New products by OJSC Power Machines December 2009 Chief Designer for Steam Turbines A.S.Lisyansky A.S.Lisyansky. - презентация

1 New products by OJSC Power Machines December 2009 Chief Designer for Steam Turbines A.S.Lisyansky A.S.Lisyansky

2 New products by OJSC Power Machines OJSC Power Machines steam turbine equipment OJSC Power Machines capabilities to deliver modern steam turbines for nuclear power stations Half speed steam turbine К ,8/25. - Principle heat flow train of turbine set К ,8/25. - Turbine hall equipment specifications. - Steam turbine К ,8/25. Main design solutions, which increase efficiency, reliability and turbine maintainability. - Turbine set К ,8/25 arrangement. - Turbine set auxiliary equipment Steam turbines for ultrasupercritical steam conditions for TPP. - Power Machines development stages of turbine set initial steam conditions. - Units efficiency upgrading by means of main steam conditions increasing. - Steam turbines for ultrasupercritical steam conditions manufacturers. - Steam turbine for ultrasupercritical steam conditions with a capacity of 660 MW. - Combined high and intermediate pressure cylinder (HIP). CONTENTS

3 New products by OJSC Power Machines 3 KTZ, 1946 Steam turbines with medium and low output Elektrosila 1898 Generators for thermal, nuclear, gas, water turbines Energomachexport, 1966Sales Founded in 2000 LMZ, 1857 Turbines for thermal, nuclear, gas, water power stations NPO CKTI, 1928 Researches and designing of Power equipment Structure of OJSC POWER MACHINES, Russia Zavod Turbinnyh Lopatok ZTL, 1964 Steam and gas turbine blades

4 New products by OJSC Power Machines Breakdown of manufactured turbines by the countries of the world (1946 to 2007, including renovation and components, for turbines manufactured by other manufacturers under LMZ license). Quantity, purchase (1782 purchase in all) Total Capacity, MW ( MW in all) RussiaRepublics of the former Soviet Union Countries of export Steam Turbines of OJSC POWER MACHINES make

5 New products by OJSC Power Machines 5 Breakdown of manufactured turbines by the countries of the world (1946 to 2007, including renovation and components, for turbines manufactured by other manufactures under LMZ license). Quantity, purchase (381 purchase in all) Total Capacity, MW (66788 MW in all) Poland, Hungary, Romania, Bulgaria China Asia (except for China and India) India Africa and South America Finland, Greece, the former DDR, republics of the former Yugoslavia Steam Turbines of OJSC POWER MACHINES make

6 New products by OJSC Power Machines 6 Steam Turbines of OJSC Power Machines make ПТ-30-3,4/0,6 ПТ-30-8,8ПТ-35-8,8 ПТ-40/50-8,8 ПТ-65/75-130/13 ПТ-30-2,9/0,8 ПТ-30/40-2,9 ПТ-35/55-8,8 ПТ-65/75-8,8/1,1 ПТ /22 ПТ-30-2,9-2 ПТ-35/55-3,2 ПТ-35/40-8,8 ПТ-65/75-90/13 ПТ-80/ /13 К-25-2,5К М К-40-62К К-55-90К-55-8,8 К-55-60К ВК-100-6МК К К К (9) К К М К МТ К (2) К ,8 К ,8-Р К М К М К К К К К Р ТК М К ,7К } К К К К К К К К К К ,5 К КТ-115-8,8-1(2) КТ ,8 КТ-120/140-12,8 КТ Т-25/30-3,4Т-50/60-8,8Т-115-8,8 Т-120-8,8Т ,8Т-30-2,9 Т Condensing turbines Condensing turbines with steam extractions for district heating Extraction turbines (without ) Extraction turbines (without reheat) Extraction turbines (with reheat) Extraction turbines with steam extractions for industrial purposes and district heating К К-600-6,9/50 К К /3000-(2) К /3000-(3)К /50 Turbines for NPPs К-80-7,0 К-110-6,5 Т-130/160-12,8 Т-150-7,7 К К-180-8,0 Turbines for combined cycle plants Р-25-90/30Р-25-8,8-2 Р-50-90/13Р-50/60-12,8/1,3-2 Р-85-8,8/0,2Р-25-90/18 Р-50/60-130/10-2 Р-50-8,8/1,0 Back-pressure turbines Т Т-180/ Т-180/ Т-185/220-12,8-1(2) N MW

7 New products by OJSC Power Machines 7 Steam turbine equipment by OJSC Power Machines Steam jet ejectors Water jet ejectors Gland steam condensers Main turbine condensers rated 25 – 1200 MW Tube fixation:expansion and welding Tube material: titanium, stainless steel, copper alloys Cooling surface from 1750 m 2 to m 2 Block-modular construction Heaters for district water and regenerative Heat exchange surface m 2 Total assembly and testing at the factory Tube material – stainless steel Filters Valves (non-return, safety, control) Heat exchange surface m 2 Tube material – stainless steel Outer ribbing of tubes Oil coolers Water-to-water heat exchangers Heat exchange and auxiliary equipment for steam turbines

8 New products by OJSC Power Machines 8 Half-speed steam turbine 1200 MW

9 New products by OJSC Power Machines 9 TurbineStation nameCountry Output, MW Commissioning year Remark 1К /3000Rivne NPP Unit 1USSR (Ukraine) In operation 2К /3000Rivne NPP Unit 2 USSR (Ukraine) In operation 3К /3000Khmelnitsk NPP Unit 1 USSR (Ukraine) In operation 4К /3000Khmelnitsk NPP Unit 2USSR (Ukraine) In operation 5К /3000South-Ukraine NPPUSSR (Ukraine) In operation 6К /3000Crimean NPPUSSR (Ukraine)998 Unmounted 7К /3000Kalininskaya NPP Unit 3USSR (Russia) In operation 8К /3000Tianwan NPP Unit 1China In operation 9К /3000-3Busher NPP Unit 1Iran Erection finished 10К /3000Tianwan NPP Unit 2China In operation 11К /3000-2Kudankulam NPP Unit 1India In erection 12К /3000-2Kudankulam NPP Unit 2India In erection 13К /3000Beloyarsk NPP Unit 4Russia In assembly 14К /3000Kalininskaya NPP 4 Russia In assembly 15К ,8/50 Novovoronezhskaya NPP- 2 (Unit 1 and 2) Russia1198,82012, 2013 In assembly 16К ,8/50 Leningrad NPP - 2 (Unit 1 and 2) Russia1198,82013, 2014In assembly 17К /3000NPP «Belene»Bulgaria Contract design Паровая турбина К ,8/25 для АЭС Total turbine quantity -17 pcs. Total output ,6 MW Capabilities of OJSC Power Machines to supply powerful steam turbines for NPP.

10 New products by OJSC Power Machines 10 OJSC Power Machines design, manufacture and maintain equipment for NPP in accordance with license terms conditions, received in Rostechnadzor: License for nuclear plants equipment designing License for nuclear plants equipment manufacturing License for NPP units operation in part of work execution and service provisioning to the operation organization Certification TŰV Паровая турбина К ,8/25 для АЭС Capabilities of OJSC Power Machines to supply powerful steam turbines for NPP.

11 New products by OJSC Power Machines 11 Regeneration scheme is typical to schemes, used on high speed units 1000MW and has positive reference; Turbine plant heat flow train is optimized, considering particular conditions at NPP; Advanced heat flow train and effective auxiliary equipment; Direct-contact LPH-2 (zero temperature difference, prime deaeration, ensuring conditions for the reliable operation of the surface LPH) Cascaded drain is used; СПП heating steam condensate is injected into the feed water line; It is possible to make additional steam extraction for the district heating or other needs; Turbine basic scheme К ,8/25. P=68 bar P=10,7 bar P=3,6 bar HIP LPC-1LPC-2 Condenser Generator GSC Condensate electric pump-1 КЭН-2LPH3 LPH LPH2 LPH4 Drip pump HPH5 feed electric pump HPH6 Condensate hydroturbo pump Moisture separator /reheater Deaerator Ball cleaning system

12 New products by OJSC Power Machines 12 Turbine hall equipment specifications Turbine – HIP and 2 LPC Hydrogen-water cooled generator Vertical moisture separator-reheater with separating part undermount with two reheat stages Horizontal LPH-1 in two casings is housed in condenser adapter sleeves Vertical direct-contact LPH-2 Vertical surface-type LPH-3 and 4 are used with drain coolers Vertical chamber-type HPH-5 and HPH-6, which are switched on by two parallel groups Turbine operating level is +16 m

13 New products by OJSC Power Machines 13 HIP application with external superheated steam between HP and IP parts; Heat drop distribution optimization between IP and LP parts; HP steam supply line in the HIP bottom half; LP steam supply line in the LPC bottom half; LPC end glands design accepts to make repairs on them without LPC uncapping; Capability of rotor balancing at site without cylinder uncapping; Cylinder steam path endoscoping capability; Capability of additional extractions for district heating organization by the Customer request; LPC last stages moving blades diagnostics; OMTI fire-resistant fluid application in lube oil and control systems; Pressure in hydraulic part of control system is 50 or 160 bar; Welded or integral disk HPR; Welded LPR; Main design solutions, which increase efficiency, reliability and steam turbine maintainability

14 New products by OJSC Power Machines 14 Half speed steam turbine 1200MW for NPP – new product of OJSC Power Machines First variant: last stage blade in length of 1760 mm ensures necessary exhaust area with LPC minimum quantity Possibility of achievement large unit power : up to 1800 MW ( >1200 MW for the project NPP 2006) Second variant: last stage blade in length of 1450 мм ensures optimal exhaust area for the worsen vacuum conditions High efficiency efficiency > 37 % High reliability availability rate is more than 0,99 Appropriate metal consumption Low total expenditure for the operation Optimal capital costs subject to the station conditions Competitive equipment cost

15 New products by OJSC Power Machines 15 High economical flow path HIP and LPC Application of 3D-design of the blade system with sabre- shaped guide blades Coordination of the rated flow and skeleton angles of the blades profiles Smooth meridian bypass Displacement of wire communications out of flow to the moving blades shrouds Moisture removal system application

16 New products by OJSC Power Machines 16 High performance HPC steam supply header High efficiency High reliability Design compactness Lack of flange joints in steam supply pipes High hermetic piston rings in conjunction of LPC outer and inner casings

17 New products by OJSC Power Machines 17 Waste aerodynamics – pressure loss decrease in unit Range of measures to decrease vibration Process fluid - fire-resistant oil Working pressure of the fluid – 50 or 160 bar HP valve box with servodrives Control valve of the СПП heating steam

18 New products by OJSC Power Machines 18 LP valve box with servodrives Range of measures to decrease require effort of the servodrive High performance aerodynamics of the valve box flow path Servodrive process fluid - fire-resistant oil Working pressure of the fluid – 50 or 160 bar Servodrive Referense usage at NPP Small weight-overall dimensions characteristic Spring – plate type Performance – block type

19 New products by OJSC Power Machines 19 High performance steam supply line to LPC Steam supply line only to the bottom LPC half Minimal loss of inlet duct High maintainability Low operating costs LPC maintenance without crossover pipes dismantling

20 New products by OJSC Power Machines 20 Effective design of LPC end glands High efficiency High reliability Insensitivity to misalignment High maintainability – sealing rings replacement without LPC uncapping and taking out rotor

21 New products by OJSC Power Machines 21 Effective moisture removal system Application of butt water separation from the surface of the diaphragm outer shroud. Organization of the peripheral moisture removal after the guide apparatus. Interchannel moisture removal through the narrow chap system on convex and concave surfaces into core spaces of the guide vanes. Organization of moisture addition and discharge out of the concave surface of the guide vanes near the trailing edge. Guide vane Moving blade

22 New products by OJSC Power Machines 22 Engineering performance of turbine control system DesignationParameter Control system type Speed control type Type of disengaging clutch Non-stop operation cycle for overspeed protection system verification Insensitivity Inequality Basic solutions reference - Electronic-and-hydraulic type (with meeting the requirements of European power utilities – UCTE) - Electronic - According to reactor facility requirements - According to UCTE (with controlled dead band) - According to UCTE (with the ability to change setting) - Turbines for TPP and CCP With electronic speed governor more than 30 pcs. With electronic disengaging clutch – 8 pcs.

23 New products by OJSC Power Machines 23 Density g/cm 3 Self-combustionºС Toxicity Safety class Mineral Fire-resistant Fire - resistant oils in steam turbines of LMZ Fyrquel-L USA Reolube-ОМТI USA OMTI Russia Comparative analysis of mineral and fire- resistant oils Taking into account Russia, CIS and Baltic states – more than 220 turbines Bearings lubrication systems on the fire-resistant oil in steam turbines of LMZ (1985 – 2009) Governing systems on the fire-resistant oil in steam turbines of LMZ (1963 – 2009) Application of fire-resistant oil – problem solution of the fire safety at NPP 1. Leningrad NPP-2, unit 1 2. Leningrad NPP-2, unit 2 3. Novovoronezhskaya NPP-2, unit 1 NPP-2, unit 1 4. Novovoronezhskaya NPP-2, unit 2 NPP-2, unit 2 1. Rivne NPP,unit 5 2. Rivne NPP,unit 6 3. Khmelnitsk NPP,unit 1 4. Khmelnitsk NPP,unit 2 5. Khmelnitsk NPP,unit 3 6. Kalininskaya NPP, unit 3 7. Kalininskaya NPP, unit 4 8. Tianwan NPP, unit 1 9. Tianwan NPP, unit Kudankulam NPP,unit Kudankulam NPP,unit Belene NPP, unit Belene NPP, unit 2 1. Zaporozhskaya GRES,unit Zaporozhskaya GRES,unit 6 3. Permskaya GRES,unit 1 4. Permskaya GRES,unit 2 5. Permskaya GRES,unit 3 6. Beloyarsk NPP,unit 7 Steam turbines 800 MW Steam turbines 1000 MW Steam turbines 1200 MW Quantity (pcs) 2 6

24 New products by OJSC Power Machines 24 Turbine Plant Layout. Plan view at elevation mark Space-saving location of equipment Main delivery and discharge pipelines are situated under machine hall floor Enough place to lay out components and parts during repair

25 New products by OJSC Power Machines 25 High-efficient and reliable condensers High-efficient and reliable condensers Improving efficiency of steam turbines Strength- metal amount optimization owing to modern calculation programs Higher reliability of tube-tube plate connection due to expansion of tubes followed by welding around Increased degree of readiness of condenser modules for erection at site Shortened erection time periods Modern methods of calculation of thermal and hydraulic characteristics of condensers

26 New products by OJSC Power Machines 26 Quick operation; Package of measures to decrease vibration used in designing modern control valves; Cute ideas to decrease noise level; Horizontal configuration of valve; Separation of sealing and control surfaces in valve; Quick-operating pressure reducing station to dump steam into condenser (BRU-K)

27 New products by OJSC Power Machines 27 Development of LMZ Steam turbines for supercritical steam parameters

28 New products by OJSC Power Machines 28 LMZ steam turbines for supercritical and ultrasupercritical steam conditions АК-25 АК-50 АК-100 Stages of mastering initial steam parameters ВК-25 ВПТ-50 ВК-100 ПТ ПТ Т К К К К К К К К Subcritical and critical steam parameters T 0 =400….540ºC P 0 =30….170 bar Supercritical steam parameters T 0 =545º… 565ºC P 0 =240…247bar T 0 =400ºC P 0 =30 bar T 0 =535ºC P 0 =130bar T 0 =540ºC P 0 =130bar T 0 =540ºC/ 540ºC P 0 =130bar T 0 =545ºC/ 545ºC P 0 =170bar T 0 =545ºC/ 545ºC T 0 =565ºC/ 565ºC P 0 =240bar T 0 =565ºC/ 565ºC P 0 =240bar К ТЭС «Sipat», ТЭС «Barh» T 0 =537ºC/ 574ºC P 0 =247bar T 0 = ºC Trh= ºC P 0 =270bar Ultrasupercritical steam parameters Total number of turbines for supercritical steam parameters – 175 pcs Efficiency br. % T 0 =560ºC/560ºC P 0 =130bar К

29 New products by OJSC Power Machines 29 Intention: Bringing into operation the new generation units with improved effectiveness Benefit: 660 MW unit ( 270 at (abs) 610º-620º C/ 610º-620º C ) - fuel saving per year ~42 mln TOE 1. 1.Increasing initial steam parameters (t and p), R&D and usage of heat-resistant materials Improvement of steam flow path blading, optimization of heat flow train Usage of new practices and materials in steam turbine seals Increase in single-unit power Others (second RH, moisture evacuating system, etc.) SPP 50…200 MW subcr. steam efficiency 40-44% CHP 30…330 MW efficiency 38-42% CCP 80…800 MW SC pressure 300…1200 MW efficiency 45-48% USCC 500…1000 MW Steam turbine unit types (turbine plants) Objectives when creating new generation units efficiency > 50% Steam turbines for supercritical steam parameters

30 New products by OJSC Power Machines 30 К steam turbine Projects: Sipat SPP, Barh SPP (India) Output: 660 MW Live steam temperature: 537 °C Reheat steam temperature:565(574) °C Live steam pressure: 247 bar Reheat steam pressure: 48 bar Steam turbines for supercritical steam parameters

31 New products by OJSC Power Machines 31 Improving efficiency of steam turbines Creation and optimization of new stages New high-efficient airfoils of fixed and moving blades Modern stage of steam turbine Fluent program is used Blank piece for moving blade Streamlines in a HPC last stage Influence of variable tangential lean of fixed blades on steam flow in a stage New designs of fixed blades with variable tangential lean

32 New products by OJSC Power Machines 32 Improvement of HP-part opening area of K turbine. 2 - Improvement of HP-part opening area steam admission – nozzle boxes – control stage – chamber 6 - Control stage with decreased thermal drop and developed over- shroud seal 1 - Piston rings with sealed joint 3 - Nozzle boxes with low level of losses and even velocity field at steam supply to nozzle segments 7 - Increased number of stages (of reaction type) 4 - Chamber with minimum pressure losses 5 - Optimal profile of control stage disc Improving efficiency of steam turbines

33 New products by OJSC Power Machines 33 3-D mathematic simulation of HPC and IPC casings of K turbine With modern 3-d programs thermal and stress state of cylinder casings exposed to high steam temperatures and pressures are optimized In the IPC steam inlet chamber of this kind of profile minimum resistance and circular evenness of steam pressure upstream of the first stage fixed blade cascades is provided that almost retains their design efficiency. In the IPC steam inlet chamber of this kind of profile minimum resistance and circular evenness of steam pressure upstream of the first stage fixed blade cascades is provided that almost retains their design efficiency. IPC HPC Improving efficiency of steam turbines

34 New products by OJSC Power Machines 34 High-efficient HPC and IPC overshroud seals of K turbine IPC HPC Smaller radial clearances Retention of radial clearances in the course of operation Working temperatures up to 960ºC Honeycomb-block Improving efficiency of steam turbines

35 New products by OJSC Power Machines 35 Cooling system of intermediate pressure rotor high-temperature zone of supercritical and superhigh steam parameter turbines Ensures operating hours of high-temperature components up to hours Implemented in K turbines Cooling steam supply Improving efficiency of steam turbines

36 New products by OJSC Power Machines 36 Improvement of reliability and repairability of steam turbine components IPC Steam supply and discharge only in the lower half. No flange connections. Connection by welding. Optimization of layout solutions. Shortened repair time periods. IPR Balancing collar Possibility of rotor after-balancing without opening the cylinders. Shortened repair time periods. LPC Steam supply only in the lower half of the casing. No pipes in the upper half. Optimization of layout solutions. Shortened repair time periods. LPC Arrangement of shaft end glands. Rings of shaft end gland can be replaced without opening the cover. Shortened repair periods. К steam turbine.

37 New products by OJSC Power Machines 37 Improvement of reliability and repairability of steam turbine components Sealing of vacuum flange connections Installation of sealing cord in LPC flange connections Elimination of air inflows HP governing valve Quick replacement of stems and discs of valves. Shortened repair time periods. Endoscopic examination of stages Possibility of inspection of stages without opening the cylinders Shortened repair time periods Diagnostics of turbine set in real time mode. Possibility of finding out a local source of high vibration of turbine set. Information to operating personnel for taking a decision whether it is possible to continue operation of turbine set. Vibrodiagnostic system К steam turbine.

38 New products by OJSC Power Machines 38 Improvement of reliability and repairability of steam turbine components Protection of last stage moving blades Active protection. Removal of pellicular moisture in last stage diaphragm Passive protection. Strengthening leading and trailing edges, shrouds of titanium moving blades by method of ion implantation with titanium nitride precipitation Removal of up to 25% of moisture Moving blade Fixed blade

39 New products by OJSC Power Machines 39 Inner casing G-X12CrMoVNbN 9-1 Inner casing G-X12CrMoVNbN 9-1 Admission hood, inner casing G-X12CrMoVNbN 9-1 Admission hood, inner casing G-X12CrMoVNbN 9-1 Outer casing, carriers 15Cr1Mo1V Outer casing, carriers 15Cr1Mo1V Shaft (LP) 26CrNi3Mo2V Moving blades (IP) 18Cr11MoNiVNb 15Cr11MoV Moving blades (IP) 18Cr11MoNiVNb 15Cr11MoV Moving blades (LP) 13Cr11Ni2W2MoV 15Cr11MoV 20Cr13 Moving blades (LP) 13Cr11Ni2W2MoV 15Cr11MoV 20Cr13 Outer casing, carriers 15Cr1Mo1V Outer casing, carriers 15Cr1Mo1V Moving blades (HP) 1Cr16Ni13Mo2Nb 18Cr11MoNiVNb 15Cr11MoV Moving blades (HP) 1Cr16Ni13Mo2Nb 18Cr11MoNiVNb 15Cr11MoV Nozzle blades 18Cr11MoNiVNb 15Cr11MoV Nozzle blades 18Cr11MoNiVNb 15Cr11MoV Shaft (HP & IP) Cr11MoNiVNbN Materials in steam turbines of OJSC Power Machines Materials of high-temperature components of steam turbine K

40 New products by OJSC Power Machines 40 Materials of high-temperature components of steam turbine K Materials in steam turbines of OJSC Power Machines Stationary parts of HP stop and governing valve block Stationary parts of IP stop valves Stationary parts of IP governing valves 25Х2М1Ф 15Х1МФ 15Х1МФЛ 25Х2М1Ф SA182F91 10Х9МФБ G-X12CrMoVNbN Х9МФБ G-X12CrMoVNbN Х9МФБ 15Х1МФ SA182F91 10Х9МФБ 15Х11МФ-Ш 18Х11МНФБ-Ш Parts of steam-distribution elements of governing and stop valves 10Х9МФБ

41 New products by OJSC Power Machines 41 Main technical problems: 1.HIPC design: combined cylinder, 3D-blading 2.Production practice of welded composite rotor 3.Experimental development of last stage blade with high mass and volumetric flows Moving blade of top-of- the-range length Steam turbines for supercritical steam parameters Steam supply to HP part Steam supply to IP part

42 New products by OJSC Power Machines 42 Creation and mastering of steam turbine units for ultrasupercritical steam conditions (new generation units) Possible ways of partnership: 1.Cooperation/ joint manufacture of turbine 2.License agreement 3.Joint venture 4.Usage of laboratory-experimental facilities Experience of joint manufacture of turbine K , Alholma SPP, Finland» SIEMENS make HPC Power Machines make LPC

43 New products by OJSC Power Machines 43 Conclusion Steam Turbines of OJSC POWER MACHINES make Steam turbines of OJSC POWER MACHINES make are operated successfully in 48 countries of the world. Each tenth worlds turbine is of OJSC POWER MACHINES make. 175 turbines of unit power from 300 MW to 1200 MW for supercritical steam parameters. OJSC POWER MACHINES produces steam turbines and heat exchange equipment for units rated up to 1200 MW inclusive. OJSC POWER MACHINES began 660 MW turbine creation with ultrasupercritical steam conditions P 0 =270bar, T 0 / T rh =620 ºC