WELCOME TO

Presentation on New Concepts in Supercritical Turbines

Sanjoy Bhattacharya
Dy. Genl. Manager, BHEL, Hardwar
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CROSS SECTIONAL ARRANGEMENT OF 500 MW STEAM TURBINE

HPT

IPT

LPT

THREE CYLINDER TURBINE

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Introduction of New Rating Sets

Major Objectives

Bring down equipment cost per MW

Having more Efficient & Reliable product Utilize available Steam turbine modules Provide Higher competitiveness New Rating to compete with Chinese/ New Indian firms

600MW Steam turbine: Built from proven modules of existing 500 & 250 MW

OPTIONS
1. HP Turbine with Extraction & 565 Deg C HRH Temp 2. HP Turbine without Extraction & 537 Deg C HRH Temp

Salient features:

Module Combination HP: H30-100 IP : M30-63 LP : N30-4x6.3 Steam parameters

170 ata / 537 0C/ (537-565) 0C

4 cylinder turbine (2 LPs) HP turbine with Extraction connection for 565 HRH Temp IP turbine suitable for 537/565 0C inlet temp.

Orders for 2 sets - N Chennai, 2 sets JITPL, 1 set -APGENCO & 2 sets Singareni received.
Orders for 4x600 MW Raigarh-III (Jindal), 2x600 MW Malwa, 2x600 MW each Avantha / Videocon/ Visa Raigarh/ DB Power & 1 x 600 MW Rayalaseema received .
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600 MW Sub critical Sets

Steam Turbine
Design Changes from existing 500 MW sets : HP module variant with Extraction 600MW Steam Turbine New Flow path in HP, IP & LP Turbines (with Advanced blading) Matching modifications in Rotors & Inner Casings New Bearing pedestal between 2 LP cylinders New design of Cross Around Pipe & its support Enhanced governing characteristics

500/ 600 MW SUB CRITICAL CYCLE

WITH 2 HP HEATERS, 3 LP HEATERS

Introduction of Steam Turbine with supercritical parameters

As the fluid pressure increases, Latent Heat (Enthalpy of Steam Enthalpy of Water) reduces. At Critical point it becomes zero. In physical terms at this pressure water transforms to steam spontaneously.
SUPER CRITICAL STEAM PARAMETERS: PARAMETERS MORE THAN CRITICAL STATE STEAM PRESSURE > 221.2 BAR STEAM TEMPERATURE > 374.15 Deg C ULTRA SUPERCRITICAL PRESSURE( 300 BAR)
Improvement
45 40 35 30 25 20 15 10 5 0

4.3 %

Subcritical 170 ata / 537 C / 537 C

500 MW

800 MW Super

Critical 247 ata / 565 C / 593 C

INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg C RESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE
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Supercritical Cycles
Steam Power plant efficiency increases with increase in steam pressure and temperature. Power plant Cycles operating above critical pressure (221.2 bar) are classified as Supercritical cycles With higher cycle efficiency, the supercritical cycle offers the advantage of burn less fuel for the same output and lower emission.

Lesser Pollutants SOX , NOX & CO2

IMPROVEMENT IN EFFICIENCY WITH INCREASING INLET PARAMETERS FOR STEAM TURBINES

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PARAMETERS FOR BHEL STEAM TURBINES

PARAMETERS MS PRESSURE MS TEMPERATURE MAIN STEAM FLOW

UNIT ATA
oC

500 MW 660 MW 800 MW 170 537 1500 247 565 1919 247 565 2380

T/HR

REHEAT PRESSURE
RH TEMPERATURE FINAL FEED WATER TEMP.

ATA
oC oC

40.5
537 253

56
593 290

60
593 290

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Typical Supercritical TG Cycle

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REGENERATIVE CYCLE CONFIGURATION

TWO EXTRACTIONS FROM IPT

FOUR LP HEATERS DEAERATOR ONE EXTRATION FROM HPT

THREE HP HEATERS
250% TURBINE DRIVEN BFP ONE MOTOR DRIVEN BFP

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STEAM TURBINE MODULE CONFIGURATION

MODULE
HP TURBINE IP TURBINE LP TURBINE

500 MW
H30-100 M30-63 N30-2 x 10

660 MW
H30-100 M30-100 N30-2 x 12.5

800 MW
H30-100 M30-100 N30-4 x 8

HP VALVES
IP VALVES

2 x FV320
2xAV560

2 xFV250A
2xAV560A

2 xFV250A
2xAV560A

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660MW Steam turbine: With Supercritical parameters

Impulse tilted blade in HP & IP turbines Heat Shield at the inlet section Increase in wall/pipe thickness Material with improved properties for higher steam temperature Optimum flow path

Salient Feature: New series of HP & IP modules for supercritical parameters Higher size LP module
247 ata Main Steam Pressure 565 0C Main Steam Temperature 593 0C Hot reheat Temperature

Order for 2x660 MW Barh- II/ DB Power & 3 x 660 Bara & Lalitpur TPP Other expected tenders 1 x 660 MW JITPL Angul, Jhabua Seoni, etc
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800MW Steam turbine

Salient features: 4 cylinder turbine (2 LPs) New series of HP, IP & LP modules for super critical parameters
Orders for Yermarus (2x800 MW), & Edlapur (1x800 MW), JV between KPCL and BHEL

Order expected for NTPC 2 x 800 MW Gajmara TPP & Udangudi (2x800 MW), JV between
TNEB and BHEL
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800MW Steam turbine: General Arrangement

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CROSS SECTIONAL ARRANGEMENT OF 800 MW STEAM TURBINE

FOUR CYLINDER TURBINE

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CONSTRUCTIONAL FEATURES OF HP TURBINE FOR 800 MW

Barrel in two pieces

SINGLE FLOW, DOUBLE SHELL OUTER CASING BARREL TYPE IN TWO PIECES INNER CASING AXIALLY SPLIT MONO BLOCK DRUM TYPE ROTOR

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CONSTRUCTIONAL FEATURES OF IP TURBINE FOR 800 MW

DOUBLE FLOW, DOUBLE SHELL CASING MONO BLOCK DRUM TYPE ROTOR STEAM ADMISSION IN L/H FROM BOTH SIDES EXTRACTIONS CONNECTIONS IN LOWER HALF ONLY VALVES BOLTED TO THE CASING IN LOWER HALF

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Diagonal Impulse Blading

HPT FIRST STAGE

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IP Turbine : HEAT SHIELD WITH VORTEX BORES

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CONSTRUCTIONAL FEATURES OF LP TURBINE FOR 800 MW

DOUBLE FLOW, DOUBLE SHELL OUTER CASING FABRICATED , INNER CASING CASTINGS MONO BLOCK ROTOR

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SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

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DIFFERENCES IN CONSTRUCTIONAL FEATURES 500 MW V/S 660 MW

LP TURBINE

500 MW

660 MW

INNER CASING RESTS ON OUTER CASING

INNER CASING IS INDEPENDENT OF OUTER CASING

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SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

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PUSH ROD ARRANGEMENT

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LP TURBINE INNER CASING SUPPORT DETAILS FOR 660 / 800 MW

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GOVERNING

THROTTLE CONTROLLED GOVERNING WITH HIGH PRESSURE ELECTRO HYDRAULIC COMPACT ACTUATORS (160 BAR)
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Turbine Governing
EXISTING DESIGN(500 MW)
THROTTLE GOVERNING ELECTRO HYDRAULIC (WITH 32 BAR PRESSURE)

NEW DESIGN(660 MW)

THROTTLE GOVERNING HIGH PRESSURE ELECTRO HYDRAULIC GOVERNING (ACTUATORS WITH PRESSURE OF 160 BAR)

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Turbine Governing
ADVANTAGES OF EHA BASED SYSTEM

Simplified plant layout due to overall compact size Control oil piping reduced Faster response due to state of art electronic control and protection system Better interconnection with other system Ease of operation and maintenance Valve room is avoided

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Turbine Governing
EHA SYSTEM CONSISTS OF

* * * * *

HYDRAULIC POWER SUPPLY UNIT HPSU CONTROL UNIT VALVES ACTUATORS CONTROLLERS PROTECTION SYSTEMS

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OVERHAULING

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SUMMARY
Proven Supercritical technology in collaboration with M/s Siemens
Steam Parameters up to 300 bar / 600C / 620C Modular Turbo set design to fit best customer needs High reliability & Availability Long Inspection intervals High efficiency by using modern CFD tools for flow path & blades

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Thank you for a Patient hearing

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