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A1-117

CIGRE 2008

HYDROGEN / WATER - COOLED TURBOGENERATORS: A MATURE TECHNOLOGY ON THE MOVE R. JOHO* Switzerland Y. SABATER France H. FERRETTO D. ABRAHAM ALSTOM France Germany W. FERENS Poland

SUMMARY
The decades from 1960 to 1980 brought a tremendous growth of hydrogen/water-cooled turbogenerators, resulting in some 1200 MVA for full-speed two-pole units and 1600 MVA for halfspeed four-pole units. This development was mainly driven by the nuclear power generation programs. With the merger of two European manufacturers in 1999, it was decided to continue with the large two-pole line of the one partner and the nuclear four-pole line of the other partner. Possible synergies of the two generator lines were thoroughly examined with the primary goal of increasing reliability and availability. In addition, both series have always been submitted to continuous improvement. Selected examples of related technology improvements will be described. Using the synergies and the continuous improvement the availability of the fleet of large units could be brought up to exceptional high numbers. Both generator lines are currently in uprating of output for power plants beginning operation around 2011-2012. Coal power plants with low-emission technologies are making use of large full-speed turbines, requiring generators up to the 1400 MVA range. Nuclear reactors of the third generation will use half-speed turbine sets requiring generators up to the 2000 MVA range. It is shown how this will be achieved by increase in utilization and by moderate increase in dimensions. Efficiency in power generation has become of utmost importance for caring of the primary energy resources. For the newly developed 2000 MVA generator it will be demonstrated how highest efficiencies can be achieved. The technologies available will also in future allow a potential for uprating. Both generator lines might get further aligned by components, in order to bring their ratings up. Four-pole units will be structured into generator families around different kind of nuclear reactors, for both 50 Hz and 60 Hz, and involving the experienced static excitation, as an option to the well-referenced brushless exciters. By the modular build-up around experienced components the manufacturer will be able to satisfy future customer requirements with a premium performance of the generator.

KEYWORDS
Turbogenerator, Hydrogen-cooling, Water-cooling, Two-pole generator, Four-pole generator, Design, Development

* reinhard.joho@power.alstom.com

1. INTRODUCTION
The years 1960 to 1980 brought a tremendous growth of hydrogen/water-cooled turbogenerators up to 1200 MVA full-speed (two-pole) and 1600 MVA half-speed (four-pole). The main driver was the fast developing nuclear power generation technology. In the mid 80'ies a complete new series of two-pole generators was introduced by a Swiss manufacturer [1]. In parallel an unsurpassed construction boom of nuclear power plants in France was served with four-pole generator solutions by a French manufacturer [2]. The two manufacturers were joining their turbomachinery program in a 1999 joint venture and a subsequent takeover in 2000. The company now cares for a fleet of more than 600 twopole generators and more than 80 four-pole generators. Soon after the merger, the generator program was clearly allocated in the new organisation. Design responsibility is in Switzerland for two-pole and in France for four-pole generators. The manufacturing lead center is in Poland for two-pole generators, in France for four-pole generators, and in Switzerland for rotors. The paper deals with the generator designs from 1985 up, which basically represent the actual main design features.

2. THE HYDROGEN/WATER-COOLED GENERATOR FLEET


Hydrogen/water-cooled generators are driven by steam turbines (Fig. 1,2). They are designed for table mounting. Today, the applied power range is from 600 MW up to the highest ratings. Table 1 shows the MW-classes built for two-pole units, as far as they originate of the new series, started in mid 80'ies. A total of 18 units are in operation for 50 Hz and 60 Hz. They total an EOH (Equivalent Operating Hours) of more than 1 million and an excellent FOR (Forced Outage Rate) of 0.05%. Table 1: Two-pole generators (Class 600 MW up, commissioning since 1985) Plant class Nuclear Coal Coal Coal Coal MW-class 1200 900 800 700 600 Units 1 2 1 5 9 6 50 Hz 60 Hz x x x x x x x Plant references Leibstadt Lippendorf Zimmer Manjung,Amer 9,Hemweg 8 Shidongkou,Staudinger,Rutenberg,.. China (Commiss. 2008/9)

Steam data of modern PWR reactors make it advantageous for turbine performance to run at the next lower synchronous speed, which is at 1500 rpm for 50 Hz, using a four-pole generator. The four-pole generator fleet is listed from 1985 up in Table 2. It consists mainly of second series of P4 types and N4 types of the French nuclear program. The 28 units in operation have accumulated an EOH of more than 1.5 million and have an excellent availability. The present references are mainly 50 Hz, but there is 60 Hz experience from units commissioned before 1985.

Fig. 1: 950 MVA two-pole generator in thermal power station Manjung, MY

Fig. 2: 1722 MVA four-pole generator of the N4 series of the French nuclear power program

Table 2: Four-pole generators (Class 1000 MW up, commissioning since 1985) Plant class Nuclear Nuclear Nuclear Nuclear MW-class 1500 1300 1200 1000 Units 5 18 2 4 6 50 Hz 60 Hz x x x x x x Plant references N4, Oskarshamn 3 Continuation of P4/P'4 Ling Ao II (Commiss. 2010/11) Hong Yan He (Commiss. 2012/14) Ulchin,Koeberg,Chinon

3. DESIGN FEATURES OF HYDROGEN/WATER-COOLED GENERATORS


Hydrogen/water-cooled generators have highest utilization number. The definition is given by C Esson = Sn / (Dr2 lfe n) where Sn: Apparent power, Dr: Rotor diameter, lfe: Core length, n: Rotational speed Both 2-pole and 4-pole generator types are achieving numbers of close to 40 kVAmin/m3. It is evident that such high utilization goes along with high specific loss densities in the generator components, be it in the windings, in the core and in the end regions. The hydrogen serves primarily for heat removal from the rotor winding and the stator core, but is also indispensable for removal of stray field losses in end regions. The water cooling of the stator winding bars is a prerequisite for achieving the high utilization inside the given housing dimensions, which themselves are subject to limits of transportation, especially the Schnabel car railway transportation (Fig. 3).

Fig. 3: A two-pole generator stator being unloaded from Schnabel car to ship Two-pole generators are characterized by (Fig. 4): - Modular housing, center-flanged vertical coolers (Fig. 1) - Range covered by three standardized rotor diameters and stepped core length - Pedestal bearings for isolating shaft from frame vibrations - Rotor winding two-path axial cooling, supported by a high-efficient radial fan on NDE allowing rotor withdrawal without fan removal - Static excitation: Simple technology, fast reacting

Fig. 4: Two-pole hydrogen/water-cooled generator

The proven key technologies applied: - Stator end winding: Clamped between rings, axial movable, support re-tightenable - Stainless steel stator bar water tubes - Laminated conical core press plate - Single- and triple-circuit shaft seal system The water tubing in the stator bars in stainless steel technology is in operation for over 30 years [3]. It is since more than 20 years the standard solution, with an excellent operation record worldwide. Customers recognize the robustness of the system, which is characterized by a functional separation of electrical connection and water box (Fig. 5).

Fig. 5: Stainless steel water tubing and functional separation of bar connection and water box

Fig. 6: Triple-circuit shaft seal: Floating rings (FR), separating the oil flows

The triple-circuit shaft seal is a unique system, used successfully for over 35 years in more than 100 hydrogen/water-cooled generators. It works with a supply of air-saturated oil and a supply of hydrogen-saturated oil, separated by an injection of vacuum oil (Fig. 6). A leakage rate of less than 5 Nm3/day at highest unit pressures of 6 bar(g) and a high hydrogen purity inside the generator, which reduces the gas friction loss in the generator, by far outweigh the higher investment. The system is fully modularized, including the shaft seal oil system auxiliary. It is applied depending on generator type, shaft diameter and rated hydrogen pressure.

Typical data of a large two-pole generator are shown in Table 3. Table 3: Typical data of a large two-pole generator [4] Model Class MVA pf UN Speed SCR pH2 (gauge) Efficiency Excitation GIGATOP 2-pole 934 MW 1167 MVA 0.8 27 kV 3000 rpm 0.51 5 bar 98.88 % Static

Fig. 7: Housing structure of a four-pole generator

Four-pole generators are characterized by (Fig. 8): - Modular housing, flanged channels for hydrogen ducting, vertical coolers in end covers (Fig. 7) - Terminal box on NDE, if needed on NDE and DE - Range covered by two standardized rotor diameters (each frequency) and stepped core length - End shield bearings - Single-circuit shaft seal (now also triple circuit) - Rotor radial-transversal cooling (now also multi-path axial), axial fans on both ends

Fig. 8: Four-pole hydrogen/water-cooled generator The proven key technologies applied: - A cantilevered brushless exciter (Fig. 9). The armature and the diode arrangement of this unique type of exciter are housed in a steel ring of bell shape, which is flanged to the rotor end. The dc field is inserted coaxially in the armature bore. The short design eliminates the usual third bearing. This results in a short overall length and an excellent shaft dynamic behaviour.

Fig. 9: Cantilevered brushless exciter

Fig. 10: Stator end winding support - A reinforced stator end winding support (Fig. 10), that has proven its sustainability in many generators. It is characterized by a solid outer glass-fiber ring and the winding ends bolted to the outer ring. This gives excellent radial and circumferential stiffness. A flexible support system allows the axial thermal cycling of the end winding. Typical data of a large four-pole generator are Table 4: Typical data of a large 4-pole generator shown in Table 4. Model GIGATOP 4-pole Class 1550 MW MVA 1722 MVA pf 0.9 Running tests for: UN 20 kV -Confirmation, -Verification, -Extrapolation Speed 1500 rpm SCR 0.38 The verification of the performance of pH2 (gauge) 3.8 bar hydrogen/water-cooled generators is done in the Efficiency 98.93 % acknowledged way of factory running tests Excitation Brushless, cantilevered (Fig. 11). As an established practice, these are Terminal Double terminal box routinely done on first units of a generator type, and are in accordance to the relevant international standards. The challenge for largest units is to provide the driving motor up to 15 MW, for both frequencies, for the electrical test runs according to the segregated loss method, and the rigid mounting on the factory hall floor. The culmination is the routinely performed sudden short-circuit test from up to 70 % rated voltage. In addition to performance confirmation for the customer, by additional special tests, the manufacturer gets valuable information to verify the design tools, which is also essential as a base for designing higher ratings. As part of the manufacturing process, all rotors are routinely passing test runs in the overspin test bed, such as excited heat runs, balancing runs, and an overspeed test at 120 % rated speed.

Fig. 11: Factory running tests on a 800 MVA two-pole generator

4. EXAMPLES OF CONTINUOUS IMPROVEMENT


The continuous product improvement system involves component improvements, learnings from operation experience, technology alignments. The continuous product improvement system is strictly subject to the same stringent product development quality rules as applied for new developments. In the following, the scope is explained by way of examples. 4.1 Laminated conical press plate A critical issue of the largest two-pole generators is the core end heating in underexcited operation. As a longstanding practice, large two-pole generators with hydrogen/water cooling are equipped with laminated press plates on the ends of the core. They consist of stacked laminations, which are compacted to a ring by vacuum pressure resin impregnation. By its one-side conical shape such a press plate receives and internally guides part of the magnetic stray flux of the end winding at lowest losses. Facing a continuous uprating of two-pole generators, a special investigation was done in a performance enhancement of the press plate. Supported by electro-magnetic and thermal numerical calculations a couple of design improvements were found. The main improvement consists in an enlargement of the lateral clearance of adjacent laminations, and the insertion of radial slits extending from the slot bottom into the yoke (Fig. 12). Both measures serve to sustainably reduce eddy currents produced by axial flux components. The improvements were integrated into the manufacturing process of press plates. The solution is also available for replacements.

Fig. 12: Laminated conical press plate with enlarged clearances and radial slits

4.2 Cross-transposed four-stack Roebel bars The use of twin Roebel bars is an established solution in large generators having water-cooled winding bars (Fig. 13). However they need an individual coil connection of the two Roebel bars in the end winding, and an additional cross-change per coil. An alternative, much easier solution is the concept of a cross-transposed four-stack Roebel bar (Fig. 14), which gives a continuous field neutralization inside each bar while keeping a simple manufacturing of the Roebel bar [5]. Since all such bars end in one large solid lug on both sides, this contributes to a considerable simplification in the stator bar end connections.

Fig. 13: Twin Roebel bar

Fig. 14: Principle of cross-transposed Roebel bar

4.3 Rotor cooling of four-pole generators As a long-standing practice, four-pole generators are equipped with a radial-transversal cooling of the rotor winding [2]. Although a proven solution it is rather complex and not suited for supporting a further increase in unit output. Facing this situation, a cooling concept of a small air-cooled type was checked and found to have potential for largest sizes. This multi-path forward flow cooling system gives uniform temperature distribution in axial and radial direction with a highly efficient use of cooling gas, and was found an optimum solution for highest ratings (Fig. 15). Because the conductors have two parallel gas ducts: The shown gas flow applies to one half cooling of the copper stack. The second half cooling (symbolized by gas outlets) is arranged with a half-pitch shift, and thus contributes to an even more uniform temperature distribution.

Fig. 15: Principle of multi-path forward flow cooling in rotor winding (2nd slot half indicated by gas outlets) 4.4 Technology alignments of four-pole generators From a manufacturer's standpoint, after merger with another manufacturer, it is obvious to compare the two existing technology lines, and to check for alignment. A detailed analysis has led to the following technology alignments of four-pole with two-pole technology: - The stainless steel tubing for the cooling water in the stator bars. This unique and robust technology is widely approved and, with the stainless steel water box gives highest availability. - The Micadur VPI (Vacuum Pressure Impregnation) system, used for the stator bar main insulation, is generally applied. This results in a unique insulation system up to the experienced 27 kV of two-pole units, and prepares for the 30 kV range. - The triple-circuit shaft seal will be applied for the new EPR generator series, which has a hydrogen pressure equal to experienced levels of two-pole units. The hydrogen loss thus can be kept at a low 5 Nm3/day.

5. TRENDS TOWARDS HIGHER OUTPUTS


A new area of large power plants brings along a need for larger steam turbines and thus for generators. There is a revival of coal plants using low-emission technologies. This goes along with a need for twopole generators beyond 1000 MW. Current projects in Germany require generator ratings up to 1400 MVA. For the new nuclear power plants of the third generation, projects require four-pole generators with ratings up to 2000 MVA (Table 5). Table 5: Typical data of a large four-pole generator for EPR (Project Flamanville 3) Model Class MVA pf UN Speed SCR pH2 (gauge) Efficiency Excitation GIGATOP 4-pole 1750 MW 1944 MVA 0.9 23 kV* / 27 kV 1500 rpm 0.42 6.0 bar 99.00 % Brushless, cantilevered

* requiring terminal box on NDE and DE

The following shows the approach of the generator manufacturer for the current and future uprate requirements of the market. Manufacturer's approach Increase hydrogen pressure Moderate increase in length Moderate increase in rotor diameter Reduced temperatures in end zone High-efficient rotor cooling Increase rated voltage Uprate brushless exciter Achieved by Enabled by triple-circuit shaft seal Checked by shaft dynamic calculation Mechanical optimization by finite element analysis Low-loss laminated conical press plate (two-pole) Improved cooling of copper shield (four-pole) Multi-path forward flow cooling Based on existing insulation system, limits current loading in stator bars and bushings Refine cooling in cantilevered exciter

This means that also the future requirements can be accomplished by using hydrogen cooling technology for the rotor winding and water cooling technology for the stator winding. These technologies and all related designs are based on mature and highly reliable solutions and allow a predictable availability and a reliable maintenance scheduling [6]. Future work of the manufacturer will also involve structuring of generator families around the different kinds of plant types, for 50 Hz and 60 Hz, and taking into account differing electrical performance requirements. A flexible modularization will allow combining static excitation with fourpole generators. Although short circuit ratios of 0.4...0.5 in this large power range are widely accepted, special SCR requirements may be considered by an optional air gap (by increasing the stator bore diameter), while keeping all other dimensions. Of course such a special option will result in a derating on other generator performances. A plant layout option for the large sizes will be the single terminal box on NDE for a high rated voltage, and a double terminal box for a low rated voltage.

6. CONCLUSIONS
A large hydrogen/water-cooled generator fleet and the shared experience of the two merged generator engineering communities results in a broad design and operational know how. The responsibilities for the two-pole and the four-pole generator line were clearly allocated. Despite the maturity of the product there is always room for continuous improvement of the components and technologies, for using synergies, and for further alignment of the technologies. The market will require considerable higher generator outputs. The investigations show that even these larger units will be based on robust, proven and accepted generator technologies and designs, hence remain in fields of known high performance reliability.

BIBLIOGRAPHY
[1] [2] [3] [4] [5] [6] K. Weigelt, Design Features of Large Turbogenerators, ABB Review 1/1989 J.M. Guillard, R. Damiron, J.C. Marino, 1710MVA Generators for the French N4 Nuclear Stage, CIGRE Session 1988, Paper 11-06 J. Oliver, J. Michalec, B. Zimmerli, R. Joho, N. Krick, A. Huber, Generator Winding Design Amos 3 with 25 Years Experience, IEEE Transactions on Energy Conversion, Vol.16, No.1, March 2001 L. Busse, K.-H. Soyk, World's Highest Capacity Steam Turbosets for the Lignite-fired Lippendorf Power Plant, ABB Review 6/1997 J. Haldemann, Transpositions in Stator Bars of Large Turbogenerators, IEEE Transactions on Energy Conversion, Vol.19, No.3, September 2004 M. Verrier, M. Thiery, P. Chay, G. Martinet, New Development in the Design of Generators for Nuclear Power Plants with Reliability Target, CIGRE Session 2004, Paper A1-105

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