Competent solutions for nuclear power plants – from flexible upgrading of existing plants to the innovative largest nuclear unit in the worldDr. Andreas Wichtmann, Siemens Power Generation
June 2-4, 2006Power Generation 2Dr. Wichtmann
Overview
Nuclear Service Engineering
Summary
Advanced Disk Design
Introduction
Engineering Analysis
Nuclear New Apparatus
June 2-4, 2006Power Generation 3Dr. Wichtmann
Nuclear Steam Turbine References
Nuclear Steam Turbines built by Siemens Power Generation as
ParsonsWestinghouseSiemens KWU
First operation ~50 years agoMore than 130 UnitsMore than 120 GW total rating
Nuclear Steam Turbines built by Siemens Power Generation as
ParsonsWestinghouseSiemens KWU
First operation ~50 years agoMore than 130 UnitsMore than 120 GW total rating
June 2-4, 2006Power Generation 4Dr. Wichtmann
0
200
400
600
800
1000
1200
1400
1600
1800
1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010
Siemens KWUParsonsWestinghouseMods&UpgradesOlkiluoto 3
Nuclear Steam Turbines References
Isar 2
MWel
Year of commission
Olkiluoto 3
June 2-4, 2006Power Generation 5Dr. Wichtmann
Overview
Summary
Advanced Disk Design
Introduction
Engineering Analysis
Nuclear New Apparatus
Nuclear Service Engineering
June 2-4, 2006Power Generation 6Dr. Wichtmann
NPP Yonggwang, South Korea
Yonggwang Nuclear Units 1 & 2
Westinghouse OEM design
997 MWe nominal rating
PWR / Moisture Separator Reheater
June 2-4, 2006Power Generation 7Dr. Wichtmann
Initiate Order
Assign Engineers and
Divide-upWork Scope
Notify Customer of Analysis
Findings / Impacts as They Occur
Perform Analyses
Customer Comments
andReview
Final (HBD or Mech.)
ReportIssuance
FinalizeParameters
Engineering Analysis Process
June 2-4, 2006Power Generation 8Dr. Wichtmann
Yonggwang thermal uprate evaluation
Thermodynamic Modelling at
Three phase evaluation:
Feasibility Evaluations of the Existing TG Components
Further System Evaluations and Recommendations
current operation parameters (HBD).uprate power level and Valves Wide opencustomer power levels (i.e. 100%, 75%, etc.)
June 2-4, 2006Power Generation 9Dr. Wichtmann
Partial Arc Impulse
Partial Arc Reaction
Full Arc Reaction with Blade Rings
Full Arc Reaction with Inner Cylinder
1st Stage Type Impulse Reaction Reaction Diagonal Reaction
Outer Cylinder Pressure
Base high highest low
Blade Path Effectiveness 0 + ++ +++ Costs 0 - - - Scope Rotor*,
Blade Rings (4), Nozzle Block
Rotor, Blade Rings (4), Reaction Nozzle Block
Rotor, Blade Rings (4) Flow Guides,
Rotor, Blade Rings (2) Inner Cylinder,
HP Upgrade Comparison
* reuse possible
June 2-4, 2006Power Generation 10Dr. Wichtmann
Monoblock rotor
3D blading
Diagonal inlet stage
10-year inspection
Inner casing replaces control stage and both #1 blade rings
Option for stainless steel inner casing and blade carriers
HP Turbine (Full-Arc) Design Features
June 2-4, 2006Power Generation 11Dr. Wichtmann
Overview
Summary
Introduction
Engineering Analysis
Nuclear New Apparatus
Advanced Disk Design
Nuclear Service Engineering
June 2-4, 2006Power Generation 12Dr. Wichtmann
2 LP Turbine Upgrades, Westinghouse BB381
Customer ContractUpgrade of 2 LP Turbines with Rotors and stationary blade path, incl. Installation in Spring 2006
Main Success:• Expected performance increase of
21 MW from technology only, with potential for future reactor uprate
• Cure from generic SCC problems
Status• Notice of Award received 2004-01-09
NPP Kuosheng, Taiwan
June 2-4, 2006Power Generation 13Dr. Wichtmann
NPP KuoshengLP Turbine, Shrunk-on Disk Design
13.9 m2 nuclear LP turbine
June 2-4, 2006Power Generation 14Dr. Wichtmann
Avoidance of Stress Corrosion Cracking
Engineering
Shot Peening
ManufacturingHeat TreatmentMaterial Know How
Quality Assurance
1400
Tim
e to
Cra
ck In
itiat
ion
[h]
Stress Corrosion Cracking due to Hydrogen Embrittlement
0.2% Yield Strength [MPa]600 800 1000
104
103
105
No Crack Initiation
1200
0.2%-Yield Strength [MPa]
Cra
ck G
row
th R
ate
[m/s
]
10-12
10-11
10-10
10-9
10-8
10-7
600 800 1000 1200
HydrogenInduced SCC
1400
Compressive Stress Area
Shoot peening
Rolling of shaft
US inspection
June 2-4, 2006Power Generation 15Dr. Wichtmann
Shrunk-on Disc Design Success against SCC
in operation more than 2.750.000 hours total= more than 40 million disk operating hours
in operation for up to 225.000 hours
more than 660 examinations on Disks
No replacement of rotors or disks due to stress corrosion cracks, as performed by most competitors
June 2-4, 2006Power Generation 16Dr. Wichtmann
Original Equipment Data
Plant OEM Country CapacityMW
RetrofitDate
RetrofitComponent
Grafenrheinfeld Siemens KWU Germany 1300 1993 HP, LPKRB II Block B Siemens KWU Germany 1310 1993 HP, LPKRB II Block C Siemens KWU Germany 1310 1994 HP, LPGrohnde Siemens KWU Germany 1393 1995 LPPhilippsburg 1 Siemens KWU Germany 901 1995 LPPhilippsburg 2 Siemens KWU Germany 1343 1995 LPUnterweser Siemens KWU Germany 1300 1995 HP, LPAlmaraz 2 Westinghouse Spain 950 1996 HP, LPAsco 2 Westinghouse Spain 930 1996 HP, LPBrokdorf Siemens KWU Germany 1367 1996 LPIsar 2 Siemens KWU Germany 1369 1996 LPAlmaraz 1 Westinghouse Spain 950 1997 HP, LPAsco 1 Westinghouse Spain 930 1997 HP, LPEmsland Siemens KWU Germany 1314 1998/2001 LPIsar 1 Siemens KWU Germany 905 1998 LPForsmark 3 ABB Sweden 1155 2004 LPNeckarwestheim II/3 DS Siemens KWU Germany 1314 2004 LPKrümmel Siemens KWU Germany 1316 2006 LP
Retrofit Data
Nuclear Steam Turbine ReferencesRetrofit/Upgrades for half speed 50 Hz
Siemens recommends for its turbines with disc type rotors a main inspection only after 100.000 h which is accepted by the German authority (VGB)
June 2-4, 2006Power Generation 17Dr. Wichtmann
Steam Turbine Retrofit/Upgrades ReferencesNon OEM products 50 Hz/60 Hz
Original Equipment Data Retrofit Data
Plant OEM Country CapacityMW
RetrofitDate
RetrofitComponent
Connecticut Yankee Westinghouse USA 648 1987 LPAlmaraz 2 Westinghouse Spain 950 1996 HP, LPAlmaraz 1 Westinghouse Spain 950 1997 HP, LPLimerick 1 GE USA 1138 1998 HP, LPLimerick 2 GE USA 1138 1999 HP, LPComanche Peak 1 Siemens USA 1215 2002 LPSusquehanna 2 GE USA 1168 2003 HP, LPSalem 2 Westinghouse USA 1170 2003 HPSalem 1 Westinghouse USA 1170 2004 HP, LPForsmark 3 ABB Sweden 1155 2004 LPSusquehanna 1 GE USA 1128 2004 HP, LPComanche Peak 2 Siemens USA 1128 2004 LPCooper Westinghouse USA 801 2005 LPSendai MHI Japan 900 2006/2005 HP, LPKuosheng Westinghouse Taiwan 1000 2006 LPSouth Texas Project Westinghouse USA 1300 2006-2007 LPDC Cook GE USA 1134 2006 LPSouth Texas 1 Westinghouse USA 1350 2006 LPSouth Texas 2 Westinghouse USA 1350 2007 LPGinna Westinghouse USA 528 2006 HP
Original Equipment Data Retrofit Data
Plant OEM Country CapacityMW
RetrofitDate
RetrofitComponent
Connecticut Yankee Westinghouse USA 648 1987 LPAlmaraz 2 Westinghouse Spain 950 1996 HP, LPAlmaraz 1 Westinghouse Spain 950 1997 HP, LPLimerick 1 GE USA 1138 1998 HP, LPLimerick 2 GE USA 1138 1999 HP, LPComanche Peak 1 Siemens USA 1215 2002 LPSusquehanna 2 GE USA 1168 2003 HP, LPSalem 2 Westinghouse USA 1170 2003 HPSalem 1 Westinghouse USA 1170 2004 HP, LPForsmark 3 ABB Sweden 1155 2004 LPSusquehanna 1 GE USA 1128 2004 HP, LPComanche Peak 2 Siemens USA 1128 2004 LPCooper Westinghouse USA 801 2005 LPSendai MHI Japan 900 2006/2005 HP, LPKuosheng Westinghouse Taiwan 1000 2006 LPSouth Texas Project Westinghouse USA 1300 2006-2007 LPDC Cook GE USA 1134 2006 LPSouth Texas 1 Westinghouse USA 1350 2006 LPSouth Texas 2 Westinghouse USA 1350 2007 LPGinna Westinghouse USA 528 2006 HP
For US-power plant „Limerick“ Siemens got the permission by the US-Nuclear Regulatory Commission (NRC) to extend the inspection intervals from 6 to 10 years
June 2-4, 2006Power Generation 18Dr. Wichtmann
Overview
Nuclear Service Engineering
Summary
Introduction
Engineering Analysis
Nuclear New Apparatus
Advanced Disk Design
June 2-4, 2006Power Generation 19Dr. Wichtmann
Finnish New Nuclear Power Plant Olkiluoto 3 - Basic Data
Location Olkiluoto, FinlandReactor Supplier Framatome ANP Reactor Type Pressurized Water
Reactor, EPR
Turbine Supplier Siemens AG, Power Generation
Net Output ~1600MWNet Efficiency >37%Com. Operation 2009
Location Olkiluoto, FinlandReactor Supplier Framatome ANP Reactor Type Pressurized Water
Reactor, EPR
Turbine Supplier Siemens AG, Power Generation
Net Output ~1600MWNet Efficiency >37%Com. Operation 2009
June 2-4, 2006Power Generation 20Dr. Wichtmann
NPP Productline
Double bearing (half speed) ; fixed bearing arrangement
High-performance LP blading for different
up to 30qm
Efficient erosionprotection measures
Fully 3-dimensional high
performance variable reaction blading (3DVTM)
Fabricated welded design
Evolution ofKONVOI turbosetfor 1000MW to 1700M application
vertical arrangement2-stage heater only 2 inlets top/bottom
2 outlets in lower part
June 2-4, 2006Power Generation 21Dr. Wichtmann
LP Turbine World largest steel blade
Hub Diameter Di ~3060 mmTip Diameter Da ~6720 mmBlade Length L ~1830 mmBlade Weight (incl. Root) ~340 kgCentrifugal Force of one LSB 12 MN
Di
L Da
June 2-4, 2006Power Generation 22Dr. Wichtmann
PerformanceEfficiency Increase from Isar II to OL3
LP TurbineUpgrade
HP TurbineUpgrade
IncreasedMain Steam
Pressure
ImprovedWater Steam
Cycle
30 sqm LSBImproved
Backpressure25 mbar
Main SteamPressure
65 to 78 bar
2 stage MSR7 feed water
reheater
~36%
34%
35%
36%
37%
38%
39%
40%
Isar II OL 3
~40 %
June 2-4, 2006Power Generation 23Dr. Wichtmann
Summary
Design features of conventional fleet are implemented
Service solution by profound engineering studies
Advanced disk design to avoid SCC
Efficiency increase by innovative bladingdesign
Design is based on proven nucleartechnology (>40 years)
Innovative nuclear turboset design forgross power output of ~1715MW at 40% gross efficiency