GENERATOR Cooling System

PRESENTED

BY

Mahendra Singh Asstt.Director

COOLING SYSTEM
STATOR SLOT

ROTOR SLOT

ACA - THW - 3 / 76

A. C. ARON 24 02 2001

MVA vs Cooling
R = Direct Radial W = Direct Water D = Direct Axial A/H = Air/Hydrogen
1860

Stator Cooling Rotor Cooling

TAR I 4 P:TAII

THWW 4P THW / THDF 1560 THDD 1150 412 880 THRI

ALSTOM
290

500

30 45

MV A

200 300 450 1000 1700

ACA - TG - 80 HO 3 A. C. ARON

TURBOGENERATORS COOLING
STATOR: I: INDIRECT COOLED W/F: DIRECT WATER ROTOR: R: RADIAL DIRECT THW / THDF D: DIRECT AXIAL 1150 THRI 412 200 300 450
ACA - THW - 4 / 79

1000 1700
A. C. ARON

MVA

THW-210: TECHNICAL SPEC.

 247

MVA, 210 MW, 15.75 kV, 9050A  Rotor field: 2600 A, 310 Volts  Negative sequence capability: 8  Short circuit ratio: 0.49  Ceiling to rated excitation 2.0  Field forcing: To nominal current: 1.5 10 sec  Response time: 40 milli sec
ACA - THW1 - 5 / 76

THW-210: TECHNICAL SPEC. - 2

at full load: 98.6%  3 phase short circuit currents: I sub transient 9.7 pu I transient 3.8 pu I steady state 1.4 pu  Hydrogen pressure: 3.5 kg/cm g  Maximum cold gas temp.: 44C  Moisture in H2: 15 gm/m (RH <30%)  DM flow in winding: 27 3 m/ hr
 Efficiency
ACA - THW1 - 6 / 76

THW-210 MW : TECH. SPEC.- 3

Zero pf lead: 75 MVA max.  Heat load: 528 kW per cooler Max cold / hot gas temps: 44 / 60C CW flow per cooler: 87.5 m / hr. Maximum CW inlet temp : 37 C Cold gas temp. minimum : 20 C  PW heat load: 751 kW  PW inlet / outlet temp.: < 44 / 75C  Temperature below 39C not desirable

ACA - THW1 - 7 / 76

THW - 210 MW: TECH. SPEC. - 4

 Short

overloading: 10.0 kA 15 min  Both ring seals oil flow: 77 litre/min  Critical speed(calcul.): 1330, 3912 rpm  Stator wt. with coolers: 170 ton  Stator shipping weight: 169 ton  Rotor weight 42 ton  Total generator weight 239 ton  Stator dia / length 3.96 / 6.58 m  Rotor dia / length 1.075 / 9.77 m
ACA - THW1 - 8 / 79

CAPABILITY DIAGRAM
80 40 MW
TURBINE LIMIT 210 STABILITY LIMIT 200
WITH AVR ROTOR ANGLE LIMITER

80 120 160 200 0.85 0.8

H2 3.5 Kg 3Kg

0.8 0.6
WITH REACTIVE CURRENT LIMITER
9 / 79

160 2Kg H2 120 80 40

0.6 0.4
ROTOR HEAT LIMIT 200
A.C.ARON

1Kg

LEADING 80

40MVAR 40

LAGGING 80 120 160

THW 210: OCC AND SCC

15.75 KV, 9.05 KA 24 20 STATOR VOLTS 12 KV 8 4 0
ACA - THW1 - 10 / 79

U0

16 ISC

STATOR CURRENT KA 12 8 4 0

400

800 1200 1600 2000 2400

A. C. ARON 99 08 05

EXCITATION CURRENT AMP

THW 210: V CURVES

9000RATED 9050 A 100% LOAD 8000 7000 75% STATOR 6000 0.9 PF 0.85 PF CURRENT5000 1.0PF 0.8 PF 50% AMP 4000 3000 0.9 0.95PF 25% 2000 1000 RATED 0 800 1200 1600 2000 2400 2600
A. C. ARON 99 08 05

EXCITATION CURRENT AMP

ACA - THW1 - 11 / 79

THW-210:UNLOADING SCHEDULE
HIGH COLD GAS TEMP.
9050 8600 8200 280 RATED CURRENT 9050 A STATOR CURRENT

7800 260 RATED 247 MVA 7400 240 AMP MVA 7000 220 MVA

220

200 6600 200 OPERATION AT >55C 6200 180 180 NOT ALLOWED 5800 160 44 COLD GAS C 160 42 (NOMINAL) 46 48 50 52 54 55 A. C. ARON

THW-210 : UNLOADING SCHEDULE

DM WATER TEMP.
CURRENT AMP 9000
RATED 9050 A 8900 STATOR CURRENT 8800 RATED 247 MVA 8700 248 8700 8600 244 MVA 8600 8500 240 8500 8400 236 236 OPERATION >48C 8300 232 232 NOT ALLOWED 8200 44 45 46 43 47 48

DM WATER TEMP C

ACA - THW1 - 13 / 79

A. C. ARON

STATOR CURRENT OVERLOAD

THW - 210 MW GENERATORS STATOR CURRENT P.U. 1.5
1.4 1.3 1.2 1.1 1.0 0 1 2 3 4 5 6 15 60

TIME IN MINUTES
ACA - THW1 - 14 / 79

A. C. ARON

THW-210: ROTOR CURRENT

CURRENT
200% 150% 120% 106% 0 20 60

240

3600

TIME SECS.
ACA - THW1 - 15 / 79

A. C. ARON

THW-210 : NEGATIVE SEQUENCE CURRENT CAPABILITY

10 8
2 I2 = 8 I2 . tt = 8

TIME t SEC

6 4 2

I2 CONTINUOUS: 5% OF
RATED STATOR CURRENT

A. C. ARON THW 16 / 79

I2

00

(I2 IN PU OF STATOR CURRENT )

10

FREQUENCY VARIATIONS
 Generator

permits operation with wide frequency variation.  Turbine LP last stage blades 6 do not permit operation with wider frequency range because of resonance.

ACA - THW1 - 17 / 79

A. C. ARON

THW-210: VOLTAGE-FREQUENCY
+10% +5% OVERFLUXING LIMITATIONS

+5%

VOLTAGE -10%
-5% -10%

-5%

+5% -5%

+10%

ACA - THW1 - 18 / 76

FREQUENCY WITH CHANGE IN VOLTAGE, STATOR CURRENT TO BE CHANGED

A. C. ARON

EFFICIENCIES - THW 210

99 98.5 98 EFFICIENCY % 97.5 97
ACA - THW1 - 19 / 76

98.6

25 50 75 % RATED MCR

100
A. C. ARON

STATOR CONSTRUCTION
 Explosion

proof stator body.  32 mm steel casing gives low noise.  Slotted spring core bars used to suspend the stator core.  Low loss C.R.N.O. core steel used.  Nonmagnetic steel core end press-rings.  Water-cooled 9 terminal bushings.  Terminal plate,press-fingers & fasteners near stator winding are nonmagnetic.
ACA - THW1 - 20 / 76 HO

STATOR COOLING
 Losses

in stator core & winding.  Core losses go to hydrogen gas.  Winding losses to winding water.  Winding temperatures are low by design.  If flow fails,copper temp. rises >150 C. (Refer to Techinfo)  If few hollow conductors plugged - heat is carried by others.
ACA - THW1 - 22 / 79 HO

THW : VENTILATION SCHEME

B C SEC C-C SEC B-B

C
A. C. ARON 99 07 19

ACA -THW1 - 23 / 79

STATOR WINDING
WATER SYSTEM
GAS TRAP EXPANSION TANK FLOW METERS DIFF PRESS SWITCH

MAGNET FILTER
FSI I

FILTERS

DIFF PRESS. CONDUCTIVITY MAKE UP

POLISH UNIT

COOLERS PUMPS
ACA - THW1 - 49/82 A. C. ARON 99 06 26

VACUUM PUMPS

STATOR CORE & VIBRATIONS

REFER TO TECHINFO, RIHAND

 100

Hz vibrations in stator body come from stator core.  Damping is achieved by slotted low alloy steel core bars that support laminations.  Damping ratio is approximately 5 : 1.
 Core

vibrations are less than 200 microns.  Vibrations in core end packets are very harmful and damage stator winding bars.
ACA - THW1 - 24 / 79 HO

STATOR WINDING
 There

are 120 winding bars - two in each slot. They are made up of hollow and solid ETP copper conductors that are Roebel transposed to reduce losses.  1500 brazed, welded,contact joints.  Hollow conductors tested: 75 bar.  Finished winding tested: 12 bar 12 hrs.  Copper headers, brass / stainless steel nipples, Teflon tubes for water feeding.
ACA - THW1 - 28 / 77

STATOR WINDING - 2
 Winding

is fed with DM water. DM water has electrical insulating property.  Water quality: Low / high oxygen, No CO2 in water  Overhang bracing.  Use of prepregs.  Ripple springs : Top of bar in slot Side of bar in slot
ACA - THW1 - 29 / 79

STATOR END WINDING

INNNER RINGS INSULATED METALLIC RINGS & BRACKETS (FOR BITUMEN INSULATION ONLY)
ACA - THW1 - 30 / 77 A. C. ARON 99 07 20

VIEW FROM TURBINE END

6T/ 31B 5T/ 30B

16 15 25 26

NOISE JOINTS
6 5

18 51T/16B 33 48
45 46

20T/45B

W
21T/46B

E
50T/15B

35 36

56 55

35T/60B
ACA - THW1 - 31 / 82

36T/1B

RASHMI 13 05 2000

VIEW FROM SLIP RING END

25B 1T 18 15B 35B 11T

E
51T

3 48 41T 5B

33

45B W 21T

31T 55B
RASHMI 17 05 2000

ACA - THW1 - 32 / 82

TURB. SIDE

STATOR WINDING - 3
OVERHANG TOP RIPPLE SPRING SOLID HOLLOW UPPER BAR LOWER BAR OVERHANG
ACA - THW1 - 33 / 82 A. C. ARON

RTD

SLOT PART

SIDE RIPPLE SPRING

EXC. SIDE

WINDING WATER HEADERS

WATER HEADER STEEL CLAMP BRASS NIPPLE CHECK NUT SS NUT

CASING INSULATORS
ACA - THW1 - 35 / 82

TEFLON TUBE & SS FITTINGS

RASHMI 11 05 2000

WINDING WATER HEADERS - 2

LOCK WASHER SEAL WASHER

DM WATER

TO GAS TRAP DEVICE

ACA - THW1 - 36 / 82

CHUCK NUT
A C ARON 03 SEP 2002

THW: STATOR WDG. NOSE JOINT

TURBINE END
UPPER BAR

LOWER BAR Cu TUBE SS FITTING TEFLON TUBE

ACA - THW1 - 37 / 82

RASHMI 05 05 2000

THW: STATOR WDG. NOSE JOINT

SLIP RING END
COIL LUG SS NIPPLE

UPPER BAR LOWER BAR

SS NIPPLE SS NUT Cu PIPE Cu WEDGES FERRULE

ACA - THW1 - 38 / 82 RASHMI 05 05 2000

Merits: Ease in disassembly. No rubber in sealing.

STATOR WATER QUALITY

 Copper

pick up in stator water is normal phenomenon. Maintaining water quality restricts it to say 25ppb. However upto 200 ppb noticed without any problem.  Dissolved CO2 in water to be nil and Dissolved O2 < 100ppb.  pH value to be between 6.5 - 8.5.  Water conductivity: 1 - 5 micro Mho/cm  Iron content in water to be < 20 ppb.
ACA - THW1 - 39 / 82 HO

STATOR WATER QUALITY - 2

 No

Ammonia, Hydrazine, Phosphates, Chloride are allowed in water.  In Open systems, O2 and CO2 get dissolved in water. Oxygen with copper forms 1 Micron CuO2 film, that gets destroyed by CO2 and the process continues.  Losses in teflon tubes are highest when conductivity is equal or greater than 40 micro Mho / cm.
ACA - THW1 - 40 / 82

TEFLON TUBES
ELECTRICAL POWER STATIONS No 7, 1969, USSR

 Length

of teflon hoses is so selected that the DM water column produces less heat and that water does not boil if flow gets stopped for 4 minutes.  Boiling water steam prevents flow.  If circulation stops, and water has high conductivity: 250 - 300 Micro mho/ cm, leakage current rises to 60-70 mA and breakdown occurs.
ACA - THW 1- 41 / 82 HO

TEFLON TUBES - 2
ELECTRICAL POWER STATIONS No 7, 1969, USSR

 Teflon

tubes may get coated with slag having Cu 6 - 8%, Fe 3 - 5%, oil and organic substances. Dielectric strength of tube drops to 20% of original value. For a healthy tube being 4 - 6 kV/cm.  In black Teflon tubes, H2 diffusion is 3 Cu cm/cm length per day. For 500MW design this gives diffusion of 100 cc per hose per day.
ACA - THW1 - 42 / 82 HO

TEFLON TUBE TOTAL LOSSES

BALABANOV ETC., ELEKTRICHESKIYE STANTSIYA N6 1971

40 30 LOSSES 20 KW 10 0
WORK RANGE

40 30 20 10 0

2.5 3.3 5 10 WATER CONDUCTIVITY

MICRO MHO / cm
ACA - THW1 - 43 / 82

A. C. ARON 99 06 30

SPECIFIC RESISTANCE VS. TEMP. FOR CHEMICAL PURE WATER

BALABANOV ETC ELEKTRICH STANTSIYA N6 1971

10 SPECIF. RESISTANCE 8 OF 6 WATER 4 OHM M 10 4 2 0

ACA - THW1 - 44 / 82

30 40

50

60

70

80

90
A. C. ARON 99 06 30

TEMP. C

STATOR WATER SYSTEM

 Stator

water pumps, coolers, filters, all 2 x 100%. Magnetic filter is 1 x 100%.  Pumps are single stage centrifugal type with spiral casing & overhung impeller.  Polishing unit consists of anion + cation resins. It maintains water purity and therefore conductivity also. Ions are exchanged within very short time.  In VSTPP, no polishing unit provided.
ACA - THW - 46 / 82 HO

STATOR WATER SYSTEM - 2

 Choked

filters are cleaned when differen. pressure reaches 0.4 Kg /cm. Measure differential pressure across the filters.  Hot water enters expansion tank through perforated pipe,releasing entrapped gas.  Make up water is fed through a float operated level regulator.  Conductivity meters initiate alarms and if it is High High, machine is auto tripped.
ACA - THW1 - 47 / 82 HO

STATOR WATER SYSTEM - 3

 Vacuum

in the expansion tank helps to keep conductivity low. Conductivity is measured at ion exchanger outlet and at inlet to stator winding.

ACA - THW1 - 48 / 82 HO

WINDING LEAKAGES
 Leakage

are caused by winding vibration and may lead to excessive temperatures.  H2 gas shall enter into winding affecting its cooling. This is also unsafe since H2 gas consumption goes up.  There is danger of flashovers. Machine to be stopped and hydrogen is removed. Hydraulic test and - visual checks done. Machine may have to be dismantled.
ACA - THW1 - 51/ 82 HO

WINDING LEAKAGES - 2
 Skilled

personnel to be called for repair. Leakage repaired by plugging affected hollow strips by brazing or by vacuumepoxy method. Later method works for several years.  Root cause to be found out by general inspection of windings.  Hydraulic and pneumatic tests are done before and after repairs. Electrical and high voltage tests to be done if required.
ACA - THW1 - 52 / 82HO

WINDING VIBRATIONS - 2
RADIAL VIBRATIONS UPPER BAR LOWER BAR TEFLON TUBES TANGENTIAL VIBRATIONS

ACA - THW1 - 55 / 82 HO

A. C. ARON 1999

ROTOR
 Cross

- pole slots given in 235 MW only.  Forged half coupling shrink fitted.  Non magnetic steel retaining ring nuts provide threaded nut axial locking.  Rotor winding has 706 kW ohmic losses  Gap pick up type direct H2 gas cooling gives intensive and uniform cooling of rotor winding copper.
ACA - THW1 - 55 / 82 HO

ROTOR WINDING
 Direct

Hydrogen gas cooling.  Self ventilation against forced ventilation  Epoxy-glass glued inter turn insulation.  Slot insulation 2 mm thick U-shape cell.  Slot wedges are optimally designed for maximum ventilation effects. They are made of Duraluminium for low stresses.  Wedge tightness not insisted now.
ACA - THW1 - 57 / 82 HO

ROTOR WINDING - 2
 Top

and bottom insulation liners have high mechanical and thermal strengths  Rubber insulated small C.C. bolts now replaced by epoxy insulated ones.  Plugs used for purge tests shouldnt be left in rotor before insertion or during heating the winding to improve its IR. They may get burnt, reducing rotor IR.
ACA - THW1 - 58 / 82 HO

ROTOR SLOT
WEDGE TOP PACKER Cu TURNS INTER TURN INSULATION SLOT CELL CREEPAGE PATH*

35

BOTTOM 27 PACKER *ABOUT 2800 CREEPAGE PATHS IN ROTOR CAUSING CREEPAGE RESISTANCE TO FALL.
ACA - THW1 - 59 / 82

99 04 20

A.C.ARON

ROTOR COOLING
 Direct

gas to copper contact.  Gap pick up ventilation provides self ventilation effect in slots.  More than 35 cooling paths / slot.  4 flute cooling in overhang.  Fans force gas flow in overhangs.  Maximum to average temp. ratio low.  IEC-34 permits120C for Cl B &135C for Class F for >8 gas outlets per slot.
ACA - THW1 - 60 / 82 HO

GAP PICK UP - ROTOR VENTILATION

4 - FLUTE COOLING IN OVERHANG OVERHANG SLOT PART

HOT GAS INLET ZONE

OUTLET ZONE

VIEW P SLOT BOTTOM PACKER

ACA - THW1 - 61 / 82 RASHMI 99-09-15

ROTOR WINDING OVERHANG

 Retaining

rings hold copper. Two layers of glass epoxy insulation provided under retaining rings. Nonmagnetic steel ring threaded nuts provide axial locking.  Over hang copper is cooled by H2 gas.  Long creepage paths are provided. Still Cleanliness of H2 gas is important.  Glass - Epoxy insulation packer blocks between Copper coil stacks provided.
ACA - THW1 - 62 / 82 HO

Thanks

ACA - THW1 - 62 / 82 HO