Meeting Buenos Aires, October 2013
Modernization of LMZ
Steam Turbines
Markus Kupetz
Luis Sanchez
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Page 1 2013-10-02 Steam Turbine Design
• Introduction
• Concepts
• Modernization Products
• Conclusions and Summary
Luis Sanchez– October 2nd 2013
Meeting with Pampa Energia
Buenos Aires, Argentina
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Page 2 2013-09-30 E F PR SU EN MO
Presenter
Dipl.-Ing. Markus Kupetz
Since 2010 Director - Global Modernization
Steam Turbine Engineering
2009 – 1997 Siemens Energy
Functions in Steam Turbine Engineering
Blade and Airfoil Design
Blading Developments
Thermal and Mechanical Design
Manufacturing Technology
Mods & Upgrades – Turbine Construction
Condenser Design
1990 – 1996 Mercator University Duisburg, Germany,
Master Degree in Mechanical Engineering
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Presenter
Ing. Luis Sanchez
Since 2005 Siemens Energy – Service Division
Steam Plants Modernizations
Marketing Manager-Region Latin America
2000 – 2005 Siemens Energy – Service Division
Functions
Strategic Marketing
Gas Turbine Product Development
Diagnostics Product Development
Education: Master degree in Management of Technology
Master degree in Industrial Engineering
Bachelor degree in Electrical Engineering
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Siemens Energy Sector – New set-up for the future
requirements of the market
Energy products and solutions – in 6 Divisions
Products and solutions – in 6 Divisions
Fossil Power Wind Solar & Oil & Gas Energy Power
Generation Power Hydro Service Transmission
(E F) (E W) (E X) (E O) (E S) (E T)
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Energy Service Division
Organizational structure
Energy Service Division
CEO Randy Zwirn
Service Fossil Oil & Gas and Industrial TurboCare Service Renewables
(E S SF) Applications Services (E S TC) (E S SR)
(E S SO)
Business Unit Business Unit Business Unit Business Segment
Comprehensive service Comprehensive service Non-OEM1) and some OEM Comprehensive service Portfolio
portfolio: portfolio: Mature products and services portfolio:
Performance Enhancement Performance Enhancement for oil & gas, industrial and
Lifecycle Management
Programs Programs power generation
applications: Onshore Service Programs
Performance Maintenance Performance Maintenance Offshore Service Programs
Service Programs Service Programs Gas Turbines Offshore Logistics
Training & Consulting Training & Consulting Steam Turbines Solutions
Environmental Systems Customized services for oil Compressors Operations Management
& Services and gas and industrial Generators Spare parts, tools and
FG/IGCC applications repairs
Modernizations and
For gas turbines (up to 60 Upgrades
MW), steam turbines (up to
150 MW), generators and
compressors
1) Original Equipment Manufacturer
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Service Organizational Set-up and Global Presence
Page 7 2 October 2013 Copyright © Siemens AG 2013 Energy Sector
Solutions to Answer
Customer Needs
Customers "Enablers" Value Proposition Potential Solutions
Optimize cycle Boilers, Auxiliaries, Controls and
"I want to Environmental systems modifications
Plant
optimize my
whole plant" study
Improve integrity Components replacement/upgrade
Energy Efficiency
Audit (RNA)
Traditional upgrades for increased
MW from turbine MW output
"I want the
Traditional
most out of
my machine" STG analysis Inspection intervals extension
Life cycle costs / Diagnostics technologies for
Steam / Gen maintenance Condition-based maintenance
in CC or Outage reduction techniques
Conventional
Optimize limits Start-up / ramp-up and shut down
"I need more
Optimization time changes
operational
flexibility" assessment Increase turbine limits Increased availability
(operational flex)
Critical part monitoring Track key components
Life
“How do I Assessment
Reduce failure risk Necessary components to get to
prepare to end of life
shut this unit
down?” Life Cycle
Operation optimiza-
Management Optimal operations for machine
tion (life time mgmt.)
Plan
Page 8 2 October 2013 Copyright © Siemens AG 2013 Energy Sector
BENEFITS OF MAINTENANCE
INVESTMENTS
Modernization &
Rehabilitation
Investment
In-Kind
Components
Replacement
Maintenance
Power Output
& Thermal
Return on Investment
Consumption
Useful Life
Extension
Useful Life
Extension
Reliability
Reliability Availability
Reliability Availability
Page 9 2 October 2013 Copyright © Siemens AG 2013 Energy Sector
Scope of Supply
I&C
Superheater Reheater
Fuel Economizer
Firing Steam turbines Generator*
System
Burners
Condenser
Pump
LP
Deaerator Pump Heaters Cooling tower
Boiler
Air Preheater
Modernization of prime mover equipment is our main target
Page 10 2 October 2013 Copyright © Siemens AG 2013 Energy Sector
LMZ Turbine Modernizations Experience
Page 11 2 October 2013 Copyright © Siemens AG 2013 Energy Sector
Siemens Solutions for CIS Steam Turbine Fleet
Siemens Experience and References
HP 300MW
Smijew, Ukraine
LP 200MW
Shetou, China
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Siemens Solutions for CIS Steam Turbine Fleet
Siemens Experience and References
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570+ GW (rated) Installed Fleet Worldwide thru 2009
2016
Fossil & Nuclear Fleet [GWs] Units Fossil & Nuclear Fleet [units]
and Market Ranking and Market Ranking
290
Gigawatts 2016
Units
177
Gigawatts
1052
902 Units
#1 94 Units
Gigawatts #1
#2
#1
#1
#2
#2 111
Units
Steam Power Gas Turbine and Nuclear Power Gas Turbines Steam Turbines SteamTurbines Generators
Plants CC Power Plants Plants Fossil Fueled Nuclear Fueled
Definitions: Siemens fleet operating in utilities > 100 MW. Operating plants only; retired, deactivated etc., and projects under construction not included.
With more than 570 GW installed capacity, we are a competitive player in the energy
market
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• Introduction
• Concepts
• Modernization Products
• Conclusions and Summary
Markus Kupetz – October 2nd 2013
Meeting with Pampa Energia
Buenos Aires
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Page 15 2013-09-30 E F PR SU EN MO
Siemens Solutions for LMZ Fossil 300MW
CONCEPT 1 : Longitudinal Section K-300-240 LMZ
Original Design
Proposed Design (new inner components)
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Siemens Solutions for LMZ Fossil 300MW
CONCEPT 2 : Longitudinal Section K-300-240 LMZ
Original Design
Proposed Design (new HP turbine, new IP outer casing)
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• Introduction
• Concepts
• Modernization Products
• Conclusions and Summary
Markus Kupetz – October 2nd 2013
Meeting with Pampa Energia
Buenos Aires
Restricted © Siemens AG 2013 All rights reserved.
Page 18 2013-09-30 E F PR SU EN MO
Siemens Solutions for LMZ Fossil 300MW
HP-Turbine
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Siemens Solutions for LMZ Fossil 300MW
HP-Turbine (new inner components)
Assumptions : Re-Use HP-Turbine
Bearings (Re-Babbitt) New Rotor
Outer Casing New HP Inner Casing
Gland Casings Integrated Piston
New Guide Blade Carrier
New Control Stage
3D-Blades Drum Stages
Optimized Sealing
New Piston Sealing
Segments
Rotor Oil-Lift System
New Gland Sealing
Segments
Machining of Outer
Casing
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Siemens Solutions for LMZ Fossil 300MW
HP-Turbine
Scope of HP Turbine modernization
• New Reverse Flow Rotor with Reaction Type Blades
• New Inner Casing with new Control Stage and Nozzle Segments and Blade Carrier
• Outer Casing will be retained - only machining
• Modification of steam inlet with L ring joint (outer to inner casing)
• Turbine Shaft Glands with Spring-Suspended Seal Segments
(front and end glands, piston gland sealing)
• Installation of Sliding Plates at Bearing No 1
• Sliding Plates at Outer Casing Support Brackets (front-end)
• HP evacuation pipe
• New protection circuits for reaction blading
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Siemens Solutions for LMZ Fossil 300MW
New HP Barrel-Type Turbine
Design M2A
-Supercritical design
-Different admission and exhaust
material possible
-Different casing supports possible
-Long (flexible) rotor
-Feasible for 1-bearing-design
-Short start-up time
-Improve element efficiency >90%
Barrel-Type HP-Turbine:
The barrel design was first introduced in 1937 and become a industry benchmark and Siemens HP-standard.
Since then more than 400 of these turbines were produced. Approximately 250 of which are still in operation.
Reference projects with GUS-manufacturers are Smijew 300MW (Ukraine, TA) and Alholma 200MW (Finland, LMZ)
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Turbine Modernization Concepts
Blading Technology (Drum Stages)
HP Inlet Ring / Full Arc Admission
• Advanced 3D low reaction blading (not
impulse)
• Single piece design: electro-discharge
machined (EDM) or milled out of a
forged stainless steel ring
Benefit
• Highest efficiency
• Reduced leakages
• Sized for maximum flow of the unit
(reduction of throttling)
• Provision of temperature protection
• Prevention of direct impingement of inlet
steam on the rotor body
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Turbine Modernization Concepts
Blading Technology (Drum Stages)
3DSTM/3DVTM Blade Path Design
• Fully 3-dimensional blading design
• Twisted blades – reduction of
incidence losses
• 3DSTM Blades – 3-dimensional
Design reducing the Secondary
Losses
• 3DVTM Bladepath – 3-dimensional
Design with Variable stage reaction
Benefit
• Efficiency of the highest level
• Broad range of application
• Customized design with a short delivery time
Cylindrical Airfoil Twisted Airfoil 3DSTM
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Turbine Modernization Concepts
Blading Technology (Drum Stages)
Controlled Assembly and Recorded Pre-Twist
• Elastically pre-stressed blades (due to pre-twist)
• Tight fit, continuously coupled shroud
Benefit
• Reduced vibration, excellent damping behavior
• Reduced leakage
• No lashing lugs, rivets or tenons
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Siemens Solutions for LMZ Fossil 300MW
IP-Turbine
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Siemens Solutions for LMZ Fossil 300MW
IP Turbine (new inner components) – design features
Original outer cylinder and 4 IP-Turbine with existing
control valves are to be reused Outer Casing
New Rotor
Blade ring design for New Guide Blade
stationary blading Carriers
New balance piston
ring in the inlet area 3D-Blades Drum Stages
New Piston Ring with
integrated Sealing
New Gland Sealing
Segments
Machining of IP Outer
Casing
ETAi~93%
Reaction rotor with
balance piston Rework of the
outer casing
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Siemens Solutions for LMZ Fossil 300MW
New IP Turbine – design features
Assumptions : Re-Use IP-Turbine
Bearings (Re-Babbitt) New Rotor
LP Outer Casing New IP Outer Casing
LP Diffuser New IP Inner Casing
LP Gland Casings Integrated Piston
New Guide Blade Carrier
3D-Blades Drum Stages
Optimized Sealing
New Piston Sealing
Segments
New Gland Sealing
Segments
Optimized Material
Concept (welded rotor)
Machining of LP Outer
Casing
ETAi~93,3%
Reference design for the IP-solution is prooved E-turbine of the
SST3000-series. More than 100 turbines of the type were produced.
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Siemens Solutions for LMZ Fossil 300MW
LP-Turbine
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Siemens Solutions for LMZ Fossil 300MW
LP-Turbine
Protection against last stage blade loss, LP-Turbine
(e.g. crash ring over bearing cover)
New Monoblock Rotor
New Inner Single Shell
Casing
3D-Blades Drum Stages
Modern LP Standard
Blades 8m2
Integral Guide Blade
Carriers
New Diffuser
New Rotor Oil-Lift System
Optimized Sealing
New Gland Sealing
Segments
Assumptions : Re-Use
Optimized Material Concept
Bearings (Re-Babbitt)
Machining of Outer Casing
Outer Casing
Rework of the
Gland Casings
Restricted © Siemens AG 2013 All rights reserved. outer casing
Siemens Solutions for LMZ Fossil 300MW
LP-Turbine
Scope of LP Turbine (2nd and 3rd Flow) Modernization
• New Monoblock Double-Flow Rotor with reaction blading and 8 m2
Exhaust End
• New Inner Casing (steam inlet)
• New Stationary Blade Carriers
• Modification of the Front-End Gland Carriers with Spring-Suspended
Seal Segments
• Rework of Bearing No 4 and 5 for the Installation of the Jacking Oil
System
• Machining of the Outer Casing
• Installation of a Water Injection System after the last Stage (2nd and
3rd Flow)
• Stiffening rods underneath LP bearing housing
• LP Efficiency after retrofit of LP : 86,0…89,0%
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Turbine Modernization Concepts
Blade Design Features
Module Stages: Rotating Blades Integral
Shroud
Sealing
• La-0 Fins
- free standing
- forged
- fir-tree root Leading
Edge
• La-1 Leading
- shrouded Edge
- forged
- fir-tree root
• La-2
Fir Tree
- shrouded Root
- milled
- T-root Free-standing rotating
blade with fir-tree root Shrouded rotating blade with fir-tree root
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Turbine Modernization Concepts
Blade Features of the LP Turbines – La-0
Design Features Rotating Blades
Full 3D Design
Freestanding L-0
Shrouded La-1 and La-2
Thin Trailing Edges
Supersonic Airfoil
Flame Hardened Leading Edges
Curved Fir Tree Root Design
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Turbine Modernization Concepts
Blade Features of the LP Turbines
Design Features
Stationary Blades
• Full 3D Design for optimum
radial flow distribution and
low exhaust loss
• Thin Trailing Edge
• Hollow Vanes
• Moisture Suction Slots
• Welded Blade Rings
Welded Blade Ring
Single Hollow Vane
Prepared for Welding
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Turbine Modernization Concepts
LP Blading Erosion Mitigation
Connected to
condenser
To
Condenser
No severe erosion observed
a Drainage through extractions A1/A2
on modern designs with
b Cylinder drainage to extraction
optimized materials e.g.
chromium steel for segmental c Hollow guide vane suction slots
---- Watertrails
rings in final LP stages
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• Introduction
• Concepts
• Modernization Products
• Conclusions and Summary
Luis Sanchez – October 2nd 2013
Meeting with Pampa Energia
Buenos Aires
Restricted © Siemens AG 2013 All rights reserved.
Page 36 2013-09-30 E F PR SU EN MO
ECONOMIC ANALYSIS
IN-KIND REPLACEMENT vs MODERNIZATION
NOTE: All figures are indicative values for comparison purposes only
Page 37 2 October 2013 Copyright © Siemens AG 2013 Energy Sector
ECONOMIC ANALYSIS
IN-KIND REPLACEMENT vs MODERNIZATION (cont)
NOTE: All figures are indicative values for comparison purposes only
Page 38 2 October 2013 Copyright © Siemens AG 2013 Energy Sector
Tender and Project Roadmap
Input for Tendering
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Page 39 2013-10-02 Steam Turbine Design
Possible Time Line
PLAN
2013 2014 2015 2016
2007 2017 2008
O N D J F M A M J J A S ON D J F M A M J J A S ON D J F M A M J J A S ON D J F M A M J J A S O N D
Customer
Budget Engineering, Fabrication and
Delivery
2010
Initial Budgetary Planning and Firm Contract OUTAGE
Meeting Proposal Authorization Proposal Award
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Tender and Project Roadmap
Input for Project Execution
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Page 41 2013-10-02 Steam Turbine Design
Tender and Project Roadmap
Typical Project Deliverables
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Page 42 2013-10-02 Steam Turbine Design
Tender and Project Roadmap
Summary Collaboration
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Page 43 2013-10-02 Steam Turbine Design
Summary - Conclusion
Demonstrated Capabilities to Modernize your Plant ...
Siemens Technology Provides the Optimal Solutions !
Improving efficiency with most modern technologies and materials
Maximizing capacity of existing unit with increased exhaust area
Gaining operation flexibility with reliable and well proven designs
We are able to upgrade your steam turbine on the basis of
our tools, knowledge and experience in close cooperation
with you, our customer!
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Page 44 2013-10-02 Steam Turbine Design
Pampas Energia - Customer Meeting
Thank You
for Your Attention!
© Siemens AG 2012. All rights reserved.
Page 45 March 2012 Iberdrola Cofrentes NPP Customer Meeting AL=N;ECCN=N.
