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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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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Water-Cooled Generators forPower Projects in India
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. A l l R i g h t s R e s e r v e
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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8/9/2019 1000MVA Class Geneartors for India by Siemens.pdf
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Power Generation PG P2 52Jan 2006
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S i e m e n s
P o w e r
G e n e r a
t i o n
2 0 0 6
. A l l R i g h t s R e s e r v e
d
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