Alstom Steam Turbine Designs for AD700 Power Plant

Andreas Pirscher (Alstom Power)

Alstom Roadmap for >700C Turbines

Material Development / Testing 1998 Testing of materials and components (forged, cast and welded) 2005 Component testing (COMTES) 2010 Demonstration turbine 2015 Advanced high temperature turbine Develop advanced designs to further reduce Nickel base alloy weight and reduce transient stresses to improve start up times
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Design First design concepts

Emax design and additional internal study based on proven technology with some high temperature specific features

Further develop design concepts Detailed design based on proven technology

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Alstom Concept 400 MW Single Reheat (1/2)

700 C

263 C

HP IP
426 C

LP1

LP2

720 C

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Alstom Concept 400 MW Single Reheat (2/2)

Thermodynamic calculations Steam path designed with standard Alstom design tools using high temperature materials Blade material nickel base alloy, austenitic steel, 12% Cr steel Rotordynamic feasibility
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Rotor Design: Welded Rotor (1/7)

Alstom has over 70 years experience in in rotor weld technology Several thousand welded rotors in operation Not a single case of a ruptured welded rotor Excellent material testing conditions, good access for ultrasonic testing Alstom methodology of designing rotor welds heavily depends on the large fleet experience therefore it is possible to design new rotor welds based on laboratory testing and analysis by reading across from existing rotor welds validated in the Alstom fleet

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Rotor Design: Welded Rotor (2/7)

Advantage: Lower stresses in welded rotor compared to monoblock rotor Example: Cold start of an HP rotor:
250 N/mm2 500 N/mm2

Monoblock rotor with center bore

500 N/mm2 200 N/mm2 200 N/mm2 300 N/mm2

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Welded rotor

150 N/mm2 300 N/mm2

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Rotor Design: Welded Rotor (3/7)

Optimal design for very high temperature application Welding technology allows the application of the appropriate material where needed
Nickel base alloys for very high temperatures > 620C (Not shown in the picture, which is only for illustration) 9-12 % Cr steel for high temperatures > 540 C 1-2 % Cr steel for steam temperatures < 540 C 1-2 % Cr low yield strength steel for low pressure applications

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Rotor Design: Welded Rotor (4/7)

Specific design aspects for rotor welds with nickel base alloys Limitation on ultrasonic inspection Different thermal expansion coefficients
17 16 15

1%CrMo V
14 13 12 11 10 9

617 S t10TS

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100 150 200 250 300 350 400 450 500 550 600 650 700 750

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Rotor Design: Welded Rotor (5/7)

Design solutions (1/2) Rotor bridge with two welds
10% Cr steel Nickel base alloy

Color codes: Temperatures in C

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Rotor Design: Welded Rotor (6/7)

Design solutions (2/2) Weld between the nickel alloy and 1 2 % Cr steel Almost cost neutral to design solution 1
1% Cr steel

Nickel base alloy

Move the bridge and the two welds by 3 4 blade stages ( 300 mm) to the cooler end
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Rotor Design: Welded Rotor (7/7)

In the course of the AD700 project successful test welds were carried out at Alstom Full scale test block weld between alloy 617 and 10% Cr steel Full scale test block weld between alloy 625 and 10% Cr steel (A nickel alloy was used as weld metal in both cases)

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HP Casing: Shrink Ring Design

Shrink ring design used by Alstom since 1960 Excellent design for very high temperatures Very low casing distortion Relatively thin structure allows good transient behavior

Ni base alloy

10 % Cr steel
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ALSTOM (Switzerland) Ltd 2005 Preliminary/for discussion purposes only. We reserve all rights in this document and in the information contained therein. Reproduction, use disclosure to third parties without express authority is strictly forbidden.

HP Casing: Shrink Ring Design

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IP Casing: Conventional Alstom Design Using Nickel Base Alloy

10 % Cr steel

Ni base alloy
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COMTES Valve (1/2)

Valve identified as one of the essential components of a 700C turboset The valve has therefore been chosen for the COMTES 700 test with real steam conditions loading The selected valve type is a full-scale main steam control valve Common design of Siemens and Alstom Crucial test results: Coatings for functional and sliding surfaces, e.g. between spindle and bushes Results will be transferable and relevant for products of both suppliers

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COMTES Valve (2/2)

Alstom Supply: Yellow, Red Siemens Supply: Blue

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Advanced Design Features

First demonstration plant will be a base load machine with relatively few starts per year. The design concept will be based on the proven conventional Alstom design with some modifications to allow for the very high temperatures In order to design a more flexible turbine with faster start up times for very high temperatures the following design features are available. Various features are in the concept phase (patents pending) Double wall valves (see next slide) Cooling concepts Multiple shell casings Improved pre-heating of the turbine Heat shield concepts

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Example: Double Wall Valve

25.0 MPa 700 C

17.5 MPa 565 C

9 10 % Cr steel Nickel base alloy

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