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1 WELCOME TO Presentation on New Concepts in Supercritical Turbines Sanjoy Bhattacharya Dy. Genl. Manager, BHEL, Hardwar.

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Presentation on theme: "1 WELCOME TO Presentation on New Concepts in Supercritical Turbines Sanjoy Bhattacharya Dy. Genl. Manager, BHEL, Hardwar."— Presentation transcript:

1 1 WELCOME TO Presentation on New Concepts in Supercritical Turbines Sanjoy Bhattacharya Dy. Genl. Manager, BHEL, Hardwar

2 2

3 3 CROSS SECTIONAL ARRANGEMENT OF 500 MW STEAM TURBINE THREE CYLINDER TURBINE

4 4  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

5 5 600MW Steam turbine: Built from proven modules of existing 500 & 250 MW 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. Module Combination HP: H30-100 IP : M30-63 LP : N30-4x6.3 Salient features: 4 cylinder turbine (2 LPs) HP turbine with Extraction connection for 565 HRH Temp IP turbine suitable for 537/565 0 C inlet temp. OPTIONS 1.HP Turbine with Extraction & 565 Deg C HRH Temp 2.HP Turbine without Extraction & 537 Deg C HRH Temp Orders for 2 sets - N Chennai, 2 sets –JITPL, 1 set -APGENCO & 2 sets Singareni received. Steam parameters 170 ata / 537 0 C/ (537-565) 0 C

6 6 600MW Steam Turbine Design Changes from existing 500 MW sets : HP module variant with Extraction 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 600 MW Sub critical Sets Steam Turbine

7 500/ 600 MW SUB CRITICAL CYCLE WITH 2 HP HEATERS, 3 LP HEATERS

8 8 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) INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg C RESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE Subcritical 170 ata / 537 °C / 537 °C Super Critical 247 ata / 565 °C / 593 °C Improvement 4.3 %

9 9 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. Supercritical Cycles Lesser Pollutants – SOX, NOX & CO2

10 10 IMPROVEMENT IN EFFICIENCY WITH INCREASING INLET PARAMETERS FOR STEAM TURBINES

11 11 PARAMETERSUNIT500 MW660 MW800 MW MS PRESSUREATA170247 MS TEMPERATURE oCoC537565 MAIN STEAM FLOWT/HR150019192380 REHEAT PRESSUREATA40.55660 RH TEMPERATURE oCoC537593 FINAL FEED WATER TEMP. oCoC253290 PARAMETERS FOR BHEL STEAM TURBINES

12 12 Typical Supercritical TG Cycle

13 13 REGENERATIVE CYCLE CONFIGURATION TWO EXTRACTIONS FROM IPT FOUR LP HEATERS DEAERATOR ONE EXTRATION FROM HPT THREE HP HEATERS 2  50% TURBINE DRIVEN BFP ONE MOTOR DRIVEN BFP

14 14 STEAM TURBINE MODULE CONFIGURATION MODULE500 MW 660 MW800 MW HP TURBINEH30-100 IP TURBINEM30-63M30-100 LP TURBINEN30-2 x 10N30-2 x 12.5N30-4 x 8 HP VALVES2 x FV3202 xFV250A IP VALVES2xAV5602xAV560A

15 15

16 16 660MW Steam turbine: With Supercritical parameters 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 Salient Feature: New series of HP & IP modules for supercritical parameters Higher size LP module 247 ata Main Steam Pressure 565 0 C Main Steam Temperature 593 0 C Hot reheat Temperature 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

17 17

18 18 800MW Steam turbine Salient features: 4 cylinder turbine (2 LP’s) New series of HP, IP & LP modules for super critical parameters HP Turbine LP Turbine 1 LP Turbine 2 IP Turbine Condenser Generator 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

19 19 800MW Steam turbine: General Arrangement

20 20 CROSS SECTIONAL ARRANGEMENT OF 800 MW STEAM TURBINE FOUR CYLINDER TURBINE

21 21 CONSTRUCTIONAL FEATURES OF HP TURBINE FOR 800 MW SINGLE FLOW, DOUBLE SHELL OUTER CASING BARREL TYPE IN TWO PIECES INNER CASING AXIALLY SPLIT MONO BLOCK DRUM TYPE ROTOR Barrel in two pieces

22 22 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

23 23 HPT FIRST STAGE Diagonal Impulse Blading

24 24 IP Turbine : HEAT SHIELD WITH VORTEX BORES

25 25 DOUBLE FLOW, DOUBLE SHELL OUTER CASING FABRICATED, INNER CASING CASTINGS MONO BLOCK ROTOR CONSTRUCTIONAL FEATURES OF LP TURBINE FOR 800 MW

26 26 SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

27 27

28 28 SECTIONAL DETAILS OF LP TURBINE FOR 660 / 800 MW

29 29 PUSH ROD ARRANGEMENT

30 30 LP TURBINE INNER CASING SUPPORT DETAILS FOR 660 / 800 MW

31 31 THROTTLE CONTROLLED GOVERNING WITH HIGH PRESSURE ELECTRO HYDRAULIC COMPACT ACTUATORS (160 BAR) GOVERNING

32 32 NEW DESIGN(660 MW) THROTTLE GOVERNING HIGH PRESSURE ELECTRO HYDRAULIC GOVERNING (ACTUATORS WITH PRESSURE OF 160 BAR) Turbine Governing EXISTING DESIGN(500 MW) THROTTLE GOVERNING ELECTRO HYDRAULIC (WITH 32 BAR PRESSURE)

33 33 Turbine Governing 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

34 34 Turbine Governing EHA SYSTEM CONSISTS OF *HYDRAULIC POWER SUPPLY UNIT *HPSU CONTROL UNIT * VALVES ACTUATORS * CONTROLLERS *PROTECTION SYSTEMS

35 35 OVERHAULING

36 36 SUMMARY Proven Supercritical technology in collaboration with M/s Siemens Steam Parameters up to 300 bar / 600°C / 620°C Steam Parameters up to 300 bar / 600°C / 620°C Modular Turbo set design to fit best customer needs Modular Turbo set design to fit best customer needs High reliability & Availability High reliability & Availability Long Inspection intervals Long Inspection intervals High efficiency by using modern CFD tools for flow path & blades High efficiency by using modern CFD tools for flow path & blades

37 37 Thank you for a Patient hearing…………


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