Nuclear Power Plants The Turbine Island
Philippe Anglaret
VP Business Development , Alstom Nuclear
Paris, 21st October 2013
p.2 p.2
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.3
Alstom in Nuclear
Nuclear Island
Reactor supplier
Turbine Island
Alstom
Nuclear Island + Turbine Island + BoP = Nuclear Power Plant
Balance of Plant
(including Alstom Grid)
p.4 p.4
Credits to EDF
Alstom in Nuclear Turbine Islands based on ARABELLE™ technology
p.5
30% of all the world’s nuclear plants have an Alstom steam turbine
55 years of experience : 136 nuclear units in operation = 113 GW
South Korea
5 GW 6 units
India
2 GW 11 units
South Africa 2 GW 2 units
China
6 GW 6 units
North America
8 GW 8 units
Europe
90 GW 103 units
Alstom in Nuclear World N°1 supplier of nuclear steam turbine generators
47
65
24< 800 MW
800 - 1200 MW
> 1200 MW
50
86
Full-speed
Half-speed
p.6
EDF French Nuclear Fleet Various generations of nuclear steam turbines
CP0 – CP1
900 MW
N4 – ARABELLE
1550 MW
P4 – P’4
1300 MW
p.7
• Competitors worldwide experience (50 & 60 Hz grids)
TG supplier
Toshiba GE Power Machines Mitsubishi Siemens Alstom
Largest unit in commercial operation (as of Sept. 2012) Largest unit under construction (as of Sept. 2012)
1100 MWe
Higashi-Dori 1 (50 Hz)
1400 MWe Braka 1-4 (50 Hz)
1410 MWe
Palo Verde 2 (60 Hz)
1455 MWe Shin-Kori 3
(60 Hz)
1060 MWe Tianwan 1
(50 Hz)
1200 MWe Leningrad II 1
(50 Hz)
1180 MWe Genkai 3 (60 Hz)
1370 MWe Lungmen 1
(60 Hz)
1500 MWe
Isar 2 (50 Hz)
1720 MWe Olkiluoto 3
(50 Hz)
1550 MWe Chooz B1 (50 Hz)
1750 MWe
Flamanville 3 (50 Hz)
• Color code:
Green = currently in Operation Blue = currently under Construction
Nuclear Business Competitive Positioning
p.8 p.8
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.9 p.9
• Non-contaminated steam goes to steam turbine
• No turbine island containment needed
The Pressurised Water Reactor (PWR)
Inside a Nuclear Power Plant Primary, Secondary, Tertiary Loops
p.10 p.10
• Contaminated steam goes to steam turbine special gland sealing system
• Turbine island needs some containment (concrete shielding) + specific material choices
The Boiling Water Reactor (BWR)
Inside a Nuclear Power Plant Primary, Tertiary Loops
p.11 p.11
0
20
40
60
80
0 500 1000 1500 2000
Fossil
Nuclear
X 5
Steam turbine generator output (MW)
Ste
am v
olum
e flo
w (
m3 /
s)
What is specific to Nuclear Power Plants ? Much larger steam volume flow
Nuclear large volume flows need for long blades high centrifugal forces
p.12 p.12
Nuclear
50-75 bar
265-290°C
Dry
Steam
S = Entropy (kJ/kg/°K)
H =
Ent
halp
y (k
J/kg
)
Wet
Steam
Fossil
150-300 bar
540-600°C
Saturation line
What is specific to Nuclear Power Plants ? Wet steam conditions
p.13 p.13
P : 10.1 bar
T : 268°C
HP
IP
LP
MSR
P : 10.7 bar
T : 183°C
x : 14.6 %
P : 71 bar
T : 287°C
x : 0.4 %
P : 3.3 bar
T : 148°C
P : 0.055 bar
x : 12.5 %
X : 0 %
Entropy
S (kJ/kg.K)
Enthalpy
H (kJ/kg)
“cold” steam at LP inlet : • small LP axial thermal expansion • reduced axial clearances • possibility to fit a 4th LP
Steam Expansion Line Mollier Diagram – N4 Reactor
p.14
Secondary Loop
NSSS PACKAGE
De-aerating
MSR Condenser,vacuum system, debris filters
Condensate extraction pumps
Circulating water
pumps
Feed heaters pumps
MSR drain pumps
HP IP LP
CI auxiliaries cooling HEX
Core
Generator, exciter
HP heaters
LP heaters
feed-water tank
Drain tanks
Steam and water pipes from/to NI Busbars
100% steam bypass to condenser
Primary Loop Tertiary Loop
EPR - Flamanville 3 Simplified steam-water cycle
p.15
Source: Alstom databases
34%
74%
9%
66%
26%
91% 100%
All sizes < 700 MW > 700 MW > 1200 MW Unit size range
Ful
l-sp
eed
/ H
alf-
spee
d
Half-speed
Full-speed
World Nuclear Power Plants Half-speed dominates the market above 700 MW
• France, U.S.A., Canada, Japan, South Korea, Brazil, Taiwan, South Africa, etc.:
− all nuclear units in operation are half-speed
• China:
− since 2005, all nuclear turbines (with output > 700 MW) ordered are half-speed
Above 1200 MW, only half-speed to keep reasonable stress levels
p.16
Full Speed vs. Half Speed – what makes the difference ? Case study : Ling Ao 1 vs. Ling Ao 3
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
3100
5,8 6 6,2 6,4 6,6 6,8 7 7,2 7,4 7,6
Entropy (kJ/kg/K)
Enthalpy (kJ/kg)
Ling Ao 3 Half speed
Ling Ao 1 Full speed
Half speed expansion lines in HP, IP and LP sections are much more efficient
HP
IP
LP
p.17
Reactors
Site cooling water temp. °C 59
12
15
17
19
21
23
24
26
27
28
30
31
32
33
A challenge for turbine designers Covering a wide range of reactors & heat sinks
Typical LP exhaust volumetric flow for a given application: 1 reactor/1 site
India
Finland
p.18
CPR1000
EPR
ABWR
PHWR700
VVER1200
AP1000
ESBWR
APWR
ATMEA1
1.5 "Hg2.5 "Hg
1.5 "Hg2 000 MWth
2 500 MWth
3 000 MWth
3 500 MWth
4 000 MWth
4 500 MWth
5 000 MWth
20 mbar30 mbar40 mbar50 mbar60 mbar70 mbar80 mbar90 mbar100 mbar
Re
ac
tor
the
rma
l o
utp
ut
in M
Wth
Condenser backpressure in mbar
Reactors
Site cooling water temp. °C 59
12
15
17
19
21
23
24
26
27
28
30
31
32
33
50 m²
75 m²
100 m²
150 m²
200 m²
A challenge for turbine designers Covering a wide range of reactors & heat sinks
Typical LP exhaust area needed for a given application: 1 reactor/1 site
250 m²
p.19 p.19
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.20 p.20
Integrated Packages Turbine Island (TI)
p.21 p.21
Integrated Packages Secondary Loop Package (SLP)
p.22 p.22
Circulating water pumps
Steam turbine
Modular condenser Condensate extraction pumps
HP & LP feed-water heaters
MSR 4-pole generator
Reactor feed-water pumps
Grid equipment
Turbine Islands key components
p.23 p.23
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions The steam turbine
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.24
Turbine Technology Use of more efficient single flow steam expansion
BP LP 1 1 BP LP 2 2 BP LP 3 3 HP HP IP
Moisture Separator
Reheater
3 bar
11 bar
71 bar
Moisture Separator
Reheater
60% of the power output comes from single flow steam expansion
p.25 p.25
HP IP
MSR
LP 1 LP 2 LP 3 HP
ARABELLE™
Efficient configuration
Single flow use
PREVIOUS GENERATION
Traditional configuration
Double flow use
MSR
MSR
LP 1 LP 2 LP 3
MSR
~75 bar
~3 bar ~10 bar
~10 bar
~75 bar
ARABELLE™ uses more efficient single flow steam expansion
ARABELLE™ Steam Turbine Advanced compared to previous generation
p.26 p.26
LP Double Flow
HP Double Flow
HP Single Flow
IP Single Flow
LP Double Flow
ARABELLE™ Steam Turbine A specific design to maximise single flow steam expansion & efficiency
2 Flows 1 Flow 6 Flows 1 Flow
ARABELLE™
PREVIOUS GENERATION
p.27 p.27
• Efficiency increases with blade aspect ratio
Longer blades have better efficiency
How to improve turbine efficiency ?
p.28
• Single flow HP and IP for best efficiency
• Combined HP/IP for maximum power density
• Same footprint for 50 and 60 Hz
• Designed to fit all large commercialised reactors
• HP/IP rotor delivers up to 60% of the overall output
ARABELLE™ Characteristics Combined HP/IP Module, Unique in the Market
p.29 p.29
Flamanville 3 rough machined HP-IP casing in VOEST ALPINE foundry
ARABELLE 1700 50 Hz Flamanville 3 HP-IP casing
p.30 p.30
Ling Ao 3 HP-IP casing in Dong Fang Works
ARABELLETM References Ling Ao 3+4 – 2 x 1080 MW
p.31 p.31
• HP/IP rotor entering balancing pit, Belfort factory
ARABELLETM References Flamanville 3 – 1 x 1750 MW
p.32 p.32
• LP2 welded rotor, fully bladed, Belfort factory
ARABELLETM References Flamanville 3 – 1 x 1750 MW
p.33
Fully bladed LP57 rotor entering Belfort balancing pit (Ling Ao 3)
ARABELLE 1000 for Ling Ao 3 Last Stage Blades : LSB57
p.34 p.34
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions The generator
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.35
• 2000 MVA • Cos-phi = 0,9 • 1500 rpm • 4 poles, 3 phases • 23 kV • Brush-less exciter • H2 and H2O cooled • Stainless steel cooling
tubes • H2 pressure: 6 bars(g) • Triple-circuit hydrogen
sealing system • 99% efficiency
• Flamanville 3 generator final assembly and running tests in Alstom factory • Validation of manufacturing quality • Validation of the design, of the electrical performances
GIGATOP 4-pole for Flamanville 3 A highly efficient turbo-generator
p.36 p.36
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions The heat exchangers
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.37 p.37
Moisture separator reheater (MSR)
LP heater
HP heater
Condenser
Nuclear purification system (NPS)
High velocity separators (HVS)
Auxiliary water/water coolers
Feedwater tank and deaerator
1
1
2
2 3
4
4
5
5
3
Key Components Heat Exchangers for Nuclear Plants
p.38
ARABELLE N4 - 1550 MW - MSR
ALSTOM MSR Moisture Separator Reheaters
p.39 p.39
• Designed by Alstom - In 3 separate pieces - 98 t + 90 t + 98 t - Transported separately - Welded at site
• When assembled, final dimension is: 47.1 m x 5.9 m x 5.3 m
Nuclear Heat Exchangers Flamanville 3 deaerating feed-water tank
p.40 p.40
• Single or multiple pressure condensers
• Optimised tube bundle arrangement for high
performances
• Compact arrangement with LP turbines directly
feeding duplex LP1&2 FW heater located in
condenser neck
• Optimised condensate extraction with 3x50%
pumps
• Optimised vacuum hogging / holding system
Nuclear Heat Exchangers A Complete Condensing System
p.41 p.41
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions The main pumps
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.42 p.42
Concrete volute circulating water pump
Condensate extraction pump
Intermediate cooling pump
Essential service pump
Open/closed loop cooling pump
Residual heat removal pump
Feedwater pump Vacuum pump
1
1
2
2 3
3
4
5
5 4
7
6
6
7
8
8
Key Components Pumps for Nuclear Plants
p.43 p.43
A
A
B
Flamanville 3 NPP : • Direct sea-water cooling
of the condenser tubes • 2 x 50% pumps
arrangement • 110 000 m3/h each (30,5
m3/s each) • 15,4 m head • Rotate at 151 rpm
• Civil engineering works on suction ducts (Sept. 2009)
Nuclear Pumps Concrete Volute Circulating Water Pumps
p.44 p.44
• Flamanville 3 CWP impeller heat treatment (photo credit: Ferry Capitain)
Nuclear Pumps Concrete Volute Circulating Water Pumps
p.45 p.45
1 Alstom in Nuclear
3 Turbine Island – Key Products & Solutions
4 Recent Projects
The Turbine Island Agenda
2 Turbine Island Basics
p.46 p.46
• Nuclear reactor: EPR (PWR)
• Turbine type, output: ARABELLE 1700, 1 x 1750 MW
• Generator type: GIGATOP 4-pole
• Steam parameters: Live steam: 75 bar / 290°C Exhaust: 46 mbar
• Customer: EDF
• Country: France
• City / region: Normandy
• Schedule: order year 2006 comm. year 2016
Unit 3
ARABELLE™ References Flamanville 3 – 1 x 1750 MW
p.47 p.47
ARABELLE™ References Flamanville 3 – 1 x 1750 MW
p.48 p.48
• Turbine HP/IP rotor entering balancing pit, Belfort factory, France
Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator
p.49 p.49
• Generator rotor
ARABELLETM References Flamanville 3 – 1 x 1750 MW
p.50 p.50
• Generator test, Belfort factory, France
Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator
p.51
Site in January 2013
Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator
p.52 p.52
• Nuclear reactor: CPR1000 (PWR)
• Turbine type, output: ARABELLE 1000, 2 x 1080 MW
• Generator type: GIGATOP 4-pole
• Steam parameters: Live steam: 64 bar / 280°C Exhaust: 56 mbar
• Customer: DEC for LDNPC
• Country: China
• City / state: Dapeng / Guang-Dong
• Schedule: order year 2005 comm. year 2010 & 2011
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW
p.53 p.53
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW
p.54 p.54
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW
p.55 p.55
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW
p.56 p.56
Ling Ao 3, China - 1080 MW
Synchronized in July 2010, ahead of schedule
Measured output level above guarantee
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW