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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
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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
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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
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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
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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