Download - Hattori r1ID31VER89
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
1
State-of-the-art Technology for Large Turbine Generators
August, 2008
Kenichi Hattori*, Kazuhiko Takahashi, Shigeki Tohnosu, and Kado Miyakawa
Hitachi, Ltd.
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
2
Hitachi Turbine Generator Development History
0
200
400
600
800
1000
1200
1400
1600
1800
1950 1960 1970 1980 1990 2000 2010Year
G
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C
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(
M
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A
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Two-Pole GeneratorFour-Pole GeneratorAir-Cooled Machine
1570 MVA ABWR
1300 MVA
940 MVA
626 MVA
520 MVA
800 MVA
778 MVA670 MVA
408 MVA
320 MVA
217 MVA165 MVA
70 MVA
250 MVA230 MVA
1120 MVA
1570 MVA 4 pole1120 (1230) MVA 2 pole
2000 MVA ?
Current
Near future
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
3
Current
1,300-MVA (1,500 rpm) Turbine Generatorat Fukushima Nuclear Power Station No.
2 (Japan)
1,570-MVA (1,800 rpm) Turbine Generator at Hamaoka Nuclear Power Station
No. 5 (Japan)
Largest Units for Nuclear Power Plants (4 poles)
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
4
Current
749 MVA 1,800 rpm 60 Hz Turbine Generator at KoriNuclear Power Plant No.1
(Korea)
Replacement of Generators for Nuclear Power Plants
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
5
Hydrogen Coolers
Stator Core
Field Winding
BearingsRotor
Stator Coil End Support
Stator Winding
Collector Rings
Brush Holders
Radial Fans (4-pole)Axial Fans (2-pole)
High Voltage Bushings
Stator Cooling Water SystemSeal Oil System
Hydrogen Control System
Retaining Rings
Bushing CTs
Typical Structure of 1,000 MVA Class GeneratorGenerator components
Radial Flow (4-pole)GPU Flow(2-pole)
W/O Suspension (4pole)With Suspension (2pole)
Ventilation Fans
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
6
Stator Core - Clamping Structure -
Clampingfingers
Key bars
Statorcore
ClampingplateReinforcement
ring
Horizontal spring bars(for 2-pole only)
Wrapper plate
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
7
Ventilation of Generator Rotor (4-pole*)
Conductor
VentilationHole
Sub-SlotRadial Flow
Discharge GasWedge
TurnInsulator
CreepageBlock
Slot Armor
InsulatingFiller
Inlet Gas
Rotor (Radial Flow Ventilation)
* Used also for 2-pole generators of smaller output
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
8
Directly cooledGap pick up flow(Diagonal flow)
Bafflefor zone separation Stator
Rotor
Exhaustzone
Suction zone
Exhaustgas zone
Suctiongas zone
Suctiongas zone
Ventilation of Generator Rotor (2-pole only) Rotor (Gap Pick-up Ventilation)
Direction ofRotation
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
9
Inlet GasDischarge Gas
GAS FLOW
Ventilation of Generator Rotor (Gap pick-up)
Direction of Rotation
H2 InH2 OutRotation
Rotation
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
10
0102030405060
- 6000 - 5000 - 4000 - 3000 - 2000 - 1000 0Axial position from rotor center (mm)
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Top5th4th3rd2ndBottom
Rotor Center
Slot portionEnd portion
Cooling gas inlet Cooling gas inlet
Example of Rotor Temperature Analysis
Outlet Inlet
End and transition portion Repetitive portion
Transition Inlet
Stator
Rotor
We Investigate interaction of
stator and rotor Control both hot spot and
average temperature
End
Stator
Rotor
Result of ventilation analysis
Ventilationnetwork
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
11
Stator Coil - Strand -Stator Coil and Cooling SystemCross Section of Stator Slot
Hollow Strand
Solid Strand 540Roebel Transposition
Slot Region
Coil Center
Cooling Water Flow
Bottom Coil
Top Coil
Wedge
Center Filler (RTD)
Strands and Transposition
Temperature Analysis
Top Ripple Springend
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
12
Bottom coil
Example of Stator Coil Temperature Analysis
Linkage fluxSec.1Sec.3 Sec.2
Sec.3 Sec.2 Sec.1
Slot Region
Coil Center
Cooling water flow
Temperature distribution
End
Loss distribution
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Eddy current
Circulatig+ DC Total Total Total
Stator core
Top coil
End Slot region End
High
Low
Sec.1Sec.3 Sec.2
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
13
Stator Coil - Coil End Support System -
End winding
Slide bearingSupport arm
Stator core
Permanentring
Nose ring
Slide bearingSupport arm
End winding
Sliding
Stator core
Permanentring
Nose ring
Binding Band
Sliding support
Secured from radial and circumferential movement
Free for axial movement
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
14
Duct piece
End duct
Stator Core - Measures against Overheating -Stator core
End Duct Teeth Cut Slits
Arrangement of the stator core end is designed to reduce detrimental heating effect (eddy current loss) due to axial leakage magnetic flux.
Stepped Teeth
Bottom coil
Top coil
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
15
Advanced Technology for Optimum Design
Vibration Analysis of Stator CasingElectro-Magnetic Force and Vibration Analysis on Stator End Windings
Mechanical Analysis of Rotor Shaft Ventilation AnalysisFan Characteristics Analysis
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
16
0102030405060
- 6000 - 5000 - 4000 - 3000 - 2000 - 1000 0Axial position from rotor center (mm)
T
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Top5th4th3rd2ndBottom
Rotor Center
Slot portionEnd portion
Cooling gas inlet Cooling gas inletCooling water flow
Generator magnetic flux analysis Magnetic filed analysis at stator core end plate
Magnetic field analysis at stator core end
Stator coil temperature distribution Rotor coil temperature distribution
Advanced Technology for Optimum Design
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
17
Quality Assurance and Tests for Development
Spinning Burst Test Using Full -Size Rotor
Quality control and inspection of components
Stator Inspection
Clean Room for Stator/Rotor Assembly
Stator End Winding VibrationTest Equipment
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
18
Quality Assurance and Tests for Development
High performance of the insulation system confirmed from thermal cyclic endurance test
Stator coil (Insulation for Class F)
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
19
Proven Technology for High-performance Generator
Shaft
High-StrengthForging Material
Radial
Flow
Retaining ring
18Mn-18Cr Anti-corrosion
Material
Stator frame
Round-type cooler boxTop-dome-
type cooler box
Stator bars
F-class Insulation
System
Terminal box
Twin terminal boxes for4 star
connection
Stator core
Reduction of stator core end
loss
Tetra-lock type stator coil end
support
Movable to axial directionRigid to radial
and circumferential
direction
2,000-MVA Class Generator for ESBWR
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
20
Future Design Philosophy
Item Country China Japan ESBWRCapacity MVA 1,120 (Max 1,230)
1,000 (Max 1,083.5)0.9
NLT 0.5027
23,949 (Max 26,302)
Connection - 2Y 4Y 4Y0.52
3,0002
Water DirectH2 Direct
(GPU Flow)Exciter - Static Static
1,570
Static
App. 1,900 2,000App. 1,700 1,800
0.9NLT 0.35 (*1)
24 - 27App. 44,000 - 38,000
0.52 0.621,800
4Water Direct
Power factor - 0.9SCR - NLT 0.58
Voltage kV 22
H2 Direct(Radial Flow)
Rotating speed rpm 1,800No. of Poles - 4
Stator cooling - Water DirectRotor cooling - H2 Direct
(Radial Flow)
Output MW 1,413
Current A 41,202
H2 Pressure MPag 0.52
* 1: According to IEEE C50.13 - 2005
Comparison of Parameters
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
21
Features of Large Turbine Generators
Difference between 4 and 2-pole generator discussed The main technique that characterize our generator is the
minute temperature analysis where the rotor and the stator
interaction was fully incorporated.
The stator strand loss and temperature are examined full 3-D scale while physically considering transposition.
From the above, the current maximum rating is 1,570 MVA (4-pole) and 1,230 MVA (2-pole). We foresee future 2,000 MVA in
the future.
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
22
Thank you
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
23
Current - 4 pole generators -
Country Capacity(MVA) RPM Voltage(KV) Service Year
Japan 1570 1800 22 2005Japan 1540 1800 24 2006Japan 1530 1800 22 2011Japan 1300 1500 19 1984Japan 1300 1500 19 1987Japan 1300 1500 19 1990Japan 1300 1500 19 1994Japan 1280 1800 22 1993Japan 1280 1800 22 1987Korea 1222 1800 22 2009Korea 1222 1800 22 2009
Current 4-pole generator for NPP including AVR
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
24
Current - 2 pole machine -
Country Capacity(MVA) RPM Voltage(KV) Service Year
China 1230 3000 27 2006Korea 1028 3600 25 2008Korea 1028 3600 25 2009USA 1025 3600 24 2007USA 986 3600 24 2010Germany 962 3000 21 2009Germany 962 3000 21 2012Netherland 962 3000 21 2012Germany 962 3000 21 2013USA 828 3600 25 2009USA 825 3600 25 2008USA 825 3600 25 2009Japan 800 3600 25 1992
Current 2-pole generator (latest upgrade)
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Hitachi Ltd.2008 All Rights Reserved.
CIGRE SC A1 2008 Panel Session
25
Bottom coil
Example of Stator Coil Loss Analysis
Linkage fluxSec.1Sec.3 Sec.2
Loss distribution
T
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B
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Eddy current
Circulatig+ DC Total
Stator core
Top coil
End Slot region End
High
Low
T
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B
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Eddy current
Circulatig+ DC Total
T
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B
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Eddy current
Circulatig+ DC Total
State-of-the-art Technology for Large Turbine GeneratorsAugust, 2008Kenichi Hattori*, Kazuhiko Takahashi, Shigeki TohnosuHitachi Turbine Generator Development HistoryCurrentCurrentTypical Structure of 1,000 MVA Class GeneratorStator Core - Clamping Structure -Ventilation of Generator Rotor (4-pole*) Ventilation of Generator Rotor (2-pole only) Ventilation of Generator Rotor (Gap pick-up) Example of Rotor Temperature AnalysisStator Coil - Strand -Example of Stator Coil Temperature AnalysisStator Coil - Coil End Support System -Stator Core - Measures against Overheating -Advanced Technology for Optimum DesignAdvanced Technology for Optimum DesignQuality Assurance and Tests for DevelopmentQuality Assurance and Tests for DevelopmentProven Technology for High-performance GeneratorFuture Design PhilosophyFeatures of Large Turbine GeneratorsThank youCurrent - 4 pole generators -Current - 2 pole machine -Example of Stator Coil Loss Analysis