A reference standard in the power generation industry · 2020. 11. 5. · with P < 100 MW:with P < 100 MW: about1000 with P>100 MW: 98about1000, with P>100 MW: 98 POWER

A reference standard in the power generation industry

4th Thermal Power India 2010

Steam and Hydraulic Turbines Steam and Hydraulic Turbines

Franco Tosi Meccanica develops, designs, manufactures Steam turbines

Today FTM is among worldwide leaders for Today FTM is among worldwide leaders for

technological capacities technological capacities g pg p

Franco Tosi Meccanica develops, designs, p , g ,manufactures Pelton, Francis, Kaplan turbines

Experience, flexibility and innovation are Experience, flexibility and innovation are

the strenght of FTMthe strenght of FTM


Product RangeProduct Range

STEAM TURBINESSTEAM TURBINES

HYDRO TURBINESHYDRO TURBINES


MANUFACTURED UNITS

ST TOTAL UNITS:

with P < 100 MW: about1000 with P>100 MW: 98with P < 100 MW: about1000, with P>100 MW: 98

POWER UNITS

> 600 MW 12

200 MW – 400 MW 46

100 MW – 200 MW 40100 MW 200 MW 40

TYPEPOWER UP TOUP TO

PELTON 140 MWFRANCIS 420 MW

HT references


KAPLAN 110 MW

INDUSTRIAL APPLICATIONS / COGENERATION / INDUSTRIAL APPLICATIONS / COGENERATION / COMBINED CYCLES COMBINED CYCLES -- Steam TurbinesSteam Turbines

IN THE RANGE OF 5 to 100 MW Reheat cycle turbines5 to 100 MW Reheat cycle turbines

FTM PROVIDES TO THE END USERS A WIDE CHOICE IN THE FORM OFFORM OF:

• CONDENSING TURBINES with exhaust down/upward, lateral oraxial

• BACK PRESSURE TURBINES

HP CONTROL STAGE STANDARD APPLICATION IP CONTROL• HP CONTROL STAGE as STANDARD APPLICATION, IP CONTROLSTAGE FOR CONTROLLED EXTRACTIONS

SINGLE OR MULTI EXTRACTIONS• SINGLE OR MULTI EXTRACTIONS

• ON SKID PRE ASSEMBLED OR PEDESTAL MOUNTED TURBINES,CLUTCH CONNECTION TO SINGLE SHAFT MACHINES TRAIN FOR


CLUTCH CONNECTION TO SINGLE SHAFT MACHINES TRAIN FORCC APPLCATIONS


REHEAT on SMALL STADVANTAGESADVANTAGES

Increase in power density of the unit, lowering cost/kgg

Improvement of cycle electrical efficiency

Cogeneration cycles: more flexibility toward thermal power userthermal power user

Increase of turbine LP section immediate and long term efficiency due to reduction of

moisture content


SteamSteam TurbinesTurbines

INDUSTRIAL APPLICATIONS

INDUSTRIAL / POWER GENERATION



U t 100 MWSubCritical (RH), Combined Cycle

Up to 100 MW

Up to 565°C, 160 bar, RH U t 565°CRH Up to 565°C

1 casing

SubCritical (RH), 100 to 200 MW

590°C, 175 bar, Combined Cycle

, ,

RH Up to 590°C

1 / 2 casing

PP titi St T biSt T bi 3 / 43 / 4PowerPower generation generation SteamTurbinesSteamTurbines: 3 / 4 : 3 / 4 CylindersCylinders

TIPICAL TIPICAL SMALL REHEAT STEAM TURBINES FOR:SMALL REHEAT STEAM TURBINES FOR:

FOSSIL, FOSSIL, CCCC, SOLAR, BIOMASS, SOLAR, BIOMASS

C fi ti t li d i l ti t• Configurations: one or two cylinders, impulse or reaction type

• High speed HP cylinderHigh speed HP cylinder

• Inlet pressure / temperature: up to 160 bar, 565°C

• Reheat temperature: up to 565 °C

• Last blade height: up to 33.5 inches (851 mm) / 6.7 m^2 anulus area))

• Power: up to 150 MW (100 MW for impulse type)


SteamSteam turbinesturbines / Last / Last rotatingrotating rowrow ((suitablesuitable alsoalso forfor high back high back pressurepressureapplappl.).)

Last rotating baldes (LLast rotating baldes (L--0R)0R)FREE STANDINGFREE STANDING

Free standing blades families,

example:GEOMETRIC scaling GEOMETRIC scaling

(typical for compressors in TG, (typical for compressors in TG, LPE TV and in turbomachineryLPE TV and in turbomachinery

p

8’’/20’’18’’/40’’

yybased on aerodinamic and strucural based on aerodinamic and strucural

similitude criteriasimilitude criteria10’’/25’’

22.8’’/50.6’’

Operating experience is 14’’/35’’22.8’’/57’’

transferred to blades of the same family

14’’/31’’25.2’’/55.8’’

14 /31

25.2’’/63’’


Rotational speed in the range 3000 - 9400 rpm

SMALL REHEAT ST’s SMALL REHEAT ST’s –– Manufactured unitsManufactured units

Qty n. Country

Unit Output

SH pressure

SHtemper.

HRHpressure

HRHtemper.

Exhaust press. Speed

Last Blade Height /

Base Diam.Turbine type

[MW] [bar(a)] [°C] [bar(a)] [°C] [bar] [RPM] [inch]

2 ITALY 75 130 538 28 4 538 0 08 3000 23/48 Single cylinder2 ITALY 75 130 538 28,4 538 0,08 3000 23/48 Single cylinder

1 BRASIL 84,1 107,5 538 29,6 539 0,06 3600 28/57 Single cylinder

1 FRANCE 66,5 115 560 23 560 0,033 3000 33/65 Single cylinder

6200 HP

1 SPAIN 20 42 Saturatedsteam 3 Saturated

steam 0,06

6200 HP

20/40 Double cylinder,solar plant

4200 LP


SMALL REHEAT ST’s SMALL REHEAT ST’s –– Recently offered unitsRecently offered units

Qty n. CountryUnit

OutputSH

pressureSH

temper.HRH

pressureHRH

temper.Exhaust press. Speed

Last Blade Height /

Base Diam.Turbine

[MW] [bar(a)] [C°] [bar(a)] [°C] [bar] [RPM] [inch] type1 PAKISTAN 115 100 540 31 540 0,1 3000 28/57 Single cylinder1 BRASIL 85,5 110 539,8 24 539,7 0,0827 3600 28/57 Single cylinder1 INDIA 135 137 537 36,8 537 0,101 3000 25.2/55.8 Single cylinder

1 SPAIN 54 116,2 539,8 31,4 540,8 0,07 3000 23/48 Single cylindersolar plantsolar plant

1 TURKEY 120 147 540 30,7 540 0,06 3000 33/67 Single cylinder

3 NEW CALEDONIA 77,5 125 540 29 540 0,0645 3000 28/57 Single cylinder

1 USA 105 5 160 540 35 480 0 1265 3600 28/57 Single cylinder1 USA 105,5 160 540 35 480 0,1265 3600 28/57 solar plant

1 SPAIN 50 100 380,6 16,8 380,6 0,0635600 HP

23/48 Double cylinder, solar plant3000 LP

1 SPAIN 25 100 375 16,8 378 0,0655800 HP

14/35 Double cylinder, l l t1 SPAIN 25 100 375 16,8 378 0,065 14/35 solar plant5400 LP

2 SPAIN 50 99,3 373,3 16,4 373,3 0,0715600 HP


1 SPAIN 50 79 6 372 18 3 369 2 0 0645600 HP

28/57 Double cylinder, 1 SPAIN 50 79,6 372 18,3 369,2 0,064 28/57 solar plant3000 LP

1 SPAIN 50 100 378 16,5 380 0,0365600 HP


1 SPAIN 50 33 325 9 325 0 073000 HP

28/57 Double cylinder,


1 SPAIN 50 33 325 9 325 0,07 28/57 Double cylinder, solar plant3000 LP

SMALL REHEAT ST’s SMALL REHEAT ST’s –– Single cylinder layoutSingle cylinder layout


SMALL REHEAT ST’s SMALL REHEAT ST’s –– Single cylinder long. sectionSingle cylinder long. section


SMALL REHEAT ST’s SMALL REHEAT ST’s –– Single cylinderSingle cylinder


SMALL REHEAT ST’s SMALL REHEAT ST’s –– Single cylinderSingle cylinder


SMALL REHEAT ST’s SMALL REHEAT ST’s –– Double cylinder layoutDouble cylinder layout

HP / IP and LP with different speeds and two gear boxes


SMALL REHEAT ST’s – Double cyl. HP long. section


SMALL REHEAT ST’s SMALL REHEAT ST’s –– Double cyl. LP long. sectionDouble cyl. LP long. section


BASIC DESIGN CONCEPTS BASIC DESIGN CONCEPTS -- Steam TurbinesSteam Turbines

APPROACH TO DESIGN FOR:

• RELIABILITY• AVAILABILITYMAINTAINABILITY• MAINTAINABILITY

• REDUCTION IN COSTS

A CONSTANT ENDEAVOUR IS MADE TO DEVELOP HIGHLY RELIABLE AND EFFICIENT

DESIGNSDESIGNS

R&D activities


Steam Turbines / Aerodinamic design Steam Turbines / Aerodinamic design

IP stage IP stage ggCFD CFD

analysisanalysis

3D stator3D stator3D stator 3D stator bladingsbladings



Steam Steam admission admission

chest; same chest; same outer outer cylcyl. . with or with or

ith tith twithout without controcontro stagestage

Pressure distributionPressure distributionPressure distribution Pressure distribution on new free standing on new free standing families blades; LSB families blades; LSB

forindustrialforindustrial


forindustrialforindustrialapplicationapplication

Steam Turbines / R&D Steam Turbines / R&D

11

p. totali FTR 7015

p. totali RZ

Seam turbines HP – IP advanced bladings:

straight straight && Fully 3DFully 3D

9

10p. totali 5600

p. di profilo FTR7015

p. secondarie FTR 7015

zona AP

CFD, FEA + TEST (PoliMI)CFD, FEA + TEST (PoliMI)

Last generation “AFT LOADED”

7

8zona APzona MP

gprofiles FTR 7015

4

5

6

2

3

4

0

1

0 0 2 0 4 0 6 0 8 1 1 20 0.2 0.4 0.6 0.8 1 1.2M a c h



Steam turbines bladings develop.:

HP/IP: HP/IP: Fully 3DFully 3DCFD FEA + TEST PoliMICFD FEA + TEST PoliMICFD, FEA + TEST PoliMICFD, FEA + TEST PoliMI



Entropy contours:

CILINDRICAL

3D

Mach in BtB planes (fully 3D)


Steam Turbines / Aerodinamic solutions Steam Turbines / Aerodinamic solutions -- R&D R&D

Turbomachinery lab Turbomachinery lab LFMLFM (POLITECNICO di MILANO)(POLITECNICO di MILANO)Main test facilities

“Blow down” tunnel for linear cascadesRotating machienery facility for compressors and turbines up to 400 mm ext diameterAnular tunnel for rotating and static rows up to 900 mm ext diameter (under construction)Hydraulic machinery components test facility



Experimental tests after CFD developing on 3D row


F ll 3D RF ll 3D R


Fully 3D RowsFully 3D Rows 3D Measurements of profile total losses

0.37

EVOLUZIONE DEL CAMPO DI PERDITA ( 6-10 MM)

0.37

Zpos

0.35

0.36

Zpos

0.35

0.36

y1%

Ypos-0.03 -0.02 -0.01 0 0.01

0.34 6 mm

Ypos-0.03 -0.02 -0.01 0 0.01

0.34 7 mm

os

0.36

0.37os

0.36

0.37

y1%2019181716151413121110

Zpo

0 34

0.35

8 mm

Zpo

0.34

0.35

9876543210

10 mm


Ypos-0.03 -0.02 -0.01 0 0.01

0.34 8 mm

Ypos-0.03 -0.02 -0.01 0 0.01

0.34

Steam Turbines / structural design Steam Turbines / structural design

Integral shroud type

CONTROL STAGES & HP- IP bladings

IP control stage

Robust and

more efficient by reduced leakage

HP control stage

reduced leakage flow


SteamSteam TurbinesTurbines / / StrucuturalStrucutural design design

Integral shrouded bladings with new blade profiles vs. riveted blades


SteamSteam TurbinesTurbines / / StrucuturalStrucutural design design

FEM calculation on IP / FEM calculation on IP / LP LP bladingsbladings


STEAM TURBINES Exhaust casings Exhaust casings -- diffusing effectsdiffusing effects

Industial s.t. axial exhaust casings



Ad dAd dAdvanced Advanced axial axial

exhaust exhaust diff serdiff serdiffuserdiffuser

(850 mm(850 mm(850 mm (850 mm last rotating last rotating

bladeblade))



Advanced Advanced CFD studyCFD studyCFD study CFD study

on on downward downward exhaustexhaustexhaust exhaust casingcasing


Steam & Hydro Turbines / ROTORDYNAMICSSteam & Hydro Turbines / ROTORDYNAMICS

Flexural eigen modes visualization


Steam & Hydro Turbines / ROTORDYNAMICSSteam & Hydro Turbines / ROTORDYNAMICS

Dynamic behavior of rotors:Dynamic behavior of rotors:RAFT code Beam elements

modelizationode at o


Pelton Turbine / R&DPelton Turbine / R&DCFD (CFX 5):CFD (CFX 5):

bi-phase l ianalysis


Pelton Turbine /R&DPelton Turbine /R&D Structural design

Dynamical stress Dynamical stress analysis on Pelton analysis on Pelton

runnerrunner


Kaplan Turbine/ R&DKaplan Turbine/ R&D

4 blades Kaplan 4 blades Kaplan modelmodelmodel model


Francis Turbine / R&D Francis Turbine / R&D –– Efficiencies tests Efficiencies tests

Cavitation studyCavitation study

Cavitation zone

100% vapour

100% water


Francis Turbine / R&D Francis Turbine / R&D –– Efficiency tests Efficiency tests

Cavitation analysis/ efficiency test Cavitation analysis/ efficiency test

CFD model


Francis Turbine / R&D Francis Turbine / R&D –– Efficiency tests Efficiency tests

Cavitation study / overall performanceCavitation study / overall performance

VVortex rope


Documents

A reference standard in the power generation industry · 2020. 11. 5. · with P < 100 MW:with P < 100 MW: about1000 with P>100 MW: 98about1000, with P>100 MW: 98 POWER