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Wet-Steam Turbines for Nuclear Power Plants
Alexander S. Leyzerovich
Copyright © 2005 PennWell Corporation 1421 South Sheridan Road Tulsa, Oklahoma 74112 1-800-752-9764 sales@pennwell.com www.pennwell.com www.pennwell-store.com
Managing Editor: Stephen Hill Cover Designer:
Book Designer: Clark Bell
Library of Congress Cataloging-in-Publication Data Leyzerovich,A. Sh. (Aleksandr Shaulovich)
Wet-steam turbines for nuclear power plants / by Alexander S. Leyzerovich.--1st American ed.
p. cm.
Includes bibliographical references and index. ISBN 1-59370-032-6
1.Boiling water reactors--Equipment and supplies.
2.Steam-turbines. I.Title.
TK9203.B6L45 2005 621.48’3--dc22
2005009821
All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or transcribed in any form or by any means, electronic or mechanical including photocopying or recording, without the prior permission of the publisher.
Printed in the United States of America
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Preface xxxv
Chinese, 1985) and Technological Fundamentals of Power Steam Turbine Start-Up Automation (1985), as well as in many papers published in various power engineering periodicals, in both Russian and English.
I would like to express my deep gratitude to E. R. Plotkin, N. S. Tchernetsky, V. B. Kirillov, A. D. Melamed, N. A. Rusanova, E. N. Sergiyevskaya, V. A. Panfilov, N. I. Davydov, B. N. Lyudomirsky, and others of my collaborators at VTI, as well as many of my colleagues from the turbine manufacturers and nuclear power plants with whom I was working in close contact during those years. I would also like to thank all of the colleagues from various countries who have helped me in gathering materials for this book.
Dr. Alexander S. Leyzerovich
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Contents |
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List of Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . xi |
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List of Tables |
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xxvii |
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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xxix |
1. The Nuclear Power Industry |
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at the Turn of the 21st Century . . . . . . . . . . |
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. . 1 |
The Early History of Nuclear Wet-Steam Turbines . |
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. . 1 |
Operating Performances in the Nuclear Power Industry |
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Main Types of Reactors Used for Power Production |
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. 18 |
The Nearest Prospects for Wet-Steam Turbine-Based |
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Nuclear Power Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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. 31 |
Bibliography |
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2. The Thermal Process in |
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Wet-Steam Turbines |
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39 |
Initial, Partition, and End Steam Conditions . . . . . . . |
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. 39 |
Features of Wet-Steam Flow in the Turbine Steam Path . . . . . . |
. 53 |
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Wet-steam flow in turbine blade rows |
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The influence of wetness on wet-steam turbine efficiency |
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Experimental research of wet-steam flow in turbines . . . |
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. 74 |
References |
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93 |
Bibliography |
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97 |
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viii Wet-Steam Turbines for Nuclear Power Plants
3. Design |
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General Design Features of Wet-Steam Turbines |
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Influence of single capacity and rotation speed on turbine design . . . |
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Blading, gland seals, and protection against erosion-corrosion wear |
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Steam admission elements |
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1 48 |
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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1 57 |
Last Stage Blades |
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1 61 |
Length of the last stage blades |
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1 61 |
Roots, shrouds, and snubbers . . . . . . . . . . . . . |
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1 70 |
Aerodynamics of LSBs |
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1 80 |
Last stage blade protection against WDE |
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1 90 |
Water Removal from Turbines . . . . . . . . . . |
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1 94 |
Peripheral moisture separation and removal between |
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the stage rows |
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Intrachannel moisture separation |
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1 99 |
Moisture separating stages, or stage-separators . . . . . . . . . . . . . . . |
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External moisture separators and reheaters |
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References |
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2 17 |
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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Operating Conditions of Wet-Steam Turbines |
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Efficiency of Wet-Steam Turbines and Heat-Rate |
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Performance Tests |
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Some Generic Damages of Wet-Steam Turbines |
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and Their Causes . . . . . . . . . . . . . . . . . . . . . . . |
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Stress-corrosion and corrosion-fatigue cracking |
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Erosion-corrosion of turbine casings . . . . . . . |
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Damages to blading . . . . . . . . . . . . . . . . . . . . . . |
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Contents |
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Protection and Preservation of Steam/Water Paths |
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Using Microadditives of Amines-Based Surfactant . . . . . . . . . . |
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Experimental Research and Calculation of Transients |
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for Wet-Steam Turbines . . . . . . . . . . . . . . . . . . . . |
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Start-up tests of wet-steam turbines . . . . . . . . . . |
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Calculation of temperature fields for main turbine design elements |
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Calculated optimization of start-up diagrams |
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Information Support for Operators and Automated Control |
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During Turbine Transients |
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References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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Bibliography |
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5. Refurbishment |
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Retrofitting Versus Repairing |
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Retrofitting LP Cylinders . . . . . . . . . . . . . . . . . . . . |
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Replacing disk-type rotors with welded ones |
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(experience of ALSTOM) . . . . . . . . . . . . . . . . . . . . . . . |
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Replacing LP disk-type rotors with solid ones |
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(experience of Westinghouse) . . . . . . . . . . . . . . . . . |
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Retrofitting LP cylinders with disk-type rotors |
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(experience of Siemens) |
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Complete Upgrading of Turbines |
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Including Both HP and LP Cylinders . . . . . . . . . |
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4 15 |
Upgrade Experience of Siemens |
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4 15 |
Upgrade Experience of Mitsubishi Heavy Industries . . . . . . . . . . . . . |
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Upgrade Experience of ALSTOM at SONGS . . . . . . . |
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References |
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Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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xWet-Steam Turbines for Nuclear Power Plants
Appendix. List of Abbreviations and Symbols |
435 |
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Abbreviations of Institutions in the Power Industry . . . . . . . . . |
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Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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Symbols |
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Subscripts and Superscripts . . . . . . . . . . |
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Criteria of Similarity. . . . . . . . . . . . . . . . . . |
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Conversion Table for Main Units Used |
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Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
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1
The Nuclear Power
Industry at the Turn of
the 21st Century
The Early History of Nuclear
Wet-Steam Turbines
The first kilowatt-hours of electricity from nuclear energy were produced on December 20, 1951, in the United States by a steam turbine generator fed with steam from Experimental Breeder Reac- tor-I (EBR-I). The turbine had a rated output of 200 kW and initial steam conditions of 2.8 MPa and 220ºC (405 psi, 429ºF). In 1953, tests began at the shore-based prototype of a steam-turbine unit for the first nuclear-powered U.S. submarine, the Nautilus, and in 1954, the Soviet Union launched the first experimental nuclear power installation, with a rated output of 5 MW.The first commercial power generating unit with a nuclear reactor as a steam supply source was placed in service in 1957 at Shippingport.1 The Westinghouse turbine of this unit was designed for a rotation speed of 1,800 rpm and a maximum capability rating of 100 MW. It was fed with saturated dry steam, with the inlet steam pressure varying from 3.8 MPa (545 psi) at the maximum load to 5.9 MPa (850 psi) when the reactor was at idle.As shown in Figure 1–1, the turbine was a single-cylinder, singleexhaust machine with 40-inch last stage blades.
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2Wet-Steam Turbines for Nuclear Power Plants
Fig. 1–1. Westinghouse nuclear wet-steam turbine (100-MW, 1,800 rpm) used at Shippingport Station, 1957
Source: J.A. Carlson2
It was the first relatively large wet-steam turbine developed for nuclear power plants. It worked with the steam expansion process occurring primarily in the moisture region.The major problem in this case is the increase of the moisture content as the steam expands. Excessive moisture primarily contributes to turbine blade erosion and blade efficiency losses. If steam at a dry and saturated condition expanded directly to the steam pressure in the condenser, the moisture content at the turbine exhaust could reach 20–25%, depending on the inlet pressure and vacuum conditions.
The first nuclear wet-steam turbines were developed from a base of design and operation experience accumulated with fossil fuel non-reheat steam turbines dating back to the 1920s and 1930s. In particular, of significance was the experience gained from bottoming turbines operated on the exhaust steam of piston engines or technology processes. However, because of essentially low initial steam pressure, the final moisture content for all of those turbines was not so great, and the rather low temperatures mitigated the intensity of the corrosion and erosion processes. In addition, all of those old turbines were inadequate in terms of capacity for turbines to be used in nuclear
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