L&T MHI TURBINE GENERATORS PRIVATE LIMITED

INDIA

SUPERCRITICAL TURBINE GENERATORS INTEGRATING ADVANCEMENTS AND EXPERIENCES

G.R. Sivaprasad Date : July 20, 2011

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Presentation Flow
1. Brief on Supercritical Technology

2.L&T MHI TURBINE GENERATORS Overview

3.Features of L&T MHI Turbine Generator

4.Projects Under Execution

5.Future Trend Ultra Supercritical Turbine Generators

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Brief On Super-Critical Technology

INDIA

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Super-Critical Parameters

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Latest Project in India (%)

Heat rate difference of turbine (relative)

0.3 0.3 1.3

0.8 0.9

MPa x degC 25.1x600/620 25.1x600/610 24.5x600/600

566/593

USC

566/566
538/566 SC

0.8
1.7

538/538
BASE
Note: The values in diagram are typical HR differences respect to steam pressure and temperature. Actual heat rate may differ and shall be determined based on a given design condition. 5

16.7 24.2 Steam pressure (MPa abs.)

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Steam Condition & Efficiency

Net Efficiency (%LHV)

46 45 44 43 42 41
Net Efficiency CO2 Reduction

0
CO2 Reduction (%)
6

-1 -2 -3 -4 -5

Main Reheat

538 538 566 600 625 566 593 593 600 625 (Base) Inlet Steam Temperature Steam Temperature (oC)

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Benefits of Super-Critical Large Size Units

Higher cycle efficiency means primarily Less fuel consumption Less per MW infrastructure investments Less emission Less auxiliary power consumption Less water consumption Large size units mean Rapid Capacity addition Reduced land requirement Reduced manpower requirement Operational flexibility Shorter start-up time, Suitable for variable pressure operation Better temp. control and load change flexibility

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L&T MHI TURBINE GENERATORS -OVERVIEW

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L&T MHI TURBINE GENERAORS PRIVATE LIMITED

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JV STRUCTURE

L&TMHI TURBINE GENERATORS PVT LIMITED

JV established on Nov.5th, 2007

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ARIEL VIEW OF L&T MHI TURBINE GENERATOR WORKS AT HAZIRA ,SURAT

JV DETAILS
JV Agreement Signed on Nov 05 ,2007

Lock-in Period

7 years

Product Range

Supercritical TG set 500 MW& above 150 MW & 300 MW ST for CCPP

Technology licence term

20 years

Governing law

As per Republic of India

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JV DETAILS
Project Cost 1257 Cr

Investment

1164 Cr

Capacity

4000 MW / annum

Manpower

900

Location

Vadodara / Hazira

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JV DETAILS

Total Area

283279 sq. mtr 70 acres

Factory buildup Area

57700 Sq. mtr

Main factory Building

250*30*42Sq. mtr

Power Reqd.

12 MW

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State of Art Facility

Major Machine Tools

Heavy Machines Medium Machines

46 Nos 38 Nos 59 Nos

Major Equipments (CNC Cutting, 200T Press, Furnace ,Shot Blast etc.,)

Generator Test Bed (1000 MW)

o High Speed Balancing ( 4500 rpm) o Blade Manufacturing

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Assembly shop

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Blade Shop Internal View

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Generator Test Facility

GENERATOR TESTING APPDCL PROJECT

Generator Test Facility

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LMTG Inauguration Jan11

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Features of L&T MHI Turbine Generator

INDIA

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MHI Steam Turbine C/S View

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History of MHI Large Steam Turbines

DEVELOPMENT OF TURBINE CAPACITY
MW
1175 MW 1000 MW 1371 MW

1180 MW
1050 MW

1000
SUPERCRITICAL 600 MW

NUCLEAR

SUPERCRITICAL 1000 MW SUPERCRITICAL 1050MW

500
75 MW REHEAT STEAM TURBINE 156 MW NUCLEAR 340 MW

FOSSIL

0 1950

1960

1970 1980 OPERATION YEAR

1990

2000
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History of MHI Large Steam Turbines

Development of Steam Pressure & Temperature
650 600 400 350 550 300 500 250 200 450 150
510 480 538 190 169
WAKAMATSU STEP2 (649/593) MATSUURA #2 50MW (593/593) 1000MW WAKAMATSU STEP1 (593/593) 50MW MISUMI #1 (600/600) 1000MW

kg/cm2g

OSAKA #3 (566/538 ) 156.25MW GOI #5 SHIN-TOKYO #4 (566/566 (538/538) ) 350MW 75MW

TACHIBANAWAN #2 (600/610) 1050MW

566 TEMPERATURE 246 PRESSURE

HEKINAN #3 (538/593) 700MW

250

255

127 102 88 100 400 59 60 50 42

350

1950

1960

1970

1980

1990

2000

2010
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OPERATION YEAR

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MHI SC Steam Turbines operating installations

N o. Unit MW Steam Condition (Turbine Inlet) Press (MPa) Temp (C) 24.1 538/552/566 24.1 538/552/566 24.1 538/566 538/552/566 24.1 24.1 24.1 24.1 24.1 24.1 24.1 24.1 24.1 24.1 24.1 24.1 538/552/566 538/538 538/552/566 538/566 538/566 538/538 538/566 538/566 538/566 538/566 538/566 Commercia l Operation

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Kansai EPCO Himeji #4 Kansai EPCO Takasago Tokyo EPCO Kashima Kansai EPCO Himeji #5 Kansai EPCO Kainan #3 Kyusyu EPCO Sendai #1 Kansai EPCO Tanagawa II #1 Tokyo EPCO Sodegaura #4 Chugoku EPCO Iwakuni #3 Kansai EPCO Gobo #1 Kyusyu EPCO Sendai #2 Kansai EPCO Ako #1 Kansai EPCO Miyazu #1 Kansai EPCO Nanko #1 EPDC Matsuura #1

450 4502 6002 600 600 500 600 1000 500 600 500 600 375 600 1000

1967 1971 1971 1973 1974 1974 1977 1979 1981 1984 1985 1987 1989 1990 1990
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MHI SC Steam Turbines operating installations

No. Unit MW Steam Condition (Turbine Inlet) Press Temp (MPa) (C) 24.1 538/566 24.1 538/593 566/593 24.1 24.1 24.5 25.0 24.1 24.5 24.5 24.1 24.5 24.5 24.5 24.1 24.7 593/593 600/600 600/610 538/566 538/566 538/566 538/566 538/566 595/595 600/600 600/610 566/593 Commerci al Operation

16 Tokyo EPCO Higashi-Ogishima 17 Chubu EPCO Hekinan #3 18 Hokuriku EPCO Nana-Ota #1 19 EPDC Matsuura #2 20 Chugoku EPCO Misumi #1 21 EPDC Tachibanawan #2 22 23 24 25 26 27 28 29 30 Thailand EGAT Ratchaburi Taiwan FPCC UP-1 China CP-1 KOBE STEEL Kobe #1 Taiwan FPCC FP-1 #5 (UP-C) Kansai EPCO Maizuru #1 Tokyo EPCO Hirono #5 ENEL Torrevaldaliga Nord XCEL Comanche #3

1000 700 500 1000 1000 1050 7512 6002 6006 700 600 900 600 6863 830

1991 1993 1995 1997 1998 2000 2000 2000 2000 2002 2004 2004 2004 (2008) (2009)
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MHI LARGE FOSSIL STEAM TURBINE

- World No.1 Share Among Leading Players(Except for Chinese Manufactures and Co-production)
Hitachi 16.3%

Siemens 12.2%

Hitachi 17.6%
Alstom 11.2%

Siemens 13.7%

Toshiba 22.4% Fuji 5.1% GE 4.1%

Alstom 12.0% Toshiba 22.4%

Fuji 4.0% GE 3.6%

Mitsubishi 28.6%

Mitsubishi 26.8%

World Market Share Over 600MW / Fossil Unit

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MHI STEAM TURBINE WORLD WIDE

Total : 182,939 MW (1,987 units)
Unit : MW ( ) : Number of Units
Iceland 1,120 (12) Ireland United 187 (1) Kingdom 1,156 (7) Netherlands 58 (1) Portugal 3 (1) Spain 5,655 (26) Algeria 29 (3) Italy 2,040 (3) Yugoslavia 64 (3) Greece 2 (1) Ukraine 110 (3) Turkey 3,721 (20) Syria 2,274 (12) Azerbaidjan 175 (3) Iraq 811 (7) Canada 563 (12)

China Iran 2,297 (15) 9,863 (39)

Pakistan 1,062 (13) India 642 (9)

Korea 4,566 (57)

U.S.A. 8,073 (92) Japan 66,079 (750) Mexico 12,753 (73) Bahama 50 (2) Dominica 198 (3) Curacao 125 (5) Venezuela 12 (1) Surinam 30 (1) Colombia 670(8) Brazil 1,062(28)

Tunisia 510 (3) Qatar264 (6) Egypt 1,217 (5) Jordan 97 (1) Kuwait 4,800 (16) U.A.E 433 (8) Saudi Arabia 9,417 (35) Bangladesh 51 (4) Myanmar Kenya 340 (5) 115 (5)
Thailand 8,322 (28)

Taiwan 10,943 (59) Hong Kong 3,165 (16) Macao 46 (2) Philippines 2,711 (38) Vietnam 721 (2) Brunei 10 (1) Singapore 660 (8)

Guatemala 181 (2) El Salvador 124(5) Costa Rica 34 (2) Ecuador 146 (2) Peru 27 (1)

Indonesia 7,443 (60) Australia 905 (18)

Malaysia 2,424 (23)

Chile 1,559(13) New Zealand 492 (5) Argentina 947 (5)

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MHI Turbine Configurations

No. of LP Casing No. of HP-IP Casing Max. Unit Capacity No. of Generator Design Constraints 50 Hz 60 Hz

2-Cylinder

1 (HP-IP Combined) 1 (HP-IP Combined) 2 HP&IP (Double Flow) 2 HP&IP (Double Flow)

LP exhaust area HP-IP blade strength Control stage blade (HP) IP last stage blade Generator capacity

750 MW* 750 MW*

3-Cylinder

1000 MW 1000 MW

4-Cylinder

1100 MW 1100 MW

4-Cylinder 2 (Cross (1500/1800 Compound) rpm)

(The efficiency is higher than that of Tandem-Compound 4-cylinder design)

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MHI Turbine Configurations

4 Casings
1200
(Cross Compound)

Application Range (MW)

1100 1000 900 800

2 Casings
1LP+HIP

700
600

4 Casings 3 Casings
2LP+HP+IP

500
400 2LP+HIP

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HP-IP Combined Turbine

F3D ISB Reaction Blade

IP Inlet Cooling

Advanced 12Cr Rotor Forging

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Features of HP-IP Combined Turbine

Shorter longitudinal span Smaller differential expansion Easy maintenance

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ISB RANGE FOR LAST BLADE (For 50Hz)

30IN

35.4IN

40.5IN

48IN

54IN Titanium

49IN

54IN

3000rpm

1500rpm
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ADVANTAGES OF ISB LP END BLADES

Larger damping is generated by the contact at the shrouds and snubbers, which is caused by the twist-back deformation due to centrifugal force.

ISB Reduction in Vibration Stress

Conventional Grouped Blade

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ADVANTAGES OF ISB LP END BLADES

Lower centrifugal stress by a large blade root and groove.

Enhancement of Reliability for Corrosive Environments Turbine Generators

ISB

Conventional Grouped Blade

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MHI ISB DESIGN BECAME WORLD STANDARD

ISB Design Since 1990 in MHI

BLADE (60Hz) 25 29.5 33 (50Hz) 30 Ht 35.4 40.5 DEVELOP 1990 1992 1993 MENT FIRST APPLICATION (60Hz) 1991 1995 1995 (50Hz) 1998 1997 1997

40 48 1998 1999 2004

45 54 2000 2003

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Operating Experience of the HIRONO #5

Date in commercial operation: July 12, 2004
HP-IP LP GEN

#1
LP Turbine HIP Turbine

#2 #3

#4 #5

#6

Turbine Entire View

Vibrational value (Peak-Peak m

Brg Metal Temp. (C)

150 100 50 0
#1 #2 #3

ANN

at 100% Load

300 200 100 0

#1 #2 #3

at 100% Load
ANN

#4

#5

#6

Bearing No.

#4

#5

#6

Bearing No.
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New Heat-Resistant Alloy for Turbine

Steam Temp Turbine Parts

566
CrMoV

610
12CrMoVNb (TMK-1) 12CrMoVNb (MJC-12) 12CrMoWVNb (10705MBU) Super 9Cr (T91)

630
3Co12CrMoWVNbB (MTR10A) 3Co12CrMoWVNbB (MTC10A) 3Co12CrMoWVNbB (MTB10A) 3Co12CrMoWVNbB (MTV10A)

650
Modified A286

HP/IP Rotor Inner Casing Nozzle Box Blade Valve

2.25CrMo

Type 316H

12CrMoWV (Type 422) 2.25CrMo

W545

Type 316H

The materials in Green column are developed by MHI.

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MHIs Steam Turbines

Over 35 years of experience in Steam turbine manufacturing, having supplied more than 1900 units worldwide.

More than 30 large sized units with supercritical parameters.

Having state of the art R&D facility and through its experience and developmental efforts MHI is continuously improving steam turbine design for better performance & reliability. Developed high heat resistant alloys for ultra supercritical steam parameters (630o C). Highly reliable control stage, Integral Shroud Blades of LP end blades results in better vibrational characteristics.

MHI ISB Blade Design became world standard

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FEATURES OF MITSUBISHI/LMTG GENERATORS

HIGH RELIABILITY PROVEN THROUGH EXTENSIVE EXPERIENCE (OVER 80 YEARS / OVER 1800 UNITS)

WIDE OUTPUT RANGE (UP TO 2000 MVA)

BEST APPLICATION OF COOLING SYSTEM (AIR / HYDROGEN / WATER)

3 9

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Supply Record For Thermal Power Plant

Total:1934 Units 639 Units (H2 Cooled) 1295 Units (Air Cooled) AS of Aug. 2010
80 70 60 50 50 80 GR EE NL AN D 70 60 60 50
P RO E

Mid-East 100 Units 86 Units

70 80 ND LA EN RE G

Asia 186 Units 179 Units

80 70 60 50

40

NO RTH AM ERICA

EU

40

40

ASI A
TR O PIC O FC AN CER

40

30 TR O PIC O FC AN CER 20

LA

30

30 20

P A C IFIC O C E A N

30 20

10

PACI F I C
EQ UATO R

IC

10

A F RI CA
O C

10

10

OC E A N
TR O PIC O F CAPRICO R N 30

10

SO UTH AM ERICA
30

10

I NDI A N OC E A N
A
10

EQ UATO R

10

N
20 TR O PO FC APRIC O RN 20

20

20

20

A U S TR A LIA
30 30 30 30 30 30

40

40

40

40

40

40

40

40

50 60 70 80 80 70 60

50

50 60 70 80 80 70 60

50

50 60 70 80 70 60

50

50 60 60

50

ANTA RCTICA 80

70 80 80

70

North/South America 99 Units 170 Units

4 0

Europe 16 Units 23 Units

Other (Pacific/Africa) 6 Units 39 Units

Japan 232 Units 798 Units

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APPLICATION OF COOLING SYSTEM

TYPE OF GENERATOR COOLING (STATOR)
AIR COOLED HYDROGEN COOLED HYDROGEN INNER COOLED

GENERATOR CAPACITY (MVA) 200

2 pole

400

600

800

1000

1200

2 pole

2 pole

WATER COOLED
4 1

2 pole
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MITSUBISHI EXPERIENCE OF LARGE CAPACITY WATER COOLED GENERATOR

LARGE CAPACITY : LONG TERM OPERATION : MAX. 1,600MVA (NUCLEAR) MAX. 1,008MVA (COAL-FIRED) MORE THAN 30 YEARS (SINCE 1979 OF FIRST 1,300MVA UNIT FOR NUCLEAR, ALL UNITS IN SERVICE) WATER LEAKAGE NEVER EXPERIENCED

HIGH RELIABILITY :

EXPERIENCE : TOTAL 22 UNITS (INCLUDING NUCLEAR) (TYPICAL UNIT FOR THERMAL POWER PLANTS) NANKO #1 670MVA 1990* HEKINAN #3 800MVA 1993* RATCHABURI #1 990MV 2000* COMANCHE #3 1,008MVA 2007**
*Commercial operation Year, **Year of manufacture

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990MVA 3,000rpm WATER COOLED GENERATOR FOR THERMAL POWER PLANT IN THAILAND

Commercial operation - 1999

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PROJECT UNDER EXECUTION

INDIA

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PROJECT UNDER EXECUTION

APPDCL 2 x 800 MW

STG

JAYPEE 2 x 660 MW

MAHAGENCO

3 x660 MW

RAJPURA 2 x 660 MW

Jaypee Karchana
3 x 660 MW STG

STG

BTG

EPC

Steam parameters M.S. Pressure 242 Bar M.s. Temp 565 Deg C Reheat Temp 593 Deg C

L&T MHI

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21 July 2011

STATOR CORE FABRICATION

BLADE ASSEMBLY

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JAYPEE PROJECT PROGRESS

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ROTOR WINDING

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Rotor insertion at MELCO

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21 July 2011

APPDCL PROJECT - ROTOR AT LMTG SHOP

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FUTURE TREND- ULTRASUPERCRITICAL

INDIA

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21 July 2011

FUTURE TREND IN INDIA- ULTRASUPERCRITICAL

IN MHI TERMINOLOGY

Subcritical :
Pressure : 16.7 M pa Temperature: 538/538 Deg-C or 538/560 Deg-C

Supercritical :
Pressure : 24.1 M pa Temperature: 538/560 Deg-C to 566/593 Deg-C

Ultra Supercritical(USC)
Pressure : 24.1 to 31.0 M pa Temperature: 593/593 Deg-C to 600/620 deg.c
HEAT RATE improvement by approx.1.3 % Compare to Supercritical 1.3 %
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21 July 2011

MHI has adequate experience for over 600/600 steam turbines

Steam Condition (0C) 600/600 600/610 600/600 600/600 600/600 600/600 600/610

Customer Station Chugoku EPCO Misumi #1 EPDC Tachibanawan #2 Tokyo EPCO Hirono #5 China Yingkou (2 units) Licenser China Kanshan (2 units) Licenser China Heyuan (2 units) Licenser

MW 1,000 1,050 600 600 600 600 678

Fuel Coal Coal Coal Coal Coal Coal Coal

C/O 1998 2000 2004 2007 2008 2009 2009

ENEL Torrevaldaliga Nord (3 units) Tokyo EPCO Hirono #6

Korea EWP Danjin (2 units)

600
1000

600/600
600/600

Coal
Coal

(2013)
(2015/6)

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EPDC Tachibanawan #2 1050MW Turbine

Largest Capacity Steam Turbine with the Highest Steam Condition

Turbine Type Steam Condition In Operation since Turbine Generators

: CC4F-46 : 25.1MPa600/610 : DEC. 2000

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Tokyo EPCO Hirono #5 600MW Turbine

600 MW Two Cylinder Steam Turbine with 48-inch Blade
2 pad journal bearing 12Cr HIP Rotor

Advanced flow guide Advanced direct support LP frame

600 class advanced HP-IP combined frame

3000 rpm 48inch Steel ISB TURBINE TYPE STEAM CONDITON IN OPERATION SINCE : TC2F-48 : 24.6MPa600/600 : Jul.2004
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THANK YOU

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