Steam Turbines

Jeddah Roadshow, 22 July 2006

Guido Raimondi
Head of Steam Turbine
Thermodynamics Design
STEAM TURBINES

New equipment
Product development
Repowering Concept
Retrofit and modernization
Application examples

2
 Steam Turbine Technology Evolution

Siemens AEG Sulzer BBC SACM Rateau AEI GEC

GE USA Siemens-KWU D Westinghouse USA BBC CH Alsthom F GEC UK

1970
IMPULSE REACTION REACTION REACTION IMPULSE IMPULSE

Ansaldo N. Pignone (1) BHEL ASEA STAL

CEM
Toshiba Parsons F. Tosi
1987 1989
Doosan
Mitsubishi ABB LMZ GEC – Alsthom

De Pretto Zamech
Fuji
Hitachi
Ansaldo

1998 1999

GE USA Siemens Westinghouse D Mitsubishi J ABB-Alstom F 2000

IMPULSE REACTION REACTION REACTION (2)

Toshiba J ESG
Hitachi J Fuji J Ansaldo I

1) Industrial Turbines
2) Impulse on Nuclear Turbines

3
STEAM TURBINES

New equipment

Product development

Repowering Concept

Retrofit and modernization

Application examples

4
 Ansaldo Energia Steam Turbines
Product Range

Type and Application

GEOTHERMAL TURBINES
GT
- Geothermal Cycle
20 100

INDUSTRIAL TURBINES
- Steam Cycle CT, IT
- Combined Heat and Power
- Combined Cycle 20 100

MIDDLE SIZE TURBINES

- Steam cycle MT, MR (2-cylinders)
- Combined Cycle
70 300
REHEAT TURBINES

- Steam Cycle
RT (3-4cylinders)
- Combined Cyle
- Combined Heat and Power

0 100 200 300 1000

Power output ( MW )
5
 Ansaldo Energia
Turbogenerators – Product Range

Type and Application

AIR COOLED
- Steam Turbines
- Gas Turbines
up to 300 MVA
- Geothermal Turbines

HYDROGEN COOLED 14 21

10 11 12 13
6

up to 600 MVA
5

4
1 3 7
2 22

- Steam Turbines
8 15
16 16
23
17
17

- Gas Turbines 18 18 24

20
19

HYDROGEN/WATER COOLED

- Steam Turbines

Up to 900 MVA

0 300 600 900 1200

Rating ( MVA )
6
Ansaldo Steam Turbines

• Modular concept – Ansaldo builds single-/multiple-casing ST’s

to match output ranges up to 1000 MW for combined cycle and
conventional fossil-fired power plants for both 50 and 60 Hz.
• Also used for steam extraction in co-generation / district
heating systems, desalination or chemical processes
Frame turbines

MT10C RT20C MT25S RT60S

RT50S
RT40S
RT30C
MT15C

7
 Ansaldo Energia Steam Turbines
Main Features
Reaction
ReactionTechnology
Technology
No
Nopiston
piston Free-standing
Free-standing
cooling
coolingsteam
steam LSB
LSB

HP
HPshrink
shrinkrings
rings

Welded
Weldedrotors
rotors One-piece
One-piece
3D
3Dblades
blades
Valves
Valvesdirectly
directlyconnected
connected
RT TURBINES – tandem compound double flow
8
 Ansaldo Energia Steam Turbines
Standard LP Sections

LP type Speed Exhaust area LSB type

per flow
(1/s) (m2)

23 50 3.2 With lacing wire

25 50 4.0 With lacing wire

33G 50 5.5 Laced

33 50 6.1 Free standing

37 50 7.2 Free standing

43 50 9.6 Free standing

48 50 11.9 Continuous coupling

23 60 3.2 With lacing wire

25 60 4.0 With lacing wire

30 60 5.0 Free standing

36 60 6.7 Free standing

9
Back-Pressure Steam Turbine
for Heat and Power

MTG20

PERFORMANCE DATA

Output range 100-250 MW

Live steam pressure 70-100 bar

Live steam temperature 540-565 °C

Back pressure 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

10
Controlled extraction, condensing Steam
Turbine for C.C. and Desalination Plant

MTG20-C Controlled
Controlledextraction
extraction
Single
Singleflow
flowaxial
axialexhaust
exhaust

PERFORMANCE DATA

Output range 100-250 MW

Live steam pressure 70-100 bar

Live steam temperature 540-565 °C

Controlled extrac. pressure 1-4 bar

Condenser pressure 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

11
 No Reheat Steam Turbine
for Combined Cycle

MT10c
PERFORMANCE DATA

Output range 90-160 MW

Live steam pressure 60- 80 bar

Live steam temperature 510-530 °C

Condenser pressure 0.035-0.25 bar

Operation mode: Sliding pressure

1 + 1 ( 50 Hz ) Configuration

2 + 1 ( 50 Hz ) Configuration

DESIGN TOPICS

Full arc admission Axial exhaust for low profile plant

One stop / control valves assembly Modular LP design for optimized

performance
HP, LP opposite flow configuration
- LSB 50 Hz 43”
Welded rotor for material optimization

12
 Reheat Steam Turbine
for Combined Cycle

MT15c
MT10c
PERFORMANCE DATA

Output range: 90-150 MW

Live steam pressure: 100-160 bar

Live steam temperature: 540-565 °C

Reheat steam temperature: 540-565 °C

Condenser pressure: 0.035 - 0.25 bar

Operation mode: Sliding pressure

1 + 1 ( 50 Hz, 60 Hz ) Configuration
( GT 180 / 260 MW )

SINGLE FLOW HP SECTION COMBINED IP-LP SECTION

Full arc admission for improved operation Axial exhaust for low profile plants

Single stop / Control valve assembly Single combined reheat valve

Shipped assembled for fast installation Welded rotor for material optimization

Modular LP design for optimized performance

LSB 50 Hz 33” - 43”

LSB 60 Hz 36”

13
 Reheat Steam Turbine
for Fossil fired Power Plants (1/2)

PERFORMANCE DATA
RT40s
Output range: 250-450 MW

Live steam pressure: 170-280 bar

Live steam temperature: 540-580 °C

Reheat steam temperature: 540-600 °C

Condenser pressure: 0.05 - 0.25 bar

No. of Extractions: 7-8

Operation mode: Fixed and/or

sliding pressure
Speed: 50 - 60 Hz

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

14
 Reheat Steam Turbine
for Fossil fired Power Plants (2/2)

PERFORMANCE DATA
RT60s
Output range: 400-700 MW

Live steam pressure: 170-250 bar

Live steam temperature: 540-580 °C

Reheat steam temperature: 540-600 °C

Condenser pressure: 0.035 - 0.25 bar

Operation mode: Fixed and/or sliding

pressure operation
Speed: 50 - 60 Hz

HP SECTION IP SECTION LP SECTION

Separated IP section for high efficiency Four flow design

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
Double casing design
Double flow design
Two combined reheat valves
Welded rotor solution for material
optimization
Shipped assembled for fast installation
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”

15
 Ansaldo Steam Turbines
Experience List

Application Units Power( MW)

Fossil fueled power plants 344 65,882

Nuclear power plants 12 6,180

Combined Cycles 89 7095

Waste to Energy power plants 26 402

Geothermal power plants 130 2,118

Industrial plants 581 5,423

Total 1,176 87,100

16
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-CH technology)
• Know-how
– Ansaldo had full access to ABB/Alstom-CH technology relating
to Design, Manufacture, Quality Control, R&D, Erection,
Commissioning
• After Termination Ansaldo has the right to
– Continue to use ABB/Alstom-CH technology on new units and
for retrofit/modification of old units, including BBC/ABB fleet
– Subcontract components manufacturing to third parties
– Grant licenses to third parties
17
STEAM TURBINES

New equipment

Product development

Repowering Concept

Retrofit and modernization

Application examples

18
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

19
Efficiency Improvement
48” Last Stage Bucket Design

L-0 rotating blade

Development of a new 3-D model
Last Stage Steel Blade
48” length with an annular area of 12 m2
(JRP Ansaldo Energia – Skoda Power)

3-D Navier-Stokes analysis

20
STEAM TURBINES

New equipment

Product development

Repowering Concept

Retrofit and modernization

Application examples

21
 Repowering
From open cycle to Combined Cycle
• In open cycle GT is alone, the high temperature combustion gases are
exhausted to atmosphere;
atmosphere; more than 61% of available energy in the fuel is lost.
lost.
• The high energy content
in exhaust gases can be
used to produce high
temperature steam by
HRSG 19%

• and produce more kW in

a new Steam Turbine 32.5%

• 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: 56 %
10%

22
 Steam Cycle Unit

In a steam cycle unit

the Net Efficiency is
Steam Turbine & Generator
about 39% mHRH=90% mLP=80%
The steam flow
mSH=100%
distribution is

mcond=70%

Condenser
Steam
Generator

Feedwatwer cycle

23
 Repowering
From Steam Cycle to Combined Cycle
Conversion of a conventional unit in C.C. (1+1 configuration)
1 - Steam Generator is replaced by mHRH=55%
GT and HRSG, Feedwater
cycle is removed mSH=40%

2 - ST steam path could be

optimized; extraction pipes mcond=65%
blanked
32.5%
3 - Condenser is maintained

4 - Deaerator is new
5 - Piping is new

10%

In combined cycle,
cycle, the Net Efficiency is higher than 56 %
24
STEAM TURBINES

New equipment

Product development

Repowering Concept

Retrofit and modernization

Application examples

25
 Steam Turbine Technology Evolution

Siemens AEG Sulzer BBC SACM Rateau AEI GEC

GE USA Siemens-KWU D Westinghouse USA BBC CH Alsthom F GEC UK

1970
IMPULSE REACTION REACTION REACTION IMPULSE IMPULSE

Ansaldo N. Pignone (1) BHEL ASEA STAL

CEM
Toshiba Parsons F. Tosi
1987 1989
Doosan
Mitsubishi ABB LMZ GEC – Alsthom

De Pretto Zamech
Fuji
Hitachi
Ansaldo

1998 1999

GE USA Siemens Westinghouse D Mitsubishi J ABB-Alstom F 2000

IMPULSE REACTION REACTION REACTION (2)

Toshiba J ESG
Hitachi J Fuji J Ansaldo I

1) Industrial Turbines
2) Impulse on Nuclear Turbines

26
 Ansaldo Steam Turbine Technologies

General
GeneralElectric
Electric BBC
BBC //ABB
ABB//Alstom
Alstom Westinghouse
Westinghouse

1949 - 1989 1989 - 2003 1949 - 1988

ESG
ESG
Ansaldo Componenti Franco
FrancoTosi
Tosi

AnsaldoEnergia
AnsaldoEnergia

27
Steam Turbines Retrofit and Rehabilitation

Non-OEM Fleet Market for Ansaldo

GE USA
IMPULSE

Toshiba J

Hitachi J

Westinghouse USA
REACTION

Mitsubishi J

ABB-Alstom F
REACTION

BBC CH

CEM F

28
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

29
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

30
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 originally designed for impulse
operation can be totally or partially retrofitted with impulse or
reaction design and viceversa

Original – Impulse type Retrofit – Reaction type (HP-IP section)

31
Retrofit process

Example of retrofit of non-OEM equipment

32
 Updated technology

Performance improvements can be realized through the introduction of

updated steam path technology
1. Three dimensional blading (3D) on HP-IP
section to reduce profile and secondary
losses.

2. Longer last stage blade to reduce exhaust

losses and convert them to additional
power output.

3. Improved gland seal arrangements to

reduce interstage leakage, particularly
important for short HP and IP blades
The application of “brush” tip seals
reduces the amount of steam leakages
and improves the stage efficiency in the
HP-IP turbine sections

33
STEAM TURBINES

New equipment

Product development

Repowering Concept

Retrofit and modernization

Application examples

34
Chivasso 2

OEM: Ansaldo (GE licence)

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 565°C/565°C.

35
Porto Corsini 3 – 4

OEM: F. Tosi (Westingh. lic.)

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.

36
Torre Valdaliga Sud 2
2x33.5”

OEM: Ansaldo (GE licence)

1 x 320 MW
Comm. Year: 1968

Retrofit Solution Reason for retrofit

The existing 320 MW unit, previously operating in
2x43” 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.

37
Fusina 3 – 4

OEM: F. Tosi (Westingh. lic.)

2 x 320 MW
BB073
Comm. Year: 1973 - 1975

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
• Nominal rating: 337.5 MW.
• Gain of 8 MW in power output with reference to the
original design.

38
 Ansaldo Steam Turbine Retrofits
Experience List
Order
Order Start-up
Start-up Country
Country Plant
Plant Manifacturer
Manifacturer( (OEM
OEM) ) Units
Units/ /MW
MW Scope
ScopeofofSupply
Supply
year
year year
year

1990
1990 1994
1994 Greece
Greece LAVRION
LAVRION General
GeneralElectric
Electric 11 xx 66.5
66.5 --New
New HP
HPRotor
Rotorand
and diaphragms
diaphragms
--New LP Rotor and diaphragms
New LP Rotor and diaphragms

1990
1990 1994
1994 Argentina
Argentina COSTANERA
COSTANERA British
BritishThompson-Houston
Thompson-Houston 44 xx 120
120 --New
New HP
HPRotor
Rotorand
and diaphragms
diaphragms
--New
New IP
IPRotor
Rotorand
and diaphragms
diaphragms
--New
New LP
LPRotor
Rotorand
and diaphragms
diaphragms

1990
1990 2002
2002 Italy
Italy PIETRAFITTA
PIETRAFITTA F.T.
F.T./ /Westinghouse
Westinghouse 22 xx 60
60 --New
New1°HP
1°HPnozzle
nozzlestage
stage

1998
1998 2000
2000 Italy
Italy LA
LASPEZIA
SPEZIA1-2
1-2 F.T.
F.T.//Westinghouse
Westinghouse 22 xx 120
120 --New
NewHP-IP
HP-IPsection
section
--New
New LP laststage
LP last stageblading
blading

1999
1999 2001
2001 Italy
Italy CASSANO
CASSANOD’ADDA
D’ADDA11 Ansaldo
Ansaldo 11 xx 80
80 --New
NewHP-IP
HP-IProtor
rotorand
anddiaphragms
diaphragms
--New LP rotor and diaphragms
New LP rotor and diaphragms

2000
2000 2001
2001 Italy
Italy LA
LACASELLA
CASELLA1-4
1-4 F.T.
F.T./ /Westinghouse
Westinghouse 44 xx 120
120 --New
NewHP
HPblading
blading

2001
2001 2002
2002 Italy
Italy PORTO
PORTOCORSINI
CORSINI F.T.
F.T./ /Westinghouse
Westinghouse 22 xx 123
123 --New
NewLP
LPinner
innerblock
block

2002
2002 2003
2003 Italy
Italy CHIVASSO
CHIVASSO22 Ansaldo
Ansaldo 11 xx 130
130 --New
NewHP-IP
HP-IPsection
section

2002
2002 2003
2003 Italy
Italy PRIOLO
PRIOLOGARGALLO
GARGALLO1-2
1-2 F.T.
F.T./ /Westinghouse
Westinghouse 22 xx 120
120 --New
NewHP
HPblading
blading

2002
2002 2003
2003 Italy
Italy TORREVALDALIGA
TORREVALDALIGASUD
SUD22 Ansaldo
Ansaldo 11 xx 267
267 --New
NewLP
LPinner
innerblock
block

2006
2006 2007
2007 Italy
Italy FUSINA
FUSINA3-4
3-4 F.T.
F.T./ /Westinghouse
Westinghouse 22xx350
350 New
NewLP
LPinner
innerblock
block

39
Steam Turbines
Jeddah Roadshow, 22 July 2006

Guido Raimondi
Head of ST Thermodynamics Design