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BOILER TURBINE
AST LP R/G
M/C
REHEATE
HP
IP
BOILER TURBINE
AST LP R/G
M/C
plant. Consequently, the Reheater tubes must be avoided tube failure by excessive tube metal temperatures. Even if tube failure occurs as worst case, continuous operation of the ship is desired. As for marine reheat boiler, it would appear that there are following three kind of type mainly. Dual Furnace Type Gas By-pass Type Individual Type Dual Furnace Type has main furnace and reheat furnace in one boiler. These furnaces are divided by Divided Water Wall or Divided Water Tube. Gas By-pass Type is divided two ~ three flow paths of combustion gas. One of path is installed Superheater and Reheater. The other paths are installed Superheater only. Also, outlet damper is arranged in outlet of each path. Individual Type is that boiler for Reheater is completely separated from Main Boiler. And exhaust steam of HP turbine is led to this separated Reheat Boiler for reheating. Each type of reheat boiler has both advantages and disadvantages (Refer to attached table). However, separated Reheater in the Dual Furnace type is selected for UST considering protection and reliability of the Reheater. In this type of boiler, Reheater and reheat furnace are located flow path outlet of combustion gas which is low gas temperature. Then, continuous operation can be done with Reheat Burner stop only when no steam flow or extremely low steam flow conditions.
Economizer
Reheater
Accordingly, increasing of heating surface area for the Superheater and improvement of thermal resistance are required. For increasing of heating surface area, secondary Superheater is added behind of primary Superheater in parallel. This construction is still remained futures of MB type main boiler, drainable and easy maintenance construction. As for improvement of thermal resistance of Superheater tubes, secondary Superheater which is higher steam temperature compare with that of primary Superheater, is not exposed from furnace radiation directory to locate downstream of flow path. Secondary Superheater Primary Superheater
Superheater Header
Fig.4 Construction of Superheater Furthermore, combustion gas temperature will be down due to heat absorption of primary Superheater. Therefore, metal temperature of Superheater tubes can be kept similar with that of conventional main boiler even if steam temperature is higher than conventional. This kind of construction for Superheater, called Twin Superheater, has been manufactured in large capacity main boilers and proven technology.
2) Construction of Superheater For improvement of plant efficiency in UST, high pressure and temperature for main steam is applied compare with conventional steam turbine plant. Table 1 Comparison between conventional and reheat boiler Conventional Boiler
Reheat Boiler
Construction
7.65 MPa LR Grade 490 Carbon Steel Plate LR Grade 410 Carbon Steel Pipe LR Grade 360 Carbon Steel Tube
12.0 MPa ASTM A299 Gr.A LR Grade 460 Carbon Steel Pipe LR Grade 410 Carbon Steel Tube
Furnace Radiation
160
140 ASME SA335 Cade Case 2199 Allowable Stress (N/mm ) 120
2
100
80
60
Reheat Boiler Superheater Metal Temp Calculation (Non RH, Oil Firing)
40
650
Metal Temp.
600
20 CST: 515 0 100 200 300 400 500 Metal Temperature () UST: 560 600 700
500
Furnace Radiation Max. Metal Temp for Conventional Boiler 18Cr Stainless Steel
Steam Temp.
450
400
350
300
250
1 pass
2 pass
3 pass
4 pass
5 pass
Primary Superheater
Superheater Tube
Fig.6 Metal Temp of Superheater Tubes For material of Superheater Tubes, Chrome-Molybdenum alloy steel, ANSI A213-T22 equivalent, is applied for relatively low metal temperature region as same as conventional main boiler and Stainless steel, ANSI A213-TP347H equivalent, which has already proven material for On/Off-shore application is applied for high metal temperature region. This stainless steel material, contained much Chrome, excels at anti high temperature corrosion by Vanadium etc. Therefore, it can prevent corrosion from progressing by bad fuel.
1 0.9
2.25Cr-Mo-W alloy steel header Fig.9 Detail of Superheater Header 3) Reliability of Reheater Reheater is designed to achieve specified steam temperature by using Reheat Burner which is located bottom of Reheat furnace. However, as mentioned former, there is case of no steam flow or extremely low flow condition in frequent load changes or astern / loading / stand-by of the ship which is the major difference points with On-shore plant. In this situation, there is possibility to burn Reheater tubes by excessive tube metal temperature due to reduction of steam cooling effect. To solve above problems, Reheater and Reheat furnace are located flow path outlet of combustion
560
580
600
620
640
660
Metal Temperature ( )
In addition, combustion gas at Reheater inlet during Reheat Burner operation will be high. However, construction of Reheater casing is applied inner insulation method which is proven construction of On-shore Heat Recovery System. Then, these constructions are protected against thermal expansion etc.
11MPa x 138
Reheater
2.0MPa x 560
6 Main Burner
Fig.12 Construction of Reheater 4) Environmental Issue Fig.12 shows exhaust gas emission for each propulsion plant during normal operation and using boil off gas as fuel. Content of carbon oxide for steam turbine plant is lower than other plant because of source of exhaust gas coming from main boiler. And fuel consumption for UST plant will be reduced compare with conventional steam turbine plant due to high plant efficiency. Therefore, further reduction can be expected. Fig.13 shows exhaust gas emission during port operating condition. During port condition, steam turbine plants have dual fuel burning modes. However, a diesel electric plant is restricted to diesel mode only, because gas mode cannot be used at low load condition. Therefore the NOx and SOx emissions from steam turbine plant will be lower than other plants.
300
Superheater Furnace
Reheat BNR
10MPa x 565
155
11MPa x 138
Reheater
2.0MPa x 450
CO2 NOx
Superheater Furnace
STOP
100 50 0
10MPa x 565
Under Sea C ST Normal UST DFEGoing G TC(Gas C G mode) TSC Fig.11 Reheat Burner Stop Condition Fig.13 Emission during normal operation
1) ACC for Reheat Burner Basically, total fuel quantity and combustion air quantity is controlled according to steam demand. And fuel distribution to main burner and reheat burner is shared with constant rate at steady operating condition. 2) Reheat Steam Temperature Control The reheated steam temperature is naturally varied according to boiler load. And rapid temperature variation or excessive high temperature is compensated the fuel quantity of reheat burner by detecting reheat steam temperature. Also, the superheated steam temperature is controlled to avoid excessive temperature difference between superheated steam temperature and reheated steam temperature at low load. 3) Reheater Protection System As mentioned former, there is case of no steam flow or extremely low flow condition in frequent load changes or astern / loading / stand-by of the ship. In this situation, there is possibility to burn Reheater tubes by excessive tube metal temperature. Therefore, automatic reheat burner operation at low load etc. is performed by this system.
600.0 Oil Firing (Non Bleed Condition)
SH Temp (RHB off)
160.0
140.0
550.0
Non Control SH - RH
450.0
RH Temp (RHB off) Control SH - RH
80.0
Fig.15 Local operation panel for Main Boiler In case of Reheat Boiler Control, following functions are required additionally. And above additional functions are confirmed by using UST plant simulator. (Fig.16)
60.0
400.0
Allowable Temp Diff
0.0 100
5. Conclusion
Generally, propulsion plant for LNGC requires reliability and safety concern. MHI Reheat Boiler designed considering these requirements mainly. Even if new technology is applied in this boiler, we carried out several confirmation not only numerical analysis but also scale model test, firing test etc. As a result of our investigation, we are confident about the design of Reheat Boiler and believe that our customers will be satisfied for applying UST plant for new LNGC.
pressure turbine, one (1) intermediate pressure turbine and one (1) low pressure turbine with an astern turbine incorporated in the low pressure turbine casing, and shall be arranged for driving a propeller through a reduction gear and shafting.
Reheat Steam Main Steam (AHD) HP/T Exh. to Reheater HP/T IP/T R/G Main Steam Reheat Steam : abt. 9.8MPa x 555 : abt. 2.0MPa x 555
LP/T
HP/T
IP/T
MS36-2 5.68MPa x 520 722mmHgv. x 27 N/A 25MW x 78rpm 25MW x 78rpm 3 3-stage F.W. system
Main Boile
Air H
Gland Condenser
Dearator
Fig.1 UST Plant (MHI) Success of the UST plant certainly depends on main propulsion reheat-steam turbine (UST turbine) for the plant (See Fig.2). The UST turbine shall consist of one (1) high
CST: Conventional Steam Turbine (Non-Reheat) UST: Ultra Steam Turbine (MHI Reheat)
Our advanced SAH system adopting the shaft generator, dual economizer and so on has equal efficiency of the plant to or higher than GAH with easy operation and maintenance-free.
The main steam and reheat steam condition at turbine inlet is designed as below. Main Steam: 9.8MPaG x 555 Reheat Steam: 2.0MPaG x 555 In a case that the reheat plant is equipped with the shaft generator held in the intermediate shaft, the main turbine has to develop a total output power including the electric power generation. In general, the electric power expected at the guaranteed point in the plant is about 1.2 1.3MW. Therefore, the plant can gain much higher efficiency by developing the electric power with using rather the main turbine than the alternator turbine (Specified output power: 3.5MW), which is of lower performance at the partial load. However, it should be decided as to whether the shaft generator is adopted in consideration of an effect-to-cost including an initial cost, installation and a complexity of PMS (power management system) etc. Meanwhile the plant is a typical SAH (Steam Air Heater) system composed of two (2)-stage feed water heating system with three (3)-stage extraction and no high pressure heater is installed. It is because a simplicity and easy maintenance in the plant is regarded as important. Theoretically GAH (Gas Air Heater) system with multi-stage high pressure heater and multi-stage extraction has a little higher efficiency (about 2 3% in terms of FOC) as compared with normal SAH system; however, GAH system is extremely complex and strictly inferior to SAH system in operativeness and maintenance.
IP/T Exhaust
HP/T Part
d) Ahead stop valve and maneuvering valve There is no big constructional change from the existing system except for valve body and bolt material. The detailed structural analysis in steady/unsteady condition has been performed in accordance with the UST plant condition. The comparison of turbine components between CST and UST is shown in Table 4. Table 4 Comparison of Turbine Components between CST and UST
CST UST MR36-II 25MW x 76rpm HR-22 LR-18 1-Curtis 2 lines + 5 Rateau 6 Rateau 6 Rateau + 4 Reaction 2-Curtis with 2 lines Unit Type Power x rpm HP/IPT Type LP/T Type HP IP LP AST MS36-2 25MW x 78rpm H-22 L-18 1-Curtis 2 lines + 7 Rateau 4 Rateau + 4 Reaction 2-Curtis with 2 lines
LP/T Inlet
Astern Turbine
Fig.3-2 Cross Section of UST turbine (LR-18) In consideration of a spare-saving, regular maintenance and overhauling each docking, it is needed to reduce a number of parts composing the UST turbine and to make it simplified for some unique requirements to marine use.
In order to improve the turbine efficiency, HR-22 type of high-Intermediate pressure turbine is composed of 12 stages (1 Curtis with 2 lines and 11 Rateau Stages) in total and LR-18 type of low pressure turbine is composed of 10 stages (6 Rateau Stages and 4 Reaction Stages) in total. UST Astern turbine is of 2 Curtis with 2 lines as well as CST, however; it is refined in accordance with the UST steam condition.
Stage
Table 5-3 Moving Blades/Nozzle & Diaphragm/Rotor Materials for UST Turbine
Part HR(HP) Turbine Moving Blades HR(HP) Turbine Nozzle & Diaphragm HR(HP) Turbine Rotor CST 12Cr.Mo. S 13Cr.Mo. S 12Cr.Mo. S 13Cr.Mo. S Ni.Cr.Mo.V. S UST 12Cr.Mo. S 13Cr.Mo. S SA 182 F91 12Cr.Mo. S Cr.Mo.V. S 2.5Ni.Cr. Mo.V. S
Cr.Mo. S
For the UST turbine casing, High-Cr. Casting Steel (MJC-12 casing steel), which was developed for land use reheat turbines as a special material used under high pressure and high temperature condition, is applied as specified in Table 5-1. Consequently it has been succeeded to make strength of the casing high enough to endure the UST steam condition. And also MTB10A, which has almost similar coefficient of linear expansion to that the material of the casing has, is applied as the material of the casing bolt (See Table 5-2). In the UST turbine, it has been confirmed by the detailed turbine condition analysis using 3-demensional FEM (Steady/Unsteady) that no fatal steam leakage from flange at casing/valve bodies occurs at all considerable operating cases such as turbine starting, running-in, steady powering and long-term operation for creep strength and the turbine condition at all the cases is sufficiently satisfactory for the criteria of MHI turbine design. Meanwhile M8B, which has a special quality of high creep strength in high temperature condition, is applied as the material of holding bolts at AHD stop valve and AHD/AST maneuvering valve cover giving because these valves are always under high temperature condition. For turbine blades, the existing materials are well applicable in the UST steam condition in consideration of application records of land and/or marine use (See Table 5-3). For nozzle and diaphragm being in high temperature steam, SA 182 F91 (Super 9Cr.) developed for power plant is applied. The materials of HR turbine rotor and LR turbine rotor are properly selected from application records of land use turbines based on metal temperature of each rotor in working condition. In addition, HR turbine is equipped with the rotor cooling system in the structure (See below for further details) and it can be expected to prevent a drop in the creep strength caused by the long-term operation and to make a lifetime of the rotor elongated even more.
1.5
0.5
Optimization of No. of Stages & Bleed Press Optimaization of Dia. of HR/T Rotor
Fig.4 Improvement of Turbine Efficiency (UST) 1) ISB with Multi-Seal Fin A tenon-shrouding type of blade (CST) can be equipped with only two (2) radial fins a stage at the tip of the blade. Meanwhile in the UST turbine, ISB (Integral Shroud Blade: See Fig.5) is applied and it can allow to be equipped with three (3) or more radial fins (Multi-Seal Fin) in accordance with a width of the blade. Due to the multi-seal fin, steam leakage in axial direction at the tip of blade can be decreased at each stage and so that turbine efficiency is improved.
2) 3-D Rateau (Bow) Nozzle (See Fig.6). Due to bowing nozzle in its height direction, main steam flow is accelerated and pressure on rear side of nozzle (especially base side) will rise up by restraining of growth of boundary layer on nozzle surface and blade force of adjacent nozzles Consequently a differential pressure between base and tip side on front and rear surface of nozzle will be decreased and it is expected that a growth of the secondary flow (Cross flow), which is of the low-energy and causes a drop in turbine efficiency, can be restrained. In stages with low aspect nozzle, the above improvement is not sufficiently anticipated. Therefore, 3-D Rateau (Bow) nozzle has been applied for Rateau stages on IP turbine and LP turbine only.
IP Turbine 1st Stage Fig.6 3-D Rateau (Bow) Nozzle 3) 3-D Stationary Blade at LP Turbine At some reaction stage(s), 3-D stationary blade (Refer to Fig.7), which improves blade profile performance and gauging distribution of the stationary blade, is applied and it results in decrease of the secondary flow.
Steam Flow 2-Dimensional Stationary Blade (CST) Big-pitched 3-Dimensional Stationary Blade (UST)
ISB (UST)
4) Optimization of Exhaust Steam Chest (Flow guide & Bearing Cone) at LP Turbine Due to the optimization of exhaust steam chest at LP turbine, exhaust loss is decreased and exhaust pressure recovery (Cp) of 0.1 or more is expected as compared with CST (See Fig.8) .
Control of steam velocity increase at diffuser hub Rectification of exhaust flow due to the modification of the exhaust skirt
18 16 14 12 10 8 6 4 2 0 0 100 200 300 400 TEMPERATURE () 500 600 MJC-12 (12Cr. Casting Steel) WC9 (2Cr. Casting Steel)
Fig.9 Comparison of Allowable Design Stress between WC9 (2.5Cr. Casing Steel) and MJC-12 2) Casing Construction of the HR Turbine In the construction, the inside temperature of HP turbine nozzle box is about 460. Meanwhile it is expected that the inside temperature of IP turbine inlet will be extremely high because high temperature reheat steam (about 555) directly flows into IP turbine. In this case, temperature gradient in axial direction at the part concerned of the HR turbine casing caused by the big temperature difference is much steep and it leads to unbalanced tightening force at neighboring casing bolts, reducing of surface pressure on casing flange of the HR turbine. It causes a dangerous steam leakage from the flange. The unexpected steam leakage must not be caused under any condition. So in addition that high-Cr. material as mentioned above is applied for the UST turbine (HR turbine) casing and the UST turbine is equipped with Thermal Shield System for Cooling of Turbine Casing to make the temperature gradient smooth and to keep the material in high creep strength (See Fig.10). At inlet part of IP turbine, a screen ring called Thermal Shield is arranged between IP turbine casing and high temperature reheat steam (Refer to Fig.11) and low temperature steam (HP Turbine exhaust steam) is led into a back space of the screen. The above-mentioned cooling system for turbine casing not to expose turbine casing inside directly to high temperature is introduced. In consequent it can be stated that no steam leakage or fatal damage of the flange occurs in the UST turbine.
600 500 400 300 200 100 0 Temperature Distribution at Flange (No Cooling System for Casing) Temperature Distribution at Flange (Cooling System for Casing) Temperature Distribution at Bolt (Cooling System for Casing)
Ex h. IP 6
H
Axial Position
Fig.12 Temperature Distribution at Casing Flange and Bolt (HR Turbine) 3) Detailed Examination of Casing/Bolt Condition at normal operation (MCR), Long Term Operation and Unsteady Operation (Starting-up/Program-in) In order to confirm the soundness of the UST turbine, 3-D FEM analysis using casing/bolt combination model (See Fig.13 and 14) at the following operations to be estimated has been performed.
HP Turbine Exhaust
Main Steam Inlet AHD Maneuvering Valve Shield Steam HP/T Exhaust
Fig.11 Thermal Shield System for HR/T Casing The estimated temperature distribution at turbine casing flange at each case is shown in Fig.12. In a way of being equipped with the thermal shield, turbine casing well drops in temperature and the temperature distribution at the flange and bolt is almost even.
P/ IP
IP 1 um m y H P1 H P2 H P3 H P4 H P5 H P6 H P Ex h. D
IP 5
IP
IP 4
IP 3
IP 2
0 L
Operation characteristic of the UST plant at starting-up and running-in is based on the output of the UST plant dynamic simulator, which has been developed in parallel and can simulate all operation modes including considerable emergency cases (Fig.18 and 19). Using with main and reheat steam condition at each time-step come from the simulator, the UST turbine performance calculation has been carried out and the calculation results have been used as input data for the unsteady state analysis.
0.1
10
100
1000
10000
100000
0 0.01
Passage TimeH
20000
500
Fig.16 Transition of Surface Pressure due to Creep Strength Analysis (See Fig.14 for Mark AD)
Turbine Output Power (kW) 10000 Main Steam Temp. () Reheat Steam Temp. () 0 0 20 40 60 80 Passage Time (min) 100 300 120 400
Fig.19 Steam Condition at Program-In (CASE: 40 min./Harbor Full to Navigation Full) There is quite small difference of coefficient of linear expansion between MJC-12 (Casing material) and MTB10A (Casing bolt material), so that uneven thermal expansion between them never occur. In also point of casing and bolt strength, those can be well kept in sufficiently safe level because casing bolts and flange do not excessively rise in temperature due to the thermal shield system.
10
Cooling Steam for Turbine Rotor (Dummy Leakage Steam: about 460)
10. Conclusion
We are much confident of achieving the absolute success of the UST plant and offering it to you as the outstanding propulsion plant. The UST turbine is the most significant key to the success and its development has been fruitfully completed due to numberless examinations for it. We are eagerly looking forward to taking the last step to make the UST plant embodied and succeeded.
HP/T Steam Flow Dummy Part between HP/T and IP/T IP/T Stages Turbine Thrust
HP/T Stages Speed Control Stage (Advanced Curtis Stage with Higher Performance for UST) IP/T Steam Flow
Fig.20 HR Turbine Rotor (HR-22) 2) Cooling System for Turbine Rotor In order to prevent high temperature creep strength of the material from decreasing and to give a sufficiently robust strength to discs of the rotor, the cooling system is adopted. The steam after the HP turbine curtis stage is led to 1st stage disc at IP turbine through the dummy ring and cool the rotor not to expose the rotor to the high temperature reheat steam directly (See Fig.21).