1000MVA Class Geneartors For India by Siemens PDF

Siemens Power Generation 2006.
All Rights Reserved
Water-Cooled Generators for

Power Projects in India
1000 MVA Class
Jan 2006
Power Generation PG P2
Generator Organization and Network
Individual Plant Management
Integrated Network Organizations

Order
Management
Design
Engineering
Supply
Management
Charlotte
Ft Payne
CHARLOTTE - New Units >

CHARLOTTE - New Units >
140 MW and Generator
140 MW and Generator
Service
Service
FT. PAYNE - Component
FT. PAYNE - Component
Parts and Assemblies
Parts and Assemblies
Charlotte
Ft Payne
ORLANDO - Back office support for

ORLANDO - Back office support for
Engineering/ Supply Management / Order
Engineering/ Supply Management / Order
Management
Management
Jan 2006

Orlando
Mlheim
Erfurt
ERFURT - New Units < 140 MW

ERFURT - New Units < 140 MW
and Stator Core Material and
and Stator Core Material and
Components
Components
Mlheim
MLHEIM - Generator
Erfurt MLHEIM
- Generator
Service
Erlangen
Service
OFFENBACH & ERLANGEN OFFENBACH & ERLANGEN Back office support for Order
Back office support for Order
Management
Management
Power Generation PG P2 2
Siemens Power Generation 2006. All Rights Reserved
Global Network
Generator Product Line
Generator Product Line Overview

50 and 60 Hz
MVA
(2 and 4 pole)
0
100
200
300
400
500
600
700
800
900
1000+ MVA
Watercooled
Hydrogencooled
Aircooled
Jan 2006

Meeting the Customers Power Needs
SIEMENS Generators Proven

Technology with Highest Availability
Type:
Design features
Two and Four-pole generators with:
Water-cooled stator winding
Hydrogen / Gas-, Water-cooled rotor
Excitation: Static or Brushless
Advantages
Highest availability due to extremely
low forced outage rate
Essentially maintenance-free stator
core and excitation system
High quality groundwall insulation
system
References
Approximately 150 generators installed
throughout the world with ratings
of 450 MVA to 1640 MVA
(Approximately 90 - Fossil; 60 Nuclear)
Jan 2006

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
MicalasticTM 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
Jan 2006

Key Features for 1000 MVA Class
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
Jan 2006

Generator Fleet Experience
Jan 2006
THDD series
78 generators
THDF series
57 generators
rated power
> 800 MW
THDF 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

References
SIEMENS Generators High Efficiency and High Availability

Technical Data
Type
Rated power
Power factor
Nominal voltage
Frequency
Water-Cooled (Stator)
450 - 1600 MVA
0.8 - 0.9 lagging
18 - 27 kV 5 %
50/60 Hz
High Efficiency 1)
High Availability
Forced outage rate [%]
1.0
0.82
FOR = 100 x
FOH
FOH + SH
0.8
FOR = Forced outage rate

FOH = Forced outage hours
SH = Service hours
0.6
0.4
100 % load
75 % load
50 % load
1)
Jan 2006
98.90 %
98.95 %
98.90 %
at 765 MVA; power factor 0.9

with tolerance acc. IEC 34-1

0.2
0.08
SIEMENS generators
Period: 1988 - 1994
NERC
average value
Reference
Reference
z Design Rating at 40C Cooling gas temperature
1150 MVA
z Power factor
0.85
z Voltage
27 kV
z Frequency
50 Hz
z Maximum transportation weight
443 Mg
z Weight of Stator including bearings, cooler head 505 Mg
Jan 2006
z Weight of Rotor
92 Mg
z Core length
6700 mm
z Rotor body diameter
1250 mm

Generator THDF 125/67 main Data
Generator outline drawing
Jan 2006

Stator frame
Bearing bracket
Cooler head
Stator winding
with stainless
steel tubes
Terminal box
Lifting plates
Compressor
Rotor
Bearing bracket
Jan 2006

THDF 125/67 all over design
Cooling Gas System
Jan 2006

Jan 2006

1 Core beam
3 Lamination
2 Insulation
4 Copper rope
Stacked outside frame
Insulated rectangular core beams
Core beams welded to end plates
Welded spring baskets
Stator core
Core to frame attachment
Jan 2006

Spring mounted
core suspension
Welded through
man holes
Jan 2006

Spring mounted core

suspension
Welded through man

holes
Core to frame attachment
Jan 2006

Gas cooled parallel

rings
Stator end winding design
Stator end winding design
Jan 2006

Gas cooled parallel

rings
The Micalastic insulation system uses solventless, heat reactive resin

impregnant and a vacuum-pressure-impregnation (VPI) process.
Micalastic is a class F insulation system
The excellent electrical properties of the resin, coupled with good
insulation consolidation result in:
Low insulation power factor
High electrical strength
High voltage indurance
The resiliant nature of the resin bond permits elastic cyclic
displacement of adjacent mica flakes and provides restoring force
within the insulation groundwall
Micalastic is ideally suitable for cyclic duty operation
Jan 2006

MicalasticTM Insulation System
Stator slot
Jan 2006

Stator slot
540 Roebel bar

Jan 2006

Jan 2006

Stainless steel tubes
Stainless steel water boxes
Water box supports copper

to stainless steel welds
Stator bar connection & water supply
Rotor
Machined from NiCrMoV alloy steel vacuum degassed forging

Tested ultrasonically for quality assurance
Designed with multi-stage axial blowers
Designed for bolt-on excitation system
Jan 2006

Jan 2006

Rotor end winding with

corner brazing
Finish drawn copper

profile
Asymmetric cold gas

inlet & outlet in straight
portion
D-cooling-system for rotor
Cooler Head
Bearing bracket side
Cooling water inlet & outlet

from top side
Avoid of sealing problems due

to termal expansion
Generator side
Jan 2006

Cold gas inlet

openings to
frame
Generator bearing
Jan 2006

Terminal box & bushings
Gas cooled bushings

Jan 2006

Anchoring of generator
Jan 2006

Exciter
Jan 2006

Exciter Rotor
Jan 2006

Exciter Rectifier Wheels
Jan 2006

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 auxiliary

systems
Hydrogen gas system

Seal oil system
Stator primary water system
Jan 2006

BGR 2880
Dichtlvorratsbehlter/
SEAL OIL STORAGE TANK
BGR 3053
PW-Behlter/
PW TANK
BGR 2770
Gastrockner/
GAS DRIER
BGR 2730
CO2 - Flaschengerst/
CO2 - BOTTLE RACK
BGR 2735
CO2 - Entspanner/
CO2 -FLASH EVAPORATOR
BGR 3052
Abgasverorgung/
WASTE GAS PIPING
BGR 2860
Flssigkeitsgebergerst/
LIQUID DETECTOR RACK
BGR 2860
Schmutzflssigkeitsbehlter/
WASTE FLUID TANK
BGR 2504
PW Pumpen-und Filter Aggregat/
PW PUMP AND FILTER UNIT
Jan 2006

BGR 2700
H2-Aggregat/
H2-UNIT
BGR 2720
H2-Flaschengerst/
H2-BOTTLE RACK
BGR 2800
Einfluss-Dichtlaggregat/
SINGLE FLOW SEAL OIL UNIT
Generator Auxiliaries Overview
Gas system
Simplified Diagram
1 H2 Bottle
2 H2 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 H2/Ar Purity Meter System
13 Multi-Way Valve before
H2/Ar Purity Meter System
14 Humidity Detector
Jan 2006

Components
H2 Supply
H2 Consumption
Measuring Device
Inert Gas
Option
Bottle Rack
Central Supply Unit
No
within the //
Argon
CO2
Inertisation
Process
Hand Valves
Automatic / Remote
Control Valves
Gas Dryer
Single Tower
Double Tower
No
Yes
Stand Still Blower

for Gas Dryer
Jan 2006
Standard

Gas System
System Design
Components:
Compressed air filter
Hose as a visible
break
Shut-off and changeover valves
Transmitter
Local indicator
Electronically purity
measuring device
Flow meter
...
Jan 2006

Gas System
H2 Unit (Example)
Gas System
Purging with Argon
Atmosphere
M
Gaseous CO2
Liquid CO2
to Generator
CO2Container or
CO2Bottles
Flash evaporators
Advantages:
Saves outage time
Fast inertisation
Increases Safety:
Purging every time
possible without use of
electrical energy
No evaporation
necessary
More Reliability
Simplified system
Gaseous
Argon
to Generator
Gaseous
Argon
ArgonContainer
or ArgonBottles
Less dangerous for the

staff
Argon is non-poisonous
Example:
Example: Typical
Typicalsteam
steamturbine
turbinegenerator
generator
Saves
2
hours
outage
time
for
each
Saves 2 hours outage time for eachpurging
purging
Jan 2006

Normal Practice: Purging with CO2
z Redundant electrical purity meter with high

accuracy
z Argon as purging gas with the advantage to purge
the generator without additional energy
z Automatic purging process possible
z Optimized monitoring
(Transmitter and local indicators)
Jan 2006

Gas System
Features & Advantages
These seals are located around the rotor

shaft where it penetrates the generator
bearing brackets
AirSide
The seals help prevent:

- hydrogen from leaking out of
the generator
- while minimizing the amount
of air and moisture that can
leak into the generator
H2Side
Example
Jan 2006

Seal Oil System

Gland Seals
Air
14
H2
10
To
turbine oil tank
11
12
1
9
2
13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Single Flow Seal Oil System

Simplified Diagram
Seal oil storage tank

Vacuum pump
Seal oil tank
Pressure controller
Main seal oil pump
Check valve
Standby seal oil pump
Seal oil cooler
Seal oil filter
Differential pressure control valve
Shaft seal
Generator prechamber
Intermediate oil tank
Flow control valve for seal ring relief
Jan 2006

Hydrogen
Seal oil
Pressure oil for seal ring relief
Design
Redundancy
2 x AC (each 100%)
1 x DC (100%)
Filter
2 x 100%
Cooler
2 x 100%
Differential pressure
control valve
2 x 100%
Seal Oil Pump
The System is designed for

highest reliability and safety operation
Jan 2006

Single Flow System

System Design
Single Flow System

Seal Oil Skid (Front view)
Jan 2006

z Vacuum Tank guarantee optimal H2 degassing

z High reliability by redundancies
z Low noises by screw pumps
z Clear structure and maintenance friendly design
z Optimized monitoring
Jan 2006

Single Flow Seal Oil System

Stator Water Cooling System

Requirements
The Stator Water Cooling System

should contain components which:
Circulate,
Jan 2006
Cool,
Filter,
Keep constant quality of,
Vent and Degas the water.


Fulfillment of the Requirements
The Requirements on the Stator Water

Cooling System are fulfilled with:
Redundant Pumps (2 x 100%)
Coolers (2 x 50%)
Main Flow Filter with 5m filter mesh size
Deionized Water Supply to make up the primary water
Expansion, Storage and Degassing Tank at the highest
point of the system, which is passed by a minor water flow
rate
Water filled U-Loop with connection to the exhaust above
the roof.
Jan 2006

Components:
1 Pumps
2 Cooler and Degassing
Pipe
3 Filter
4 Make up
5 Expansion and Storage
Tank
6 Draining and Degassing
7 Throttle
8 N2-Connection
R Drainage and Degassing
Pipe
S Inspection Glass
V Flow Meter
Jan 2006


Simplified Diagram

Pump-, Filter- and Cooler Unit
Jan 2006


Water Tank
Located above the

highest point of the
generator
Volume: 300 Liter
- 200 Liter water
- 100 Liter gas
Local level indicator
Min-level switch
Overflow pipe
Jan 2006

z Redundant System with proved components

(2 x 100% Pumps, 2 Cooler, ...)
z Clear structured and maintenance friendly design
(Plate heat exchangers, Filter cartridges, )
z Optimized Monitoring
Jan 2006


Monitored
Process Variables
(typical Water Cooled Generator)
Jan 2006
68
35
19
17
12
2
2
2
1
1
Temperatures
Pressures
Flow rates
Levels
Vibrations
Volumes
Gas purities
Conductivities
Dew point temperatures
Positions (switch)

Transmitter
132 Measuring Points
Local Indicators
27 Measuring Points
Monitoring of
Generator Systems
Siemens 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.
Jan 2006

Quality Assurance
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
Jan 2006
=>
- high safety factor for material at shrink fit for retaining rings
crack free
=>
low maintenance

Advantage of large Siemens-Generators
Thank you very much for

Attention
Jan 2006
Power Generation PG P2
52

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Formats disponibles

Siemens Power Generation 2006.

All Rights Reserved

Water-Cooled Generators for

Generator Organization and Network

Individual Plant Management

Integrated Network Organizations

CHARLOTTE - New Units >

ORLANDO - Back office support for

Water-Cooled Generators for

ERFURT - New Units < 140 MW

Siemens Power Generation 2006. All Rights Reserved

Generator Product Line

Generator Product Line Overview

Water-Cooled Generators for

Siemens Power Generation 2006. All Rights Reserved

Meeting the Customers Power Needs

SIEMENS Generators Proven

Siemens Power Generation 2006. All Rights Reserved

Water-Cooled Generators for

Directly water-cooled stator winding with stainless steel tubes

Water-Cooled Generators for

Siemens Power Generation 2006. All Rights Reserved

Key Features for 1000 MVA Class

Built on more than 100 years of evolution in manufacturing and

Water-Cooled Generators for

Siemens Power Generation 2006. All Rights Reserved

Generator Fleet Experience

THDF 115/78 Goesgen

1141 MVA 1978

THDF 115/67 Bergkamen

911 MVA 1981

THDF 115/67 Heyden

950 MVA 1987

THDF 115/78 Trillo

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

1144 MVA 1999

THDF 125/78 Niederaussem

1223 MVA 2002

THDF 125/67 Waigaoqiao 1

1000 MVA 2003

THDF 125/67 Waigaoqiao 2

1000 MVA 2004

Water-Cooled Generators for

Siemens Power Generation 2006. All Rights Reserved

SIEMENS Generators High Efficiency and High Availability

FOR = Forced outage rate

at 765 MVA; power factor 0.9

Water-Cooled Generators for

Siemens Power Generation 2006. All Rights Reserved

z Design Rating at 40C Cooling gas temperature

z Maximum transportation weight

z Weight of Stator including bearings, cooler head 505 Mg

z Rotor body diameter

Water-Cooled Generators for

Siemens Power Generation 2006. All Rights Reserved

Generator THDF 125/67 main Data

Siemens Power Generation 2006. All Rights Reserved

Generator outline drawing