Proceedings of PWR2005

ASME POWER
April 5-7, 2005, Chicago, Illinois

PWR2005-50085

MODERN REACTION HP/IP TURBINE TECHNOLOGY ADVANCES &

EXPERIENCES

Paul Hurd, P. E. Frank Truckenmueller

Siemens Westinghouse Power Corporation Siemens Westinghouse Power Corporation
4400 Alafaya Trail 4400 Alafaya Trail
Orlando, Florida 32826 Orlando, Florida 32826

Norbert Thamm Helmut Pollak

Siemens PG Siemens PG
Rheinstr. 100 Rheinstr. 100
Muelheim, Germany 45478 Muelheim, Germany 45478

Matthias Neef Mathias Deckers

Siemens PG Siemens PG
Rheinstr. 100 Rheinstr. 100
Muelheim, Germany 45478 Muelheim, Germany 45478

ABSTRACT HP High Pressure

Modern steam turbines of the author’s company are based IP Intermediate Pressure
on advanced technology such as high efficiency seals, 3D LP Low Pressure
blading, single inner cylinders, and advanced materials. These SPP Steam Power Plant (Fossil)
technologies result in a compact opposed-flow HP/IP combined η Stage Efficiency
cylinder design with high long-term efficiency, reliability, and Ψ Stage Loading
availability.
This paper will illustrate the features, benefits, and
operational experience of large steam turbines with advanced INTRODUCTION
technologies using an opposed-flow HP/IP cylinder. The paper Today’s power generation markets require power plants
will also address the relative performance of this type of steam with low life-cycle costs, high efficiency, high availability, and
turbine against its predecessors. operating flexibility. Paramount for plant performance is a highly
Specific examples will be examined: 350 MW fossil units in efficient steam turbine designed to meet market demands.
the Asian market, a typical 250 MW combined cycle steam For steam turbines, the main design parameters are power
turbine in the American market, a 700 MW three-cylinder class output, steam conditions, ambient temperature, cooling water
design for conventional steam plants developed for the global availability and power plant configuration. In combined cycle
coal market, and a 600 MW steam turbine upgrade. power plants (CCPP), steam conditions depend on the exhaust
energy of the applied gas turbine and level of duct firing. As a
result of the ongoing gas turbine development, steam
NOMENCLATURE temperatures and mass flows are continuously increasing.
Current generation of CCPP’s are designed for main steam
BB Building Block conditions of up to 2550 psig and 1050°F, and reheat
CCPP Combined Cycle Power Plant temperatures of 1050°F with potential for main steam and reheat
h Enthalpy steam temperatures up to 1112°F.

1 Copyright © 2005 by Siemens Westinghouse Power Corp.

 For subcritical steam power plants (SPP), the market In addition, existing HP/IP designs can be upgraded with
requires main steam and reheat steam temperatures up to 1050°F inner cylinder and rotor packages based on the same design
at main steam pressures of up to 2550 psig. Typical supercritical philosophies, features, and technology developed for the new
SPP’s require main steam temperatures of 1050°F at main steam apparatus HP/IP turbine. The Building Block (BB) 44 Full Arc
pressures of up 3685 psig. Advances in chromium alloy (FA) turbine upgrade is discussed in detail in later sections of
materials for ultra super-critical applications have resulted in this paper.
main steam temperature capability of up to 1112°F, and reheat
steam temperatures of up to 1112°F at main steam pressures of DESIGN FEATURES & TECHNOLOGY OF THE NEW
up to 3685 psig. APPARATUS HP/IP TURBINE
Market conditions also require upgrades for existing older
design steam turbines to newer designs with advanced General
technologies, higher efficiencies, and improved reliability. The new apparatus combined HP/IP (Figs. 2, 3) is a compact
Drawing on a wealth of experience gained in designing, double shell design with horizontally-split inner and outer
building and the operating experience feedback from more than casings and features full-arc admission. A full-arc admission
1,300 steam turbine-generators, the author’s company has turbine design provides optimal efficiency for variable-pressure
developed two-cylinder and three-cylinder class designs for operation and results in low thermal stressing due to low steam
new apparatus and upgrade applications. This paper will velocities and forces at the first-stage blading. [1].
provide an overview of these designs including technology,
features, function, benefits, performance benefits, and
operational experiences

MODULAR DESIGN APPROACH

Combinations of the new apparatus HP/IP and LP modules in

different sizes are available and may be configured with down,
side, and single-side LP exhaust arrangements. One or more
double-flow LP sections can be utilized depending on the
requirements of the particular application.
For the new apparatus HP/IP turbine, the full application
range for CCPP and SPP cycles up to 700 MW is covered with 4
turbine module sizes (Fig. 1). All modules are based on the same
design philosophy in order to apply similar proven design
features to all turbines. The scaling factors between the
different turbine modules have been chosen to provide optimal
Figure 2 – New Apparatus HP/IP and LP Turbine
turbine efficiency and consistently high performance across the
Longitudinal for CCPP
application range.

Figure 1 – Modular Concept to Cover Broad Range of CCPP

and SPP Applications

2 Copyright © 2005 by Siemens Westinghouse Power Corp.

 Main steam enters the single-piece inner casing through between the rotor and casing during transient conditions,
two HP admission inlets, one on each side, located below the maximizing sealing efficiency.
casing joint. Steam then flows through the high-pressure All stationary parts are fully integral with the casing,
blading towards the front bearing pedestal. Steam from the HP reducing the number of parts and installation time. Extraction
section is exhausted vertically downwards through one or more and overload admission features can be incorporated for
nozzles with flanged exhaust connections to the reheater. The specific applications.
steam leaving the reheater enters the IP section via two The inner casing material is dependent upon application
admission inlets, one on each side, located below the casing temperatures. 1% Cr alloy is utilized for applications with main
joint and flows through the intermediate-pressure blading and reheat steam temperatures of up to 1050°F. For higher
towards the LP turbine. Steam leaving the IP section exhausts temperature applications of up to 1112°F, 10% Cr alloy is used.
vertically upwards. A flanged joint is provided for connecting
the cross-over pipe which carries the steam to the LP turbine.
The HP and IP bladepath areas are separated by spring-
backed or retractable shaft seals. A combined journal and thrust
bearing is located in the front bearing pedestal. This bearing
pedestal also forms the fixed point for the outer and inner
casing, allowing thermal expansion of the rotor and casings to
be in the same direction. Axial thrust forces are balanced by the
opposed direction of steam flow and the balancing pistons.

Outer Casing
The outer casing consists of top and bottom halves. Forces
due to steam pressure and thermal loading are absorbed by the
casing joint bolts.
The turbine rests on bearing pedestals at the turbine
centerline. Displacement due to thermal expansion in the axial
direction originates at the front bearing pedestal of the HP/IP
turbine. Figure 3 – New Apparatus HP/IP Turbine 3D View
Displacement transverse to the turbine centerline originates
from the centering guides located under the turbine centerline,
which consist of lugs on the bearing pedestals and forks on the
outer casing. At the generator end, the joint flange of the
bottom half of the HP/IP turbine outer casing is provided with
lugs for attachment of thrust bolts to couple its expansion with
that of the LP inner casing as shown in Figure 7.
The design consists of special features which shield the
outer casing from the hot main steam and reheat steam
temperatures. The valve is connected to the inner casing via a
flexible L-ring and to a sleeve which guides the hot steam
directly into the inner casing and blading. As a result, the outer Figure 4 – Advanced 3D FEA Used to Design Single Piece
casing is only exposed to IP-exhaust pressures and Inner Casing
temperatures.
Rotor
Inner Casing The rotor consist of a mono block, no-bore forging allowing
The single-piece cast inner casing is centered within the for fast start-up times. Coupling flanges are integral to the rotor
outer casing via support brackets. This unique configuration body and tee-grooves are fitted with inserted rotating blades.
minimizes the differential expansion between the rotor and 1% Cr alloy is typically utilized for applications with main and
casing and maintains rotor alignment and seal clearances, reheat steam temperatures of up to 1050°F. For higher
allowing for optimal efficiency. temperature applications of up to 1112°F, 10% Cr alloy is used.
The inner cylinder was designed using the latest 3D Finite The HP/IP turbine rotor can be shipped pre-assembled into the
Element Analysis (FEA) techniques (Fig. 4) and incorporates inner and outer casings, allowing shorter erection times and
vertical ribs, flanges and end rings to maintain proper alignment high standards of workmanship (Fig. 5).

3 Copyright © 2005 by Siemens Westinghouse Power Corp.

 Valves
Main and reheat steam enter the turbine directly in front of the
blading after flowing through two combined main steam and two
combined reheat steam valves, located on each side below the
casing joint (Fig. 6). Each control valve is combined with a stop
valve. The valve assemblies are bolted to the HP and IP
admission inlets on the outer casing and allow for short service
times.

LP Turbine
The double-flow LP turbine section consists of a welded
inner and outer casing. The horizontally-split inner casing
includes the admission section with stationary blade carriers.
The LP inner casing is provided with support arms and thrust
rod connections (Fig. 7) to the outer casing of the HP/IP turbine.
This design minimizes the impact of thermal expansion on
sealing by maintaining seal clearances, providing performance
Figure 5 – Fully Assembled New Apparatus HP/IP Turbine benefits. The exhaust diffuser of the LP turbine has been
Ready for Shipment carefully optimized by means of extensive fluid analyses in order
to improve turbine efficiency.
Bearings
The rotors are designed with a single bearing system, with
the shaft system consisting of one bearing between each pair of
turbine casings (Fig. 6). This arrangement results in a compact
steam turbine train and minimizes the impact of any foundation
distortions and bending stresses acting on the journals.
The bearing pedestals consist of cast top and bottom
halves which are bolted together at the level of the casing joint.
They are rigidly mounted to the foundation via a system of
anchor bolts and are separate from the turbine casings to
minimize vibration sensitivity. In addition to supporting the
rotors, the bearing pedestals also support and guide the turbine
cylinders, acting as a fastening point for the LP shaft seal
casings and LP inner casing.

Figure 7 – Thrust Bolt Connection for IP Outer Casing and

LP Inner Casing

Sealing
In addition to the standard non-contacting seals such as
labyrinth seals, advanced sealing technologies such as
abradable, brush, and retractable seals may be used in the
design of the new apparatus HP/IP turbine and HP/IP turbine
upgrades, providing significant performance benefits (Fig. 8).
Figure 6 – Valve and Bearing Pedestal Configuration for
These technologies are further examined here.
New Apparatus HP/IP Turbine

4 Copyright © 2005 by Siemens Westinghouse Power Corp.

 Brush seals provide a curtain of metal bristles between
Abradable Retractable adjacent areas of different pressure. Since the bristles are canted
Coating at an angle relative to the radial direction of the shaft, the seal
closes as soon as pressure is applied even if the brush seal is
built with an initial gap between rotor and bristles.
This “blow-down-effect” results in a more than 50%
reduction in leakage flow compared to standard labyrinth seals.
The flexible nature of the bristle pack allows for relative
movement of rotating and stationary parts during transient
operation.

Brush Seals Bristle angle

Figure 8 – Application of Advanced Sealing Technology

Abradable Seals
Bristle Pack
The seal segments in the shaft glands, balance pistons, and
the low-height spring-backed seals below the stationary blades
Flow
can be coated with an abradable material (Fig. 9), which
decreases the effective clearance of the seal, but wears away if a
rub with opposed labyrinth fins should occur. This design Reduced Rotor
effectively reduces the leakage flow in the seal by approximately Clearance
20% compared to uncoated seals without compromising
operational safety [2]. This technology was introduced after Figure 10 – Brush Seal Element
several years of experience with abradable coatings for smaller
turbines and service applications. An extensive test program, to
optimize durability and wear behavior of the coating has verified
the effectiveness and contact properties. The coating wears
locally and gives way to the intruding labyrinth fin, leaving the
adjacent seal surface and fin fully intact.

Standard
Segment
Abradable
Coating

Hard Part
Clearance
Rotor Reduced
Clearance Figure 11 – Spring-Backed Seal Segment with Two-Stage
Figure 9 – Abradable Coating Seal Segment Shown With Brush Seal and Labyrinth Fins
and Without Coating
Retractable Seal Segments
Brush Seals Retractable seal segments (Fig. 12) can be used to further
Even higher reductions in leakage flow rates can be minimize wear of the seal fins during transient operation. During
achieved with the use of brush seals (Fig. 10). After several startup, the seal segments remain open until a certain threshold
years of operating experience with multiple stage brush seals in of the standard operating pressure is reached. Retractable seal
small turbines, brush seal technology has been introduced to technology has been successfully applied to steam turbines for
new apparatus HP/IP turbines and turbine upgrade designs. more than 15 years [3, 4].
Brush seals can be used in the shaft glands and low-pressure
balance piston. Fig. 11 shows two-stage brush seals used in
combination with spring-backed labyrinth seal segments.

5 Copyright © 2005 by Siemens Westinghouse Power Corp.

 developing a completely new generation of fully three-
dimensional steam turbine blades for highest efficiencies. In a
first step, the 3DSTM blade was developed (3D low secondary
losses).
In shorter blades, relatively large end-wall losses occur at
the hub and shroud (secondary losses). Bowing the blades at
the hub and shroud boundary improves the flow conditions at
the end walls and minimizes losses. Longer blades are of twisted
design depending on the hub-to-tip ratio, whereby each profile
section is adapted to suit the local inlet and exit angle
conditions. The blade profiles themselves have also been
Figure 12 – Retractable Seal Segment optimized using numerical optimization methods to provide
better flow and strength properties.
Blading
The drum-type HP/IP blade construction features a fully
integrally shrouded blade design concept (Fig. 13). Key
characteristics of this concept are based upon using rhombic
tee-roots and rhombic integral shrouds.
The integral shrouds provide two basic functions: First,
they form a circumferential steam path boundary allowing
efficient seal designs to be utilized; and second, they provide
individual blade tip support between neighboring blades in each
blade row. The latter is accomplished by elastically pre-
stressing the rhombic shrouds when the blades are installed in
the circumferential rotor tee-grooves. These pre-stressed
blades display excellent damping behavior while enabling
dynamic stresses to be absorbed under all operating conditions
without impacting their long-term life. The author’s company
has more than 40 years of successful experience with fully Figure 14 – 3DSTM Blades
integrally shrouded blade designs [5, 8].
A typical 3DSTM blade is presented in Figure 14. Detailed
experimental investigations performed on a 4-stage close-loop
model turbine under representative Mach and Reynolds
numbers show that a stage efficiency improvement of up to 2%
points can be achieved with these 3DSTM blades in comparison
to purely cylindrical designs as shown in Figure 15 [5].

3DSTM Blade

η, efficiency
+2 % %

Cylindrical Blading

Figure 13 – Integrally Shrouded Tee-Root Blade Design

3DS TM Blade
In recent years, an intensive research and development Ψ, stage loading
program was carried out at the author’s company aimed at
Figure 15 – Efficiency Improvement 3DSTM Blading

6 Copyright © 2005 by Siemens Westinghouse Power Corp.

 The benefits of utilizing 3DSTM blading have been verified
in new apparatus and major service upgrade applications. A
prominent example is a 907 MW SPP in Germany, which is
regarded as the one of world’s most modern lignite-fired power
plant with a record-breaking gross-efficiency of 48.5% [6]. The
turbine features fully three-dimensional bladepath designs
using the 3DSTM blading technology throughout the HP and IP
resulting in measured cylinder efficiencies of 94.2% and 96.1%
for the HP turbine and IP turbine, respectively [7].
A major pre-requisite for the development of the 3DSTM
blade was the introduction of advanced Computational Fluid
Dynamics (CFD) methods (Fig. 16), numerical optimization,
Finite Element Analysis (FEA), experimental verification, linked
Computer-Aided Design Engineering and Manufacturing
(CAD/CAE/CAM) tools, and modern blade manufacturing
facilities [8]. In addition, the availability of these advanced
Figure 17 – 3DVTM Blades
design and manufacturing methods has enabled additional
design parameters to be varied in order to obtain high efficiency
levels.

Figure 16 – Use of Advanced CFD in Design of 3DSTM

blade

3DVTM Blade
A second major development step led to the development
of the 3DVTM blading technology (3D variable reaction). The
3DVTM Blade (Fig. 17) features the fully three-dimensional airfoil
shape of the 3DSTM blade with an added characteristic of the
ability to vary stage reaction and stage loading [5, 8]. Figure 18 – 3DVTM Blading Showing Variable Reaction for
The use of the 3DVTM blading represents the most Each Stage in Length of Bladepath
advanced method of optimizing the high-pressure and
intermediate-pressure blading. The use of numerical 3DVTM blading technology was first applied to a 1000 MW
optimization methods has enabled the author’s company to SPP in Germany which featured the world’s largest supercritical
individually vary stage reaction and stage loading (Figure 18) lignite-fired power station [7]. Since then, 3DVTM blading has
for each stage in order to obtain maximum efficiency. This allows been employed in all new machines and the majority of service
cylinder efficiency to be increased by up to 1% compared to upgrades.
blading with constant 50% reaction [5, 9, 10].

7 Copyright © 2005 by Siemens Westinghouse Power Corp.

 IP Inlet – Low Reaction Diagonal Stage The latest blading and casing design technology has been
The first stage of IP blading may utilize a low reaction incorporated. The full-arc admission design eliminates the
design with a diagonal arrangement (Fig. 19) to provide nozzle chamber, nozzle block and control stage. The inlet nozzle
favorable flow conditions where the radial steam flow enters the direction is reversed, eliminating the 180° turn around flow. 8
reaction blading axially. This first nozzle ring is integrated in the HP inlet nozzles (4 base and 4 cover) feed the same 360° inlet
casing, which minimizes tip losses and their detrimental effect geometry, which has been optimized using the latest 3D CFD
on efficiency, and protects the turbine rotor against high thermal technology. These blading enhancements along with
stressing. application of advanced sealing technology result in high
efficiency and performance of the machine.
The BB44FA design is one of simplicity. All internal
components are being removed and replaced with a single, fully
integral cylinder. This single inner cylinder design has all
stationary parts fully integral with the casing, which reduces the
number of parts and significantly reduces the installation and
outage time.
The single inner cylinder was designed using the latest 3D
FEA techniques. The unique features of this design (vertical
ribs, flanges and end rings) are necessary to maintain the proper
alignment between the rotor and the casing during transient
conditions, thus maximizing the seal efficiency while minimizing
rubbing conditions.
This design has the same mating features as the existing
inner cylinder, to assure that it will mate up to all axial, vertical
and transverse anchor points in the outer cylinder. The existing
outer cylinder is re-used with all of the HP inlet sleeves, and all
of the flexible skirts. The BB44FA is truly a “drop in place”
Figure 19 – IP Inlet with Low Reaction Diagonal Stage replacement for the existing BB44, and allows inspection
intervals of 10 years.
Maintenance
The new apparatus HP/IP turbine is designed for ease of Figure 20 – Comparison of BB44FA and Existing BB44
maintenance and long maintenance intervals. Borescope ports
are provided to allow for inspection of the inlet and exit areas of
the HP and IP elements. Minor inspections are required every
25,000 operating hours including visual inspection of the outer
casings, borescope inspection, valve function, bearing
inspection, pedestal alignment checks. The first major
inspection (covers off) is required at 100,000 operating hours.

BB44FA HP/IP UPGRADES

The BB44FA turbine retrofit design (Fig. 20) targets existing
Westinghouse Building Block (BB) 44, sub-critical fleet,
operating at inlet conditions of 2,400 psig and 1,000°F and is
typical of design solution techniques than can be used to
upgrade existing HP/IP turbines. Currently, these machines are
operating between a nominal range of 350 to over 680 MW. Figure 20 – Comparison of BB44FA and existing BB44
The design incorporates the design philosophies, features,
and technology developed for the afore-mentioned modern new
apparatus HP/IP turbine, resulting in the highest possible PERFORMANCE AND OPERATION
efficiency and reliability for this turbine configuration. This
upgrade has been proven to increase HP element efficiency by The new apparatus HP/IP turbine is a proven, reliable
8-10% and IP efficiency by 2-4% with a potential 25 MW output design based on more than 30 years of design, manufacturing,
increase over the older designs. and operating experience and over 280 applications of combined
HP/IP design. In the past decade, over 50 new apparatus HP/IP

8 Copyright © 2005 by Siemens Westinghouse Power Corp.

turbine units have been designed and installed. Several
particular new apparatus applications which incorporate some
of the newly developed technologies described in this paper are
highlighted here in addition to a recent BB44FA upgrade. All
tested units have met or exceeded stated performance
guarantees and fleet reliability has been excellent with over
98.5% availability.

350 MW SPP (Fig. 21)

Ten (10) 2-cylinder HP/IP turbines were provided for the

Asian market in the late 1990’s. Application was SPP with MW
range of 350 to 378 MW and typical cycle conditions of 1000°F
main steam temperature at 2400 psig main steam pressure, and
reheat steam temperature of 1000°F. The design utilized 3DSTM
blading and several units featured overload admission to
provide additional flow passing capability and efficient part load
performance.
Figure 22 – 252 MW 2x1F CCPP

BB44FA Upgrade (Fig. 23)

A BB44FA upgrade was performed in 2004 with less than 4

weeks of field installation and resulted in an improvement of
over 10% in HP element efficiency, over 3% in IP element
efficiency, and output increase of over 20 MW. Three B44FA
upgrades were performed in 2004 with similar results,
demonstrating how the newly developed technologies
described in this paper can be used to upgrade the performance
of existing turbines. An additional two BB44 upgrades are
planned for implementation in 2005.

Figure 21 – 350 MW SPP

252 MW 2x1F CCPP (Fig. 22)

A 252 MW CCPP for 2x1F application began commercial

operation in 2002, with main steam pressure of 2280 psia, main
steam temperature of 1050°F, and reheat temperature of 1050°F.
The turbine was designed for up to 50 MW of duct-firing
capability and featured 3DVTM blading. The unit achieved HP
and IP element efficiencies of 90.2% and 93.8%, respectively.
More than 20 similar units have been successfully designed,
manufactured, and installed for CCPP operation over the past 4
years, with outputs ranging from 160 to 360 MW.

Figure 23 – BB44FA Upgrade

9 Copyright © 2005 by Siemens Westinghouse Power Corp.

 700MW SPP (Fig. 24) Ø Unique single-piece inner casing configuration minimizes
the differential expansion between the rotor and casing and
The culmination of the technology advances described in maintains rotor alignment and seal clearances, allowing for
this paper is a three-cylinder class turbine rated at over 700 MW optimal efficiency.
which was developed for the coal market in 2004. The design Ø All stationary parts are fully integral with the casing,
incorporates all of the newly developed technologies and allows reducing the number of parts and overhaul installation time.
for highly efficient performance for a subcritical cycle with Ø Main and reheat steam valves and HP exhaust directly
1050°F main steam temperature at 2520 psig main steam flanged to lower half of outer casing for short service times.
pressure, and reheat steam temperature of 1050°F. Ø Thrust bolt design to minimize LP differential expansion and
maintain optimal sealing geometry and efficiency.
Ø No-bore rotor design for fast start-up and flexible operation.
Ø HP/IP can ship completely assembled providing for short
erection times and factory-optimized alignment.
Ø Advanced chromium alloy materials provide high
temperature capability.
Ø Fully integrally shrouded blade design concept with tee-
roots, allowing efficient seal designs to be utilized and pre-
stressed blades display excellent damping behavior..
Ø Three-dimensional, bowed 3DSTM blading minimizes
secondary losses and results in high efficiency HP and IP
blading with stage efficiency improvement of up to 2% over
conventional cylindrical blading.
Ø 3DVTM blading is latest advancement in blading technology
where each stage has variable reaction and loading to
provide additional cylinder efficiency increases of up to 1%
Figure 24 – 700 MW SPP Developed for Coal Market
over blading with constant 50% reaction.
Ø Low reaction diagonal stage for IP inlet provides optimal
flow conditions as steam flow enters the reaction blading.
Ø Use of advanced sealing technologies such as retractable,
SUMMARY AND CONCLUSION
abradable, and brush seals to further enhance performance
and reliability.
The authors company has developed two and three
Ø Designed for ease of maintenance and long maintenance
cylinder class designs for new apparatus HP/IP and upgrade
intervals.
applications which incorporate advanced technology to provide
Ø Proven designs based on over 30 years of design,
reliable, highly efficient steam turbines to meet the demands of
manufacturing, and operating experience.
today’s power generation markets.
Ø Excellent reliability and availability of over 98.5%.
This paper illustrates the evolution and application of
these newly developed technologies to the HP/IP element of
these designs, and illustrates the key features and benefits,
which are highlighted here.
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10 Copyright © 2005 by Siemens Westinghouse Power Corp.

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11 Copyright © 2005 by Siemens Westinghouse Power Corp.