GE Power Systems Oil & Gas

www.gepower.com

CONTENTS
Introduction Design Philosophy Steam Turbine Series 1 2 3

Steam Turbines by Nuovo Pignone - Product/Model Description - Components - Seals - Lube Oil and Control System 4 8 10 11

Steam Turbines by Thermodyn - Product/Model Description - Components - Seals - Lube Oil and Control System 12 14 15 16

Test Facilities Quality Program Research & Development Global Services Training Some Installations

18 20 21 22 23 24

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

GE Oil & Gas

Steam

Turbines

Nuovo Pignone - Thermodyn

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

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

Design Philosophy
GE Oil & Gas product lines are based on modular product structures that assure a reliable design and outstanding turbine performance through standardization. This structure enables optimization of a turbine configuration for a customers specific operating conditions. By selecting and integrating pre-engineered and fieldproven components from an array of alternate offerings and designing a custom steam path, the unique requirements of the application are satisfied. Component modules making up the building-blocks of the product line include front bearing standards, inlet sections, valve gear and extraction and exhaust sections. The barrel section of the turbine is custom designed for each unit, based on the users specific operating conditions. By using this flexible modular structure, performance and reliability are maximized, while product cost and the delivery cycle are kept to minimum. Research & Development efforts associated with this product line focus on the development of advanced components modules, for improved performance, maintainability and life. GE Oil & Gas steam turbines are manufactured in Florence, Italy by Nuovo Pignone and in Le Creusot, France by Thermodyn. Nuovo Pignone steam turbine main features: - basic design with impulse control stage(s) followed by reaction stages with high steam expansion efficiency - solid rotors - blade carriers which together with the outer casing form a double shell design and allow a thinner outer casing and consequently lower thermal inertia and shorter start-up time - inlet and control valves designed to reduce pressure losses - tilting pad journal and thrust bearings The design meets API 612 recommendations. Thermodyn steam turbine main features: - impulse stages providing enhanced wear resistance and ability to withstand water inflows, twisted blade profiles to improve last stage efficiencies - solid rotor - inlet and control valves designed to reduce pressure losses - tilting pad journal and thrust bearings - spring-back labyrinth seals The design meets API 611 or 612 recommendations.

Front section

Intermediate section

Rear section

Modular steam turbine structure

Steam Turbine Series

Manufactured by Nuovo Pignone NG backpressure up to 20bar, multi-valve, live steam up to 70bar/540C HNG backpressure up to 20bar, multi-valve, live steam up to 140bar/540C HG backpressure up to 60bar, multi-valve, live steam up to 140bar/540C NK condensing, multi-valve, live steam up to 70bar/540C HNK condensing, multi-valve, live steam up to 140bar/540C

Axial exhaust steam turbine assembly

Manufactured by Thermodyn P backpressure, single valve, live steam up to 80bar/480C MP backpressure, multi-valve, live steam up to 150bar/540C C condensing, single valve, live steam up to 80bar/480C MC condensing, multi-valve, live steam up to 150bar/540C

Energie France Sollac Cogeneration high speed balancing chamber

Impulse+Reaction Steam Turbines by Nuovo Pignone

Product/Model Description
Nuovo Pignone steam turbines utilize a hybrid design combining impulse and reaction stages. The impulse stage, with partial or full arc admission, 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 produces top steam turbine performance over a wide range of steam flow and speed. Main Application map of GE Oil & Gas Nuovo Pignone Steam Turbines. NK and HNK (condensing) LNG Ethylene/Methanol Urea/Ammonia Refinery Synfuels Process air Co-generation Combined cycle Small P. G. Geothermal P. G. High High Medium High High High High High High NG, HNG and HG (backpressure) Medium Medium Low Extraction

High High Low High High Low Low -

Impulse+reaction backpressure type, Nuovo PignoneNG, HNG and HG series Back pressure turbines are used as mechanical or generators drivers. In industrial plant applications they are installed between two steam lines at different pressures. The exhaust steam is generally used for plant requirements. This turbine design is particularly suitable for injecting or extracting steam at intermediate pressure. The best turbine efficiency and the injection/extraction requirements are satisfied by adjustment of the number of blade carriers and the number of stages of each blade carrier.

TURBINE MODEL Power (kW) Speed (RPM) Max. live steam cond. (BAR/C) Max. back pressure (BAR)

NG 1,000 50,000 3,000 16,000 70 / 540 20

HNG 1,000 50,000 3,000 16,000 140 / 540 20

HG 1,000 40,000 3,000 16,000 140 / 540 60

Steam

Turbines

Back pressure turbine cross section

5
Back pressure steam turbine partially assembled

Impulse+Reaction Steam Turbines by Nuovo Pignone

Product/Model Description
Impulse+reaction condensing type, Nuovo PignoneNK and HNK series Condensing turbines are applied as mechanical or generator drivers. Structurally, they are characterized by a large exhaust section which is dictated by the large steam volume flow caused by the low condensing pressure. The last section of two or three stages is completely standardized and its moving blades have twisted airfoils. Various families have been standardized 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 injection and/or extraction, matching the requirements of petrochemical or power generation applications such as co-generation or combined cycles.

TURBINE MODEL Power (kW) Speed (RPM) Max. live steam cond. (BAR/C)

NK 1,000 65,000 3,000 16,000 70 / 540

HNK 5,000 100,000 3,000 12,500 140 / 540

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

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

Steam

Turbines

Condensing turbine casing

bine with low

Condensing turbine cross section

Impulse+Reaction Steam Turbines by Nuovo Pignone

Components
(Casing, Rotor, Blades, Stop and Control Valves)
CASING: The turbine casing is horizontally split. In back pressure turbines each half-casing is made of cast steel in one single piece. For condensing turbines, the outer casing is made of a cast steel high pressure section, bolted with a vertical flange to a cast iron or fabricated steel low pressure section. ROTOR: The shaft consists of a solid forging made of low-alloy steel for low pressure applications or high-alloy steel (13% chromium steel) for high pressure and temperature. The bladed rotor is balanced and overspeed tested before assembly in the turbine. MOVING BLADES: Cylindrical moving blades of reaction stages have T roots, and integral shrouds. Impulse and reaction airfoils have been standardized. Materials have been standardized for the moving blades: 13% chromium steel with molybdenum and vanadium for temperatures over 350C; 13% chromium steel for lower temperatures. The last group of two or three stages in condensing turbines has been completely standardized in families, for low, medium and high speed applications.
Casing of turbine model ENK applied as propylene gas compressor driver Journal and thrust bearing

8
View of a condensing turbine rotor blading

Steam
Emergency stop valve schematic drawing

Turbines

FIXED BLADES: The impulse stage nozzles are inserted (without any welds) into a slot machined in the inner casing and are easily removable even after years of operation. The nozzle material is the same as that for the impulse stage moving blades. The fixed blades of the reaction stage are cantilevered in the blade carriers and are held together by riveted shrouds or inserted in the blade carriers as complete diaphragms; they are made of 13% chromium steel. STOP AND CONTROL VALVES: Nuovo Pignone steam turbines are equipped with emergency stop valves which serve to protect the whole turbounit against overspeed; such valves have a response time in the order of 50 milliseconds and are safe and reliable even after long periods of operation (operator can check that the valve is ready to operate at any time using a testing device). Emergency stop valves are installed on each live steam inlet flange and are mounted directly on the casing to minimize the steam volume that continues to expand through the turbine after valve closure. Steam flow is regulated by four or five control valves admitting steam to the impulse stage nozzles. Control valves are operated by a horizontal bar activated by two valve stems. Generally, the two valves at the end of the bar open at the same time to allow uniform heating of the casing during start-up. The remaining valves open in a sequence designed to optimize the distribution of forces on the rotor produced by the steam in the impulse stage. The shape of the cones is optimized to provide a quasi-linear relationship between the steam flow and valve lift for the best operation of the control system. JOURNAL AND THRUST BEARINGS: Tilting-pad journal bearings are generally used. Double-acting, tilting-pad thrust bearings are installed with a thrust equalizing device. Both journal and thrust bearings can be fitted with thermoelements for temperature detection and monitoring.

Regualting valves sectional drawing

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

Impulse+Reaction Steam Turbines by Nuovo Pignone

Seals
The end seals are of the labyrinth type. The operating philosophy of the end seals of a condensing turbine is shown in the schematic diagram.

Front seals, labyrinth type

Chambers 1, front and rear, are connected to the main condenser and a low pressure steam supply. The automatic valves A and B keep the pressure just a little above atmospheric level, thus minimizing the steam flow of the atmosphere from chambers 2. A steam gland condenser is not required. When applied, it is connected to chambers 2.

vent

Balancing PIiston Leakages

vent

Seal Steam Line

A B
To main condenser

10

End seals schematic diagram

Impulse+Reaction Steam Turbines by Nuovo Pignone

Lube Oil and Control System

The lube and control systems generally have a common reservoir, pumps, filters and coolers. Lube and control oil for mechanical drive applications is supplied from the turbounit oil console. In generator drive applications in combined cycle plants with a gas turbine in a single shaft arrangement the lube and control oil may come from the gas turbine console. In any other generator drive applications an oil console is provided. 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 the turbine baseplate or on a separate skid. The electronic governor may have a different redundancy configuration and may be custom engineered. The turbounit start up sequence may be manual or completely automatic. The turbounit trip device is a redundant electronic type unit. The control oil system for straight backpressure or condensing turbines is basically in accordance with the simplified schematic diagram below. The control oil diagram is basically the same for extraction turbines but with an addition of a second electro-hydraulic converter and a second valve actuator.

Lube and control system schematic diagram

Steam line 8 to 10 BAR oil

EMERGENCY STOP VALVE

1,5 to 4,5 BAR modulated oil pressure

Power piston

CONTROL VALVES

VALVE ACTUATOR
8 to 10 BAR oil

Power oil distributer

Solenoid valve

Modulated oil pressure (1,5 to 4,5 BAR

ELECTRO HYDRAULIC CONVERTER PICK-UP SPEED GEAR

Speed sensors
OVERSPEED LOGIC TACHOMETER

Set signal

ELECTRONIC GOVERNOR

11

Impulse Steam Turbines by Thermodyn

Product/Model Description
Thermodyn steam turbines are impulse turbines of simple design, which, together with retractable seal technology, insures that performance is maintained over a long period of time BACK - PRESSURE TYPE Impulse-type Back-pressure, Thermodyn P series Thermodyn P series steam turbines have a single inlet valve and a back pressure exhaust designed to drive low-power machinery and offer easy servicing. They are commonly used as compressor drives in petrochemical refinery applications and for power generation in these industries or 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 480C API 612
Sucrerie Ile Maurice - Savannah sugar estates

Impulse-type Multivalve Backpressure, Thermodyn MP series The MP series steam turbines have multi-valve inlet and a back pressure exhaust and are designed to drive variable speed machinery compressors, fans, blowers, pumps, as well as generators. Applications are in petrochemical and refinery plants, power plants or combined heat and power plants with fossil fuel, crushed cane in the sugar industry, municipal waste for 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 540C STEAM EXTRACTION or INJECTION API 612

Cnim Thumaide France Domestic waste incinerator

12
Air liquide Otor France - Cogeneration on 1x560

Steam

Turbines

CONDENSING TYPE Impulse-type Condensing, Thermodyn C series The C series steam turbines have a single inlet valve and a condensing exhaust and are designed to drive low-power machinery with easy servicing. They are commonly used as compressor drivers in petrochemical and refinery applications, and for power generation in these industries or heat recovery process such as municipal 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 480C STEAM EXTRACTION or INJECTION API 612

Cogeneration in gas treatment plant France Eap Lacq. Power Generator

Iran Total south pars

Impulse-type Multivalve Condensing, Thermodyn MC series The MC series steam turbines have multivalve inlet and a condensing exhaust and are designed to drive variable speed machinery compressors, fans, blowers, pumps, as well as generators. Applications are in petrochemical and refinery plants, power plants or combined heat and power plants with fossil fuel, crushed cane in the sugar industry, municipal waste for incineration or waste energy in heat recovery plants. The MC turbines can be equipped with a controlled extraction, that is, with a supplementary regulating action, making it possible to jointly optimize the production of heat and mechanical power in accordance with the needs 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 540C STEAM EXTRACTION or INJECTION API 612

13

Impulse Steam Turbines by Thermodyn

Components

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

CASINGS Cast steel casings are made by using patterns built up from standard modules. Exhaust casings for the P and MP turbine series can be cast or welded 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 adaptation to site conditions: axial, upward or downward discharge, sized according to water cooling source with a hydro condenser, air cooling source with air-condenser or with a hydro-condenser associated with a cooling tower.

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

BLADES: Blades are made of stainless steel. They undergo special treatments to improve fatigue strength and erosion resistance. Rotating blades have T or Fir tree roots and are grouped in packets with riveted bands or, only for MC turbine series, welded links.

Rotor groves for steam turbine blade roots

14

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

Turbines

JOURNAL AND THRUST BEARINGS: Journal and thrust bearings are of the tilting pad type which are particularly suitable for multi-valve turbines. They provide stability over a wide range of running speeds and ensure safety at the highest rotational speeds.

STOP AND CONTROL VALVES: The stop-valve is designed to be leak-tight and has an easily removable steam strainer and diffusertype seat ensuring instant closure when tripped. For the P and C turbine series, there is one control valve regulating the steam flow through the turbine. This valve can be of the double seat or single seat type with a diffuser. For the MP and MC turbine series, there are up to eight control valves regulating the steam flow through the turbine and maintaining high efficiencies at low power. To obtain the best possible efficiency, the extraction, if any, is adjusted by means of an extraction grid valve which is adapted to the high-volume flow rates admitted in the low pressure section of the turbine. This element is composed of two grids which move in relation to each other, and which is equivalent to a group of six control valves with low throttling.

Power Plant - Compagnie Thermique du Gol La Reunion

15

Impulse Steam Turbines by Thermodyn

Seals
Spring-back labyrinth seal technology cuts down internal leakage in the turbine and prevents premature deterioration of the steam sealing system.

Domestic waste incinerator - France Emeraude Crete il

Retractable Seals

Domestic waste incinerator - France Astria/C.T.E. Be Control oil system

16

Impulse SteamTurbine by Thermodyn

Lube Oil and Control System

Thermodyns oil units are designed to supply lube oil and high pressure control oil. They are free standing consoles but can be integrated into the base supporting the shaft line for compressor units. These units comply with Thermodyns standards or with API 614 code rules. Electronic speed governors are employed. The advantage of digital electronic governors is that they are versatile enough to adapt smoothly to any required configuration. The parameters are simply set in the computer at start-up or during turbine operation. Thermodyn has developed a standard high pressure oil system using servo-valves to actuate the stop-valve, the inlet control valve and the extraction valve. Performance (stability, dead band, response time) meets NEMA SM22, API 612 or CEI 45 recommendations.

egles

Lube Oil Console

17

Test Facilities
The Florence Test Facilities are equipped with 4 test benches and a complete steam plant, with max. 70 t/h live steam at 50 bar /450C. The Le Creusot Test Department is equipped with 5 test benches supplied by a steam plant capable of generating 28 t/h of vapor at 45bar 450C. Le Creusot is also equipped with a large-size anechoic chamber with suspended low-frequency foundation block for vibration and noise measurements. Mechanical string tests can be conducted on the complete trains both in Florence and in Le Creusot. Full load, full pressure tests may be carried out, within the steam plant capacities.
12 10 8 6

FLORENCE PLANT Indoor test stands fo and steam turbines

12 OVEST

7 NORD 11 9 OVEST

7 SUD

Centrifugal compressor test Steam turbine test location

Steam Turbine test stands

18

Anechoic Chamber

Steam
CONTROL ROOM

Turbines

T or centrifugal compressors

14

LUBE OIL CONSOLE A VACUM SYSTEM LUBE OIL CONSOLE B

CONTROL ROOM

Shop electric motor Shop steam turbine

Condensing turbine driving a centrifugal compressor under load testing

FLORENCE PLANT Stand Utilities

TO INDOOR STANDS FOR GAS TURBINE TESTS 1 - 4 Evaporating Towers

2HM 2BVTN 2BVTN

TO OUTDOOR STANDS 1 - 4 TO OUTDOOR STANDS 5 - 8

TO INDOOR AND OUTDOOR STANDS

GAS STORAGE

Steam generator

Air cooler
OUTDOOR STANDS

MEASURING STATION

a b d
COMPRESSED AIR SYSTEM

NATURAL GAS

Condenser

COGENERATION PLANT

c
Back Pressure

LIQUID GAS

ELECTRIC SYSTEM

INDOOR TEST S TA N D S

FROM INDOOR AND OUTDOOR STANDS

FROM DOMESTIC NETWORK

a,b,c,d Steam System Cooling Water e

19

Quality Program
All production processes, whether in Florence or in Le Creusot, are carried out under the GE Oil & Gas Quality System that integrates the GE Six Sigma Quality Program with ISO 9001 Quality Standards to guarantee satisfaction of customer expectations. The Program insures the long-term stability and sustainability of process improvements guaranteeing the quality of products. 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 has specialized testing and measurement facilities: - Special laboratories accredited by SINAL (National System for Accreditation of Laboratories), equipped for testing to determine mechanical properties, chemical analysis and spectrometer analysis, fatigue tests, macro and micrographic examinations (optical microscope and scanning electron microscope). - A Calibration Center certified as an SIT (Italian Calibration Service) Center to control the reference standards used to calibrate all measuring and testing instruments used in the Company Plants.

Last stage blade experimental modal analysis

Scanning electron microscope analysis of materials

20

Research & Development

GE Oil & Gas believes that product excellence is a moving target that can only be achieved through constant improvement and innovation. This philosophy has driven our commitment to Research & Development as a means of remaining a leader in providing the most advanced products for the Oil & Gas Industry. The combined talents of GE Oil & Gas research engineers along with hundreds of scientists and engineers from GEs Corporate Research & Development Center located in Schenectady, New York and many Universities worldwide form a team dedicated to advancing the state-of-the-art of turbomachinery. This team is constantly working to exploit the latest developments in advanced materials and leading edge engineering design to produce machinery with higher performance and longer life for the Oil & Gas Industry. Our tools for insuring the integration of advanced technology into reliable, long-life machines include: - Computer-aided design tools such as CFD (Computational Fluid Dynamics) and 3D Auto CAD modeling for the design of high efficiency compressors, expansion stages and low emission combustion systems - Advanced test facilities for both components under development and full scale machines - The proven, quality-centered development processes that have been the mainstay of product development throughout all of the GE family of businesses GE Oil & Gas is dedicated to providing the worlds best solutions for the Oil & Gas Industry.

High pressure black Modal Analysis with shroud vibration

Low pressure black Finite Element Modelling

21

Global Services
GE Oil & Gas Global Services provides a complete set of services to support the entire steam turbines product line. Global Services offers an extensive portfolio of proactive and interactive service products such as condition-based maintenance and long term service agreements. This complements the traditional service product offerings of OEM spare parts, repairs, and field services. Ready access to Nuovo Pignone and Thermodyn product engineering organization and their advanced technology, design experience and manufacturing capabilities ensures GE Oil & Gas Global Services customers the highest quality engineering know-how, spare parts, repair and field services. GE Oil & Gas innovations have not been limited to mechanical engineering. Business solutions have been developed, such as long term service agreements that include remote monitoring & diagnostics to help drive customer value by providing higher equipment reliability, availability and productivity at a predictable cost. Other advanced information-based developments include electronic parts catalogs, and e-commerce solutions to improve customer productivity. GE OIL & GAS MEANS HIGH-TECH SERVICE SOLUTIONS Global Services engineers are backed up by the new product design engineering groups of GE Oil & Gas and by GE Corporate Research & Development. Thousands of creative minds working to provide the high-tech prodst ucts and business solutions for the 21 century.

22

Training
GE Oil & Gas offers Training for the Operation and Maintenance of our complete line of machinery and equipment. This Training can be provided either at the clients site or at the Florence Learning Center located at GE Oil & Gas headquarters in Florence Italy. GE Oil & Gas Nuovo Pignone and Thermodyn have over 20 years of experience in training clients. - Unique opportunity GE Oil & Gas instructors are field-seasoned experts who combine their under standing of theory with practical experience. The quality training that they provide is a prerequisite for improving the skills of operating and maintenance personnel to assure safety and superior equipment efficiency and availability. - Close to the customer Courses and documentation are designed to meet the customers needs focusing on GE Oil & Gas machinery actually installed at their sites. Courses cover the entire product range: gas and steam turbines, centrifugal and reciprocating compressors, control panels, and complete power and compressor plants. Self-paced training and pre-packaged courses are available on standard GE Oil & Gas machinery configurations. - Effectiveness & efficiency Traditional training tools are augmented by computer-based training and interactive multimedia technology. Courses and technical literature can be provided in a variety of languages.

23

Some Installations

Nuovo Pignone
Generator driver in combined cycle in a paper plant, Lucca (Italy)

Recycle compressor driver at Warry refinery (Nigeria)

Pipeline compressor driver installed in Messina Italy

Steam turbine driving an ammonia syntesis compressor train

24

Generator driver in solid refuse burning plant - Bologna (Italy)

Thermodyn

Steam

Turbines

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

Steam Cracking Turbocompressor Exxon N.D. de Gravenchon - France

Power plants - La reunion Compagnie Thermique Gol.

SNLE - NG Le Triomphant submarine for French navy

Nuovo Pignone S.p.A. Via Felice Matteucci, 2 50127 Florence - Italy Tel. +39-055-423211 Fax +39-055-4232800 e-mail: info.geoil&gas@np.ge.com www.gepower.com

Thermodyn Site Industriel - B. P. 119 71203 Le Creusot Cedex, FRANCE Tel. +33-3-85806810 Fax +33-3-85806811

MARK/COMK 777/II - Studio Tre Fasi - 6-2001

GE Power Systems Oil & Gas