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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.
Published by Donald Bradley Modi ed about 1 year ago
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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 di erent 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 di erent 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 di erent 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 di erent 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 pro le dimension;
Good performance for cooling;
Installation-easy feature with e ective contact to slot wall
E ective Anti-Corona Shielding System
Customer Bene t:
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
signi cantly 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 xed “radial-free” by means of double-dovetail studs with
additional parallel guidance, in order to avoid any “buckling” e ect 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 oating 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 ow on the NDE side.
End winding region on DE side direct in the air ow.
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 sti ness 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 plasti cation has to be considered but does not a ect 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 plasti cation has to be considered but does not a ect 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 sti ness 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 de ection 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 de ection: 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 sti ness 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
De nition of proven Quality control for the components to ensure that
the de ned quality is applied
Ensure that the machine could be operated with 2 (out of 12) coolers out
of operation inside speci ed 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 air ow
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 anged shaft ends;
Pole fastening with 4 T-Heads per pole;
Shaft anges 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
Download ppt "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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