable operation modes while the existing high-reliability, maintenance-free and easy-operation are being preserved as they are. Major features including the mentioned above are enumerated as follows. Turbine performance About 25% Improvement of Steam Consumption Rate by Comparison to CST Reliability Proven Design Based on Land Use Reheat Turbine Safety Higher Creep Strength, No Steam Leakage from flange parts Steadiability and Livability Low-Vibration, Low-Noise Maintenance No Additional Consumable Part, Extremely Low Maintenance Cost, Easy-Overhauling Lifetime Robust Design with Sufficient Safety Factors, Support of Long Lifetime due to Regular Maintenance every dock The improvement of turbine performance is expected as the mentioned above, and just over 12% improvement of fuel oil consumption rate (FOC) specified as the plant performance is estimated due to the steam condition for the UST plant, the application of reheat cycle and the improvement of turbine internal efficiency etc. Based on the latest technologies for improvement of the turbine internal efficiency, which have been already proven by MHI land use reheat turbines and they have given satisfactory results as expected, the UST turbine has been tuned up and optimized as marine use reheat turbine and the turbine performance proposed at present has been methodically and empirically validated. And also, steady state analysis, simulation of starting-up/program operation and examination of long-term creep strength were performed for a safety aspect and in addition to them, unsteady state analysis for the UST turbine has been completed to grasp an ever-changing turbine condition with the plant dynamic simulator developed for the UST turbine plant. Due to extracting any unforeseen troubles beforehand, taking the correct measures for and getting rid of them, all possible measures to ensure the success of the UST turbine have been taken.
7. The Latest Technologies to Improve Turbine Internal Efficiency

As mentioned above, just over 12% improvement of FOC can be achieved only by applying the UST turbine and boiler to a plant. Steam condition for the UST turbine about 2% FOC gain Application of Reheat Cycle about 8% FOC gain Improvements of Turbine Internal Efficiency about over 2% FOC gain To achieve the further FOC gain in the plant, it is strictly imperative to improve the internal efficiency in the UST turbine itself. The following items are considered and applied for the UST turbine to optimize its performance. a) Optimization of Base Diameter at the HR/T Rotor b) Optimization of Number of Turbine Stages and Steam Pressure of Each Extraction c) Application of ISB with Multi-Seal Fin d) Optimization of Nozzle Angle at HP Stages e) Development of the Latest Curtis (Control) Stage with much higher efficiency for the UST steam condition f) Application of 3-D Rateau (Bow) Nozzle g) Application of 3-D Stationary Blades at LR Reaction Stages h) Application of Unsteady Loss Reduced Blade i) Optimization of Flow Guide for LR/T Exhaust It is expected that each item will contribute to the turbine efficiency as shown in Fig.4.


2.5
Optimization of Flow Guide at LR/T Exh.

2
Unsteady Loss Reduced Blade 3-Dimensional Stationary Brade
1.5
3-Dimensional Rateau (Bow) Nozzle Development of UST Turbine Curtis Stage
Optimization of HR Turbine Nozzle (HP/T) ISB with Multi-Seal Fin
0.5
Optimization of No. of Stages & Bleed Press Optimaization of Dia. of HR/T Rotor
Fig.4 Improvement of Turbine Efficiency (UST) 1) ISB with Multi-Seal Fin A tenon-shrouding type of blade (CST) can be equipped with only two (2) radial fins a stage at the tip of the blade. Meanwhile in the UST turbine, ISB (Integral Shroud Blade: See Fig.5) is applied and it can allow to be equipped with three (3) or more radial fins (Multi-Seal Fin) in accordance with a width of the blade. Due to the multi-seal fin, steam leakage in axial direction at the tip of blade can be decreased at each stage and so that turbine efficiency is improved.
2) 3-D Rateau (Bow) Nozzle (See Fig.6). Due to bowing nozzle in its height direction, main steam flow is accelerated and pressure on rear side of nozzle (especially base side) will rise up by restraining of growth of boundary layer on nozzle surface and blade force of adjacent nozzles Consequently a differential pressure between base and tip side on front and rear surface of nozzle will be decreased and it is expected that a growth of the secondary flow (Cross flow), which is of the low-energy and causes a drop in turbine efficiency, can be restrained. In stages with low aspect nozzle, the above improvement is not sufficiently anticipated. Therefore, 3-D Rateau (Bow) nozzle has been applied for Rateau stages on IP turbine and LP turbine only.
Improvement of Turbine Efficiency (%)
IP Turbine 1st Stage Fig.6 3-D Rateau (Bow) Nozzle 3) 3-D Stationary Blade at LP Turbine At some reaction stage(s), 3-D stationary blade (Refer to Fig.7), which improves blade profile performance and gauging distribution of the stationary blade, is applied and it results in decrease of the secondary flow.
Fig.5-1 ISB (Integral Shroud Blade)
Decrease of Steam Leakage
Steam Flow 2-Dimensional Stationary Blade (CST) Big-pitched 3-Dimensional Stationary Blade (UST)
Tenon Blade (CST)
ISB (UST)
Fig.5-2 ISB with Multi-Seal Fin
Fig.7 3-D Stationary Blade (LP Turbine Reaction Stage)


Allowable Stress (kg/mm2)
4) Optimization of Exhaust Steam Chest (Flow guide & Bearing Cone) at LP Turbine Due to the optimization of exhaust steam chest at LP turbine, exhaust loss is decreased and exhaust pressure recovery (Cp) of 0.1 or more is expected as compared with CST (See Fig.8) .
Control of steam velocity increase at diffuser hub Rectification of exhaust flow due to the modification of the exhaust skirt
18 16 14 12 10 8 6 4 2 0 0 100 200 300 400 TEMPERATURE () 500 600 MJC-12 (12Cr. Casting Steel) WC9 (2Cr. Casting Steel)
Fig.9 Comparison of Allowable Design Stress between WC9 (2.5Cr. Casing Steel) and MJC-12 2) Casing Construction of the HR Turbine In the construction, the inside temperature of HP turbine nozzle box is about 460. Meanwhile it is expected that the inside temperature of IP turbine inlet will be extremely high because high temperature reheat steam (about 555) directly flows into IP turbine. In this case, temperature gradient in axial direction at the part concerned of the HR turbine casing caused by the big temperature difference is much steep and it leads to unbalanced tightening force at neighboring casing bolts, reducing of surface pressure on casing flange of the HR turbine. It causes a dangerous steam leakage from the flange. The unexpected steam leakage must not be caused under any condition. So in addition that high-Cr. material as mentioned above is applied for the UST turbine (HR turbine) casing and the UST turbine is equipped with Thermal Shield System for Cooling of Turbine Casing to make the temperature gradient smooth and to keep the material in high creep strength (See Fig.10). At inlet part of IP turbine, a screen ring called Thermal Shield is arranged between IP turbine casing and high temperature reheat steam (Refer to Fig.11) and low temperature steam (HP Turbine exhaust steam) is led into a back space of the screen. The above-mentioned cooling system for turbine casing not to expose turbine casing inside directly to high temperature is introduced. In consequent it can be stated that no steam leakage or fatal damage of the flange occurs in the UST turbine.
LP Turbine Exhaust (CST)
LP Turbine Exhaust (UST) Bearing Cone 12/35 (UST)
Bearing Cone 30 (CST)
Fig.8 Exhaust Steam Chest at LP Turbine
8. High-Intermediate Pressure Turbine Casing (HR Turbine/HR-22)

1) Casing Material for the HR Turbine As mentioned the above, High-Cr. casting steel (The UST turbine: 12Cr. casing steel) is applied for the HR turbine casing. In general, a material is in a creep region when used in high temperature condition (400~450) and its strength extremely lowers in the region as compared with that in a normal temperature. The high-Cr. casing steel is no exception to the above; however, it still keeps much higher strength even in high temperature. The comparison of allowable design stress between a conventional material (WC9: 2.5Cr. casing steel) and MJC-12 is shown in Fig.9. Allowable stress of MJC-12 under the UST steam condition (560) is about twice as much as WC9 and its stress level is almost equal to that of WC9 in temperature of about 480. In the UST turbine, this MJC-12 is uniformly applied for all valves and casing which exposed to higher temperature.


Thermal Shield
Themperature inside Casing ()
HR Turbine Casing (IP/T Inlet)
Shield Steam (abt. 420)
Inside of HP Turbine Nozzle Box (abt. 460)
600 500 400 300 200 100 0 Temperature Distribution at Flange (No Cooling System for Casing) Temperature Distribution at Flange (Cooling System for Casing) Temperature Distribution at Bolt (Cooling System for Casing)
Ex h. IP 6
IP turbine Inlet (Reheat Steam: 555)
HR Turbine Rotor (HP/IP Turbine Rotor)
H
Axial Position
IP Turbine Exhaust AHD Maneuvering Valve
Fig.12 Temperature Distribution at Casing Flange and Bolt (HR Turbine) 3) Detailed Examination of Casing/Bolt Condition at normal operation (MCR), Long Term Operation and Unsteady Operation (Starting-up/Program-in) In order to confirm the soundness of the UST turbine, 3-D FEM analysis using casing/bolt combination model (See Fig.13 and 14) at the following operations to be estimated has been performed.
Dummy Ring integrated with Nozzle Block
HP Turbine Exhaust
Thermal Shield Integrated with Multi-Stage Diaphragm Ring
Fig.10 Cross Section of HR Turbine
HR Turbine Casing (IP Turbine Side) Thermal Shield
Main Steam Inlet AHD Maneuvering Valve Shield Steam HP/T Exhaust
Dummy Ring IP Turbine Exhaust Reheat Steam Inlet Shield Steam
HR Turbine Casing (HP Turbine Side) HP/T Exhaust
Fig.13 3D-FEM Model (Casing/Bolt Combination)
Fig.11 Thermal Shield System for HR/T Casing The estimated temperature distribution at turbine casing flange at each case is shown in Fig.12. In a way of being equipped with the thermal shield, turbine casing well drops in temperature and the temperature distribution at the flange and bolt is almost even.
Fig.14 Temperature Distribution at MCR Powering

P/ IP
IP 1 um m y H P1 H P2 H P3 H P4 H P5 H P6 H P Ex h. D
IP 5
IP
IP 4
IP 3
IP 2

a) Steady State Analysis at Normal Operation (See Fig.15) b) Low-Cycle Fatigue Strength Analysis at normal operation (104 cycles) c) Creep Strength Analysis at Long Term Operation (2104 hours) (See Fig.16 and 17) d) Unsteady (Starting-up/Running-in) State Analysis
Criteria for Surface Pressure at Casing Flange HP/T SIDE : 1.0kgf/mm2 or more IP/T SIDE : 0.5kgf/mm2 or more 2 or more H
0 L
Surface Pressure (kgf/mm2) 1
Operation characteristic of the UST plant at starting-up and running-in is based on the output of the UST plant dynamic simulator, which has been developed in parallel and can simulate all operation modes including considerable emergency cases (Fig.18 and 19). Using with main and reheat steam condition at each time-step come from the simulator, the UST turbine performance calculation has been carried out and the calculation results have been used as input data for the unsteady state analysis.
Bolt (MTB10A): Initial Tightening 32kgf/mm2 IP SIDE HP SIDE
Fig.15 Distribution of Surface Pressure at Casing Flange

6 Surface Pressurekgf/mm2) 5 4 3 2 A B C D
Fig.18 UST Plant Dynamic Simulator

30000 600 Main/Reheat Steam Temp. ( )
0.1
10
100
1000
10000
100000
Turbine Output Power (kW)
0 0.01
Passage TimeH
20000
500
Fig.16 Transition of Surface Pressure due to Creep Strength Analysis (See Fig.14 for Mark AD)
Turbine Output Power (kW) 10000 Main Steam Temp. () Reheat Steam Temp. () 0 0 20 40 60 80 Passage Time (min) 100 300 120 400
Fig.19 Steam Condition at Program-In (CASE: 40 min./Harbor Full to Navigation Full) There is quite small difference of coefficient of linear expansion between MJC-12 (Casing material) and MTB10A (Casing bolt material), so that uneven thermal expansion between them never occur. In also point of casing and bolt strength, those can be well kept in sufficiently safe level because casing bolts and flange do not excessively rise in temperature due to the thermal shield system.
Fig.17 Creep Strength Analysis (2 x 104 hours/Mises Stress)

10

And also as a result of creep strength analysis, it has been confirmed that bolt tightening force does not extremely go down and specified surface pressure at casing flange is properly maintained.
IP Turbine Inlet (555) Dummy Ring between HP Turbine and IP Turbine
9. High-Intermediate Pressure Turbine Rotor (HR Turbine/HR-22)

1) Vibration Characteristic of Turbine Rotor As the mentioned above, the intermediate turbine is incorporated into the HR turbine and a bearing span of the HR turbine extends by about 1.2m from that in CST (See Fig.20). In accordance with the extension of the HR turbine rotor, detailed rotor characteristic analysis (Rotor Dynamics) has been performed to confirm the rotor critical speed, stability, response and balancing characteristic. With reference to the result, characteristics of the rotor and bearing have been settled. The Tilting type bearing is adopted in the UST turbine to improve the vibration characteristic.
IP Turbine Side HP Turbine Side
Cooling Steam for Turbine Rotor (Dummy Leakage Steam: about 460)
Fig.21 Turbine Rotor Cooling System (HR Turbine)
10. Conclusion
We are much confident of achieving the absolute success of the UST plant and offering it to you as the outstanding propulsion plant. The UST turbine is the most significant key to the success and its development has been fruitfully completed due to numberless examinations for it. We are eagerly looking forward to taking the last step to make the UST plant embodied and succeeded.
HP/T Steam Flow Dummy Part between HP/T and IP/T IP/T Stages Turbine Thrust
HP/T Stages Speed Control Stage (Advanced Curtis Stage with Higher Performance for UST) IP/T Steam Flow
Fig.20 HR Turbine Rotor (HR-22) 2) Cooling System for Turbine Rotor In order to prevent high temperature creep strength of the material from decreasing and to give a sufficiently robust strength to discs of the rotor, the cooling system is adopted. The steam after the HP turbine curtis stage is led to 1st stage disc at IP turbine through the dummy ring and cool the rotor not to expose the rotor to the high temperature reheat steam directly (See Fig.21).


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1

Mitsubishi Reheat Boiler

Fig.1 Comparison of Plant Configuration

2. Basic Design Concept of Reheat Boiler

Reheat Burner Fig.2 Overview of Reheat Boiler

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Boiler

Fig.3 Basic construction of Reheat Boiler

Design Pressure Material of Drum Material of Header Material of Tube

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Boiler

Fig.5 Conceptual image of furnace radiation

LR Gr.440 Steel Pipe

550 Steam / Metal Temperature ()

Fig.8 Allowable Stress Curves

18Cr Stainless Steel

18Cr Stainless steel tube

Corrosion Rate (mm/yr)

0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 540

Composition of Test Soot : 80%V2O5 - 20%Na2SO4

Estimated Max Metal Temp. 2.25Cr-1Mo Alloy Steel

18Cr Stainless Steel

Fig.7 Characteristics of 18Cr Stainless Steel

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Boiler

420 2.2MPa x 360

Fig.10 Normal Operating Condition

365 2.2MPa x 335

530 Main Burner

250 200 150

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Boiler

Fig.14 Emission during port operation

4. Boiler Control System

120.0 500.0 Temp Difference () 100.0 Steam Temp ()

40.0 350.0 20.0

300.0 0 10 20 30 40 50 Turbine load (%) 60 70 80 90

Fig.17 Characteristics of Steam Temperature

Fig.16 Example of Simulator Output

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Turbine

AST/T Main Steam (AST) M/C

Fig.2 Components of the UST Turbine

2. Basic Specification of UST Turbine

LP/T Main Condenser

Exhaust Steam Shaft Generator Turbine Output Thrust Electric

LP F.W.Heater Drain Tank

Feed Water Pump

Total No. of Extraction Feed Water Heater

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Turbine

3. Introduction of UST Turbine

Thermal Shield Integrated with Multi-Stage Diaphragm Ring

Reheated Steam Inlet IP/T Part

Dummy Ring integrated with Nozzle Block

Fig.3-1 Cross Section of UST Turbine (HR-22)

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Turbine

LP/T Exhaust To Main Condenser

4. Major Parts in UST Turbine

5. Major Materials in UST Turbine

MITSUBISHI HEAVY INDUSTRIES, LTD.

Mitsubishi Reheat Turbine

Table 5-2 Materials for Bolt