Generator

Phase 2B - Heidenheim

Stator Rotor Bearing | Tobias Särnholm | October 2016 1

Proprietary Information:
This document and the information contained herein is the property of Voith Hydro. No
exploitation, use or reproduction of any information contained herein is permitted without the
written consent of Voith Hydro.

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Course Overview

This training will provide participants with basic knowledge of

generator and its main components.

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Instructor

Tobias Särnholm.
Lead engineer, Proposal Engineering, VHV
Tobias has held various Engineering positions
for the past 10 year in Hydro business.
Engineering roles include: generator design in
sales, proposal engineering and rehabilitation
as well as lead engineer in delivery projects.
Tobias is part of the Voith Global Product
Standard team and at VHV responsible for
Layout application work.

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Course Topics

1. Stator
2. Rotor
3. Bearing

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Topic – Stator

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Stator Topics

1. Function
2. Forces
3. Foundation forces
4. Flexible stator foot
5. Short circuit response on stator
6. Stator core
7. Ventilation

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Learning Objectives

1. Identify the main function of the stator frame.

2. Identify the loads acting on a stator.
3. Identify how buckling of the stator core is prevented.

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Topic – Stator
Function

Mechanical stiffness and transmit forces.

Support and keep in place. 1
•Stator core with winding.
Maintain sufficient stator core pressure with respect to:
•Sufficient stiffness (“solid ring”).
•Prevent stator core “buckling” (low thermal stresses may cause stator core “buckling” if
the stator core pressure is insufficient).
•Prevent individual stator core laminations to vibrate and cause wear.
•Axial heat transfer in stator core packages.
Direct and guide air flow.
•Stator frame and air duct spacers.
– Cooling air from stator core and winding to heat exchanger.

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Topic – Stator
Force / load

Thermal load
•Stator core ”buckling”, foundation forces
Magnetic load
•Magnetic stability, vibration
Operation torque, Short circuit torque
•Foundation forces
Intermittent duty
•Number of load changes
”Strict demands” on fatigue stresses

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Topic – Stator
Forces
Vibrations caused by rotor out of roundness
•Interference frequency
• Multiple of normal speed

Vibrations caused by interaction between stator and rotor

magnetic forces
•Interference frequency
• 2 x Power frequency

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Topic – Stator
Forces

A stator out of roundness effect on:

•Rotor rim stability
•Key device
• Dimensioned for stator out of roundness
•Welded torque transfer device
• Fatigue
•Stator movement
• Change in shape

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Topic – Stator
Foundation forces
2
Axial
•Dead weight
•Weight from upper bracket, machine top,
exciter- stator, etc.
•Weight of turbine and water (thrust bearing
placed above the rotor).
Radial
•Thermal load
– Elastic deformation (stator with flexibel
feet).
– Friction force (stator with sliding feet).
– Pre-tension.
Tangential
•Short circuit torque.
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Topic – Stator
Flexible stator foot
Low radial and tangential
foundation forces due to the flexible
foot.
Direct connection to foundation
results in a robust and
maintenance-free design.

Upper and lower foot plate

Sheet metal plates

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Topic – Stator
Short circuit response on stator

Avoid stator with eigen frequency close to 50 and 100 Hz.

The torque down to the foundation is ”equal” to the dynamic amplification factor multiplied with
the short circuit torque in the air gap.
The difference is the mass forces needed to accelerate the stator backward and forward

Dynamic amplification

3.5

3
Amplification

2.5

2 Series1

1.5

0.5

0
0 50 100 150 200 250 300 350
Stator eigenfrequency

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 Beam supports the dove tail
Topic – Stator (transfer forces from stator core)
Stator core •Tangential force from
Beam for supporting
Support dove tail normal torque.
•Radial temperature- and
magnetic forces.

•Tangential short circuit force.

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Topic – Stator
Stator core

”Buckling”:
Tangential stresses

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Topic – Stator
Stator core 3

Risk for stator core buckling is avoided by:

•Secure stator core pressure:
• Through bolts / elongation.
• Intermediate pressing during stacking.
• Check/Re-tightening of bolts.
•Limit thermal load:
• Design.
• Dimensioning of frame / pillar.
• Flexible stator feet.
• Check temperature differances
•Minimize initial waviness
• Check/Take measure during stacking and intermediate pressing.
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Topic – Stator
Ventilation

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Summary of Topics for this Module

1. Function
2. Forces
3. Foundation forces
4. Flexible stator foot
5. Short circuit response on stator
6. Stator core
7. Ventilation

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Review Learning Objectives

1. Identify the main function of the stator frame.

2. Identify the loads acting on a stator.
3. Identify how buckling of the stator core is prevented.

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Topic – Rotor

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Rotor Topics

1. Function mechanical
2. Mechanical design
3. Rotor pole complete, assembled
4. Rotor rim
5. Floating rim
6. Torque transfer (Bending type)
7. Rim support structure
8. Torque transfer - Shaft / Rotor hub
9. Ventilation
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Learning Objectives

1. Identify the loads acting on the rotor rim.

2. Identify what “floating rim” means.
3. Identify the connection between the rotor and shaft.

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Topic – Rotor
Function mechanical

Transfer the torque from

turbine/shaft to air gap
•Rotor frame

Support the poles

•Rotor rim
•Rotor frame

Required moment of inertia

•Rotor rim

•Act as a fan

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Topic – Rotor
Mechanical design

• Thermal load and centrifugal load

1
• Magnetic load
• Nominal torque, Short circuit torque
• Intermittent operation
Number of load changes
”Strict demands” on fatigue stresses

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Topic – Rotor
Mechanical design

Weight

Torque
•M=P/  [Nm]

Centrifugal force
•F=m*r*  2 [N]

Dynamic force

Magnetic stability

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Topic – Rotor
Rotor pole complete, assembled

• Flexible coil to coil connections.

• Damper winding without short circuit ring
in the air gap.
• Wedged towards the rotor ring (inwards).

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Topic – Rotor
Rotor rim

• Keep itself together and carry the rotor poles up to runaway speed with a comfortable
margin.

• Sufficient moment of inertia, GR2

• Round and centred around the center of rotation to minimize the forces on the stator.
• Eccentricity result in magnetic and mechanical unbalance which gives load on the bearings.

• Stable for magnetic forces caused by eccentric or oval stator.

• The stability of the rotor rim is affected by the connection to the frame and the stiffness of the
frame.

• Earthquake forces
• Transmit magnetic field between rotor pole cores.
• Demand for a minimum cross-section area in rotor rim.

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Topic – Rotor
Rotor rim
“Friction-rim”
•Kept together by friction.
•Lamination thickness, t = 2-4 mm.

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Topic – Rotor
Floating rim
2
Floating rim principle: The rotor rim weight is transferred to
•The radial expansion is not restrained by the the rotor disc by vertical beams and
mechanical coupling between rotor frame and supporting plates.
rotor rim.

The coupling between rotor frame and rotor Torque transfer:

rim shall with •Tangential device (friction).
torsional rigidity transfer the torque. •Friction device.
•Bending device.
The rotor frame must have sufficient tangential
stiffness.
•Two discs with stiffening plates, welded to a
Used since early -60`s
hub.
•Sufficient tangential stiffness can not be
achived for rotor spider with arm

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Topic – Rotor
Torque transfer (Bending type)

• Transfer the torque by tangential force.

• High tangential stiffness.
• Low radial stiffness.

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Topic – Rotor
Rim support structure

The weight of the rotor rim and rotor poles is

transferred by plates and beams to the rotor
frame.

Clearance.
Only in contact when the unit is lifted with
the brake and lift cylinders.

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Topic – Rotor
Torque transfer - Shaft / Rotor hub

Dimensioning stresses
•Surface pressure - Slot in shaft. 3
•Surface pressure - Slot in rotor hub.
•Shear stress - Wedge.

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Topic – Rotor
Ventilation Air inlet
Cut-out for air passage

Cut-out for air passage

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Summary of Topics for this Module

1. Function mechanical
2. Mechanical design
3. Rotor pole complete, assembled
4. Rotor rim
5. Floating rim
6. Torque transfer (Bending type)
7. Rim support structure
8. Torque transfer - Shaft / Rotor hub
9. Ventilation
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© Voith Hydro
Review Learning Objectives

1. Identify the loads acting on the rotor rim.

2. Identify what “floating rim” means.
3. Identify the connection between the rotor and shaft.

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Topic – Bearing

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Bearing Topics

1. Hydrodynamic lubrication
2. Losses
3. Load carrying losses
4. Combined bearing
5. Separate guide bearing
6. Hydrodynamic lubricated guide bearing segment
Preload
7. High pressure oil lubrication

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Learning Objectives

1. Identify where the losses of the bearing occurs.

2. Identify the oil flows through the bearing.
3. Identify the reason of using Babbitt.

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Topic – Bearing
Hydrodynamic lubrication

Plain bearing
•Hydrostatic, Hydrodynamic

Plain bearing
•Radial: Pivot supported segment, Sleeve
•Axial: Pivot supported segment, Step segment

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Topic – Bearing
Hydrodynamic lubrication

Stribeck-curve Full film

•Effect of Viscosity, Speed and Load on Bearing Friction lubrication
c-d
 3
All load is transferred by the oil film

Mixed
lubrication
b-c
  1 3
Main part of the load is transferred by the oil film

Boundary
lubrication
k a-b
Full film lubrication
with margin  1
The load is mainly transferred by metal contact

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Topic – Bearing
Hydrodynamic lubrication Hair: ~ 70 m
Sight limit: ~ 40 m

Hydrodynamic lubrication Hydrostatic lubrication

Running
Start
•No speed.
•High pressure oil lubrication

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Topic – Bearing
Hydrodynamic lubrication

Symmetrical segment for reversible bearing

v=0 Thrust runner

Bearing segment

Resulting pivot location, 60 %

17 (83) (50 % for reversible bearing)

50
Bed with helical springs

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Topic – Bearing dp
0 p  f (x)
dx
Hydrodynamic lubrication v

v

Pressure flow
- Poiseulle flow

Velocity flow
- Couette flow v

faces
ren ce to sur
Oil adhe

Sum/Total flow
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Topic – Bearing 1) Axial load
• Thrust bearing losses
Losses 2) Rotating surface/stationary sealing
• Sealing losses
Where are the bearing losses generated? 3) Rotating surface
• Rotational losses
4) Radial load
• Guide bearing losses
4 5) Pump
• Pump losses

3
1
5

1
2

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Topic – Bearing
Load carrying losses


Pthrust  f v a , b , Ac , F d  hmin
v
= losses at thrust bearing surface
= peripher speed
 = oil viscosity
A = thrust bearing area
F = axial load

Bearing losses vs Generator rating:

In the range of 0.1 – 0.3 %.

Losses at thrust bearing surface vs Total bearing losses:

In the range of 50 – 80 %.

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Topic – Bearing
Combined bearing

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Topic – Bearing
Separate guide bearing

1. Guide bearing sleeve

(centrifugal pump)
2. Guide bearing segment.
3. Key system for adjustment
of guide bearing clearance.
4. External cooler on the
outside of the bearing
house.

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Topic – Bearing
Hydrodynamic lubricated guide bearing segment
Preload = m
Preload
R pivot  Rsleeve
m  1
Rsegm  Rsleeve

Segment radius › Guide bearing sleeve radius

Ensures a converging, pressure generating, hydro

dynamic oil wedge between segment and sleeve.
Guide bearing
sleeve radius = Rsleeve

Converging clearance/oil film

from leading to trailing edge

Pivot radius = Rpivot

Guide bearing segment

machined radius = Rsegm
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Topic – Bearing
High pressure oil lubrication

Plain design
•Small diameter of oil inlet port on thrust bearing segment.
•Check valve on each thrust bearing segment. Check valve for each
thrust bearing segment
•Flexible hose from supply piping to thrust bearing segment.
•A single main supply piping, from pump to bearing housing.
•One check valve in main supply piping.
•One relief valve prevent pressure shock at start of high
pressure oil pump.
•One pressure gauge supervising the whole high pressure oil
lubrication system.
•One oil filter before the high pressure oil pump, protect the
pump.
One oil filter after the high pressure oil pump, protects the
thrust bearing segments.
Without high pressure oil lub
•Internal gear pump, high pressure, quiet “Lift unit before start
after ~ 2-4 days standstill.”

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Topic – Bearing
Coating / Bearing metal / Babbitt

Babbitt - White metal - Tin based

3
•Reluctant to weld together or jam
with other material.
•Can embed hard particles.
•Can be manual worked, scraped.
• Flat surface
• Today: Machining
• Oil pockets
• Today: High pressutre oil lubrication

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Summary of Topics for this Module

1. Hydrodynamic lubrication
2. Losses
3. Load carrying losses
4. Combined bearing
5. Separate guide bearing
6. Hydrodynamic lubricated guide bearing segment
Preload
7. High pressure oil lubrication

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Review Learning Objectives

1. Identify where the losses of the bearing occurs.

2. Identify the oil flows through the bearing.
3. Identify the reason of using Babbitt.

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© Voith Hydro
Contact:
Tobias Särnholm
Voith Hydro AB
Tel. +46 70 334 84 33
tobias.sarnholm@voith.com

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© Voith Hydro
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© Voith Hydro