Renovation, Modernization and Life Time Extension Measures on Steam Turbines

8/11/2019 Renovation, Modernization and Life Time Extension Measures on Steam Turbines

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Siemens AG 2012. All rights reserved.

Power-Gen India & Central Asia 2012

Renovation, Modernization and Life TimeExtension Measures on Steam Turbines

Thorsten Strunk, Siemens Energy &Subrata Kumar Kundu, Siemens Power Engineering Pvt Ltd.



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Page 2 April 2012 Power-Gen India & Central Asia 2012

Content of Presentation

Contents

Introduction

Lifetime Extension Methode

Modernization Technology

Upgrade ProductsUpgrade References

Turbine St ress Limits


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Coal

GasNuclear

Hydro

Oil

Renewable

2010 12 th PlanSource: Siemens AG

Installed Capacity(rounded)

R&M & LE are imperative in order to accommodate

power demand

Additional Capacity

R&M, LEor

shut down

160 GW

160 GW

94 GW

94 GW

68 GW

68 GW


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Improve competitiveness of your plant -Production costs and life cycle costs

Environmental regulations/Climate change

Increasing share of renewables

Ageing fleet Lifetime extension

Availability and reliability

Need for more capacity (MW)

Unstable political boundaries for new powerplant projects

Steam Plant Modernization

Main Market Drivers

2008 2030

20,300 TWh

33,000 TWh

Fossilenergy

sources

54%68%

Gas20%

Hydro15%

Hydro15%

Nuclear15%

Nuclear15%

Coal32%

Coal32%

Oil2%

17%17%

21%

16%

13%

41%

3%

6%

2.3% per year 2)


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Contents

Introduction






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Service concept for Turbine Components

Design Service (NDE, RLA)

Real Life Time of Component Up To Failure

OperationalHours

ComponentFailureProbability

NDE Non-Destructive Examination

RLA - Remaining Life Analysis


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Lifetime evaluation

Life Time Assessment by NDTat major outages

Life Time Extension by Lifetime Assessment (LTA) Operational data evaluation Future operational Scenario Remaining Lifetime Analysis (RLA)

Extended LifetimeLifetime

ExtensionDesign Lifetime

Lifetime Assessment by NDTat major outages

Repair /Replace

Components

OperationalRestriction,

Limitation

Modernizationand

upgradation


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Fatigue of major steam turbine components

HP and IP turbine casings and rotorsLow cycle fatigue due to starts and shutdowns

Creep damage due to stationary operation

LP turbine rotor Low cycle fatigue due

to starts and shutdowns

IP/LP bypass valve casings Low cycle fatigue due

to bypass operation

Main Steam and Reheat turbine valve casingsLow cycle fatigue due to starts and shutdowns

Creep damage due to stationary operation


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Life Time Extension of steam turbine components

Damage reduction DD and component release forthe further operations based on:

Updated computational conditions

Local repair Transient and steady state operational

conditions adjustmentEvaluation Repair vs. Replace by three steps

ComponentDamage D

(Creep + LCF)

OperationalTime

Warning Time Point(Outage required)

D

Step 1: Lifetimeassessment by NDT

Step 2: Evaluation ofoperational history

Step 3: Remaininglifetime analysis


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I n v e s t m

e n

t

ReliabilityReliability

Lifetime

Reliability

EfficiencyCapacityFlexibility

Lifetime

V a

l u e

t o C u s

t o m e r Inspection/

Repair

Component

Exchange

Upgrade


Service Differentiation


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-

Upgrade solutions for fossil and nuclearsteam turbines

All power output ranges (200-1400 MW)

HP, IP, LP turbines

Condenser, Generator and I&C upgrades

Siemens (incl. KWU), Parsons andWestinghouse designs (incl. license ST)

Other OEM products

Continuous R&D investment for technologyimprovements and product range

enlargementLarge list of references

> 25 years of experience. More than 270fossil units modernized (64 O-OEM)


Product Portfolio


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Contents

Introduction






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Overview of Key Technologies for Efficiency

Improvements for Modernization Projects

State-of-the-art 3DS TM Drum Stage Blading

3D Blading

EarlierBlading

Modern3D

Blade

Stage Load

E f f i c i e n c y

+ 2 %Customer Benefits

World-class performance

Wide range of applicationSpecific design for each applicationwithin short delivery timesLong life & high reliability

Stationary Blades Rotating Blades


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LP Blading Design Features

State-of-the-art fully 3D design by

means of advanced computationalmethodsOptimized last stage blade sizeOptimized LP exhaust areaNew Shrouded L-2, L-1 and

Freestanding or Shrouded Last StageBlade with Trans- and Supersonic TipSections, 3D-Flow Design

Customer BenefitsImproved blade efficiency byadvanced 3D blade design

Increased efficiency by shroudedrotating blades

Reduced exhaust losses

LA-0L-0R

LE-0L-0C

p1p

1

p1p2

-LA-0L-2R

LA-0L-1R

LE-0L-1CLE-0L-2C

Standardized Stage Package

CustomizedDesign


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Overview of Key Technologies

LP-Blading Reliability Features

Customer BenefitsIncreased Reliability and Service Life dueto Reduced Stress Levels and effectiveErosion Protection MeasuresReduction of Maintenance Costs

Suction of the water filminto interior of guide blade

Suction of the boundary-flowwater into blade-carrier ring

Highly effective Erosion ProtectionMeasures based on extensiveExperience and Use of High AlloyMaterials

Fir Tree Root Design for improvedStrength and Reliability by ResidualStress Application and Control


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Siemens AG 2012. All rights reserved.Page 16 April 2012 Power-Gen India & Central Asia 2012



Optimized Sealing Concept

Brush Seals inBladepath & Shaft Sealing

Abradable Coatings inShaft Sealing

Spring-Backed SealSegments

Customer BenefitsMinimization of clearancelosses for higher efficiency

Brush Sealsin BladepathAbradable

Coatings


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Concepts for Efficiency Improvement

Technologies

Blading Technology

Protection via coatingRetrieve original roughnessApplication of shroudedL-1 standard stageReblading 3DS

Sealing Technology(Shaft & Blading)

Improved seal stripsAdvanced segment designAbradable coatingBrush seals

TE GEIP

1

2

3 4 5 6

HP LP


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Contents

Introduction



Upgrade Products

Upgrade References



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Typical Upgrade Scope

Modernization of HP, IP and LP Turbines, Condenser

Exchange of bladepath components: Rotor, blading, inner casing

Newest blading and sealing technology

Outer casing, auxiliary systems, interfaces to foundation etc remainunchanged

For Other OEM an upgrade study with adaptation measurement ismandatory


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LP

IP

HP

LP

IP

HP

LP

IP

HP

Turbine

N30-2x10m

M30-50

M30-63

H30-63

H30-100

N30-2x5m

M30-25

H30-25

N30-2x5m

K-200 IP

K-200 HP

KWU 500 MW

KWU 200 / 210 MW

LMZ 200 / 210 MW

Frame

Products for Mods&Ups Market in India

principle example

principle example

principle example


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Contents

Introduction



Upgrade Products

Upgrade References



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Upgrade References

Ibbenbren (Germany) Upgrade of fossil OEM-Turbines & Condensers

Hard coal-fired HP-IP-LP-LP configuration with approx. 838 MW (after Retrofit)

Extended upgrade scope: all turbine sections + condenser + bearing


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Upgrade References

Overview Total Scope

Offset-halves bearings

HP IP LP1 LP2

Reinforced connectionbearing pedestal to foundation

Condenser 1 Condenser 2


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Performance increase of 86MW(43 green MW due to increased thermal efficiency)

Up to 260.000t CO 2 reduction p.a.

All requirements fulfilled for characteristics such as Heat rate

Swallowing capacity Rotor & Bearing Vibrations Start up and shutdown times Noise Emissions

Total retrofit time 72 days

Commissioning without any obstacles and delays

Upgrade Reference

Conclusions


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Experiences with Fossil Turbine Modernizations

Fossil Fleet

Siemens

GE

Alstom

MHI

LMZ

Skoda

Chinese

No. of Units Rating (MW)

278 104GW

214

2

24

32

1

23

88250

1200

6501700

7120

120

4950

includes Westinghouse and Parsons Steam Turbines

*

*

Experiences with fossil turbine modernizations over the last 20 years


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Upgrade ReferencesKardia, Greece 300 MW LMZ Steam Turbine Upgrade


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Upgrade ReferencesSyrdarinskaya, Uzbekistan 300 MW LMZ Steam Turbine Upgrade

Scope of the upgrade :

IP/LP Cylinder: IP section: Installation of a rotor

cooling system

LP section: Renewal of the shrunk-on

disks, including rotating blades and

diaphragms

LP Cylinder:

New rotor, inner casing and blading.


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Upgrade ReferencesLoy Yang Power , Australia 500 MW SIEMENS / KWU Steam Turbine Upgrade

Awards celebration

The outage has set an international benchmarkfor outage management and sustainable plantenhancement and has been therefore citedwith two Engineering Excellence Awards.

Ausindustry Excellence Award for

Industrial Development

Victorian Workcover Excellence Award

for Workplace Practice.

Customer benefits

Increased power output by almost 10%to more than 545 MW

Improved efficiency.


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Improvement of turbine efficiencyHigher load output, GREEN MW

Lower CO 2 emissionsLower production costs

Improved profitability

Improvement of total plant efficiency

Through boiler and condenser upgradeIncreased mass flow, steam parameters

Lifetime Extension ageing fleetReduced maintenance costs

Improvement of availability and reliability

Improved Operational Flexibility Flex PowerFaster start up/load changes

Flexible use of lifetime

Improvement of turbine efficiencyHigher load output, GREEN MW

Lower CO2

emissions

Lower production costs

Improved profitability

Improvement of total plant efficiencyThrough boiler and condenser upgrade

Increased mass flow, steam parameters

Lifetime Extension ageing fleetReduced maintenance costs

Improvement of availability and reliability

Improved Operational Flexibility Flex PowerFaster start up/load changes

Flexible use of lifetime

Steam Plant Modernization Fossil Plants

Customer Benefits


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Power-Gen India & Central Asia 2012

Thank Youfor Your Attention!


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Disclaimer

This document contains forward-looking statements and information that is, statements related tofuture, not past, events. These statements may be identified either orally or in writing by words asexpects, anticipates, intends, plans, believes, seeks, estimates, will or words of similarmeaning. Such statements are based on our current expectations and certain assumptions, and are,therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyondSiemens control, affect its operations, performance, business strategy and results and could causethe actual results, performance or achievements of Siemens worldwide to be materially different fromany future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in generaleconomic and business conditions, changes in currency exchange rates and interest rates,

introduction of competing products or technologies by other companies, lack of acceptance of newproducts or services by customers targeted by Siemens worldwide, changes in business strategy andvarious other factors. More detailed information about certain of these factors is contained inSiemens filings with the SEC, which are available on the Siemens website, www.siemens.com andon the SECs website, www.sec.gov . Should one or more of these risks or uncertainties materialize,or should underlying assumptions prove incorrect, actual results may vary materially from those

described in the relevant forward-looking statement as anticipated, believed, estimated, expected,intended, planned or projected. Siemens does not intend or assume any obligation to update or revisethese forward-looking statements in light of developments which differ from those anticipated.

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Renovation, Modernization and Life Time Extension Measures on Steam Turbines