1000mva class geneartors for india by siemens.pdf

8/9/2019 1000MVA Class Geneartors for India by Siemens.pdf

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Power Generation PG P2 1Jan 2006

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Water-Cooled Generators forPower Projects in India1000 MVA Class


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Water-Cooled Generators forPower Projects in India

Jan 2006 Power Generation PG P2 2

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Generator Organization and NetworkGlobal Network

Charlotte

Orlando Erlangen

Mülheim ErfurtFt Payne

MÜLHEIM - GeneratorService

MÜLHEIM - GeneratorService

ERFURT - New Units < 140 MW

and Stator Core Material andComponents

ERFURT - New Units < 140 MWand Stator Core Material andComponents

OFFENBACH & ERLANGEN -Back office support for OrderManagement

OFFENBACH & ERLANGEN -Back office support for OrderManagementORLANDO - Back office support for

Engineering/ Supply Management / OrderManagement

ORLANDO - Back office support forEngineering/ Supply Management / OrderManagement

FT. PAYNE - ComponentParts and Assemblies

FT. PAYNE - ComponentParts and Assemblies

CHARLOTTE - New Units >140 MW and Generator

Service

CHARLOTTE - New Units >140 MW and GeneratorService

Order Management

SupplyManagement

DesignEngineering

Integrated Network Organizations

Charlotte Ft Payne Mülheim Erfurt

Individual Plant Management


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Generator Product LineMeeting the Customer’s Power Needs

Generator Product Line Overview

0 100 200 300 400 500 600 700 800 900 1000+ MVA

Air-cooled

Hydrogen-cooled

Water-cooled

50 and 60 Hz (2 and 4 pole)

MVA


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SIEMENS Generators –ProvenTechnology with Highest Availability

Design features

Type: Two and Four-pole generators with:• Water-cooled stator winding• Hydrogen / Gas-, Water-cooled rotor

Excitation: Static or Brushless

References

Approximately 150 generators installedthroughout the world with ratingsof 450 MVA to 1640 MVA

(Approximately 90 - Fossil; 60 Nuclear)

Advantages

Highest availability due to extremely

low forced outage rateEssentially maintenance-free stator core and excitation systemHigh quality groundwall insulationsystem


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Key Features for 1000 MVA Class

Directly water-cooled stator winding with stainless steel tubes

Directly hydrogen-cooled stator core

Axially directly cooled rotor winding

Hydrogen cooled Parallel Rings and Bushings

Micalastic TM single bar stator winding impregnation

Proven Stator end winding

High pressure multi-stage compressor blower for efficient cooling

Spring mounted stator core to minimize vibration transmission to foundation

Pressure tight frame with bearing brackets to support rotor and stator weight


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Generator Fleet Experience

Built on more than 100 years of evolution in manufacturing and

operational experience of Siemens and Westinghouse

Global fleet of more than 9000 generators

Total capacity exceeding 700 GW

Applications in:

Simple Cycle Plant

Combined Cycle Plant

Co-generation Plant

Fossil and Nuclear Steam Power Plant


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References

THDD series 78 generators

THDF series 57 generators

rated power > 800 MWTHDF 115/78 Goesgen Swiss 1141 MVA 1978

THDF 115/67 Bergkamen Germany 911 MVA 1981

THDF 115/67 Heyden Germany 950 MVA 1987

THDF 115/78 Trillo Spain 1147 MVA 1988

THDD 115/72 Schwarze Pumpe1 Germany 1000 MVA 1997

THDD 115/72 Schwarze Pumpe2 Germany 1000 MVA 1997

THDF 125/78 Boxberg Germany 1144 MVA 1999

THDF 125/78 Niederaussem Germany 1223 MVA 2002

THDF 125/67 Waigaoqiao 1 China 1000 MVA 2003

THDF 125/67 Waigaoqiao 2 China 1000 MVA 2004


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dSIEMENS Generators – High Efficiencyand High Availability

High AvailabilityTechnical Data

High Efficiency 1)

Type Water-Cooled (Stator)Rated power 450 - 1600 MVAPower factor 0.8 - 0.9 laggingNominal voltage 18 - 27 kV ± 5 %Frequency 50/60 Hz

100 % load 98.90 %

75 % load 98.95 %50 % load 98.90 %

1) at 765 MVA; power factor 0.9with tolerance acc. IEC 34-1

Forced outage rate [%]

1.0

0.8

0.6

0.4

0.20.08

0.82

SIEMENS generatorsPeriod: 1988 - 1994

NERCaverage value

FOR = 100 x

FOR = Forced outage rateFOH = Forced outage hoursSH = Service hours

FOHFOH + SH

ReferenceReference


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Generator outline drawing


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Cooling Gas System


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Stator core

• Stacked outside frame

• Insulated rectangular core beams

• Core beams welded to end plates• Welded spring baskets

1 Core beam 3 Lamination

2 Insulation 4 Copper rope


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Core to frame attachment

• Spring mountedcore suspension

• Welded through

man holes


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Core to frame attachment

• Spring mounted coresuspension

• Welded through manholes


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Stator end winding design

• Gas cooled parallelrings


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Stator end winding design

• Gas cooled parallelrings


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Micalastic TM Insulation System

The Micalastic insulation system uses solventless, heat reactive resinimpregnant and a vacuum-pressure-impregnation (VPI) process.

Micalastic is a class F insulation system

The excellent electrical properties of the resin, coupled with goodinsulation consolidation result in:

Low insulation power factor High electrical strengthHigh voltage indurance

The resiliant nature of the resin bond permits elastic cyclicdisplacement of adjacent mica flakes and provides restoring forcewithin the insulation groundwall

Micalastic is ideally suitable for cyclic duty operation


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Stator slot


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Stator slot

540 ° Roebel bar


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Stator bar connection & water supply

• Stainless steel tubes

• Stainless steel water boxes

• Water box supports copper to stainless steel welds


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D-cooling-system for rotor

• Rotor end winding withcorner brazing

• Finish drawn copper profile

• Asymmetric cold gasinlet & outlet in straight

portion


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Cooler Head

Bearing bracket side

Generator side

Cooling water inlet & outletfrom top side

Avoid of sealing problems dueto termal expansion

Cold gas inletopenings toframe


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Generator bearing


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Terminal box & bushings

Gas cooled bushings


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Anchoring of generator


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Exciter


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Exciter Rotor


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Exciter Rectifier Wheels


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Generator Auxiliaries

Design principles

Designed to world wide standards

Compact skid installation

Ease of maintenance

High reliability

Siemens water-cooled generators are provided with proven technology auxiliarysystems

Hydrogen gas system

Seal oil system

Stator primary water system


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Generator Auxiliaries Overview

BGR 2770Gastrockner/GAS DRIER

BGR 2860Flüssigkeitsgebergerüst/LIQUID DETECTOR RACK

BGR 2860Schmutzflüssigkeitsbehälter/WASTE FLUID TANK

BGR 2504PW Pumpen-und Filter Aggregat/PW PUMP AND FILTER UNIT

BGR 2880Dichtölvorratsbehälter/SEAL OIL STORAGE TANK

BGR 3053PW-Behälter/PW TANK

BGR 2730CO 2 - Flaschengerüst/CO 2 - BOTTLE RACK

BGR 2735CO 2 - Entspanner/CO 2 -FLASH EVAPORATOR

BGR 3052 Abgasverorgung/WASTE GAS PIPING

BGR 2700H2-Aggregat/H2-UNIT

BGR 2720H2-Flaschengerüst/H2-BOTTLE RACK

BGR 2800Einfluss-Dichtölaggregat/SINGLE FLOW SEAL OIL UNIT

Gas system


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Gas systemSimplified Diagram

Components1 H 2 Bottle

2 H 2 Pressure Reducer

3 Compressed Air Filter

4 Compressed Air Hose

5 Upper Generator Gas Header

6 Lower Generator Gas Header

7 Gas Dryer Chamber 8 Gas Dryer Heater

9 Gas Dryer Fan

10 Argon Container

11 Argon Pressure Reducer 12 H 2/Ar Purity Meter System

13 Multi-Way Valve beforeH2/Ar Purity Meter System

14 Humidity Detector

Gas System


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ySystem Design

Standard Option

H2 Supply Bottle Rack Central Supply Unit

H2 ConsumptionMeasuring Device No within the //

Inert Gas Argon CO 2 InertisationProcess

Hand Valves Automatic / RemoteControl Valves

Gas Dryer Single Tower Double Tower

Stand Still Blowerfor Gas Dryer No Yes

Gas System


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Gas SystemH2 Unit (Example)

Components:

• Compressed air filter

• Hose as a visiblebreak

• Shut-off and change-over valves

• Transmitter

• Local indicator

• Electronically purity

measuring device• Flow meter

• ...

Gas System


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yPurging with Argon

Advantages:Saves outage time⇒ Fast inertisation

Increases Safety:Purging every timepossible without use of electrical energy

⇒ No evaporationnecessary

More Reliability⇒ Simplified system

Less dangerous for thestaff ⇒ Argon is non-poisonous

Gaseous CO 2to Generator

Liquid CO2CO 2 –Container or

CO 2 –Bottles

AtmosphereM

M

Normal Practice: Purging with CO 2

Gaseous

Argon Argon–Container or Argon–Bottles

Gaseous Argon

to Generator

Flash evaporators

Example: Typical steam turbine generator

Saves 2 hours outage time for each purging

Example: Typical steam turbine generator

Saves 2 hours outage time for each purging

Gas System


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yFeatures & Advantages

Redundant electrical purity meter with highaccuracy

Argon as purging gas with the advantage to purgethe generator without additional energy

Automatic purging process possible

Optimized monitoring(Transmitter and local indicators)

Seal Oil System


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yGland Seals

These seals are located around the rotorshaft where it penetrates the generatorbearing brackets

The seals help prevent:- hydrogen from leaking out of

the generator

- while minimizing the amountof air and moisture that canleak into the generator

Air-Side

H2-Side

Example


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Single Flow Systeml l k d ( )


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Seal Oil Skid (Front view)

Single Flow Seal Oil SystemF & Ad


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Features & Advantages

Vacuum Tank guarantee optimal H 2 degassing

High reliability by redundancies

Low noises by screw pumps

Clear structure and maintenance friendly design

Optimized monitoring(Transmitter and local indicators)

Stator Water Cooling SystemR i


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Requirements

The Stator Water Cooling Systemshould contain components which:

Circulate,Cool,

Filter,

Keep constant quality of,

Vent and Degas the water.


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Stator Water Cooling SystemSimplified Diagram


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Simplified Diagram

V

Components:1 Pumps2 Cooler and Degassing

Pipe3 Filter 4 Make up5 Expansion and Storage

Tank

6 Draining and Degassing7 Throttle8 N2-Connection

R Drainage and Degassing

PipeS Inspection GlassV Flow Meter

Stator Water Cooling SystemPump Filter and Cooler Unit


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Pump-, Filter- and Cooler Unit

Stator Water Cooling SystemWater Tank


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Water Tank

Located above thehighest point of thegenerator

Volume: 300 Liter - 200 Liter water - 100 Liter gas

Local level indicator

Min-level switch

Overflow pipe

Stator Water Cooling SystemFeatures & Advantages


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Features & Advantages

Redundant System with proved components(2 x 100% Pumps, 2 Cooler, ...)

Clear structured and maintenance friendly design(Plate heat exchangers, Filter cartridges, …)

Optimized Monitoring

(Transmitter and local indicators)

Monitoring ofGenerator Systems


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Generator Systems

MonitoredProcess Variables

(typical Water Cooled Generator)Transmitter

132 Measuring Points

Local Indicators27 Measuring Points

68 Temperatures35 Pressures19 Flow rates17 Levels

12 Vibrations2 Volumes2 Gas purities

2 Conductivities1 Dew point temperatures1 Positions (switch)

Quality Assurance


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dSiemens is ISO 9001 certified company.

Siemens inspects and tests generator components during different steps of

manufacturing.

Customers have visibility of inspections and tests.

Records of all inspections and tests available within:

Customer Witness Points Program

Quality Records Documentation

Records are used to support customer quality programs.

Advantage of large Siemens-Generators


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d• MICALASTIC Insulation System for stator bars- proven and reliable optimized insulation thickness and heat transfer

• Stainless steel hollow strands- simple cooling water system

=> no special water treatment needed, no iron-exchanger required• Stator end winding

- Stable supports- Strong Bandage and Fixing

=> low vibration values and therefore low fretting no loosening, short circuit proof

• Stator core- Durable initial tension

=> Low vibration values no loosening of the core lamination

- high insulation between the sheets=> low Hot Spots (grinding of sheets after punching)=> No overheating

• End parts of rotor tooth- high safety factor for material at shrink fit for retaining rings

=> crack free

=> low maintenance


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Power Generation PG P2 52Jan 2006

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Thank you very much for

Attention

1000mva class geneartors for india by siemens.pdf

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