Alstom Steam Turbine Designs for

AD700 Power Plant

Andreas Pirscher
(Alstom Power)
 Alstom Roadmap for >700°C Turbines

Material Development / Testing Design .

1998
Testing of materials and First design concepts
components (forged, cast and
welded) Emax design and additional internal study
based on proven technology with some
high temperature specific features
2005

Component testing (COMTES) Further develop design concepts

2010 Detailed design based on proven

technology
Demonstration turbine

2015
Develop advanced designs to further
Advanced high temperature turbine reduce Nickel base alloy weight and
reduce transient stresses to improve
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start up times
disclosure to third parties without express authority is strictly forbidden.
 Alstom Concept
400 MW Single Reheat (1/2)

700 °C 263 °C

HP
IP LP1 LP2 G

426 °C

720 °C

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disclosure to third parties without express authority is strictly forbidden.
 Alstom Concept
400 MW Single Reheat (2/2)

z Thermodynamic calculations
z Steam path designed with standard Alstom design tools using high
temperature materials
z Blade material nickel base alloy, austenitic steel, 12% Cr steel
z Rotordynamic feasibility
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disclosure to third parties without express authority is strictly forbidden.
 Rotor Design: Welded Rotor (1/7)

z Alstom has over 70 years experience in in rotor weld technology

z Several thousand welded rotors in operation
z Not a single case of a ruptured welded rotor
z Excellent material testing conditions, good access for ultrasonic testing
z 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)

z Advantage: Lower stresses in welded rotor compared to monoblock rotor

z 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

Welded rotor 150 N/mm2 300 N/mm2

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disclosure to third parties without express authority is strictly forbidden.
 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 > 620°C
(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)

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

16

15
α
1%CrMo V
14

13

12
617

11
S t10TS

10

9
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
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disclosure to thirdT
parties
e mpwithout express
e ra ture (C)authority is strictly forbidden.
 Rotor Design: Welded Rotor (5/7)

z Design solutions (1/2) 10% Cr steel

– Rotor bridge with two welds Nickel base alloy

Color codes: Temperatures in °C

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 Rotor Design: Welded Rotor (6/7)

z 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)

z 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

z Shrink ring design used by Alstom since 1960

z 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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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)

z Valve identified as one of the essential components of a 700°C turboset

z The valve has therefore been chosen for the COMTES 700 test with real
steam conditions loading
z The selected valve type is a full-scale main steam control valve
z Common design of Siemens and Alstom
z Crucial test results: Coatings for functional and sliding surfaces, e.g.
between spindle and bushes
z 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

z 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
z 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 ºC

17.5 MPa
565 ºC
9 … 10 % Cr steel
Nickel base alloy

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disclosure to third parties without express authority is strictly forbidden.
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