dec pump-turbine introduction
TRANSCRIPT
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东方电机有限公司东方电机有限公司DONGFANG ELECTRIC MACHINERY CO., LTDDONGFANG ELECTRIC MACHINERY CO., LTD
PRESENTATION FOR PUMPPRESENTATION FOR PUMP--TURBINETURBINE
Pump-Turbine of DFEM MadePumpPump--Turbine of DFEM MadeTurbine of DFEM Made
2012Cooperating with ALSTOM and manufacturing 4(four) complete set units
HOHOT
2014Self-design and manufacturing 4(four) complete set units
XianYou
2009Cooperating with ALSTOM and manufacturing 4(four) complete set units
HeMiFeng
2008Cooperating with ALSTOM and manufacturing 1(one) complete set unit
HuiZhou97Self-design XianHongDian95Cooperating with VIOTHShiSan Ling93Main partsGuangZhou 1st
Operating date
Outstanding achievementPower Station
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Experiences List of DFEM Made Pump-TurbineExperiences List of DFEM Made Pump-Turbine
5002093.88
55.27320503595
4905215803064×300
HOHOT
428.6300500Rated speed (r/min)202020Guide vane 999Runner blade 4.1585.043.82Runner Diameter (m)
Other 368.110656.02Maximum flow (m3/s)302325330Maximum input (MW)421275529Minimum head (m)475337.6565Maximum head (m)
Pump condition2421270509Minimum head (m)430295517Rated head (m)475335553.7Maximum head (m)306306306Turbine output (MW)4×3004×3004×300Unit Power (MW)
Turbine condition1
XianYouHeMiFengHuiZhou
Typical Pump-TurbineTypical Pump-Turbine
DFEM Typical ProductsXianHongDian 2X40MW HuiZhou 4X300MWHeMiFeng 4X300MWHOHOT 4X300MWXianYou 4X300MW
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Principles of Pump-Turbine DesignPrinciples of PumpPrinciples of Pump--Turbine DesignTurbine Design
The Best CFD tools can be used in pump-turbine hydraulic design.
Making full use of the outcomes in key technology research for large
Pump-turbines.
Fully use of mature and advanced proposal and structure proven by
successful operations.
Carefully chosen data with certain surplus.
Taking the convenience for installation, maintenance, manufacturing
and transportation into full consideration .
Reliable、advanced、durable、easy-operation、nice-looking.
Our company has been cooperating with many
famous overseas companies, such as Vioth-
Siemens, Alstom, GE, VA-TECH, ANDRITZ, Toshiba.
Among which, we have cooperated with Vioth,
Alstom for pump-turbine.
Cooperation with overseas companyCooperation with overseas company
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Established test stand specially for pump-turbine
Model runner diameter: 350~500 mm
Maximum test head: 100 m
Maximum Test discharge: 1.5m3/s
Test system accuracy: ±0.3%
The whole system data will be got and processed automatically by computer.
Pump-turbine model runner research
Technical transfer from the overseas companies
Based on overseas advanced runner, making hydraulic design by CFD analyze
Machining the blades by 5-axis NC milling and boring machine
Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
DFEM Universal Test Stand For Pump-Turbine
Test Stand For Hydraulic Machinery Test Stand For Hydraulic Machinery Test Stand For Hydraulic Machinery
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Whole analyzing Runner and Spiral case and Draft tube
Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
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Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
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Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5
Effic
ienc
y
Measurements Calculations
Q11/Q11 opt
2 %
Comparison of experiment results and calculation
Confidential
Confidential
CFD tools to predict performances, and comparison
with measurement results
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Typical cavitation "bucket" curve
50
100
150
200
250
300
350
80 85 90 95 100 105 110 115 120
Q/Qd (%)
Req
uire
d su
bmer
genc
e N
PSH
/NPS
Hop
t (%
)
bucket curvesubmergence
a specific tool for entrance cavitation
analysis
Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
Pump-Turbine Basic Research- Hydraulic DesignPump-Turbine Basic Research- Hydraulic Design
Softwares for pressure fluctuations prediction
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Pump-turbine integrity rigidity and strength calculation analysis
Simulation the true turbine’s discharge, normal operation,
load-rejection and runaway condition.
Using ANSYS calculation software to calculate static stress
for whole unit and large components.
Using ADINA calculation software to calculate the runner
and shaft system fem dynamic stress.
Pump-Turbine Basic Research- Rigidity & Strength Calculation AnalysisPump-Turbine Basic Research- Rigidity & Strength Calculation Analysis
Pump-Turbine Basic Research- Rigidity & Strength Calculation AnalysisPump-Turbine Basic Research- Rigidity & Strength Calculation Analysis
Intensity calculation of runner at any load conditionIntensity calculation of runner at any load condition
Load distribution Load distribution on obverse surface of bladeon obverse surface of blade
Load distribution Load distribution on back surface of bladeon back surface of blade
Load distribution On waterLoad distribution On waterway surface of crownway surface of crown
Load Load distribution distribution On On waterway waterway surface of surface of bandband
Load Load distribution On distribution On nonnon--waterway waterway surface of band surface of band and crowand crow
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Pump-Turbine Basic Research- Rigidity & Strength Calculation AnalysisPump-Turbine Basic Research- Rigidity & Strength Calculation Analysis
Combining calculation of Combining calculation of spiral case and stay vanespiral case and stay vane
Stress distribution of Stress distribution of head coverhead cover
Stress distribution of bottom ringStress distribution of bottom ring
Stress distribution of Stress distribution of wicket gatewicket gate
Design and calculation of main shaft seal Design and calculation of main shaft seal
Pump-Turbine Basic Research- Rigidity & Strength Calculation AnalysisPump-Turbine Basic Research- Rigidity & Strength Calculation Analysis
Floating ring Springs
Cover
ORIFICE PLATE
Ressorts
Couvercle Anneau flottant
DIAPHRAGME
R5
R4
R3 R2
R1
Qtot
Qext Qint
p5
p3 p2 p1
Fig 1
Sealing water
Shaft
Bearing force Bearing force
ANSYS calculation of seal ring ANSYS calculation of seal ring
ANSYS calculation of seal ring distortion ANSYS calculation of seal ring distortion
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Runner combination jointingRunner combination jointing
Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture
Turbine Cross Section—Pump-TurbineTypical Pump-Turbine StructureTypical Pump-Turbine Structure
17.750
SHAFT SEAL ? 1500
CIRCULAR RAILWAY 3.5t ? 5904环形吊车 3.5t
接力器中心线
水导轴承
主轴密封
导水机构中心线
转轮出口(水轮机模式)
转轮进口(水轮机模式)
水泵模式(顺时针)
水轮机模式(逆时针)
尾水管肘管进口内径
尾水管进
人廊
道
20个导叶
机坑进人
廊道
转轮叶片数 9
DISTRIBUTOR AXIS
SERVOMOTOR AXIS
TURBINE MODE COUNTERCLOCKWISE 300 rpm
PUMP MODE CLOCKWISE 300 rpm
8.500
15.000
17.800
18.300
9.500
? 2700 RUNNER OUTLET ( TURBINE MODE )
522
? 1500 h8 BEARING
20.500
? 5904 Z=20 GUIDE VANES
? 7880
? 5040 RUNNER INLET ( TURBINE MODE )
? 1095 h10
? 1480 9-M110x4 9-? 150
? 1480 18 M100x4
2500
TU
RB
INE
PIT
ACC
ES G
ALLE
RY
2000
? 6820 80 - M 105x4
RUNNER 9 BLADES
? 7130 40 - M 80x4拉紧螺杆
2000
DR
AFT
TUBE
CO
NE
AC
CES
GA
LLER
Y
DRAFT TUBE ELBOW ? 3596 INLET DIAMETER
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Gate shaft cone sleeveGate shaft cone sleeve
Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture
Transferred wring moment by pin Transferred wring moment by pin sleeves and connected by bolts sleeves and connected by bolts between runner and main shaftbetween runner and main shaft
Gate frictionGate friction
Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture
Thin oil ,selfThin oil ,self--lubricating , segment and lubricating , segment and External oil circulationExternal oil circulation guide bearing guide bearing
Adopted to Adopted to HuiZhouHuiZhou ,,HeMiFengHeMiFeng ,HOHOT etc. ,HOHOT etc.
Pad瓦
Intermediate collar中间轴翎Turbine shaft水机轴
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Spring, selfSpring, self--adjusting faceadjusting face--type main shaft sealtype main shaft sealseal rings in Carbon material or seal rings in Carbon material or CestidurCestidur
Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture
Adopted to Adopted to HuiZhouHuiZhou ,,HeMiFengHeMiFeng ,HOHOT ,,HOHOT ,BaoQuan,ThreeBaoQuan,Three Gorge,LongTan,XiaoWan,PuBuGouGorge,LongTan,XiaoWan,PuBuGou etc. etc.
Inflatablemaintenance seal
Adaptedaxial shaft seal
Spiral case and stay ring:Spiral case and stay ring:
1 Integer1 Integer
2 Segmented by transport limit2 Segmented by transport limit
3 Designing spiral case under 3 Designing spiral case under maximum water pressure maximum water pressure
4 Water pressure test of spiral 4 Water pressure test of spiral case at site.case at site.
Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture
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Stay ring:Stay ring:
SegmentSegment
Combination at siteCombination at site
Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture
2,63°18°20°
475
Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture
Gate operation control mechanismGate operation control mechanism
single gate servomotorsingle gate servomotor
single gate servomotor single gate servomotor and control ringand control ring
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DRAINAGE PIPES IN THE PITDRAINAGE PIPES IN THE PIT
15
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Item.
Stay seal ring
Wearing ring and seal ring
Pit liner
Cone and elbow of draft tube
Servomotor cylinder and gate lever
Coupling bolt
Guide vanes
Main shaft seal
Guide bearing
Gate operating ring
Bottom ring and discharge ring
Head cover
Stay ring
Spiral case
Main shaft
Runner
Name of Part
ZCuAl10FeNi5
s135
Q235A
16Mn
ZG20SiMn
42CrMo
ZG06Cr13Ni4Mo
Q345C
Q235C
S355J0+N or Q345C
S355J0+N or Q345C
S355J0+N or Q345C
S500Q-Z25
B610CF、ADB610D or WDB620
DG20SiMn
ZG06Cr13Ni4Mo
Material
GB/T 5231-2001
GB13237-91
GB700
GB/T1591-1994
JB/ZQ4297
GB3077-88
GB6967
GB3274-88
GB700
GB3274-88
GB3274-88
GB3274-88
CF 62/WCF80
JB/T6396
GB6967
Standard and Grade (China)
ASTM C63200
ASTM A240-93b
ASTM A36
ASTM A516-90 Cr70
ASTM A216 WCC
ASTM A304
ASTM A743 CA-6NM
ASTM A633m
ASTM A36
EN10025-2
EN10025-2
EN10025-2
EN10025-6
G3128-87
ASTM A668 CI.D
ASTM A743 CA-6NM
Equality America Standard
Main Parts Material Table for Pump-TurbineMain Parts Material Table for Pump-Turbine
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Pressure cycle
0%10%20%30%40%50%60%70%80%90%
100%110%
0 1 2 3 4 5 6 7 8 9 10time in hours
% o
f pre
ssur
e
Design pressure
if embedded with partial pressure
Pump-Turbine Field TestPump-Turbine Field Test
Water pressure test of Water pressure test of Spiral case at siteSpiral case at site
Pump-Turbine Condenser OperationPump-Turbine Condenser Operation
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Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare
A) Dismantling PT A) Dismantling PT from middle from middle
1 step: dismantling middle shaft 1 step: dismantling middle shaft
Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare
A) Dismantling PT A) Dismantling PT from middle from middle
2 step: dismantling main shaft 2 step: dismantling main shaft
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Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare
A) Dismantling PT A) Dismantling PT from middle from middle
3 step: dismantling head cover 3 step: dismantling head cover
Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare
A) Dismantling PT A) Dismantling PT from middle from middle
4 step: dismantling runner 4 step: dismantling runner
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Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare
dismantling head cover dismantling head cover
B) Dismantling PT from B) Dismantling PT from stator stator
Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare
C) Dismantling PT from C) Dismantling PT from movable cone of Draft tube movable cone of Draft tube
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Inlet spherical valve made by DFEMInlet spherical valve made by DFEM
4479.92.3XianYou12
200923933181.5DILuo11
200834203211.6LIZhiPing10
200827756201.9RenZhongHai9
200827936201.9JinWo8
201029005852.0HOHOT7
good200925003352.9HeMiFeng6
good200835504551.3ShiZiPing5
good200824003012.5WaWuSan4
good200615003901.6XiaoTianDu3
good200423002301.75HuanGuangTan2
good199427254831.75ShiSan Ling1
Operating status
Operating year
UnitsRising head (m)
Head (max)Diameter (m)Power stationIte
m
Inlet spherical valve Design Inlet spherical valve Design
下游密封环行程 11
Inlet spherical Valve:Inlet spherical Valve:
1 Two surface seal1 Two surface seal
2 Two servomotor2 Two servomotor
3 Hydraulic operated seal ring 3 Hydraulic operated seal ring
4 Movable operating seal ring 4 Movable operating seal ring replaces byreplaces by--pass system pass system
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DFEM IS YOUR BEST CHOICEDFEM IS YOUR BEST CHOICE
THANKS!THANKS!
HeMiFeng Power station
Type of turbine: HLP()-LJ-504Runner diameter: 5.04mRated speed: 300r/minTurbine condition:Maximum head: 335mRatedRated head: 295mMinimum head: 270m270mTurbine rated output: 306.0MWPump condition:Maximum pump head: 337.6mMinimum pump head: 275.0mMax. pump discharge : 106m3/sMax. pump input: 325MW
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HuiZhou Power Station
Type of turbine: HLP()-LJ-382Runner diameter: 3.82mRated speed: 500r/minTurbine condition:Maximum head: 553.7mRatedRated head: 517mMinimum head: 509m509mTurbine rated output: 306.0MWPump condition:Maximum pump head: 565mMinimum pump head: 529mMax. pump discharge : 56.02m3/sMax. pump input: 330MW