Recent Steam Turbine

Retrofit Technology
for
Improving Performance and Reliability
16th September, 2011

Toshiba Corporation
Copyright 2011, Toshiba Corporation.

1. Toshibas Products and Activity in India

2. Recent Retrofit Experience on Steam Turbine
3. Steam Path Up-grading
4. EHC Conversion from MHC

Copyright 2011, Toshiba Corporation.

1. Toshibas Products and Activity in India

2. Recent Retrofit Experience on Steam Turbine
3. Steam Path Up-grading
4. EHC Conversion from MHC

Copyright 2011, Toshiba Corporation.

Environmentally-conscious products

CCS

Renewable energy:
Geothermal
Wind, Solar

Carbon Dioxide
Capture and Storage

Toshibas
CCS Pilot Plant

Further improvement
of Coal-fired P.P.

700degC Advanced USC

CCPP with highest

efficiency

Over 60% efficiency (LHV)

High performance
Hydroelectric
equipment

Improve efficiency of core components

Copyright 2011, Toshiba Corporation.

TOSHIBAs Footprints for Thermal and Hydro Power in INDIA

LEGEND GUIDE
BLUE COLOR: HYDRO POWER
RED COLOR : THERMAL POWER

KOLDAM HEP
(4x200MW)
(TSB,BHEL,MC)

TEESTA V (3x170MW)
(TSB,MBK) 2008

SSNNL HEP
(6x200 MW)
(TSB, HTC, SC, BHEL)

UMIAM I&II HEP

(4x10.5MW, 2x9MW)
1965-1967

TATA MUNDRA
UMPP
(5x800 MW)

UMIAM I R&M (MBK)

2003

Under construction
Ordered 2007

PURULIA (4X225 MW) (TSB, MBK)

2008

Customer A
(2x 660 MW )
2011

ANPARA-B TPP (2x500MW)

(TSB,MHI,MBK) 1994

DAM (2x10.6MW WT)

HAMPI (2x10.6MW WT)
1962
Copyright 2011, Toshiba Corporation.

AP Gas (172MW )
Combined Cycle
1997

NTPC Meja (2x660MW)

2011/LOI received

TOSHIBAs Business Bases in INDIA

Toshiba Thermal and Hydro Power
Systems Company,
Toshiba India Pvt. Ltd. (TTPS)

Location: Gurgaon
Sales, Plant Engineering and
Procurement

TPSC (India) Pvt. Ltd.

Location: Hyderabad
Construction

Toshiba JSW Turbine & Generator Pvt. Ltd.

Location
: Chennai
Established : Sep., 2008 (Operation: Jan.,2011)
Toshibas share : 75%
Main Products : Steam Turbines, Turbine Generators
Copyright 2011, Toshiba Corporation.

1. Toshibas Products and Activity in India

2. Recent Retrofit Experience on Steam Turbine
3. Steam Path Up-grading
4. EHC Conversion from MHC

Copyright 2011, Toshiba Corporation.

Experience for Turbine Modernization

Toshiba has successfully upgraded more than 100 units.
 Steam path upgrade
 Reliability enhancement
 Maintenance improvement

Copyright 2011, Toshiba Corporation.

LP Turbine Up-rating
Brunner Island Unit-3 (USA) designed by GE
Up-rating 784MW 803MW

Replace LP-A/B rotors, nozzles and LP inner casings

Longer last stage blade (original 30 new 33.5)
Without boiler modification
Completed at December 2006
Before

Copyright 2011, Toshiba Corporation.

After Retrofit

HIP Turbine Up-rating

Yallourn Unit-3 & 4 (Australia)
Up-rating 386MW 396MW

Replace HIP turbine module with rotor and casing

Nozzle and Blade (AFP and snubber blade)
Without boiler modification
Completed at May 2010 and May 2011
TC4F-26

Copyright 2011, Toshiba Corporation.

10

Up-rating for Russian design Steam Turbines

Maritsa East Unit- 6 & 8 (Bulgaria) designed by LMZ
Modernization of HP and LP turbine

Replace LP rotor with updated steam path

Re-blading HP stage with the existing HP rotor
Up-rating from 210 to 225MW without boiler modification
Completed at July 2010 and March 2011, respectively

Refurbish in 2006
Copyright 2011, Toshiba Corporation.

11

Maritsa East Unit - 6 & 8

LMZ K-210-130 Original

Unit-6 started operation since 1988

Unit-8 started operation since 1996

Steam path design is an old type

IP and LP rotor employ the elderly shrink-on type
Copyright 2011, Toshiba Corporation.

12

Maritsa East Unit - 6 & 8 / HP Turbine

New
New blades
blades
with
with original
original fixture
fixture

Replaced
Replaced by
by
original
original designed
designed
blades
blades

New
New inner
inner case
case

Updated
Updated steam
steam path
path design
design

Using
Using original
original rotor
rotor

New
New nozzle
nozzle
diaphragms
diaphragms
Copyright 2011, Toshiba Corporation.

Using
Using original
original outer
outer case
case

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Maritsa East Unit - 6 & 8 / IP Turbine

Replace
Replace first
first stage
stage
nozzle
nozzle &
& blades
blades

Using
Using original
original rotor
rotor

Using
Using original
original casings
casings
The first stage nozzle and blades were replaced for countermeasure of
solid particle erosion
Copyright 2011, Toshiba Corporation.

14

Maritsa East Unit - 6 & 8 / LP Turbine

Original
Original LP
LP Section
Section
New
New LP
LP Section
Section

New
New mono-block
mono-block rotor
rotor
Doubled
Doubled last
last stages
stages
36
36 Last
Last stage
stage blades
blades
Original
Original outer
outer case
Copyright 2011, Toshiba Corporation.

Up-rating with re-used outer casing

15

Maritsa East Unit - 6 & 8 / Site Installation

New HP blades assembled

in existing HP rotor

New HP nozzles installed in HP turbine

Copyright 2011, Toshiba Corporation.

Existing LP outer casing lower half

New LP rotor installed in LP turbine

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Maritsa East Unit - 6 & 8 / Site Installation

Site Installation
Completion of Installation Work

Copyright 2011, Toshiba Corporation.

17

1. Toshibas Products and Activity in India

2. Recent Retrofit Experience on Steam Turbine
3. Steam Path Up-grading
4. EHC Conversion from MHC

Copyright 2011, Toshiba Corporation.

18

Up-to-date Steam Path Technology

Advanced
Advanced Flow
Flow Pattern
Pattern
 Fully 3-Dimensional Viscous Analysis
by CFD (Computational Fluid Dynamics)
 Curves in the radial direction enables
to reduce secondary flow loss
from nozzle walls or blade roots/tips
 Validation Test was performed to
confirm the improvement of performance

CFD Models

Controlled Secondary
Flow Losses

Copyright 2011, Toshiba Corporation.

AFP Blades
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Up-to-date Last Stage Blade Technology

Advanced
Advanced Last
Last Stage
Stage Blades
Blades (LSB)
(LSB)
Cover Segment
(loose cover)

Tie-wire
(Brazed)

Self-shielded
Erosion Protection

Brazed Stellite Shield

Erosion Protection

Flo
w

Lug

Sleeve
(Loose)
Pinned Nest-Finger
Dovetail

Advanced Flow
Pattern Design
with modified Airfoil
Flo
w

Pinned Flat-Finger
Dovetail

Conventional
Copyright 2011, Toshiba Corporation.

Latest
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Up-to-date L-1, L-2 Stage Blades

Snubber
Snubber Blades
Blades
 L-1 and L-2 blades are
operated in the moisture
condition.
 As the snubber blades
eliminate corrodent traps
such as lacing wire holes
and reduce vibration
stresses, they protect
against stress corrosion
cracking and corrosion
fatigue.

Copyright 2011, Toshiba Corporation.

L-1
blades

L-2
blades

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Up-to-date Rotor Forging Technology

High pure and homogeneous rotor forging by latest
manufacturing technology.
Impurities such as Sulfur and Phosphorus are controlled
in steel making process.

Copyright 2011, Toshiba Corporation.

22

1. Toshibas Products and Activity in India

2. Recent Retrofit Experience on Steam Turbine
3. Steam Path Up-grading
4. EHC Conversion from MHC

Copyright 2011, Toshiba Corporation.

23

D-EHC Conversion from MHC

Modernization
Modernization for
forTurbine
TurbineGoverning
GoverningSystem
System
from
from original
original MHC
MHC
Operator
Station

Linear
Variable
Differential
Transformer

D-EHC Cubicle

System
Controller

(position
transmitter)
Hydraulic
Oil Inlet Servo
Valve

Master
Controller

Steam
Inlet
Hydraulic
Cylinder

Steam
Outlet
Control
Valve

Speed
Pickup
Copyright 2011, Toshiba Corporation.

24

D-EHC Conversion from MHC

EXAMPLE
EXAMPLE OF
OF MODIFICATION
MODIFICATION
Backup governor
Speed
regulation
adjuster
Speed
relay

Worm wheel

Speed/Load changer
Limit switch

Newly
Newlyinstalled
installedsimple
simple
speed
speed sensor
sensorfor
forEHC
EHC

Governor
bracket
Sleeve
Rotating
pilot valve
Rotating
centrifugal flywheel

Existing
Existingcomplex
complexmechanical
mechanical
speed
speedgovernor
governor

Copyright 2011, Toshiba Corporation.

Gear
Gearfor
for
speed
speedsensor
sensor
Speed
Speedsensor
sensor

25

D-EHC Conversion from MHC

EXAMPLE
EXAMPLE OF
OF MODIFICATION
MODIFICATION

New cover of CV hydraulic cylinder box

Existing CV hydraulic cylinder box

New cover after assembled
Copyright 2011, Toshiba Corporation.

26

D-EHC Conversion from MHC

Existing
Existingpanel
panel

New
New operator
operatorstation
station

Operation display

Control switch type

Copyright 2011, Toshiba Corporation.

Historical trend graph

27

Conclusion
For of the aged units, it goes without saying the adequate
rehabilitation and upgrading are useful for the following
stable operation.
Toshiba has a lot of experience for rehabilitation and
upgrading projects on OEM and Other-OEM existing steam
turbines.
For the rehabilitation and upgrading, Toshibas advanced
technologies have been applied.

Toshiba
Toshiba Thermal
Thermal and
and Hydro
Hydro Power
Power
Toshiba
Toshiba JSW
JSW Turbine
Turbine &
& Generator
Generator Pvt.
Pvt. Ltd.
Ltd. Systems
Company,
Toshiba
India
Systems Company, Toshiba India Pvt.
Pvt. Ltd.
Ltd.
Copyright 2011, Toshiba Corporation.

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Copyright 2011, Toshiba Corporation.

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