Nuclear Power Plants The Turbine Island

Philippe Anglaret

VP Business Development , Alstom Nuclear

Paris, 21st October 2013

p.2 p.2

1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

p.3

Alstom in Nuclear

Nuclear Island

Reactor supplier

Turbine Island

Alstom

Nuclear Island + Turbine Island + BoP = Nuclear Power Plant

Balance of Plant

(including Alstom Grid)

p.4 p.4

Credits to EDF

Alstom in Nuclear Turbine Islands based on ARABELLE™ technology

p.5

30% of all the world’s nuclear plants have an Alstom steam turbine

55 years of experience : 136 nuclear units in operation = 113 GW

South Korea

5 GW 6 units

India

2 GW 11 units

South Africa 2 GW 2 units

China

6 GW 6 units

North America

8 GW 8 units

Europe

90 GW 103 units

Alstom in Nuclear World N°1 supplier of nuclear steam turbine generators

47

65

24< 800 MW

800 - 1200 MW

> 1200 MW

50

86

Full-speed

Half-speed

p.6

EDF French Nuclear Fleet Various generations of nuclear steam turbines

CP0 – CP1

900 MW

N4 – ARABELLE

1550 MW

P4 – P’4

1300 MW

p.7

• Competitors worldwide experience (50 & 60 Hz grids)

TG supplier

Toshiba GE Power Machines Mitsubishi Siemens Alstom

Largest unit in commercial operation (as of Sept. 2012) Largest unit under construction (as of Sept. 2012)

1100 MWe

Higashi-Dori 1 (50 Hz)

1400 MWe Braka 1-4 (50 Hz)

1410 MWe

Palo Verde 2 (60 Hz)

1455 MWe Shin-Kori 3

(60 Hz)

1060 MWe Tianwan 1

(50 Hz)

1200 MWe Leningrad II 1

(50 Hz)

1180 MWe Genkai 3 (60 Hz)

1370 MWe Lungmen 1

(60 Hz)

1500 MWe

Isar 2 (50 Hz)

1720 MWe Olkiluoto 3

(50 Hz)

1550 MWe Chooz B1 (50 Hz)

1750 MWe

Flamanville 3 (50 Hz)

• Color code:

Green = currently in Operation Blue = currently under Construction

Nuclear Business Competitive Positioning

p.8 p.8

1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

p.9 p.9

• Non-contaminated steam goes to steam turbine

• No turbine island containment needed

The Pressurised Water Reactor (PWR)

Inside a Nuclear Power Plant Primary, Secondary, Tertiary Loops

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• 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)

Inside a Nuclear Power Plant Primary, Tertiary Loops

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0

20

40

60

80

0 500 1000 1500 2000

Fossil

Nuclear

X 5

Steam turbine generator output (MW)

Ste

am v

olum

e flo

w (

m3 /

s)

What is specific to Nuclear Power Plants ? Much larger steam volume flow

Nuclear large volume flows need for long blades high centrifugal forces

p.12 p.12

Nuclear

50-75 bar

265-290°C

Dry

Steam

S = Entropy (kJ/kg/°K)

H =

Ent

halp

y (k

J/kg

)

Wet

Steam

Fossil

150-300 bar

540-600°C

Saturation line

What is specific to Nuclear Power Plants ? Wet steam conditions

p.13 p.13

P : 10.1 bar

T : 268°C

HP

IP

LP

MSR

P : 10.7 bar

T : 183°C

x : 14.6 %

P : 71 bar

T : 287°C

x : 0.4 %

P : 3.3 bar

T : 148°C

P : 0.055 bar

x : 12.5 %

X : 0 %

Entropy

S (kJ/kg.K)

Enthalpy

H (kJ/kg)

“cold” steam at LP inlet : • small LP axial thermal expansion • reduced axial clearances • possibility to fit a 4th LP

Steam Expansion Line Mollier Diagram – N4 Reactor

p.14

Secondary Loop

NSSS PACKAGE

De-aerating

MSR Condenser,vacuum system, debris filters

Condensate extraction pumps

Circulating water

pumps

Feed heaters pumps

MSR drain pumps

HP IP LP

CI auxiliaries cooling HEX

Core

Generator, exciter

HP heaters

LP heaters

feed-water tank

Drain tanks

Steam and water pipes from/to NI Busbars

100% steam bypass to condenser

Primary Loop Tertiary Loop

EPR - Flamanville 3 Simplified steam-water cycle

p.15

Source: Alstom databases

34%

74%

9%

66%

26%

91% 100%

All sizes < 700 MW > 700 MW > 1200 MW Unit size range

Ful

l-sp

eed

/ H

alf-

spee

d

Half-speed

Full-speed

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

Above 1200 MW, only half-speed to keep reasonable stress levels

p.16

Full Speed vs. Half Speed – what makes the difference ? Case study : Ling Ao 1 vs. Ling Ao 3

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

3100

5,8 6 6,2 6,4 6,6 6,8 7 7,2 7,4 7,6

Entropy (kJ/kg/K)

Enthalpy (kJ/kg)

Ling Ao 3 Half speed

Ling Ao 1 Full speed

Half speed expansion lines in HP, IP and LP sections are much more efficient

HP

IP

LP

p.17

Reactors

Site cooling water temp. °C 59

12

15

17

19

21

23

24

26

27

28

30

31

32

33

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

India

Finland

p.18

CPR1000

EPR

ABWR

PHWR700

VVER1200

AP1000

ESBWR

APWR

ATMEA1

1.5 "Hg2.5 "Hg

1.5 "Hg2 000 MWth

2 500 MWth

3 000 MWth

3 500 MWth

4 000 MWth

4 500 MWth

5 000 MWth

20 mbar30 mbar40 mbar50 mbar60 mbar70 mbar80 mbar90 mbar100 mbar

Re

ac

tor

the

rma

l o

utp

ut

in M

Wth

Condenser backpressure in mbar

Reactors

Site cooling water temp. °C 59

12

15

17

19

21

23

24

26

27

28

30

31

32

33

50 m²

75 m²

100 m²

150 m²

200 m²

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

250 m²

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1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

p.20 p.20

Integrated Packages Turbine Island (TI)

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Integrated Packages Secondary Loop Package (SLP)

p.22 p.22

Circulating water pumps

Steam turbine

Modular condenser Condensate extraction pumps

HP & LP feed-water heaters

MSR 4-pole generator

Reactor feed-water pumps

Grid equipment

Turbine Islands key components

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1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions The steam turbine

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

p.24

Turbine Technology Use of more efficient single flow steam expansion

BP LP 1 1 BP LP 2 2 BP LP 3 3 HP HP IP

Moisture Separator

Reheater

3 bar

11 bar

71 bar

Moisture Separator

Reheater

60% of the power output comes from single flow steam expansion

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HP IP

MSR

LP 1 LP 2 LP 3 HP

ARABELLE™

Efficient configuration

Single flow use

PREVIOUS GENERATION

Traditional configuration

Double flow use

MSR

MSR

LP 1 LP 2 LP 3

MSR

~75 bar

~3 bar ~10 bar

~10 bar

~75 bar

ARABELLE™ uses more efficient single flow steam expansion

ARABELLE™ Steam Turbine Advanced compared to previous generation

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LP Double Flow

HP Double Flow

HP Single Flow

IP Single Flow

LP Double Flow

ARABELLE™ Steam Turbine A specific design to maximise single flow steam expansion & efficiency

2 Flows 1 Flow 6 Flows 1 Flow

ARABELLE™

PREVIOUS GENERATION

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• Efficiency increases with blade aspect ratio

Longer blades have better efficiency

How to improve turbine efficiency ?

p.28

• 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

ARABELLE™ Characteristics Combined HP/IP Module, Unique in the Market

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Flamanville 3 rough machined HP-IP casing in VOEST ALPINE foundry

ARABELLE 1700 50 Hz Flamanville 3 HP-IP casing

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Ling Ao 3 HP-IP casing in Dong Fang Works

ARABELLETM References Ling Ao 3+4 – 2 x 1080 MW

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• HP/IP rotor entering balancing pit, Belfort factory

ARABELLETM References Flamanville 3 – 1 x 1750 MW

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• LP2 welded rotor, fully bladed, Belfort factory

ARABELLETM References Flamanville 3 – 1 x 1750 MW

p.33

Fully bladed LP57 rotor entering Belfort balancing pit (Ling Ao 3)

ARABELLE 1000 for Ling Ao 3 Last Stage Blades : LSB57

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1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions The generator

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

p.35

• 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

GIGATOP 4-pole for Flamanville 3 A highly efficient turbo-generator

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1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions The heat exchangers

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

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Moisture separator reheater (MSR)

LP heater

HP heater

Condenser

Nuclear purification system (NPS)

High velocity separators (HVS)

Auxiliary water/water coolers

Feedwater tank and deaerator

1

1

2

2 3

4

4

5

5

3

Key Components Heat Exchangers for Nuclear Plants

p.38

ARABELLE N4 - 1550 MW - MSR

ALSTOM MSR Moisture Separator Reheaters

p.39 p.39

• Designed by Alstom - In 3 separate pieces - 98 t + 90 t + 98 t - Transported separately - Welded at site

• When assembled, final dimension is: 47.1 m x 5.9 m x 5.3 m

Nuclear Heat Exchangers Flamanville 3 deaerating feed-water tank

p.40 p.40

• 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

Nuclear Heat Exchangers A Complete Condensing System

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1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions The main pumps

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

p.42 p.42

Concrete volute circulating water pump

Condensate extraction pump

Intermediate cooling pump

Essential service pump

Open/closed loop cooling pump

Residual heat removal pump

Feedwater pump Vacuum pump

1

1

2

2 3

3

4

5

5 4

7

6

6

7

8

8

Key Components Pumps for Nuclear Plants

p.43 p.43

A

A

B

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

• Civil engineering works on suction ducts (Sept. 2009)

Nuclear Pumps Concrete Volute Circulating Water Pumps

p.44 p.44

• Flamanville 3 CWP impeller heat treatment (photo credit: Ferry Capitain)

Nuclear Pumps Concrete Volute Circulating Water Pumps

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1 Alstom in Nuclear

3 Turbine Island – Key Products & Solutions

4 Recent Projects

The Turbine Island Agenda

2 Turbine Island Basics

p.46 p.46

• 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: order year 2006 comm. year 2016

Unit 3

ARABELLE™ References Flamanville 3 – 1 x 1750 MW

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ARABELLE™ References Flamanville 3 – 1 x 1750 MW

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• Turbine HP/IP rotor entering balancing pit, Belfort factory, France

Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator

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• Generator rotor

ARABELLETM References Flamanville 3 – 1 x 1750 MW

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• Generator test, Belfort factory, France

Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator

p.51

Site in January 2013

Flamanville 3 – 1750 MWe ARABELLE™ - Turbine & Generator

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• 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: order year 2005 comm. year 2010 & 2011

ARABELLE™ References Ling Ao phase II – 2 x 1080 MW

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ARABELLE™ References Ling Ao phase II – 2 x 1080 MW

p.54 p.54

ARABELLE™ References Ling Ao phase II – 2 x 1080 MW

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ARABELLE™ References Ling Ao phase II – 2 x 1080 MW

p.56 p.56

Ling Ao 3, China - 1080 MW

Synchronized in July 2010, ahead of schedule

Measured output level above guarantee

ARABELLE™ References Ling Ao phase II – 2 x 1080 MW