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VOITH SIEMENS HYDRO Generator Presentation to CIGRE SC A1 – Paris 2008 Thomas Hildinger Germany Phone: +49 7321 37 2500 e-mail: thomas.hildinger@vs-hydro.com.

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Presentation on theme: "VOITH SIEMENS HYDRO Generator Presentation to CIGRE SC A1 – Paris 2008 Thomas Hildinger Germany Phone: +49 7321 37 2500 e-mail: thomas.hildinger@vs-hydro.com."— Presentation transcript:

1 VOITH SIEMENS HYDRO Generator Presentation to CIGRE SC A1 – Paris Thomas Hildinger Germany Phone:

2 1.0. Hydro Generators – Project History
| Presentation | 2

3 1.1. Hydro Generators - Generator Technology Index
estimated upper limit for air cooled mach. | Presentation | 3

4 1.2. Hydro Generators - Plant types that applies...
a) Hydro-Generators with a diameter over 11 meters and generators with a nominal speed over 300 RPM over 100 MW Year Sn [MVA] Un [kV] ns [rpm] Di [m] Develop , , ,8 Three Gorges , , ,5 Grand Coulee , , ,808 Itaipu Extension , , ,0 Itaipu Extension , , ,0 Revelstoke , , ,9 Machadinho , , ,5 Long Kai Kou , , ,0 | Presentation | 4

5 1.2. Hydro Generators - Plant types that applies...
a) Hydro-Generators with a diameter over 11 meters and generators with a nominal speed over 300 RPM over 100 MW Year Sn [MVA] Un [kV] ns [rpm] Di [m] Guangzhou II , , ,5 Eastmain 1A , , , ,0 Wehr , , ,854 Taian , , , ,0 Zhanghewan , , , ,63 Picote II , , , ,3 Lajeado , , , ,4 | Presentation | 5

6 1.2. Hydro Generators - Plant types that applies...
a) Hydro-Generators with a diameter over 11 meters and generators with a nominal speed over 300 RPM over 100 MW Year Sn [MVA] Un [kV] ns [rpm] Di [m] Peixe Angical , , , ,15 Cana Brava , , , ,0 Develop , , , ,85 Ghatghar , , , ,5 Irape , , , ,4 Gilgel Gibe II , , , ,8 Baspa II , , , ,2 El Platanal , , , ,97 | Presentation | 6

7 1.2. Hydro Generators - Plant types that applies...
b) hydroelectric generators with different types of turbines: I - Generators with Francis turbines with a capacity larger than 300 MW Year Sn [MVA] Un [kV] ns [rpm] Di [m] Develop , , ,8 Three Gorges , , ,5 Grand Coulee , , 18,808 Itaipu Extension , , ,0 Itaipu Extension , , ,0 Revelstoke , , ,9 Machadinho , , ,5 Long Kai Kou , , ,0 | Presentation | 7

8 1.2. Hydro Generators - Plant types that applies...
b) hydroelectric generators with different types of turbines: II - Generators with Kaplan turbines with a capacity larger than 150 MW Year Sn [MVA] Un [kV] ns [rpm] Di [m] Lajeado , , , ,4 Peixe Angical , ,8 85, ,15 Cana Brava , , , ,0 | Presentation | 8

9 1.2. Hydro Generators - Plant types that applies...
b) hydroelectric generators with different types of turbines: IV - Generators with Pelton turbines with a capacity larger than 200 MW Year Sn [MVA] Un [kV] ns [rpm] Di [m] Silz , , , ,2 Malta/Rottau , , , ,0 Gilgel Gibe II , , , ,8 | Presentation | 9

10 1.2. Hydro Generators - Plant types that applies...
b) hydroelectric generators with different types of turbines: III - Generators with Bulb turbines with a capacity larger than 50 MW Year Sn [MVA] Un [kV] ns [rpm] Di [m] Santo Antonio* , , , ,5 *In cooperation with Alstom Power and Andritz-VAT | Presentation | 10

11 1.3. Hydro Generators – Design Guidelines
High Reliability High Performance Thrust Bearing Anti Fatigue Structure Anti Heat cycle Coil Low Vibration System Magnetic Thrust Bearing Optimization of Ventilation Design Optimization High Maintainability Project Economical Self Oil Circulating System Rim Ventilation Low Electrical Loss Small size design | Presentation | 11

12 1.4. Hydro Generators – Challenges to Insulation System
Requirements: Uniform thickness of the main insulation; Able to handle higher voltage strength (dielectric stress); Accurate profile dimension; Good performance for cooling; Installation-easy feature with effective contact to slot wall Effective Anti-Corona Shielding System Customer Benefit: Longer service life of stator bars. Reliability must be proven on long term basis Expected life time: 30~40 years (normal operation) | Presentation | 12

13 1.4. Hydro Generators - Micalastic® System Records
The MICALASTIC ® insulation system is widely use by Voith Siemens Hydro for high voltage winding of medium and large hydro generators. Main facts: Used since 1957 VPI Epoxy based Installed base: more than bars and coils Accumulated service hours: more than Accumulated service years: more than 6300 Applied to more than 500 hydro units worldwide (over 5 MVA) No failure due to premature aging of insulation has been reported | Presentation | 13

14 1.4. Hydro Generators - Micalastic® System Records
Main facts: Highest Output Water Cooled: Three Gorges (China) – 840 MVA Highest Output Air Cooled: Guri (Venezuela) – 805 MVA Highest Rated Voltage Water Cooled: Raccoon (USA) – 23 kV Highest Rated Voltage Air Cooled: Bath County (USA) – 20.5 kV Largest Core Inner Diameter: Gran Coulee III (USA) – mm Largest Core Length – Guri (Venezuela) – 3800 mm Highest Output per Pole – Guangzhou II (China) – 31.7 MVA / Pole | Presentation | 14

15 1.4. Hydro Generators - Micalastic® System Slot Arrangement
| Presentation | 15

16 1.4. Hydro Generators - Micalastic® System Slot Arrangement
Thermal Expansion Inside Stator Winding Stator bars are pressed and cured under temperatures between 140°C – 160°C; Forces inside the bars arise from cool down; In ambient temperature 25°C forces inside the bars are higher than under rated conditions and temperatures; Under rated load the mechanical stresses inside the ground wall are significantly lower as in stand still mode. | Presentation | 16

17 1.4. Hydro Generators - Micalastic® System End Winding Bracing System
The winding overhang must be braced and reinforced to prevent damage due to electro-mechanical forces that occur under normal operation (vibrations) and fault conditions (deformations). The winding overhang bracing consists of: intermediate bracing ring radial support rings rows of tangential blocks (top) rows of tangential blocks (bottom) | Presentation | 17

18 1.5. Hydro Generators – Buckling Prevention - Stator Core/ Frame
Stator Frame Clamping Strap Stator Core Fixation to the Stator Frame By means of pre-stressed studs or disc springs, the pressure on the core is assured in case of an eventual setting of the stator core. The core is fixed “radial-free” by means of double-dovetail studs with additional parallel guidance, in order to avoid any “buckling” effect due to thermal elongation. Double Dovetail Bar Stator Core No Evidence of Any Buckling Appearances Since the Start Application in the 1970’s | Presentation | 18

19 1.5. Hydro Generators – Buckling Prevention - Stator Core/ Frame
| Presentation | 19

20 1.6. Hydro Generators – V-Arm Rotor Hub Design
Advantages: Improved mechanical stability. High shrinkage forces can be absorbed by the V-arms. One rib per two head beams  better welding access in the center hub. Rotor hub design corresponds perfect in regard with the floating rim concept as well as with the shrinkage rim concept. 3D model of Revelstoke Umbrella type Rotor Hub | Presentation | 20

21 1.7. Hydro Generators – Cooling System Design
Figure 3-2 | Presentation | 21

22 1.7. Hydro Generators – Cooling System Design Air Distribution on DE and NDE side
advantages: Unequal air distribution acc. to the needs – the cooling of the ring leads requires more flow on the NDE side. End winding region on DE side direct in the air flow. Ventilation concept corresponds with the V-Arm rotor hub design. Yeywa - Rim ventilated Current Projects foreseen for double side rim ventilation Revelstoke Yeywa Eastmain Karcham Wangtoo Picote II Revelstoke - Rim ventilated | Presentation | 22

23 1.7. Hydro Generators – Cooling System Design
Case1 ( original design) Case 2 (Bypath=200mm) Case 3 (Bypath = 200mm) (Add.Rim duct = 25mm) Case 4 (Bypath = 50mm) (Add.Rim duct = 50mm) 115.3℃ 101.7℃ 102.8℃ 102.5℃ | Presentation | 23

24 1.8. Hydro Generators – Mechanical Design Investigation (FEA)
Stator Frame Deformations in circumference direction due to short circuit Stresses in support area (von Mises) | Presentation | 24

25 1.8. Hydro Generators – Mechanical Design Investigation (FEA)
Rotor Hub Deformations in circumference direction Stresses in rotor hub Modal analysis of complete rotor | Presentation | 25

26 1.8. Hydro Generators – Mechanical Design Investigation (FEA)
Thrust Bracket Deformations due to axial load Deformations due to radial load Stresses due to axial load | Presentation | 26

27 1.8. Hydro Generators – Mechanical Design Investigation (FEA)
Guide Bracket Boundary conditions Stresses due to radial load Radial deformations due to radial load | Presentation | 27

28 Upper Guide Bracket and Stator Frame
1.8. Hydro Generators – Mechanical Design Investigation (FEA) Upper Guide Bracket and Stator Frame Radial stiffness calculation Stresses due to short circuit in 50% of poles | Presentation | 28

29 1.8. Hydro Generators – Mechanical Design Investigation (FEA)
Poles Deformations due to runaway speed Stresses due to runaway speed | Presentation | 29

30 Air guide (Optimization of ventilation between poles)
1.8. Hydro Generators – Mechanical Design Investigation (FEA) Air guide (Optimization of ventilation between poles) Deformation due to runaway speed Stresses due to runaway speed | Presentation | 30

31 1.9. Hydro Generators – Bearing Design
Plain bearings Lubrication by oil or water Hydrodynamic built-up of pressure Friction losses to be transfered by a cooling system | Presentation | 31

32 1.9. Hydro Generators – Bearing Design
Upper generator guide bearing Lower generator guide bearing Thrust bearing Turbine guide bearing | Presentation | 32

33 1.9. Hydro Generators – Guide Bearing Features
Bearing segments, coated with white metal Adjustable support that allows for tilting Bearing housing | Presentation | 33

34 1.9. Hydro Generators – Thrust Bearing Features
Bearing segments with hydrostatic piping Segment support by mattress of rubber springs Pipes with jets for cold oil injection | Presentation | 34

35 1.10. Hydro Generators – High Speed Machines Pole Design
| Presentation | 35

36 1.10. Hydro Generators – High Speed Machines Pole Design - Pole End Platte
Stresses in Pole end plate under runaway speed Only small regions above Yield Point limits. Local plastification has to be considered but does not affect performance or lifetime. | Presentation | 36

37 1.10. Hydro Generators – High Speed Machines Pole Design - Rotating Wheel
Stresses in Rotating Wheel under runaway speed Only small regions above Yield Point limits. Local plastification has to be considered but does not affect performance or lifetime. | Presentation | 37

38 2.1. Hydro Generators – Considerations to Develop. 1
855.6 MVA / 20 kV / 125 rpm / 50 Hz

39 2.1. Hydro Generators – Considerations to Develop. 1
What are the main design features that were applied to achieve the larger design? Enlarge the operating range for the radial guidance of the rotor Hub to the Rim from 110% to up to 140 % rated speed and usage of V-arms. Usage of Jarret springs to enlarge the upper bracket stiffness by not applying thermal forces to the civil structure. Radial free stator frame assembly on the sole plates to allow thermal grow. Give Clearance in the assembly between stator core and stator frame to allow thermal grow. Restrict the axial deflection of the thrust bracket to 3mm. Bearing Design with rubber spring mattress | Presentation | 39

40 2.1. Hydro Generators – Considerations to Develop. 1
How is transportation solved? The route of transport is checked locally and the transport restrictions in view to weight and dimensions are considered and applied in the Design of the Generator Beside others are stator frame, bearing brackets and rotor hub are manufactured with joints, transported in segments and assembled (welded/ bolted) at site. Stacking of core and rim is done at site | Presentation | 40

41 Center Part for Transportation
2.1. Hydro Generators – Considerations to Develop. 1- LKK Thrust Bracket Center Part for Transportation Complete Bracket Max. 70 t Outer dia. 6,1 m; Height 3.2 m Approx. 125 t Max. axial deflection: 3mm Arms to be welded at site Guide Bearing part to be mounted separately on top of bracket | Presentation | 41

42 ½ Center Part without arms(*)
2.1. Hydro Generators – Considerations to Develop. 1- LKK Thrust Bracket ½ Center Part without arms(*) ½ Center Part with arms m = 42t (± 5%) (*) if transported as one piece weight will be 79 t. m = 70t (± 5%) Note: split only for transportation – after welding same stiffness as one piece. | Presentation | 42

43 2.1. Hydro Generators – Considerations to Develop. 1
What design assessments have been carried out to ensure the reliability and long term integrity of the generator? Validation that the stresses in the components are endurable to ensure reliability for normal operation, and also failure operations as for 2- or 3 phase short circuit, ½ of the poles not in operation, load rejection speed, max. runaway speed, earthquake situation, hydraulic forces Application of state of the art FEA to verify the stresses in detail Application of proven Class F Micalastic© Insulation technology to ensure long life for the windings | Presentation | 43

44 2.1. Hydro Generators – Considerations to Develop. 1
What design assessments have been carried out to ensure the reliability and long term integrity of the generator? Performing a Design for limited temperature rise to enlarge the long life of the insulation Definition of proven Quality control for the components to ensure that the defined quality is applied Ensure that the machine could be operated with 2 (out of 12) coolers out of operation inside specified temperature rise to enlarge maintenance intervals Application of Brush holders which allow exchange of brushes while operation | Presentation | 44

45 2.2. Hydro Generators – Features of Large Bulb Generator
Santo Antonio* : 82,5 MVA / 13,8 kV / 100,0 rpm / 60 Hz * - In cooperation with Alstom Power and Andritz-VAT | Presentation | 45

46 Santo Antonio* and Jirau*
2.2. Hydro Generators – Features of Large Bulb Generator Santo Antonio* and Jirau* Minimal radial heightsmaller bulb diameter (hydraulic req.) Reverse Air Flow (VAT)Improved cooling of stator core (buckling prevention) Unhindered cooling airflow V-Element (AP) to attach stator core to frameImproved thermal expansion capability (buckling prevention) Reduced welding volume Good circularity by turning of inner diameter * - In cooperation with Alstom Power and Andritz-VAT | Presentation | 46

47 1.4 Plant types that applies...
2.3. Hydro Generators – Features to Develop. 2 150 MVA / 14.4 kV / 750 rpm / 50 Hz | Presentation | 47

48 Generator Complete Rotor With Poles and Field Windings
2.3. Hydro Generators – Features to Develop. 2 Generator Complete Rotor With Poles and Field Windings Rotating Wheel (3 Parts) 28NiCrMoV 115 Pole End Plate ASTM A 148 GR 135/125 Pole End Plate Yield Point 900 N/mm² Pole Sheet XTRA70 Pole Sheet Yield Point 700 N/mm² Total Weight (for one Pole without fastening) approx. 11 t Total Weight (Without Shaft) approx. 120 t | Presentation | 48

49 Reference: Guangzhou II
2.3. Hydro Generators – Features to Develop. 2 Reference: Guangzhou II Number of Machines 4 Rated Output Power 380 MVA Rated Voltage 18 kV Rated Current 12189 A Power Factor 0.90 Rated / Runaway Speed 500 / 725 rpm Number of Poles 12 Field Voltage 252V 120°C) Field Current 2370 A Moment of Inertia ≥ 950 tm² Bore Diameter 4500 mm Stator Length 3435 mm Ventilation System External Fans (Blowers) Construction Type IM8425 W41) | Presentation | 49

50 Reference: Guangzhou II
2.3. Hydro Generators – Features to Develop. 2 Reference: Guangzhou II Mechanical Design Rotor Solid forged rings with flanged shaft ends; Pole fastening with 4 T-Heads per pole; Shaft flanges with coupling bolts; Pole winding - air cooled. Stator Frame - welded steel structure; Core fastening with double-dovetail bars; Core and winding - air cooled. Bearings Combined thrust / guide bearing – upper; Guide bearing – lower; External oil / water coolers ; Radial bracket supported on the foundation. Generator Cross Section | Presentation | 50

51 Thank You For Your Attention

52 | Presentation | 52


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