geothermal power plant excellence

© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Mitsubishi Geothermal Power Plant

December, 2012

© 2012 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2

CONTENTS

1. Supply Record

2. What we can do for you

3. Technologies for higher performance and reliabilities

5. Collaboration with PEI


1. Supply Record

4

Iceland 15-Units 565 MW

Greece 1-Unit 2 MW

Turkey 2-Unit

94.8 MW

Kenya 6-Units

149.8 MW

Indonesia 6-Units

386.3 MW

Phillipine 19-Units

702.7 MW

New Zealand 3-Units 113 MW

Costa Rica 2-Units 32 MW

El Salvador 3-Units

61.1 MW

Mexico 12-Units 210 MW

USA 18-Units 511.5 MW Japan

14-Units 272.3 MW

Portugal 1-Unit 3 MW

Total Output 3,103 MW Total Unit 102 Units Coped with Different Steam & Brine in 13 Countries

Supply Record of Mitsubishi Geothermal Power Plant


As of 2012 December


Projects in Indonesia ( KAMOJANG #1, 2 & 3)

Specification #1 Unit

OD: 1983 #2 & 3 Unit OD: 1987

Type 5 stage×2,

Condensing, Down Exhaust

5 stage×2, Condensing,

Down Exhaust Last Stage Blade

17 inch 23 inch

Output 30,000 kW 55,000 kW

Speed 3,000 rpm 3,000 rpm

Pressure 0.65 MPa 0.65 MPa

Temp. 162 ˚C 162 ˚C

Flow Rate 240 t/h 380 t/h Exhaust Pressure

0.013 MPa 0.01 MPa


Projects in Indonesia ( DARAJAT #1)

Specification OD: 1994

Type 6 Stages x 2, Condensing, Down

Exhaust Last Stage Blade 23 inch

Output 55,000 kW

Speed 3,000 rpm

Pressure 0.95 MPa

Temperature 180 ℃

Flow Rate 340 t/h Exhaust Pressure

0.01 MPa


Projects in Indonesia ( DARAJAT #2, 3)

Specification OD: 2000 (#2), 2007 (#3)

Type 8 Stages x 2, Condensing, Down Exhaust

Last Stage Blade 30 inch ISB

Output 81,300 kW (#2) 110,000 kW (#3)

Speed 3,000 rpm

Pressure 1.35 MPa (#2) 1.45 MPa (#3)

Temperature 193 ℃ (#2) 199 ℃ (#3)

Flow Rate 450 t/h (#2) 630 t/h (#3)

Exhaust Pressure

0.006 MPa (#2) 0.008 MPa (#3)


Share in the World

Share in total (MW basis)

MHI24.6%

T23.6%

F20.1%

A10.7%

O10.3%

5.1%

Others

5.6%G

Ref. Proceedings World Geothermal Congress 2010 Geothermal Power Generation in the World 2005-2010 Update Report


Wide Output Range from 100kW to 151MW

UNITS

APPR

ICAT

ION

RAN

GE

(MW

)

SC1F

SC2F

TC4F

59

81414

181212

41111

0 5 10 15 20

～1

～10

～30

～50

～70

～90

～160

Approx. 60MW

Approx. 120MW


Number of Casing (Exhaust Flow)

2

31

67

0 20 40 60 80

UNITS

TC4F

SC2F

SC1F

ST TYPE


Turbine Exhaust Direction

Condenser

Turbine

Condenser

Condenser Turbine

50

37

13

0 20 40 60

UNITS

UPPER

LOWER

AXIAL

ST EXHAUST DIRECTION

Turbine


Plant Cycle

Aux. Steam

Turbine

Cooling Water

Cooling Tower

Non - condensable Gas

Hot Well Pump

Gas Extractor （ Ejector ）

Steam

Separator

Production Well

Reinject ion We ll

Condenser

Single Flash Cycle

Turbine

Cool ing Water

Cooling Tower

Non - condensable Gas

Hot Well Pump

Gas Extractor （ Ejector ）

HP Steam

Separator

Production Well

Condenser

Reinjection Wel l

LP Steam

Double Flash Cycle

Separator Evaporator

Production Well

Binary Turbine

Generator

R ecuperator

Cooling Tower CWP

Work Fluid Pump

Reinjection Wel l

Preheater

Condenser

Binary Cycle

2

16

75

7

0 20 40 60 80

UNITS

Binary

Double Flash

Single Flash

Dry Steam

PLANT CYCLE


RECENT PROJECTS


ICELAND HELLISHEIDI #1～#6



FL 3300

FL 1925

FL 0

TURBINE GENERATOR

Specification #1 ~ 4(COD2006,2008) #5, 6(COD 2010)

Type 6 stage x 1, Condensing, Axial Exhaust

←

Last Stage Blade 30 inch ISB ← Output 40,000 kW ×4 units 45,000 kW ×2 units Speed 3,000 rpm ← Pressure 0.75 MPa ← Temperature 168 ˚C ← Exhaust Pressure 0.01 MPa ←

CONDENSER



TURBINE SECTIONAL DRAWING



Low Turbine House (Crane Level)

CRANE



Complete Turbine Module fully assembled before Shipping


KENYA OLKARIA Ⅱ #1~#3

Specification OD: #1,2 2003, #3 2010

Type 6Stages x 1, Condensing,

Down Exhaust

Last Stage Blade 30 inch

Output 34,830 kW

Speed 3,000 rpm

Pressure 0.5 MPa

Temperature 150 ℃

Flow Rate 389 t/h

Exhaust Pressure 0.007 MPa


TURKEY GERMENCIK


Type 6 Stages x 2, Condensing, Top Exhaust

Last Stage Blade 24 inch ISB

Output 47,400 kW

Speed 3,000 rpm

Pressure 0.588 MPa

Temperature 158 ℃

Exhaust Pressure

0.02 MPa

Feature

◆High Gas Content: 12.4% in HP steam ◆High Availability: 99.9% in first year


ICELAND NESJAVELLIR #1~ #4

Specification OD: 1998 (Unit#1,2), 2001 (Unit#3), 2005 (Unit#4)

Type 8 Stages x 1, Condensing, Top Exhaust

Last Stage Blade

24 inch

Output 30,000 kW (Rated),

Speed 3,000 rpm

Pressure 1.2 MPa

Temperature 188 ℃

Flow Rate 206.1 t/h

Exhaust Pressure

0.02MPa


JAPAN SUMIKAWA

Feature

◆Applied Top Exhaust Design to Double Flow

Turbine

◆Water Cooled Nozzle


Type 5Stages x 2,

Condensing, Top Exhaust

Last Stage Blade 23 inch Output 50,000 kW Speed 3,000 rpm Pressure 0.49 MPa Temperature 151 ℃ Flow Rate 389 t/h Exhaust Pressure 0.011 MPa


2. What we can do for you


Unit Output

・If you provide - Production Well Characteristic

- Atmospheric Conditions (Pressure and Wet Bulb Temperature)

・MHI propose ECONOMICAL Plant with - Optimum Cycle

- Optimum Design Conditions Main Steam Pressure Condenser Pressure Wet Bulb Temperature - Plant Output based on above conditions - Optimum Turbine Type with minimum exhaust loss


Single Flash Cycle

Aux. Steam

Turbine

Cooling Water

Cooling Tower

Non-condensable Gas

Hot Well Pump

Gas Ejector

Steam

Separator

Production Well

Reinjection Welｌ

Condenser

Vacuum Pump


Double Flash Cycle

Turbine

Cooling Water

Cooling Tower Hot Well Pump

HP Steam

Separator

Production Well

Condenser

Reinjection Welｌ

LP Steam

Non-condensable Gas

Vacuum Pump Gas Ejector


10.0

15.0

20.0

25.0

30.0

150 200 250 300

Advantage Double Flash

Bottom Hole Temp. (℃)

ΔkW

(%)

＊Calculated Conditions Brine flow rate of production well : Constant Turbine exhaust pressure : 0.1 bara HP main steam pressure : Optimized Pressure LP main steam pressure : Constant (1.2 bara)


Main Steam Pressure

0

100

200

300

400

500

600

0 5 10 15Main Steam Pressure (bara.)

Stea

m F

low

(ton

/h)

40

50

60

70

80


Gen

erat

or O

utpu

t (M

W)

Conditions : ・Turbine Exhaust Press. = 0.1 bara ・Inlet Steam : Saturated

Steam Flow

Heat Drop in

Turbine

MW ∝ X


Main Steam Pressure

5

10

15

20


Wet

ness

of T

urbi

ne E

xhau

st (%

) Exhaust Press. = 0.05 bara

0.10 bara

0.15 bara


Condenser Pressure

Condenser Pressure(bara.)

Out

put (

MW

) ⇒ ($

)

Gross Output (A)

Net Output (C)= (A) - (B)

Parasitic Load (B)


Con

stru

ctio

n C

ost (

$) Construction Cost(D)


(C) -

(D)

($)

Opt

imum

Pres

sure


Design Wet Bulb Temperature

Case-1 Case-2

Design Wet Bulb Temp. Low High

Generator Output Low High

Cost for Cooling Water System

Low High

Design Wet Bulb Temp.

Case-1

Case-2

Case-1

Case-2

90

100

110

Gen

erat

or O

utpu

t (%

)

(month)

0

10

20

30

0 2 4 6 8 10 12

Wet

Bul

b Te

mp.

(℃)


3. Technologies for higher performance and reliabilities

40

Last Stage Stationary： Drain Groove/Hallow Blade

Last Stage Rotating Blade：Stelight Shield

Rotor Material：Low Sulfiur CrMoV Alloy Rotating Blade

Material：12Cr, 17-4PH

Nozzle Material：12Cr,18Cr-8Ni

High Stress Part in Rotor： Shot Peening

Rotor Disc： Low stress by Tapered Shape

Standard Feature for Geothermal Steam Turbine

Rotating Blade： Integral Shroud Blade

Drain Chatcher

41

Casing（Carbon Steel）： Diaphragm Fitting Part : Stainless Welding

Rotor Material：12Cr Alloy

Rotor Gland：Inconel Coating （for Low Sulfur CrMoV Alloy）

Rotating Blade：Titanium Alloy

Diaphragm（Carbon Steel）Horizontal Surface and Fitting Part : Stainless Welding

Optional Feature for Dirty Steam


Con

vent

iona

l 3-D Design Blade

3-D

Des

ign

Efficiency Improvement due to 3-D Nozzle

Conventional

F3-D Nozzle

Velocity Ratio 0.2 0.3 0.4 0.5 0.6 0.7 0.8

1.15

1.10

1.05

1.00

0.95

0.90

0.85 Inte

rnal

Effi

cien

cy R

atio


Erosion Protection

Stellite Strip

Stellite Strip on Moving Blade

Hollow Nozzle

Drain Hole

Drain Hole

To Turbine Exhaust

Drain Ditch on Stationary Blade

Ditch

Ditch Drain


Measures Against Scaling (at 1st Stage Nozzle)

: Clogged Condition

How to Supervise

Scaling

G: Flow Rate P: Pressure at Nozzle Inlet

A: Nozzle Flow Area

A

: Clean Condition

: Clogged

G ∝ P x A ∝

(P/G)0

1 A

Measures

Verification in Actual Turbine

Conventional Nozzle

Water Cooled Nozzle

After 9 Months Operation

Water Cooled Nozzle

To Water Cooler

Steam

Cooling Water

Cooling Water Hole

Nozzle

Width Convex

Concave

Steam (Inlet)

Steam (Outlet)

Flow Area

Steam Temp.

Nozzle Metal Temp.

Conventional Nozzle

Water Cooled Nozzle

Re- Evaporation

No Re-Evaporation

Temperature Distribution

0

１目２目３目

1％の水噴射 2％の水噴射

Scrubber & Blade Washing

Scrubber

Geothermal Steam Clean Steam To Turbine

Separator

Injection Pump

Clean Water ( 10 % of Steam) ～～

Drain with Impurity

Clean Water ( 2 % of Steam) ～～

To Turbine

Geothermal Steam

Blade Washing

0 24 48 72 (Hour)

10

5

1 % Water Inject 2 % Water Inject

Test Results in Actual Turbine

(P/G

) 0

(P/G

) 0

(P/G

) -

Narrower Flow Area

Less Output


PEEK LINING BEARING

0

20

40

60

80

100

120

従来軸受（ホワイトメタル）次世代PEEK樹脂軸受

軸受損失比　　%

62%減

PEEK : PolyEtherEtherKetone

Journal Bearing

Thrust Bearing

Higher allowable contact pressure - Downsizing - Lower mechanical loss

PEEK Conventional (White metal)

62% Reduction

0

20

40

60

80

100

Bea

ring

Loss

[%]


Rotor Gland Protection

Welding overlay and thermal spraying for rotor gland area were developed to protect a rotor from erosion-corrosion.

Inconel 625 (thermal spray)

Base metal

Thermal spray by Inconel 625

Damaged part

Damage on rotor gland

Air + Geothermal Steam

Erosion/Corrosion

Problem at Rotor Gland Area Countermeasure

Inconel 625 (Welding overlay or Thermal spray)


Material Selection for Geothermal Turbine

*: Tested in Actual Geothermal Steam

_

Susceptibility against SCC*

0.0015 0.023 mm/Year Corrosion Rate* ＜ 40 ＜ 80 ℃ 50 % FATT

＞ 30 ＞ 20 J Absorbed Impact Energy at 25 ℃

＞ 45 ＞ 40 % Deduction in Area

＞ 16 ＞ 15 % Elongation

＞ 740 ＞ 740 MPa Tensile Strength

＞ 635 ＞ 635 MPa 0.2 % Yield Stress

10325GSR1 10325MGB Unit Property

at σ0.2 x 3.3 at σ0.2 x 3.3

Moving Blade 1. Materials

12Cr (10705BA) ◆ For Intermediate Stages 17-4PH (10705BX, 10725BX, 10725DW) ◆ For 1st Stage and Last 2 ～ 3 Stages ◆ Tensile Strength, Corrosion Fatigue Strength: Higher ◆ Corrosion Rate: Lower Titanium Alloy (Ti-6A-4V) ◆ For 1st Stage in Very Corrosive Geothermal Steam ◆ Tensile Strength, Corrosion Fatigue Strength: Highest ◆ Corrosion Rate: Lowest

Ti-6A-4V

17-4PH

12Cr

Corrosion Fatigue Strength (in Geothermal Steam)

50 40 30 20

105 106 107 108

Failu

re S

tres

s (k

g/m

m2 )

Ti-6A-4V SUS 304

SUS 316

17-4PH

SS400

SB410

12CrMo

8

6 4 2

Corrosion Rate in Geothermal Steam

Material

Cor

rosi

on R

ate

(mg/

cm2 /3

Mon

ths)

Rotor 1. Materials

Low Sulfur CrMoV (10325MGB) ◆ Standard Material ◆ Low Susceptibility against SCC 12Cr (10325GSR) ◆ For Very Corrosive Geothermal Steam ◆ Low Susceptibility against SCC ◆ Low Corrosive Rate ◆ High Toughness 2. Mechanical Properties


Exhaust Direction

Exhaust Direction Bottom Top Axial TG Pedestal Tall Middle Low Turbine House (Crane Hook Height)

Tall (FL 16.4m)

Middle (FL 13.5m)

Low (FL 10m)

Pressure Loss in Exhaust ~ Zero High Recover No. of Exhaust Flow Any Any Only 1 Flow

Condenser

Turbine

Condenser Turbine

Condenser Turbine


Condenser (Direct Contact, Shell & Tube)

Direct Contact Condenser Shell & Tube Condenser

Cooling Tower

Condenser

Hotwell Pump

Cooling Tower

Condenser

Circ. Water Pump

・No Level difference between Cooling Tower and Condenser is required. ・Additional small condensate pump is required. ・NCG temperature is higher

Level difference between Cooling Tower and Condenser is required.


Condenser (Direct Contact vs. Shell & Tube)

Direct Contact Shell & Tube

Condenser at lower level than turbine.

Condenser at the same level as turbine.



Shell & Tube Condenser


Advanced Direct Contact Condenser (ADCC)



Fill Material


CONTROL SYSTEMS DEPARTMENT


Installation Records of DIASYS ( for Power Plant )


Installation Records of DIASYS ( for Geothermal Plant )

Nation Plant Name / Location Unit Capacity

ICELAND KRAFLA 2U 30MW

ICELAND NESJAVELLIR 3U,4U,COMMON 30MW

ICELAND HELLISHEIDI 3U,4U 40MW

ICELAND HENGILL 5U 45MW

MEXICO CERRO PRIETO 1U,2U,3U,4U 25MW

EL SALVADOR AHUACHAPAN 1U,3U 30MW

KENYA OLKARIA II 1U,2U,3U 35.1MW

INDONESIA DARAJAT 3U 110MW

JAPAN TAKIGAMI 1U 25MW

JAPAN OHNUMA 1U 12.5MW

JAPAN YAMAGAWA 1U 30MW

JAPAN OGIRI 1U 30MW


High Speed , Critical and Scalability

For Total DCS Use -Combined Cycle / Conventional Power / Coal Gasification -Plant Coordination Control / Automatic Start & Shutdown Control, Training Simulator

For Critical Control Use -Steam/Gas Turbine Speed Control & Interlock System -Gas Engine / Turbine for Shipment -Super Critical Boiler

For Utility Control Use -Desulfurizing Plant -Coal Handling -Water Treatment

Applied to Wide Range of Power Plant

geothermal power plant excellence

Documents