SST6000 – steam turbine for future coal-based power generation Prof Peng Zeying Shanghai Turbine Plant, China Michael Wechsung Siemens AG, Germany PowerGen-Asia 2011, Kuala Lumpur, Malaysia Copyright © Siemens AG 2011. All rights reserved. Energy Sector Agenda Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat Outlook - 700°C Summary Page 2 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Shanghai Turbine Plant - STP the world’s biggest steam turbine manufacturer 1953 Shanghai Turbine Plant founded 1981 Westinghouse design and manufacturing license 300MW & 600MW 1995 STP and Westinghouse Joint Venture Shanghai Turbine Co., LTD. (68% STP and 32% Westinghouse) 1999 Siemens took over Westinghouse Chinese / German Joint Venture 2003 Licensee for several Siemens Steam Turbines in China Page 3 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Siemens Steam Turbine History More than 80 Years 2008 1996 1985 1970 1954 Delivery world’s largest ST for NPP Olkiluoto3 3DS technology: Efficiency SPP > 48% „Isar 2“ is today the most powerful steam turbo set Start delivery of all German nuclear power plants First super critical steam turbo set worldwide 2010 2004 2001 Opening expansion of new office building Official opening of new heavy machinery workshop „Hafen“ site new office facilities 1996-1998 1927 Page 4 Purchase of Thyssen machinery plant in Mülheim 1970 Ground breaking ceremony for „Hafen“ site Merge Westinghouse, Parsons ALSTOM (Industrial turbine) © Siemens AG 2011. All All rights reserved. For internalCopyright use only. Copyright © Siemens AG 2008. rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy EnergySector Sector Product Portfolio Steam Turbine Series SST-3000 for Combined Cycle Power Plants single-flow LP axial exhaust max. 177bar/ 565°C/565°C 90-250 MW CCPP SST-5000 for sub critical SPP and CCPP SPP CCPP CSP SST-6000 for Steam Power Plants SPP SST-9000 for Nuclear Power Plants NPP with down, double-side or single-side exhaust max. 177bar/ 600°C/600°C with two, four or six-flow LP turbines max. 280bar/ 600°C/610°C with shrunk-on disc rotor design max. 80bar/ 300°C 150-700 MW 300-1200 MW 1500 rpm 1000-1900 MW 90 – 1900 MW (50 Hz and 60 Hz) Page 5 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Agenda Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat Outlook - 700°C Summary Page 6 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector SST 6000 series turbine Bypass cooling for minimum wall thickness Advanced sealing technologies Symmetrical casing design for minimum radial clearances High-performance LP blading for different sizes of exhaust area Barrel type: minimum radial clearances fast thermal loading capability high performance 3DVTM blading Page 7 Push rod arrangement for reduced axial clearances IP-admission blade ring with integral cooling Power range: 600..1200 MW Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Design Principle Modular Concept example: HP Turbine H50 material change main steam conditions T, p H60 H70 V4 …… …… …… …… …… …… V3 V2 V1 scaling of modules power output/mass flow MW Page 8 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Design Principle Modular Concept example: HP Turbine Page 9 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector USC references Plant Country Power output Main steam Reheat steam Commercial operation Isogo Yuhuan Wai Gao Qiao 3 Westfalen Eemshafen Lünen Mainz Japan China China Germany Netherlands Germany Germany 1 x 600 MW 4 x 1000 MW 2 x 1000 MW 2 x 800 MW 2 x 800 MW 1 x 800 MW 1 x 800 MW 251 bar / 600°C 262 bar / 600°C 270 bar / 600°C 275 bar / 600°C 275 bar / 600°C 270 bar / 600°C 273 bar / 600°C 610°C 600°C 600°C 610°C 610°C 610°C 610°C 2001 2007 2008 2011 2012 2012 2013 Page 10 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Operating Experience - Isogo, 48000 EOH Power Output: 600 MWel Main Steam: 251 bar/600°C Reheat Steam: 610°C Condenser: 0,0507bar Type of cooling: once through, sea water Fuel type: hard coal comm. operation: 2002 Page 11 martensitic 13% chrome seal strips Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector References Wai Gao Qiao 3, China Max. proven power output: 1112 MW ! Power Output: 1040 MWel Main Steam: 270 bar/600°C Reheat Steam: 600°C Condenser: 0.053/0.042 bar With Stage Bypass (Overload) Fuel type: hard coal Comm. Operation: 2008 Page 12 Asian Power Plant of the Year Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Steam Cycle Efficiency (net) Steam Power Plant Development Roadmap Covers Double Reheat and 700°C Page 13 Single reheat Double reheat 55% Nickel Alloys (350 bar, 700°C) 50% Ferrites / Martensites (240 bar, <~620°C) 45% Higher parameter 40% Larger size 35% Improved cycle 30% 1950 1970 1990 2010 2030 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Agenda Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat Outlook - 700°C Summary Page 14 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector DRH studies at Siemens Steam Turbines 1. Danish Customer 900MW; 50Hz; 590/604/604; Master Cycle 2. Wai Gao Qiao Unit 9 1350MW; 50Hz; Cross Compound; 600/620/610 Variants: SRH, DRH & adv. DRH 3. Japanese Customer 600MW; 60Hz; 600/610/610 (625) Variants: SRH, DRH & adv. DRH 4. Siemens Plant concept 900MW; 50Hz; Design for CCS; 600/610/610 Variants: SRH, DRH, 1½-RH Page 15 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 1350 MW double-reheat with Siemens components – example WGQ 9 Cross over pipe: 31.2 m m.st. RH1 RH2 RH2 50 m Thrust Rotor dynamics Axial expansion 71 m Too long rotor train and challenging generator size Cross compound Page 16 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 1350 MW double-reheat cross-compound with Siemens components – 1350MW WGQ9 540 t w/o Generator 990 t with Generator 27 m 55.6 m Page 17 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 1350MW DRH Steam turbine arrangement and systems of 1st train HRH piping 1 Hydraulic Supply Unit Lubricating Oil Module Weight of turbine deck + turbine train: ~3500 t MS piping CRH piping 2 Gland Steam Condenser Evacuated Stand Pipes Seal Steam Header CRH piping 1 Page 18 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 1350MW DRH Steam turbine arrangement and systems of 2nd train IP turbine 2b IP turbine 2a Hydraulic Supply Unit for turbine valves Lubricating Oil Module Page 19 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Overall plant efficiency development 48.8 Overall plant net efficiency in % 43.5 2.5 46.0 46.3 2.5 2.8 43.5 43.5 46.3 Heat Rate / kJ/kWh 7320 7140 6947 6765 Station Power Rate 4.5% 3.5% 4.0% 3.0% Boiler efficiency 93.6% 95.5% 94.0% 95.5% State-of-the-art single reheat DRH 1350 MW at design conditions DRH 1350 MW with state-of-theart technology Typical CHN 1000 MW unit Page 20 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Agenda Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat Outlook - 700°C Summary Page 21 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 700°C Steam Power Plant Affected Components Boiler Boiler house superheater Flue gas Flue gas train Cleaned flue gas 7 Live & reheat steam piping Ammonia 6 2 Main steam 1 Lime emulsion Power distribution grid Turbine building Feed water 8 Electric power 11 5 3 13 10 4 14 4 12 9 AIR Ash Coal Gypsum Fly ash 1 2 3 4 5 6 7 Steam generator DeNOx plant Air preheater Fan Electrostatic precipitator Desulfurization plant Stack 8 9 10 11 12 13 14 Steam turbine Condenser Pump Feedwater heater Feedwater tank Generator Transformer Steam conditions: 700°C / 350 bar 720°C / 70 bar Page 22 HP & IP turbines 11 and valves10 Condensate Circulating 10 water Cooling tower Cooling air Fresh water Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 700°C Steam Turbine Technology Challenges Drawback Material costs and machining effort (time) Pressure Requirements Increased temperature and pressure Qualification of available Nickel alloys for very heavy and thick-walled parts (forgings and castings > 10 tons) Steam/Gas Parameters 350 bar 700°C 700°C Steam Turbine USC Steam Turbine Gas Turbine 250 bar 600°C 25 bar 1400°C Temperature Development Focus Production procedures (large forgings & castings, welding, machining) Material properties for steam environment, thick-walled components Non-destructive evaluation Blade and seal technologies Design concepts, including cooling Page 23 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 700°C Steam Turbine Development Project Status Large Nickel alloy forging and casting demonstrated Welding of dissimilar materials (Nickel alloys / steel) Machining tests on Nickel alloy performed Design concepts available Source: AD700 Source: AD700 Page 24 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector 700°C Steam Turbine Principle of Construction for HP Turbine Design Cooling Steam Live Steam 350bar 700°C HP Characteristics Proven basic concept (Siemens barrel-type) Solid rotor shaft Welded rotor and inner casing Cooled outer casing with full pressure load Inner casing with low pressure load at inlet Flanged valve attachment Page 25 Ni-based alloys Exhaust Steam Weld Seams of different materials Principle of Construction Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Agenda Shanghai Turbine Plant & Siemens State of the Art - USC Next step - Double Reheat Outlook - 700°C Summary Page 26 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Further increase of efficiency with different technology 52.0 Overall plant net efficiency in % 49.2 1) 3.2 48.8 3.2 46.0 48.8 46.0 1000 MW SRH with state-of-theart technology Page 27 700 °C SRH DRH 1350 MW with state-of-theart technology 700°C DRH 1) 50.1% with open circuit cooling @ North Sea Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector Steam Turbine Technology Development – 700°C as ‘final’ step ~~ 2010 2010 State State of of the the art art USC single reheat (280 bar / 600°C / 620°C) in tandem compound configuration up to 1200 MW power output hub i. D l R& angha a b o / 600°C USC double reheat (310 Sh / 610°C / 620°C) glbar ~~ 2015 n s i 2015 n me IV lin ded compound configuration up to e n i Pilot WaiGaoQiao cross a S Next Next step step the icially , t ns s e f 1 f 1350 MW power output m t o e Si gus rbines & u A C e tu SE n Sinc steam e twe e P b P r S 700°C single on (350 bar / 700°C / 720°C) in tandem tireheat a ~~ 2020 r 2020fo e p coo p configuration up to 550 MW power output e: compound v e e Future i t Future step step h t c a e d j m ob ten rGerman ad pilot project Wilhelmshaven postponed x y o e e t r K e a h h t t r fu work an to Increase power output of 700°C (350 bar / ≤ 720°C) in Beyond Beyond 2020 2020 tandem compound configuration to 900+ MW Operational experience of 550 MW mandatory Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector * Ultra super critical / Hyper super critical Page 28 Thank you for your attention! Michael Wechsung Head of ST Product Strategy Siemens Energy Rheinstr. 100 45478 Muelheim an der Ruhr Phone: +49 (208) 456-3644 E-mail: [email protected] Page 29 Copyright © Siemens AG 2011. All rights reserved. PowerGen Asia 2011 - Kuala Lumpur, Sep 2011 Energy Sector