ISSN 0040-6015, Thermal Engineering, 2017, Vol. 64, No. 11, pp. 787–793. © Pleiades Publishing, Inc., 2017.

Original Russian Text © V.E. Mikhailov, L.A. Khomenok, I.I. Pichugin, I.A. Kovalev, V.V. Bozhko, O.A. Vladimirskii, I.V. Zaitsev, Yu.Ya. Kachuriner, I.A. Nosovitskii, V.G. Orlik,
2017, published in Teploenergetika.

STEAM TURBINE, GAS TURBINE, STEAM-GAS PLANTS

AND ACCESSORY EQUIPMENT

Concept of Turbines for Ultrasupercritical, Supercritical,

and Subcritical Steam Conditions
V. E. Mikhailov*, L. A. Khomenok**, I. I. Pichugin, I. A. Kovalev***, V. V. Bozhko***,
O. A. Vladimirskii, I. V. Zaitsev***, Yu. Ya. Kachuriner***, I. A. Nosovitskii***, and V. G. Orlik***
Polzunov Research and Production Association for Investigation and Design of Power Generating Equipment (NPO TsKTI),
St. Petersburg, 191167 Russia
*e-mail: gendir@ckti.ru
**e-mail: zamdir2@ckti.ru
***e-mail: turbina@ckti.ru
Received February 25, 2016; in final form, April 26, 2017

Abstract⎯The article describes the design features of condensing turbines for ultrasupercritical initial steam
conditions (USSC) and large-capacity cogeneration turbines for super- and subcritical steam conditions hav-
ing increased steam extractions for district heating purposes. For improving the efficiency and reliability indi-
cators of USSC turbines, it is proposed to use forced cooling of the head high-temperature thermally stressed
parts of the high- and intermediate-pressure rotors, reaction-type blades of the high-pressure cylinder (HPC)
and at least the first stages of the intermediate-pressure cylinder (IPC), the double-wall HPC casing with
narrow flanges of its horizontal joints, a rigid HPC rotor, an extended system of regenerative steam
extractions without using extractions from the HPC flow path, and the low-pressure cylinder’s inner casing
moving in accordance with the IPC thermal expansions. For cogeneration turbines, it is proposed to shift the
upper district heating extraction (or its significant part) to the feedwater pump turbine, which will make it
possible to improve the turbine plant efficiency and arrange both district heating extractions in the IPC. In
addition, in the case of using a disengaging coupling or precision conical bolts in the coupling, this solution
will make it possible to disconnect the LPC in shifting the turbine to operate in the cogeneration mode. The
article points out the need to intensify turbine development efforts with the use of modern methods for
improving their efficiency and reliability involving, in particular, the use of relatively short 3D blades, last
stages fitted with longer rotor blades, evaporation techniques for removing moisture in the last-stage dia-
phragm, and LPC rotor blades with radial grooves on their leading edges.

Keywords: turbines, ultrasupercritical, supercritical, and subcritical steam conditions, economic efficiency,
reliability
DOI: 10.1134/S0040601517110076

Achieving higher initial parameters of steam has extractions for district heating purposes. The aim the
always been a top-priority concern of turbine manu- TsKTI specialists pursued in elaborating these con-
facturers, because the higher the initial steam condi- ceptual designs was not only to show that such turbines
tions, the higher the turbine plant efficiency. Turbines can be constructed but also to identify the questions
designed for the ultrasupercritical steam conditions and problems (apart from metallurgical ones) that
24 MPa and 540–560°С have the highest parameters have to be solved to obtain high economic and perfor-
among the units that have been mastered in mass-scale mance indicators of these turbines.
production and operation. Construction of turbines A solution that is of fundamental importance for
designed for the new level of parameters, namely, the achieving this aim is to arrange cooling for the ther-
initial pressure equal to 30 MPa and the live and reheat mally stressed parts of rotors and the conjugated stator
steam temperature equal to 600°С or higher is a chal- elements of the high-temperature parts of the high-
lenge of utmost importance. and intermediate-pressure cylinders (HPC and IPC)
In recent years, NPO TsKTI specialists have elab- in the steam inlet areas. If attempts to do this are met
orated conceptual designs of condensing turbines with with success, reliable operation of, primarily, the
capacities of 350–900 MW for ultrasupercritical steam rotors of these cylinders will be secured while keeping
conditions (a pressure of 28–30 MPa and temperature the creep and long-term strength conditions within
of 600–650°С) [1, 2] and cogeneration turbines for the permissible limits. Such a solution is corroborated
super- and subcritical parameters with increased by positive experience gained from the operation of

787
788 MIKHAILOV et al.

0 flowrate does not exceed 1.5% of the nominal flow-

rate, and the number of cooled stages is from four to
Efficiency reduction, %

1 seven depending on the temperature. Calculations

–0.4 have shown that the use of such cooling results even in
2 a somewhat higher cylinder efficiency, because, first,
–0.8 the cooling steam replaces the working steam in the
end seal, which has higher enthalpy, and, second, this
steam makes useful work as it enters into the flow path.
–1.2 3
With the cooling arrangement put into operation,
–1.6 the temperature of the rotor head part decreases to
14 15 16 17 18 19 20 480–490°С, a level at which Grade 25Kh1M1FA steel
Number of stages can be used for manufacturing the rotors.
The use of split pressure increased to 7 MPa, which
Fig. 1. Effect of stage diameter on the HPC efficiency. Dr, is close to its optimal level, improves the power unit
mm: (1) 850, (2) 900, and (3) 950.
thermal efficiency and opens the possibility of not
only making the HPC with a rigid rotor and without
200–800 MW turbines for supercritical steam condi- extractions from its flow path but also decreasing the
tions, for which systems for separate and combined reheat path sizes. Such design also results in a signifi-
forced cooling of the HPC and IPC rotors fitted with cantly lower risk of the occurrence of steam-induced
impulse-type blades were developed at TsKTI in the low-frequency shaft system vibration.
1980s in order to extend their service life and that were Fitting the turbines, as was mentioned above, with
used in more than 65 turbines produced by the Lenin- reaction-type blades in at least the first HPC and IPC
grad Turbine Works (LMZ), Ural Turbine Works stages was another important design solution. The
(UTZ), and Kharkiv Turbine Works (KhTZ) [3, 4]. In designers who proposed this solution also had to select
addition, the possibility of cooling the rotor without the optimal stage root diameter. This was because this
supply of cooling steam from outside through the use diameter is a factor determining, on the one hand, the
of stages featuring a low negative degree of reaction in number of stages, the blade heights, and the flow path
the root section was considered [5]. efficiency, and, on the other hand, the rotor length
However, when a shift is made for ultrasupercritical and stiffness. Calculations, the results of which are
steam conditions (USSC), the use of such systems fails shown in Fig. 1, enabled the designers to determine
to cool the required number of stages. In view of this the optimal HPC rotor diameter equal to approxi-
circumstance, a forced rotor cooling system similar to mately 900 mm. The first-stage blades had a height of
that used in the SKR-100 turbine produced by the 30–45 mm, and the number of stages (from 15 to 17)
Kharkiv Turbine Works, which has passed successful depended on the turbine power capacity. The cylinder
efficiency is 91–92%, which is achieved, in particular,
check in the course of its long-term operation at the
also by using a well-developed system for ensuring
Kashira district power plant [6, 7], was adopted in the
contactless sealing of gaps above the blade bucket
subsequent designs. Such a system is implemented in
shrouds [8] and owing to the use of variable-profile
the easiest way in turbines fitted with reaction-type
blades designed with due regard to the spatial flow
blades, the use of which makes it possible, apart from pattern. It should be emphasized that some foreign
this feature, to achieve better efficiency of stages while companies use such blades [9–11] that make it possi-
using relatively short blades. The system consists of a ble to increase the efficiency of stages with relatively
heat exchanger in which cooling steam is prepared and short blades by 2–3%. To achieve this effect, a shift
HPC and IPC cooling paths. Live steam supplied to shall be made to an approach according to which the
the heat exchanger is cooled by steam from the cold blade system of each stage containing the guide vanes
reheat system and is forwarded for cooling the high- and rotor blades with profiles varying along the height
pressure rotor (HPR) and the heated cold reheat is designed individually, unlike the existing approach,
steam is forwarded for cooling the intermediate-pres- according to which all stages of this class are made
sure rotor (IPR). The cooling paths are formed by cal- with the same cylindrical blade buckets and only differ
ibrated holes made in the roots of rotor blades and in from each other in the blade heights. The HPC flow
the inserts of guide vanes. The hole sizes are selected path is shown in Fig. 2.
so as to keep hotter working steam from being admixed
to cooling steam and, on the contrary, to let the cool- An analysis of the considered versions with the
ing steam being admixed to working steam. Cooling number of HPC stages decreased owing to the use of a
steam is supplied to the zone downstream of the first- loop-type flow path with the increased back flow
stage guide vanes; approximately two thirds of its diameter or through the use of an impulse-type first
amount is forwarded to the end seal and the remaining stage has shown that such solution causes the cylinder
part is admitted to the cooling path. The cooling steam efficiency to decrease by 1.0–1.5%.

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 CONCEPT OF TURBINES FOR ULTRASUPERCRITICAL 789

17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Fig. 2. HPC flow path.

According to the adopted design, the HPC is made efficiency due to larger radial gaps in the cylinder
as a single-flow one with a rigid rotor, due to which the during its operation. A steam-induced low-frequency
dynamic misalignments are kept to a minimum. The vibration may also occur.
cylinder casing shape is close to cylindrical (except The low-pressure cylinder is made according to the
with the inlet part, the shape of which is close to spher- classic arrangement, i.e., as a double-flow one with
ical), a solution that has become possible also due to external bearings. Each flow comprises five stages; the
lack of steam extractions from the flow path. Such a last-stage rotor blades have a length of 1200 mm, as a
solution, taken in combination with the use of narrow result of which the total exhaust area is the same as in
high flanges of the horizontal joints in the inner and the design with three exhausts with the last blade
outer casings, results in smaller radial temperature- length equal to 960 mm. The number of low-pressure
induced misalignments and stresses in the cylinder cylinders, which is governed by the permissible volu-
walls. Calculations of the inner cylinder’s thermally metric flowrate of steam in the last stage, is from one
stressed state have shown that there is no need to cool to two. The exhaust hood is designed with stiffening
the cylinder with such a design. The use of tangential bands; moisture is separated and removed from the
steam admission helps decrease the inlet losses and inner cone upper part.
make the flow more uniform over the circumference.
Of course, the problem of making longer blades,
The IPC flow path is assembled from either a few which, if having been successfully solved, would make
forcedly cooled reaction-type and subsequent it possible to achieve both a fewer number of stages in
impulse-type stages or only from reaction-type stages. the flow and a fewer number of cylinders, still remains
In the first case, the number of stages is 15–17, and the of much relevance. It is important to emphasize that
cylinder can be made as a single-flow one, whereas the the use of longer blades in the LPC last stage results in
number of stages reaches 18–20 in the second case, a higher heat drop across it, thus causing a higher pres-
and the cylinder is made as a single-flow one and a
double-flow-one for large-capacity turbines. The cyl-
inder efficiency is 94–95%. The IPC cross-sectional Steam admission
view is shown in Fig. 3. from the IPC exhaust

The steam flows passing through the HPC and

IPC move in counter directions, thus balancing the
axial force applied to the rotors. In addition, a dummy
560
165

cylinder is installed in each of the cylinders. Apart

∅ 1220

from a four-support scheme for resting the rotors of 1 2 3 4 5 6 7 8 91011 121314 1516 17 18 19
these cylinders, a three-support arrangement has also
∅ 435
∅ 360

∅ 1054

∅ 1202
∅ 95

been elaborated, which will make it possible to

decrease the turbine length and reduce the mechanical 5599
losses in it. In the latter case, the common external
bearing can be combined with the shaft coupling.
A still greater effect is achieved in the case of using
a combined high- and intermediate-pressure cylinder.
However, calculations have shown that the efficiency Cooling steam admission
of such a turbine will drop by 2–3% in this case. In
addition, such a cylinder will have a flexible rotor,
which will have an additional adverse effect on the Fig. 3. Longitudinal section through the IPC.

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790 MIKHAILOV et al.

It should be pointed out that the last extraction is

located upstream of the last stage, due to which mois-
ture is separated more efficiently, which results in less
intense droplet impingement erosion of the rotor
blades in this stage. Other solutions that are proposed
to pursue the same purpose include a shift for using an
evaporative moisture removal method in the last stage,
which has shown positive results in the course of com-
mercial tests [13, 14], and the use of rotor blades with
radial grooves on the leading edge in the preceding
LPC stages, a solution that allows several times better
moisture separation efficiency to be obtained [15].
As an example, Fig. 5 shows the longitudinal sec-
tion of the K-660-29.4 turbine fitted with a prospec-
tive LPC the last-stage rotor blades that have a length
of 1320 mm. The cylinders of such a turbine have effi-
ciencies equal to 92.1, 93.8, and 89%, and the gross
Fig. 4. LPC flow path. efficiency of the power unit as a whole is 46.2% (the
efficiencies of the turbine plant and boiler are equal to
sure upstream of the LPC, a circumstance that opens 49.9 and 92.9%, respectively; the pressure in the con-
the possibility to do without the last stage in the IPC denser is 5 kPa, and the pressure losses in the reheat
path and in other pipelines are equal to 11 and 3%,
and make this cylinder a single-flow one, even in a
respectively). The heat rate in the K-660-29.4 turbine
large-capacity turbine.
is 9% smaller than it is in the K-300-23.5 turbine.
The keeping of symmetric axial gaps in the oppo- Type T-330/400-23.5 and type T-200/250-12.8
site flows in heating up the turbine and when the stator turbines replacing the type T-250/300-23.5 and type
and rotor undergo corresponding thermal expansions T-180/220-12.8 turbines were considered in elaborat-
has always been a problem. Deviations of these gaps ing the new-generation cogeneration turbines for the
from their design patterns entail the occurrence of steam conditions 12.8–23.5 MPa and 565–600°С and
asymmetrical temperature fields in the flows and with the district heating extractions increased by no
increased off-design leaks through the shroud and dia- less than 12%.
phragm seals. Nonetheless, there is a solution that is The following three possible turbine design ver-
widely used by foreign turbine manufacturers [12]. To sions have been proposed:
this end, the LPC should be fitted with an inner casing
arranged so that it would be able to move within (1) A “classic” one, in which the upper and lower
restricted limits in the axial direction. A special system heating extractions are arranged in the IPC and LPC,
of levers and pushers transmits the axial forces result- respectively. However, with the turbine used in the
ing from the thermal displacement of the IPC casing cogeneration mode, the LPC stages operate under
and moves the LPC inner casing, thus equalizing the almost no-steam conditions, which, as is well known,
stator and rotor displacements. A special hydraulic results in additional losses and much more intense
drive helps to return the LPC inner casing when droplet impingement erosion wear of the leading and
changes occur in thermal expansions. The authors of trailing edges in the last-stage rotor blades.
this article used a similar design solution in their (2) A version in which the upper extraction (or its
developments. Physically, the low-pressure cylinder considerable part) is shifted to the feedwater pump
consists of an external casing and an inner casing, the turbine. The use of this solution improves the turbine
latter housing the diaphragms of all stages. The outer plant efficiency but does not remove the LPC draw-
casing’s lower half contains guide pieces along which backs.
the inner casing’s longitudinal keys can move. The (3) A version in which both the heating extractions
longitudinal section of the LPC for 660 and 900 MW are arranged in the IPS. With this solution, it becomes
steam turbines is shown in Fig. 4. in principle possible to disconnect the LPC in shifting
To achieve high efficiency of the power unit, the the turbine to operate in the cogeneration mode and,
turbine is fitted with an extended regenerative feedwa- hence, to remove the above-mentioned drawbacks
ter heating system comprising eight heaters and a inherent in the basic versions.
deaerator. The first extraction is taken from the HPC It can also be added in regard of the last version that
exhaust, and the subsequent five and three extractions similar proposals were put forward long ago, but
are taken from the IPC and LPC flow paths, respec- recent years have seen an especially large number of
tively. With such an arrangement, the feedwater tem- such proposals [16–18], which is attributed to the fact
perature reaches as high as 295°С. that the issue of blade erosion wear due to loss of a

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 CONCEPT OF TURBINES FOR ULTRASUPERCRITICAL 791

21 292

1428 4348 6016

7820

Fig. 5. Longitudinal section through the K-660-29.4 turbine.

Disengaging coupling

Fig. 6. Longitudinal section through the turbine equipped with a disconnectable LPC.

large number of stellite plates has become especially IPC efficiency and design. On the other hand, the use
acute [19]. of steam with lower parameters upstream of the feed-
water pump turbine allows its design to be greatly sim-
The designs of HPCs and IPCs used in turbines for
plified and even results in a somewhat better effi-
supercritical steam conditions also include features for
ciency. Steam from the feedwater pump turbine is
forcedly cooling the head parts of their rotors, and the
directed to the upper heating extraction when the
LPCs of these turbines contain the movable inner cas-
main turbine operates in the cogeneration mode and
ing rigidly connected with the IPC casing. All HPC
to the LPC when the main turbine operates in the con-
stages are equipped with reaction-type blades, and the
densing mode; thus, the feedwater pump turbine does
IPC uses reaction-type blades in its cooled stages. The
not have a condenser.
HPC and IPC efficiencies are equal to 91–92 and
93.0–94.5%, respectively. The T-200/250-12.8 turbine for subcritical steam
conditions has also been elaborated in a few versions.
The IPC flow path for the version in which the In the first version, this is a three-cylinder turbine with
upper district heating extraction is taken from the flow the upper district heating extraction taken, as is usually
path and the lower one from the exhaust hood is done, from the IPC, and with its lower extraction
shown in Fig. 6. This version allows the LPC to be dis- taken from the LPC. The LPC can be made, depending
connected during operation in the cogeneration on the particular conditions, either as a double-flow
mode, which can be implemented with the cylinders one with five stages in each flow (with the 830-mm-
arranged in a nonconventional manner. The LPC in long last-stage rotor blades) or as a single-flow one
this turbine is connected using a disengaged coupling with four stages (with the 960-mm-long last-stage
or a coupling with high-precision conical bolts. rotor blades).
The extraction taken from the IPC for moving the Versions of a two-cylinder turbine with its interme-
feedwater pump turbine has hardly any effect on the diate- and low-pressure sections combined in one cyl-

THERMAL ENGINEERING Vol. 64 No. 11 2017

792 MIKHAILOV et al.

Fig. 7. Longitudinal section through the T-200/250-12.8 turbine.

inder and with the 1000- or 1200-mm-long last-stage CONCLUSIONS

blades have also been elaborated (see Fig. 7). Although (1) The following solutions are proposed for tur-
being slightly inferior to the three-cylinder version in bines designed for ultrasupercritical steam conditions:
efficiency, they give an essential gain in the cost of the
turbine itself and of the turbine building’s civil engi- (i) fitting the high-temperature parts of the HPC
neering part, due to which these versions may turn out and IPC rotors with forced cooling that does not
degrade the cylinder efficiency and allows well-known
to be more preferred by their technical-and-economic Grade 25Kh1M1FА steel to be used for manufactur-
indicators. ing the rotors;
The matter of selecting the last-stage blade length (ii) using an HPC with a rigid rotor and having no
in elaborating the detailed design deserves a separate heat extractions from the flow path, which is feasible
analysis. On the one hand, the requirement for making in case of using an increased split pressure;
the plant with the highest possible efficiency entails (iii) fitting the HPC and at least the first cooled
the need to make the blades as long as possible. On the IPC stages with 3D reaction-type blades; and
other hand, if the turbine operates in a cogeneration (iv) using the LPC with a movable inner casing rig-
mode, the last-stage blades should preferably have a idly connected with the IPC casing, which makes it
small height to decrease losses resulting from the flow possible to keep the axial gaps in both flows.
separation phenomena in the root zone and from the (2) The following solutions are proposed for
peripheral torus-shaped vortex as well as windage cogeneration turbines:
losses. The latter, apart from affecting the overall effi-
ciency, entail excessive heating of the blades and cas- (i) shifting the upper district heating (or its essential
ing, which results in greatly intensified erosion wear of part) to the feedwater pump turbine, which will help
blades due to loss of a large number of stellite plates. In improve the turbine plant efficiency;
our opinion, this problem should be settled in each (ii) placing both district heating extractions in the
particular case with due regard to specific conditions IPC, a solution which, in case of using a disengaged
(the number of turbines installed at the combined heat coupling or high-precision conical bolts in the cou-
and power plant and in the power system, the attain- pling, will make it possible to disconnect the LPC
able vacuum, etc.) and the turbine operation schedule when the turbine is switched to operate in the cogene-
in the condensing and cogeneration modes. ration mode, thus helping improve the turbine effi-
ciency and enhance the LPC reliability.
It should be pointed out in conclusion that such (3) Efforts should be taken to speed up the develop-
important matters as selection of the optimal vacuum ment and application of modern methods aimed at
value, the turbine thermal expansion system, type of achieving more efficient and reliable operation of tur-
seals, etc. are not considered in the article, because bines, including the use of relatively short 3D blades,
different companies settle them in some way or last stages fitted with longer blades, evaporation-based
another, and because their designs do not have a direct moisture removal techniques in the last-stage dia-
effect on the main features of the proposed versions phragm, and LPC rotor blades having radial grooves
described in the article. on their leading edges.

THERMAL ENGINEERING Vol. 64 No. 11 2017

 CONCEPT OF TURBINES FOR ULTRASUPERCRITICAL 793

ACKNOWLEDGMENTS 8. RTM 108.020.33-86. Labyrinth Packings of Stationary

Steam and Gas Turbines and Compressors. Design and
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nos. 2013-16-14-516-0073-025 and 2014-14-576-0123. 9. K. Segavo and E. Ulikano, “An Improvement of perfor-
mance in steam turbine by developing three-dimen-
sionally designed blades,” JSME Int. J., Ser. B 41,
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doi 10.1134/S004060151510002X Translated by V. Filatov

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