ge steam turbines

GE Power SystemsOil & Gaswww.gepower.com

2001 Nuovo Pignone S.p.A., all rights reserved;any use or reproduction even if partial is prohibited without a specific written authorization.

CONTENTSIntroduction 1

Design Philosophy 2

Steam Turbine Series 3

Steam Turbines by Nuovo Pignone

- Product/Model Description 4

- Components 8

- Seals 10

- Lube Oil and Control System 11

Steam Turbines by Thermodyn

- Product/Model Description 12

- Components 14

- Seals 15

- Lube Oil and Control System 16

Test Facilities 18

Quality Program 20

Research & Development 21

Global Services 22

Training 23

Some Installations 24

GE Oil & Gas designs and manufactures a complete line of steam turbines for mechan-ical and generator drive applications.They are designed for top thermodynamic and mechanical performance, for installationin chemical, petrochemical and industrial plants, provided as either stand-alone drivers oras part of a GE Oil & Gas complete turboset.

GE Oil & Gas total system capability guarantees the best thermodynamic and mechani-cal match between the steam turbine and the driven machines. It also offers the advantage of single source responsibility. All the machines are manu-factured, assembled and tested by a single company and serviced by the same compa-ny. The advantages of this single supplier responsibility are easy installation, long periodsof continuous service, low maintenance cost and high reliability and availability.The modular design combines the advantage of optimum efficiency with the highestavailability and reliability. 1

SteamTurbines

GE Oil & GasNuovo Pignone - Thermodyn

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Design PhilosophyGE Oil & Gas product lines are based on modu-lar product structures that assure a reliabledesign and outstanding turbine performancethrough standardization. This structure enablesoptimization of a turbine configuration for a cus-tomer’s specific operating conditions. By select-ing and integrating pre-engineered and field-proven components from an array of alternateofferings and designing a custom steam path,the unique requirements of the application aresatisfied. Component modules making up the“building-blocks” of the product line include frontbearing standards, inlet sections, valve gear andextraction and exhaust sections. The barrel sec-tion of the turbine is custom designed for eachunit, based on the user’s specific operating con-ditions. By using this “flexible” modular struc-ture, performance and reliability are maximized,while product cost and the delivery cycle are keptto minimum. Research & Development effortsassociated with this product line focus on thedevelopment of advanced components modules,for improved performance, maintainability andlife.

GE Oil & Gas steam turbines are manufacturedin Florence, Italy by Nuovo Pignone and in LeCreusot, France by Thermodyn.

Nuovo Pignone steam turbine main features:- basic design with impulse control stage(s)

followed by reaction stages with high steamexpansion efficiency

- solid rotors- blade carriers which together with the outer

casing form a double shell design and allowa thinner outer casing and consequentlylower thermal inertia and shorter start-uptime

- inlet and control valves designed to reducepressure losses

- tilting pad journal and thrust bearingsThe design meets API 612 recommendations.

Thermodyn steam turbine main features:- impulse stages providing enhanced wear

resistance and ability to withstand waterinflows, twisted blade profiles to improve laststage efficiencies

- solid rotor- inlet and control valves designed to reduce

pressure losses- tilting pad journal and thrust bearings- spring-back labyrinth sealsThe design meets API 611 or 612 recommen-dations.

Front section Intermediatesection

Rear section

Modular steam turbine structure

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Manufactured by Nuovo PignoneNG backpressure up to 20bar,

multi-valve, live steam up to70bar/540°C

HNG backpressure up to 20bar, multi-valve, live steam up to140bar/540°C

HG backpressure up to 60bar, multi-valve, live steam up to140bar/540°C

NK condensing, multi-valve, livesteam up to 70bar/540°C

HNK condensing, multi-valve, livesteam up to 140bar/540°C

Manufactured by ThermodynP backpressure, single valve,

live steam up to80bar/480°C

MP backpressure, multi-valve,live steam up to150bar/540°C

C condensing, single valve,live steam up to80bar/480°C

MC condensing, multi-valve, livesteam up to 150bar/540°C

Steam Turbine Series

Energie France Sollac Cogeneration highspeed balancing chamber

Axial exhaust steam turbine assembly

Nuovo Pignone steam turbines utilize a hybrid design combiningimpulse and reaction stages. The impulse stage, with partial or full arcadmission, controls the steam flow efficiently over a wide flow range,while the reaction stages give the highest steam expansion efficiency.The combination of one impulse stage with reaction stages producestop steam turbine performance over a wide range of steam flow andspeed.

Main Application map of GE Oil & Gas Nuovo Pignone Steam Turbines.

Impulse+reaction backpressure type, Nuovo Pignone“NG”, “HNG”and “HG” seriesBack pressure turbines are used as mechanical or generators drivers. Inindustrial plant applications they are installed between two steamlines at different pressures. The exhaust steam is generally used forplant requirements.This turbine design is particularly suitable for injecting or extractingsteam at intermediate pressure. The best turbine efficiency and theinjection/extraction requirements are satisfied by adjustment of thenumber of blade carriers and the number of stages of each bladecarrier.

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Impulse+Reaction Steam Turbines by Nuovo Pignone

Product/Model Description

NK and HNK NG, HNG and HG Extraction(condensing) (backpressure)

LNG - Medium -Ethylene/Methanol High - HighUrea/Ammonia High - HighRefinery Medium Medium LowSynfuels High - HighProcess air High - -Co-generation High Low HighCombined cycle High - LowSmall P. G. High - LowGeothermal P. G. High - -

TURBINE MODEL NG HNG HG

Power (kW) 1,000 – 50,000 1,000 – 50,000 1,000 – 40,000Speed (RPM) 3,000 – 16,000 3,000 – 16,000 3,000 – 16,000Max. live steam cond. 70 / 540 140 / 540 140 / 540(BAR/°C)Max. back pressure 20 20 60(BAR)

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SteamTurbines

Back pressure turbine cross section

Back pressure steam turbine partially assembled

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Impulse+reaction condensing type, Nuovo Pignone“NK” and “HNK”series

Condensing turbines are applied as mechanical or generator drivers.Structurally, they are characterized by a large exhaust section which isdictated by the large steam volume flow caused by the low condens-ing pressure.The last section of two or three stages is completely standardized andits moving blades have twisted airfoils. Various families have beenstandardized for low, medium and high speed applications.The exhaust casing flange may be directed upwards or downwards.Solutions with axial exhaust flanges are also available.The condensing turbines are particularly suitable for steam injectionand/or extraction, matching the requirements of petrochemical orpower generation applications such as co-generation or combinedcycles.

TURBINE MODEL NK HNK

Power (kW) 1,000 – 65,000 5,000 – 100,000Speed (RPM) 3,000 – 16,000 3,000 – 12,500Max. live steam cond. 70 / 540 140 / 540(BAR/°C)


Product/Model Description

Typical cross-section drawing of an extraction condensing turbine equippedwith a control stage in both high and low pressure sections

Typical cross-section drawing of an extraction condensing turbpressure sections throttle controlled

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SteamTurbines

bine with low Condensing turbine cross section

Condensing turbine casing

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CASING:The turbine casing is horizontally split. In back pressure tur-bines each half-casing is made of cast steel in one single piece.For condensing turbines, the outer casing is made of a caststeel high pressure section, bolted with a vertical flange to acast iron or fabricated steel low pressure section.

ROTOR:The shaft consists of a solid forging made of low-alloy steel forlow pressure applications or high-alloy steel (13% chromiumsteel) for high pressure and temperature.The bladed rotor is balanced and overspeed tested beforeassembly in the turbine.

MOVING BLADES:Cylindrical moving blades of reaction stages have “T” roots, andintegral shrouds. Impulse and reaction airfoils have been stan-dardized.Materials have been standardized for the moving blades: 13%chromium steel with molybdenum and vanadium for tempera-tures over 350°C; 13% chromium steel for lower temperatures.The last group of two or three stages in condensing turbineshas been completely standardized in families, for low, mediumand high speed applications.


Components(Casing, Rotor, Blades, Stop and Control Valves)

Casing of turbine model ENK applied as propylene gas compressor driver Journal and thrust bearing

View of a condensing turbine rotor blading

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FIXED BLADES:The impulse stage nozzles are inserted (with-out any welds) into a slot machined in theinner casing and are easily removable evenafter years of operation. The nozzle materialis the same as that for the impulse stagemoving blades. The fixed blades of the reac-tion stage are cantilevered in the blade carri-ers and are held together by riveted shroudsor inserted in the blade carriers as completediaphragms; they are made of 13% chromi-um steel.

STOP AND CONTROL VALVES:Nuovo Pignone steam turbines are equippedwith emergency stop valves which serve toprotect the whole turbounit against over-speed; such valves have a response time inthe order of 50 milliseconds and are safeand reliable even after long periods of opera-tion (operator can check that the valve isready to operate at any time using a testingdevice).Emergency stop valves are installed on eachlive steam inlet flange and are mounteddirectly on the casing to minimize the steamvolume that continues to expand through theturbine after valve closure.Steam flow is regulated by four or five controlvalves admitting steam to the impulse stagenozzles. Control valves are operated by ahorizontal bar activated by two valvestems. Generally, the two valves at the endof the bar open at the same time to allow uni-form heating of the casing during start-up.The remaining valves open in a sequencedesigned to optimize the distribution offorces on the rotor produced by the steam inthe impulse stage. The shape of the cones isoptimized to provide a quasi-linear relation-ship between the steam flow and valve lift forthe best operation of the control system.

JOURNAL AND THRUST BEARINGS:Tilting-pad journal bearings are generallyused. Double-acting, tilting-pad thrust bear-ings are installed with a thrust equalizingdevice. Both journal and thrust bearings canbe fitted with thermoelements for tempera-ture detection and monitoring.

SteamTurbines

Emergency stop valve schematic drawing

Regualting valves sectional drawing

Turbine front side view of the main inlet flange and emergency stop valve

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SealsThe end seals are of the labyrinth type.The operating philosophy of the end seals of a condensing turbineis shown in the schematic diagram.

Chambers 1, front and rear, are connected to the main con-denser and a low pressure steam supply. The automatic valves“A” and “B” keep the pressure just a little above atmosphericlevel, thus minimizing the steam flow of the atmosphere fromchambers 2.A steam gland condenser is not required. When applied, it is con-nected to chambers 2.

Seal Steam Line

To main condenser

Balancing PIiston Leakages

2

1

2

1

B

A

vent vent

Front seals, labyrinth type

End seals schematic diagram

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Lube Oil and Control System

EMERGENCYSTOPVALVE

Powerpiston

Poweroil distributer

Modulatedoil pressure(1,5 to 4,5 BAR

ELECTRO HYDRAULICCONVERTER

ELECTRONIC GOVERNOR

Set signalPICK-UP SPEED

GEAR

Speedsensors

OVERSPEEDLOGIC TACHOMETER

CONTROL VALVES

Solenoidvalve

8 to 10 BAR oil

Steam line

8 to 10 BAR oil

1,5 to 4,5 BARmodulated oil pressure

VALVE ACTUATOR

The lube and control systems generally have a common reser-voir, pumps, filters and coolers.Lube and control oil for mechanical drive applications is suppliedfrom the turbounit oil console.In generator drive applications in combined cycle plants with agas turbine in a single shaft arrangement the lube and controloil may come from the gas turbine console.In any other generator drive applications an oil console is pro-vided.The most common configurations are:- oil reservoir is separate from the turbine baseplate- oil reservoir is in the turbine baseplate and the auxiliaries are on theturbine baseplate or on a separate skid.

The electronic governor may have a different redundancy con-figuration and may be custom engineered.The turbounit start up sequence may be manual or completelyautomatic. The turbounit trip device is a redundant electronictype unit.The control oil system for straight backpressure or condensingturbines is basically in accordance with the simplified schematicdiagram below.The control oil diagram is basically the same for extraction turbinesbut with an addition of a second electro-hydraulic converter and asecond valve actuator.

Lube and control system schematic diagram

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Impulse Steam Turbines by Thermodyn

Product/Model DescriptionThermodyn steam turbines are impulse turbines of simpledesign, which, together with retractable seal technology, insuresthat performance is maintained over a long period of time

BACK - PRESSURE TYPEImpulse-type Back-pressure, Thermodyn “P” seriesThermodyn “P” series steam turbines have a single inlet valveand a back pressure exhaust designed to drive low-powermachinery and offer easy servicing.They are commonly used as compressor drives in petrochemicalrefinery applications and for power generation in these industriesor for emergency power supply such as for nuclear plants.

• POWER RANGE: up to 5 MW• SPEED RANGE: up to 16,000 rpm• INLET PRESSURE: up to 80 bar• INLET TEMPERATURE: up to 480°C• API 612

Impulse-type Multivalve Backpressure, Thermodyn “MP”seriesThe “MP” series steam turbines have multi-valve inlet and aback pressure exhaust and are designed to drive variablespeed machinery – compressors, fans, blowers, pumps, as wellas generators. Applications are in petrochemical and refineryplants, power plants or combined heat and power plants withfossil fuel, crushed cane in the sugar industry, municipal wastefor incineration or waste energy in heat recovery plants.

• POWER RANGE: up to 40 MW• SPEED RANGE: up to 16,000 rpm• INLET PRESSURE: up to 150 bar• INLET TEMPERATURE: up to 540°C• STEAM EXTRACTION or INJECTION• API 612

Sucrerie Ile Maurice - Savannah sugar estates

Cnim Thumaide FranceDomestic waste incinerator

Air liquide Otor France - Cogeneration on 1x560

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SteamTurbines

CONDENSING TYPEImpulse-type Condensing, Thermodyn “C”seriesThe “C” series steam turbines have a singleinlet valve and a condensing exhaust and aredesigned to drive low-power machinery witheasy servicing.They are commonly used as compressor dri-vers in petrochemical and refinery applica-tions, and for power generation in theseindustries or heat recovery process such asmunicipal or industrial waste incineration.

• POWER RANGE: up to 6 MW• SPEED RANGE: up to 16,000 rpm• INLET PRESSURE: up to 80 bar• INLET TEMPERATURE: up to 480°C• STEAM EXTRACTION or INJECTION • API 612

Impulse-type Multivalve Condensing,Thermodyn “MC” seriesThe “MC” series steam turbines have multi-valve inlet and a condensing exhaust and aredesigned to drive variable speed machinery –compressors, fans, blowers, pumps, as wellas generators. Applications are in petrochemical and refineryplants, power plants or combined heat andpower plants with fossil fuel, crushed cane inthe sugar industry, municipal waste for incin-eration or waste energy in heat recoveryplants.The “MC” turbines can be equipped with acontrolled extraction, that is, with a supple-mentary regulating action, making it possibleto jointly optimize the production of heat andmechanical power in accordance with theneeds of the process.

• POWER RANGE: up to 40 MW• SPEED RANGE: up to 16,000 rpm• INLET PRESSURE: up to 150 bar• INLET TEMPERATURE: up to 540°C• STEAM EXTRACTION or INJECTION • API 612

Iran Total south pars

Cogeneration in gas treatment plant France - Eap Lacq. Power Generator

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Components(Casing, Rotor, Blades, Stop and Control Valves)

CASINGSCast steel casings are made by using patterns built up from stan-dard modules.Exhaust casings for the “P” and “MP” turbine series can be cast orwelded according to the exhaust back-pressure.Exhaust casings for the “M” and “MC” turbine series are welded.For the “MC” turbine series, the modular design permits adaptationto site conditions: axial, upward or downward discharge, sizedaccording to water cooling source with a hydro condenser, air cool-ing source with air-condenser or with a hydro-condenser associatedwith a cooling tower.

ROTORS:Rotors are solid forgings made from chrome-molybdenum steel.The bladed rotor is balanced dynamically, if necessary at ratedspeed in a vacuum balancing stand.

BLADES:Blades are made of stainless steel. They undergo special treat-ments to improve fatigue strength and erosion resistance. Rotatingblades have “T” or “Fir tree” roots and are grouped in packets withriveted bands or, only for “MC” turbine series, welded links.

Rotor groves for steam turbine blade roots

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SteamTurbinesJOURNAL AND THRUST BEARINGS:Journal and thrust bearings are of the tilting padtype which are particularly suitable for multi-valveturbines. They provide stability over a wide range ofrunning speeds and ensure safety at the highestrotational speeds.

STOP AND CONTROL VALVES:The stop-valve is designed to be leak-tight and hasan easily removable steam strainer and diffuser-type seat ensuring instant closure when tripped.For the “P” and “C” turbine series, there is onecontrol valve regulating the steam flow through theturbine. This valve can be of the double seat or sin-gle seat type with a diffuser.For the “MP” and “MC” turbine series, there are upto eight control valves regulating the steam flowthrough the turbine and maintaining high efficien-cies at low power.To obtain the best possible efficiency, the extrac-tion, if any, is adjusted by means of an extractiongrid valve which is adapted to the high-volume flowrates admitted in the low pressure section of theturbine. This element is composed of two gridswhich move in relation to each other, and which isequivalent to a group of six control valves with lowthrottling.

Power Plant - Compagnie Thermique du Gol La Reunion

Model T6-7 MC9E with gride valve for extraction control.Rating 25 MW, extraction pressure 2.5 bar.

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SealsSpring-back labyrinth seal technology cuts down internal leakage inthe turbine and prevents premature deterioration of the steamsealing system.

Domestic waste incinerator - France Astria/C.T.E. BeControl oil systemRetractable Seals

Domestic waste incinerator - France Emeraude Crete il

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Impulse SteamTurbine by Thermodyn

Lube Oil and Control System

Thermodyn’s oil units are designed to supply lube oil and highpressure control oil. They are free standing consoles but canbe integrated into the base supporting the shaft line for com-pressor units. These units comply with Thermodyn’s stan-dards or with API 614 code rules.Electronic speed governors are employed. The advantage ofdigital electronic governors is that they are versatile enoughto adapt smoothly to any required configuration. The para-meters are simply set in the computer at start-up or duringturbine operation.Thermodyn has developed a standard high pressure oil sys-tem using servo-valves to actuate the stop-valve, the inletcontrol valve and the extraction valve. Performance (stability, dead band, response time) meetsNEMA SM22, API 612 or CEI 45 recommendations.

Begles

Lube Oil Console

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The Florence Test Facilities are equipped with 4 test benchesand a complete steam plant, with max. 70 t/h live steam at50 bar /450°C.The Le Creusot Test Department is equipped with 5 test benchessupplied by a steam plant capable of generating 28 t/h of vaporat 45bar 450°C.Le Creusot is also equipped with a large-size anechoic chamberwith suspended low-frequency foundation block for vibration andnoise measurements.Mechanical string tests can be conducted on the complete trainsboth in Florence and in Le Creusot.Full load, full pressure tests may be carried out, within the steamplant capacities.

Centrifugal compressor test

Steam turbine test location

FLORENCE PLANTIndoor test stands foand steam turbines

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Test Facilities

Anechoic Chamber

Steam Turbine test stands

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CONTROLROOM

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Shop steam turbine

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LIQUIDGAS

BackPressure

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FROM INDOORAND OUTDOOR

STANDS

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OUTDOORSTANDS

Air cooler

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TO OUTDOORSTANDS 1 - 4

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EvaporatingTowers

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Steam generator

TO INDOOR STANDS FOR GAS TURBINE TESTS 1 - 4

SteamTurbines

Condensing turbine driving a centrifugal compressor under load testing

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All production processes, whether in Florence or in Le Creusot,are carried out under the GE Oil & Gas Quality System that inte-grates the GE Six Sigma Quality Program with ISO 9001 QualityStandards to guarantee satisfaction of customer expectations.The Program insures the long-term stability and sustain-ability of process improvements guaranteeing the quality ofproducts.

The quality program has the following objectives: - supplying customers with reliable products, delivered and

installed on time- supplying quality spare parts within the contractually specified

dates

To support the quality assurance program GE Oil & Gas hasspecialized testing and measurement facilities:

- Special laboratories accredited by SINAL (National System forAccreditation of Laboratories), equipped for testing todetermine mechanical properties, chemical analysis andspectrometer analysis, fatigue tests, macro and micro-graphic examinations (optical microscope and scanning elec-tron microscope).

- A Calibration Center certified as an SIT (Italian CalibrationService) Center to control the reference standards used to cal-ibrate all measuring and testing instruments used in theCompany Plants.

Quality Program

Last stage blade experimental modal analysis

Scanning electron microscope analysis of materials

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GE Oil & Gas believes that product excellence is a moving tar-get that can only be achieved through constant improvementand innovation. This philosophy has driven our commitment toResearch & Development as a means of remaining a leader inproviding the most advanced products for the Oil & GasIndustry.

The combined talents of GE Oil & Gas research engineers alongwith hundreds of scientists and engineers from GE’s CorporateResearch & Development Center located in Schenectady, NewYork and many Universities worldwide form a team dedicated toadvancing the state-of-the-art of turbomachinery. This team isconstantly working to exploit the latest developments inadvanced materials and leading edge engineering design to pro-duce machinery with higher performance and longer life for theOil & Gas Industry.

Our tools for insuring the integration of advanced technologyinto reliable, long-life machines include:- Computer-aided design tools such as CFD (Computational

Fluid Dynamics) and 3D Auto CAD modeling for the design ofhigh efficiency compressors, expansion stages and low emis-sion combustion systems

- Advanced test facilities for both components under develop-ment and full scale machines

- The proven, quality-centered development processes thathave been the mainstay of product development throughoutall of the GE family of businesses

GE Oil & Gas is dedicated to providing the world’s best solu-tions for the Oil & Gas Industry.

Research & Development

High pressure black Modal Analysis with shroud vibration

Low pressure black Finite Element Modelling

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Global ServicesGE Oil & Gas Global Services provides a complete set of servicesto support the entire steam turbines product line.Global Services offers an extensive portfolio of proactive and inter-active service products such as condition-based maintenance andlong term service agreements. This complements the traditionalservice product offerings of OEM spare parts, repairs, and field ser-vices.Ready access to Nuovo Pignone and Thermodyn product engi-neering organization and their advanced technology, design expe-rience and manufacturing capabilities ensures GE Oil & Gas GlobalServices customers the highest quality engineering know-how,spare parts, repair and field services.GE Oil & Gas innovations have not been limited to mechanical engi-neering. Business solutions have been developed, such as longterm service agreements that include remote monitoring & diag-nostics to help drive customer value by providing higher equipmentreliability, availability and productivity at a predictable cost. Otheradvanced information-based developments include electronicparts catalogs, and e-commerce solutions to improve customerproductivity.

GE OIL & GAS MEANS HIGH-TECH SERVICE SOLUTIONSGlobal Services engineers are backed up by the new productdesign engineering groups of GE Oil & Gas and by GE CorporateResearch & Development.Thousands of creative minds working to provide the high-tech prod-ucts and business solutions for the 21

st century.

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TrainingGE Oil & Gas offers Training for the Operation and Maintenanceof our complete line of machinery and equipment.This Training can be provided either at the client’s site or at theFlorence Learning Center located at GE Oil & Gas headquartersin Florence Italy. GE Oil & Gas Nuovo Pignone and Thermodynhave over 20 years of experience in training clients.

- Unique opportunityGE Oil & Gas instructors are field-seasoned experts whocombine their under standing of theory with practical expe-rience.The quality training that they provide is a prerequisite forimproving the skills of operating and maintenance personnelto assure safety and superior equipment efficiency and avail-ability.

- Close to the customerCourses and documentation are designed to meet the cus-tomers’ needs focusing on GE Oil & Gas machinery actuallyinstalled at their sites. Courses cover the entire productrange: gas and steam turbines, centrifugal and reciprocatingcompressors, control panels, and complete power and com-pressor plants. Self-paced training and pre-packaged coursesare available on standard GE Oil & Gas machinery configura-tions.

- Effectiveness & efficiencyTraditional training tools are augmented by computer-basedtraining and interactive multimedia technology. Courses andtechnical literature can be provided in a variety of languages.

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Some Installations Nuovo Pignone

Generator driver in combined cyclein a paper plant, Lucca (Italy)

Recycle compressor driver at Warry refinery (Nigeria)

Pipeline compressor driver installedin Messina Italy

Steam turbine driving an ammoniasyntesis compressor train

Generator driver in solid refuseburning plant - Bologna (Italy)

SteamTurbinesThermodyn

Turbo-generator for domestic waste incenerator - CNIM Avignon (France)

Steam Cracking TurbocompressorExxon N.D. de Gravenchon - France

Power plants - La reunion CompagnieThermique Gol.

SNLE - NG Le Triomphant submarine for French navy

GE Power SystemsOil & GasNuovo Pignone S.p.A.Via Felice Matteucci, 250127 Florence - ItalyTel. +39-055-423211Fax +39-055-4232800e-mail: info.geoil&[email protected] www.gepower.com

ThermodynSite Industriel - B. P. 119 71203 Le Creusot Cedex, FRANCETel. +33-3-85806810Fax +33-3-85806811

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