Nuclear Power Plants The Turbine Island Philippe Anglaret VP Business Development , Alstom Nuclear Paris, 21st October 2013
The Turbine Island Agenda
p.2
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
4
Recent Projects
Alstom in Nuclear
Nuclear Island
Turbine Island
Balance of Plant
Reactor supplier
Alstom
(including Alstom Grid)
Nuclear Island + Turbine Island + BoP = Nuclear Power Plant p.3
Alstom in Nuclear Turbine Islands based on ARABELLE™ technology
Credits to EDF
p.4
Alstom in Nuclear World N°1 supplier of nuclear steam turbine generators 55 years of experience : 136 nuclear units in operation = 113 GW Europe North America 8 GW 8 units
90 GW 103 units
China India
South Korea 5 GW 6 units
6 GW 6 units
2 GW 11 units
50 86
Full-speed
Half-speed
South Africa 2 GW 2 units
< 800 MW
24 47 65
30% of all the world’s nuclear plants have an Alstom steam turbine p.5
800 - 1200 MW > 1200 MW
EDF French Nuclear Fleet Various generations of nuclear steam turbines
CP0 – CP1
P4 – P’4
900 MW
1300 MW
N4 – ARABELLE 1550 MW p.6
Nuclear Business Competitive Positioning
• Competitors worldwide experience (50 & 60 Hz grids) TG supplier
Toshiba
Largest unit in commercial operation (as of Sept. 2012) Largest unit under construction (as of Sept. 2012)
GE
1100 MWe 1410 MWe Higashi-Dori 1 Palo Verde 2 (50 Hz) (60 Hz) 1400 MWe Braka 1-4 (50 Hz)
1455 MWe Shin-Kori 3 (60 Hz)
Power Machines
Mitsubishi
Siemens
Alstom
1060 MWe Tianwan 1 (50 Hz)
1180 MWe Genkai 3 (60 Hz)
1500 MWe Isar 2 (50 Hz)
1550 MWe Chooz B1 (50 Hz)
1200 MWe Leningrad II 1 (50 Hz)
1370 MWe Lungmen 1 (60 Hz)
1720 MWe Olkiluoto 3 (50 Hz)
1750 MWe Flamanville 3 (50 Hz)
• Color code: Green = currently in Operation Blue = currently under Construction p.7
The Turbine Island Agenda
p.8
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
4
Recent Projects
Inside a Nuclear Power Plant Primary, Secondary, Tertiary Loops
• •
Non-contaminated steam goes to steam turbine No turbine island containment needed
The Pressurised Water Reactor (PWR) p.9
Inside a Nuclear Power Plant Primary, Tertiary Loops
• •
Contaminated steam goes to steam turbine special gland sealing system Turbine island needs some containment (concrete shielding) + specific material choices
The Boiling Water Reactor (BWR) p.10
What is specific to Nuclear Power Plants ? Much larger steam volume flow
Steam volume flow (m3/s)
80 60
Fossil Nuclear
40
X5
20 0 0
500
1000
1500
2000
Steam turbine generator output (MW)
Nuclear large volume flows need for long blades high centrifugal forces p.11
What is specific to Nuclear Power Plants ? Wet steam conditions
Fossil
Dry Steam
H = Enthalpy (kJ/kg)
150-300 bar 540-600°C
Saturation line
Nuclear
Wet Steam
50-75 bar 265-290°C
S = Entropy (kJ/kg/°K) p.12
Steam Expansion Line Mollier Diagram – N4 Reactor P : 10.1 bar T : 268°C P : 71 bar T : 287°C x : 0.4 %
“cold” steam at LP inlet : • small LP axial thermal expansion • reduced axial clearances • possibility to fit a 4th LP
IP HP
MSR P : 3.3 bar T : 148°C
X:0% P : 10.7 bar T : 183°C x : 14.6 %
Enthalpy H (kJ/kg)
Entropy S (kJ/kg.K) p.13
LP
P : 0.055 bar x : 12.5 %
EPR - Flamanville 3 Simplified steam-water cycle Steam and water pipes from/to NI
Busbars
HP
IP
MSR 100% steam bypass to condenser
Generator, exciter
LP
Circulating water pumps
Condenser,vacuum system, debris filters
Drain tanks
De-aerating feed-water tank MSR drain pumps
Core
Condensate extraction pumps LP heaters
HP heaters
Feed heaters pumps
NSSS PACKAGE
Primary Loop p.14
Secondary Loop
CI auxiliaries cooling HEX
Tertiary Loop
World Nuclear Power Plants Half-speed dominates the market above 700 MW •
France, U.S.A., Canada, Japan, South Korea, Brazil, Taiwan, South Africa, etc.: −
•
all nuclear units in operation are half-speed
China: since 2005, all nuclear turbines (with output > 700 MW) ordered are half-speed
Full-speed / Half-speed
−
26%
66%
Half-speed
91%
100%
Full-speed
74%
34% 9% All sizes
< 700 MW
> 700 MW
> 1200 MW
Unit size range
Source: Alstom databases
Above 1200 MW, only half-speed to keep reasonable stress levels p.15
Full Speed vs. Half Speed – what makes the difference ? Case study : Ling Ao 1 vs. Ling Ao 3 Enthalpy (kJ/kg) 3100
Ling Ao 1 Full speed
3000
2900
Ling Ao 3 Half speed
IP
2800
2700
HP
2600
Half speed expansion lines in HP, IP and LP sections are much more efficient
2500
LP 2400
2300
2200
2100 5,8
p.16
6
6,2
6,4
6,6
6,8
7
7,2
7,4
7,6
Entropy (kJ/kg/K)
A challenge for turbine designers Covering a wide range of reactors & heat sinks Typical LP exhaust volumetric flow for a given application: 1 reactor/1 site Reactors
p.17
5
9
12
15
17
19
21
23
24
26
27
28
30
31
32
Finland
33
India
Site cooling water temp. °C
A challenge for turbine designers Covering a wide range of reactors & heat sinks Typical LP exhaust area needed for a given application: 1 reactor/1 site
Reactor thermal output in MWth
5 000 MWth
250 m² 200 m² 150 m²
4 500 MWth
4 000 MWth
EPR ESBWR APWR
ABWR
100 m² 3 500 MWth
AP1000
75 m²
VVER1200
3 000 MWth CPR1000 ATMEA1
50 m²
2 500 MWth
2 000 MWth 100 mbar
90 mbar
PHWR700
1.5 "Hg 2.5 "Hg
80 mbar
70 mbar
60 mbar
1.5 "Hg
50 mbar
40 mbar
30 mbar
20 mbar
5
9
12
15
17
19
21
23
24
26
27
28
30
31
32
33
Condenser backpressure in mbar
p.18
Reactors
Site cooling water temp. °C
The Turbine Island Agenda
p.19
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
4
Recent Projects
Integrated Packages Turbine Island (TI)
p.20
Integrated Packages Secondary Loop Package (SLP)
p.21
Turbine Islands key components
Steam turbine
Grid equipment
MSR
4-pole generator
Condensate extraction pumps
p.22
Circulating water pumps
Reactor feed-water pumps
HP & LP feed-water heaters
Modular condenser
The Turbine Island Agenda
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
The steam turbine 4
p.23
Recent Projects
Turbine Technology Use of more efficient single flow steam expansion
Moisture Separator Reheater
71 bar
3 bar
HP
IP
11 bar p.24
Moisture Separator Reheater
LP BP 1
LP BP 2
LP BP 3
60% of the power output comes from single flow steam expansion
ARABELLE™ Steam Turbine Advanced compared to previous generation MSR
~75 bar
HP
~10 bar
IP
LP 1
LP 2
~3 bar
ARABELLE™ Efficient configuration Single flow use
LP 3
MSR MSR ~75 bar
HP
LP 1
~10 bar
LP 2
LP 3
PREVIOUS GENERATION Traditional configuration Double flow use
MSR
ARABELLE™ uses more efficient single flow steam expansion p.25
ARABELLE™ Steam Turbine A specific design to maximise single flow steam expansion & efficiency IP Single Flow
LP Double Flow
HP Single Flow
2 Flows
1 Flow
ARABELLE™
6 Flows
1 Flow
HP Double Flow
PREVIOUS GENERATION LP Double Flow
p.26
How to improve turbine efficiency ? • Efficiency increases with blade aspect ratio
Longer blades have better efficiency p.27
ARABELLE™ Characteristics Combined HP/IP Module, Unique in the Market
• Single flow HP and IP for best efficiency • Combined HP/IP for maximum power density • Same footprint for 50 and 60 Hz
• Designed to fit all large commercialised reactors
• HP/IP rotor delivers up to 60% of the overall output
p.28
ARABELLE 1700 50 Hz Flamanville 3 HP-IP casing
Flamanville 3 rough machined HP-IP casing in VOEST ALPINE foundry
p.29
ARABELLETM References Ling Ao 3+4 – 2 x 1080 MW
Ling Ao 3 HP-IP casing in Dong Fang Works p.30
ARABELLETM References Flamanville 3 – 1 x 1750 MW
• HP/IP rotor entering balancing pit, Belfort factory p.31
ARABELLETM References Flamanville 3 – 1 x 1750 MW
• LP2 welded rotor, fully bladed, Belfort factory p.32
ARABELLE 1000 for Ling Ao 3 Last Stage Blades : LSB57
Fully bladed LP57 rotor entering Belfort balancing pit (Ling Ao 3) p.33
The Turbine Island Agenda
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
The generator 4
p.34
Recent Projects
GIGATOP 4-pole for Flamanville 3 A highly efficient turbo-generator • • • • • • • •
2000 MVA Cos-phi = 0,9 1500 rpm 4 poles, 3 phases 23 kV Brush-less exciter H2 and H2O cooled Stainless steel cooling tubes • H2 pressure: 6 bars(g) • Triple-circuit hydrogen sealing system • 99% efficiency • Flamanville 3 generator final assembly and running tests in Alstom factory • Validation of manufacturing quality • Validation of the design, of the electrical performances p.35
The Turbine Island Agenda
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
The heat exchangers 4
p.36
Recent Projects
Key Components Heat Exchangers for Nuclear Plants Condenser
Auxiliary water/water coolers
1
5
2 Moisture separator reheater (MSR) 2
3
High velocity separators (HVS)
4 1
HP heater 3
LP heater 4
p.37
Feedwater tank and deaerator 5
Nuclear purification system (NPS)
ALSTOM MSR Moisture Separator Reheaters
ARABELLE N4 - 1550 MW - MSR p.38
Nuclear Heat Exchangers Flamanville 3 deaerating feed-water tank • When assembled, final dimension is: 47.1 m x 5.9 m x 5.3 m
• Designed by Alstom - In 3 separate pieces - 98 t + 90 t + 98 t - Transported separately - Welded at site
p.39
Nuclear Heat Exchangers A Complete Condensing System • Single or multiple pressure condensers • Optimised tube bundle arrangement for high performances • Compact arrangement with LP turbines directly feeding duplex LP1&2 FW heater located in condenser neck • Optimised condensate extraction with 3x50% pumps • Optimised vacuum hogging / holding system
p.40
The Turbine Island Agenda
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
The main pumps 4
p.41
Recent Projects
Key Components Pumps for Nuclear Plants Essential 8 service pump Open/closed loop 7 cooling pump 6 Residual heat removal pump
3
6
2 5
7 4
1 Concrete volute circulating water pump 1
p.42
Condensate extraction pump 2
Feedwater pump 3
Intermediate cooling pump
8
Vacuum pump 5
4
Nuclear Pumps Concrete Volute Circulating Water Pumps Flamanville 3 NPP : • Direct sea-water cooling of the condenser tubes • 2 x 50% pumps arrangement • 110 000 m3/h each (30,5 m3/s each) • 15,4 m head • Rotate at 151 rpm
A A
B • Civil engineering works on suction ducts (Sept. 2009) p.43
Nuclear Pumps Concrete Volute Circulating Water Pumps
• Flamanville 3 CWP impeller heat treatment (photo credit: Ferry Capitain) p.44
The Turbine Island Agenda
p.45
1
Alstom in Nuclear
2
Turbine Island Basics
3
Turbine Island – Key Products & Solutions
4
Recent Projects
ARABELLE™ References Flamanville 3 – 1 x 1750 MW • Nuclear reactor:
EPR (PWR)
• Turbine type, output:
ARABELLE 1700, 1 x 1750 MW
• Generator type:
GIGATOP 4-pole
• Steam parameters:
Live steam: 75 bar / 290°C Exhaust: 46 mbar
• Customer:
EDF
• Country:
France
• City / region:
Normandy
• Schedule: p.46
order year comm. year
2006 2016
Unit 3
ARABELLE™ References Flamanville 3 – 1 x 1750 MW
p.47
Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator
• Turbine HP/IP rotor entering balancing pit, Belfort factory, France p.48
ARABELLETM References Flamanville 3 – 1 x 1750 MW
• Generator rotor p.49
Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator
• Generator test, Belfort factory, France p.50
Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator
Site in January 2013
p.51
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW • Nuclear reactor:
CPR1000 (PWR)
• Turbine type, output:
ARABELLE 1000, 2 x 1080 MW
• Generator type:
GIGATOP 4-pole
• Steam parameters:
Live steam: 64 bar / 280°C Exhaust: 56 mbar
• Customer:
DEC for LDNPC
• Country:
China
• City / state:
Dapeng / Guang-Dong
• Schedule: p.52
order year comm. year
2005 2010 & 2011
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW
p.53
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW
p.54
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW
p.55
ARABELLE™ References Ling Ao phase II – 2 x 1080 MW Synchronized in July 2010, ahead of schedule Measured output level above guarantee
Ling Ao 3, China - 1080 MW p.56