Advanced Turbine Technologies for

High Efficiency Coal-Fired Power Plants

2nd India-Japan Energy Forum

Promoting cooperation in energy efficiency

4-5 February 2008

Mitsubishi Business Confidential

 CONTENTS

1. THERMAL EFFICIENCY & STEAM

CONDITIONS
2. MITSUBISHI 500 1000MW

CLASS TURBINE
3. MHI ADVANCED TECHNOLOGY FOR
HIGH EFFICIENCY
4. CONCLUSION

Mitsubishi Business Confidential 

 1. THERMAL EFFICIENCY &
STEAM CONDITIONS

Mitsubishi Business Confidential 

 STEAM CONDITON & EFFICIENCY
Net Efficiency (%LHV)




 

CO2 Reduction (%)




 


CO2 Reduction  




 Net Efficiency
 




 


  


      
 


   
 
 
 
     



Inlet Steam Temperature
Steam Temperature (  )
Mitsubishi Business Confidential 
 THERMAL EFFICIENCY & HEAT RATE

Heat Rate difference of Turbine

MPa x degC
(%)


600/600
0.9
566/593
0.8
566/566
0.9
538/566
0.8
538/538
1.7
BASE

16.7 24.2
Steam Pressure (MPa abs.)

Mitsubishi Business Confidential 

HISTORY OF MHI LARGE STEAM TURBINES
DEVELOPMENT OF TURBINE CAPACITY
1371 MW
MW
1180 MW
1175 MW

1050 MW
1000 MW
1000 NUCLEAR

SUPERCRITICAL SUPERCRITICAL
600 MW 1000 MW
SUPERCRITICAL
1050MW
FOSSIL
500

75 MW REHEAT NUCLEAR
STEAM TURBINE 340 MW

156 MW
0
1950 1960 1970 1980 1990 2000
OPERATION YEAR
Mitsubishi Business Confidential 


HISTORY OF MHI LARGE STEAM TURBINES
DEVELOPMENT OF STEAM PRESSURE & TEMPERATURE
WAKAMATSU
 STEP2 (649/593 )
TACHIBANAWAN #2
50MW MATSUURA #2
650 OSAKA #3 (593/593 )
(600/610 )

1050MW
kg/cm2g (566/538 )

WAKAMATSU 1000MW
156.25MW STEP1 (593/593 )
400 GOI #5

600 SHIN-TOKYO #4 (566/566 )

50MW
(538/538 )

350MW 566 MISUMI #1
350 75MW

(600/600 )


TEMPERATURE HEKINAN #3 1000MW
550 300 (538/593 )

538
700MW
250 255
510
246
250
500 PRESSURE
480
190
200
169
450 150 127
102
100 88
400 59 60
50 42
350 0
1950 1960 1970 1980 1990 2000 2010
Mitsubishi Business Confidential OPERATION YEAR 
 MHI EXPERIENCE OF SUPER
CRITICAL LARGE STEAM TURBINE

LARGE CAPACITY ( 600MW)

LONG TERM OPERATION
EXPERIENCE
: 28 UNITS
(ALL UNITS IN SERVICE)
: MORE THAN 34 YEARS

ADVANCED STEAM CONDITION
HEKINAN #3 700MW 24.1MPa 538/593 C

NANAO-OTA #1 500MW 24.1MPa 566/593 C
MATSUURA #2 1000MW 24.1MPa 593/593 C

MISUMI #1 1000MW 24.5MPa 600/600 C
TACHIBANAWAN #2 1050MW 25.0MPa 600/610 C

HIRONO #5 600MW 24.5MPa 600/600 C
MAIZURU #1 900MW 24.5MPa 595/595 C
Mitsubishi Business Confidential 
 HIGHEST STEAM TURBINE
THERMAL PERFORMANCE
J-POWER TACHIBANAWAN #2 1050MW

Turbine Type : CC4F-46

Steam Condition : 25.1MPa 600/610

YEAR IN OPERATION : DEC. 2000

Mitsubishi Business Confidential 

HIGH EFFICIENCY AND ECONOMICAL DESIGN
600MW CLASS with 3000rpm 48inch ISB
TOKYO ELEC. HIRONO #5 600MW
2 pad
journal bearing

12Cr HIP Rotor

Advanced
flow guide

Advanced direct
support LP frame

600C class advanced

HP-IP combined frame
3000rpm 48inch Steel ISB
TURBINE TYPE : TC2F-48
STEAM CONDITON : 24.6MPa 600/600



Mitsubishi Business Confidential YEAR IN OPERATION : Jul.2004


 2. MITSUBISHI 500MW 1000MW


Class Turbine

Mitsubishi Business Confidential

 OPTIMIZED COMBINATION OF TURBINE
COMPONENTS FOR VARIOUS POWER OUTPUT

4 Casings
1200 (Cross Compound)
2 Casings
1100
Application Range (MW)

1000
1000MW

900 1LP+HIP
800
800MW

700 660MW 4 Casings

600 3 Casings
500MW
500
2LP+HP+IP
400
2LP+HIP

Mitsubishi Business Confidential


 OPTIMIZED COMBINATION OF TURBINE
COMPONENTS FOR VARIOUS POWER OUTPUT

 

 
HIP Turbine


 
HIP Turbine

  
 

Generator
LP Turbine IP Turbine HP Turbine
Mitsubishi Business Confidential

 HP-IP Combined Turbine
F3D ISB
Features of HP-IP Combined Turbine
Reaction Blade
Shorter longitudinal span
Smaller differential expansion
Easy maintenance

IP Inlet Cooling

Advanced 12Cr Rotor Forging

Mitsubishi Business Confidential


 F3D ISB REACTION BLADE
F3D blades are now applied to all new orders since 1991
Advanced steam path design
by fully 3-D CFD analysis methodologies

Stationary Blades Rotating Blades

EFFICIENCY VERIFICATION TEST IN LABORATORY
Test Result of Static Pressure CFD Analysis

Mitsubishi Business Confidential


 ROTOR COOLING ARRANGEMENT
Rotor surface around IP inlet is cooled by the HP exhaust steam
COOLING
STEAM
FROM HP
EXHAUST

Cooling
Steam Path

Mitsubishi Business Confidential


 ISB FLEET FOR LAST BLADE (For 50Hz)


      

                    
  
Mitsubishi Business Confidential

 ADVANTAGES OF ISB LP END BLADES




ISB GB
Larger damping is generated by the
contact at the shrouds and snubbers, Damping
which is caused by the twist-back
deformation due to centrifugal force.
ISB Conventional
Grouped Blade
Reduction
in Vibration Stress
Mitsubishi Business Confidential

 3. MHI ADVANCED TECHNOLOGY FOR
HIGH EFFICIENCY

Mitsubishi Business Confidential





LATEST CFD ANALYSIS
Steady Flow


Unsteady Flow
Tip Tip

Measured Measured
Blade Exit Blade Exit

Base Base

CFD CFD

Mitsubishi Business Confidential 

COLLABORATION WITH CAMBRIDGE UNIV.
Test Equipment Test of MHI blade
at Cambridge Univ.

Measurement

Stationary blade

CFD
Sectional View Loss Coefficient
Mitsubishi Business Confidential Rotating blade 

 COLLABORATION WITH ETH
Measuring at MHI Model Test Turbine
with Fast Response Aerodynamic Probe (FRAP)

Model Test Turbine Measurement Result

(Total pressure at blade exit)
ETH: Eidgenossische Technische Hochschule Zurich
Swiss Federal Institute of Technology Zurich
Mitsubishi Business Confidential 
 CFD APPLICATION TO ENTIRE TURBINE

Mitsubishi Business Confidential 

 NEW HEAT-RESISTANT ALLOY DEVELOPMENT

Steam
Temp 566




 610 630 650
Turbine Parts

12CrMoVNb 3Co12CrMoWVNbB Modified

HP/IP Rotor CrMoV
A286
(TMK-1) (MTR10A)

Inner
12CrMoVNb 3Co12CrMoWVNbB
Casing 2.25CrMo Type 316H
(MJC-12) (MTC10A)
Nozzle Box
12CrMoWV 12CrMoWVNb 3Co12CrMoWVNbB
Blade W545
(Type 422) (10705MBU) (MTB10A)

Super 9Cr 3Co12CrMoWVNbB

Valve 2.25CrMo Type 316H
(T91) (MTV10A)

Developed by MHI
Mitsubishi Business Confidential 
 WAKAMATSU HIGH TEMPERATURE TURBINE  J-POWER 
 New heat-resistant material were tested in the actual turbine in 1986-91

102kg/cm2g x 593/593  102kg/cm2g x 649/593


STEP
STEP 
FERRITIC MATERIAL
 AUSTENITIC MATERIAL

NEW 12Cr Rotor Forging TMK1
Modified A286 Rotor Forging

NEW 12Cr Cast Steel MJC12

SUSF316H Forged Steel

9Cr2Mo Forged Steel HCM9M

Mitsubishi Business Confidential 
SUSF316H Forged Steel
 LP TURBINE TEST FACILITY

Turbine Casing

Control Room Condenser

400ton/h steam can be applied to test facility.
Mitsubishi Business Confidential 
 VERIFICATION TEST RESULT
(3000RPM 48-INCH BLADE)

Blade Vibratory Stress Turbine Efficiency

Low Stress in All Range High Efficiency Confirmed







Model Turbine Test




&%


Field Telemetry Test (700mmHg)
!

)


'(
"#
$
$

 Vibratory Stress


Field Telemetry Test (722mmHg)



!

)


'(
"#

&%
$
$



Test Result
500mmHg
600mmHg Design Value
722mmHg


Exhaust flow (t/h)




0 150 300 450 600 Exhaust Volumetric Flow

Load (MW)

Mitsubishi Business Confidential 

 ROTATING VIBRATORY TEST RESULT
(3000RPM 48-INCH BLADE)

2nd Mode

Frequency (Hz)
1st Mode

Rotating speed (rpm)

Rated Speed

Rotating vibratory test rotor Test results of the vibratory

with 48-inch steel blades Characteristics
Mitsubishi Business Confidential 
 IN-HOUSE POWER PLANT
(T-Point)

ACC

Steam Turbine
HRSG

Gas Turbine

ST Type : SRT-36 Execute the Verification Program

(Single Cylinder Reheat Turbine)
in Order to Confirm the Reliability
ST Output : 105MW
of New Technology
Steam Condition : 139 kg/cm2g 566 / 410


Commercial Operation : JULY 1997
Mitsubishi Business Confidential 
 NEW TECHNOLOGY VERIFICATION
(IN-HOUSE POWER PLANT)

WIRING WIRING
(LOWER CASING & ROTOR INSTALLATION) (UPPER CASING INSTALLATION)

Mitsubishi Business Confidential 

 4. CONCLUSION

1. MHIs abundant experience of super-critical turbines

with high temperature represents that the technologies
are innovative and reliable.

2. MHI achieves a high level of technologies, especially for

steam flow optimization with CFD and heat-resistance
material development, which are regarded as the key
technology.

3. Comprehensive verification, utilizing world-class facility

and full-scale test turbine, ensures the performance and
reliability of the latest technologies, even which are
innovative ones.

Mitsubishi Business Confidential 

 L&T-MHI Turbine Generator Private Limited
-Indigenized Domestic Company-

JV has been established on Nov.5th, 2007 by

L&T (LARSEN & TOUBRO LIMITED) of 51% share,
MHI (Mitsubishi Heavy Industries, Ltd.) of 49% share
(MELCO takes 10% share from 49%)

<Investment > 1,030 Crores

<Capability> 4,000MW
per annum
Surat
(Factory) <Employee> 900
<Location> Mumbai and
Surat (Hazira)
!
!" #

Mitsubishi Business Confidential 

 L&T-MHI Turbine Generator Private Limited
-Indigenized Domestic Company-

<Line up of Products >

500/600/800/1000MW
Supercritical Steam Turbine
Generator
and
150/300MW Steam Turbine
Generator for
Gas Turbine
Combined Cycle
Assembly of 1000MW Turbine in MHI Nagasaki

Mitsubishi Business Confidential 

 L&T-MHI Turbine Generator Private Limited
-Indigenized Domestic Company-

Rotor Assembly Shop in MHI Nagasaki

JV can;
(1) Solve Huge Electric
Demand

(2) Achieve Customer

Satisfaction in
Maintenance
JV factory will have the same
capability as of MHI Nagasaki (3) Produce Lots of
Employment in India

High Speed Balance Machine

Mitsubishi Business Confidential 

 L&T-MHI Turbine Generator Private Limited
-Indigenized Domestic Company-

JV Should be Qualified,
Because;
(1) Fully Supported by MHI, MELCO and L&T Financially and
Technically

(2) Transferring Mitsubishis Most Advanced Technology for

Steam Turbine Generator

(3) Of Course, Indigenized Domestic Company

Mitsubishi Business Confidential