Hydro Generators

Maintenance Introduction
May 31, 2017
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Hydro Generators – Maintenance Introduction

Agenda
• Introduction
• AC Three-Phase Salient Pole Synchronous Generator
Nameplate Elements
• Design Approach
• Maintenance
• Interfaces

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Introduction
Introduction

Maintenance
Design: 3D Models, Drawings, Bill of Material, Catalogs

Manufacturing Records

Manuals, Reports and Records: Erection, Commisioning, Operation and Maintenance

People: Skill Matrix, Job Description, Training

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AC Three-Phase Salient Pole
Synchronous Generator
Nameplate Elements
AC – Alternating Current

Sinusoidal Wave:
Maximum:
Average:
RMS:

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3–Phase

Three-Phase:
A, B, C
R, S, T
U, V, W

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Salient Pole

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Synchronous

 A R

BusInfinita
(-)

(system))
(+)

Bar


( sistema
B S

Barra
C T

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Generator

ELECTRICAL ENERGY

MECHANICAL ENERGY

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Generator

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Generator

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Design Approach
Working Principle

DC FIELD WINDING IN THE ROTOR AND

AC ARMATURE WINDING IN THE STATOR

AIR-GAP FLUX

INDUCTANCE OF THE STATOR WINDING DEPENDS ON THE ROTOR POSITION

ENERGY IS STORED IN THE MAGNETIC FIELD

AS THE ROTOR TURNS THE STORED ENERGY CHANGES

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Vertical Assembly

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Working Principle

POWER = 𝑇𝑂𝑅𝑄𝑈𝐸 . SPEED

1
𝐸𝑁𝐸𝑅𝐺𝑌 = 2 . 𝐿. 𝐼 2

𝑑(𝐸𝑁𝐸𝑅𝐺𝑌)
POWER = 𝑑𝑡

SYNCHRONOUS:
WHEN THE FIELD IS ENERGIZED WITH DC CURRENT AND THE STATOR WITH AC
CURRENT THERE WILL BE AVERAGE TORQUE WHEN SPEED OF THE ROTOR IS EQUAL
TO THE SPEED OF THE MAGNETIC FIELD.

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Design Approach

CUSTOMER’S ENGINEERING OFFICE

TURBINE GRID STANDARDS CUSTOMERS

GENERATOR
DESIGN

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Design Approach

TURBINE REQUIREMENTS

FLYWEEL
POWER S=V.I J= 𝑚𝑟 2
GD²

120𝑓 ROTATING MAIN

RATED SPEED 𝑝=
𝑟𝑝𝑚 DIRECTION DIAMETER

RUNAWAY 𝜋𝐷𝑛 HYDRAULIC

SPEED Vp = 60 THURST

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Design Approach

GRID REQUIREMENTS

GRID
RATED
STABILITY
VOLTAGE
STUDY

INERTIA VOLTAGE
CONSTANT VARIATION

POWER LINE
REACTANCES SCR
FACTOR CHARGING

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Design Approach

STANDARDS

IEC IEEE GRID

ANSI ASTM CUSTOMER

MANUFACTURER
SAFETY DESIGN
ISO
REGULATION KNOW-HOW

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Design Approach

CUSTOMER

WATER STRESS
LAY-OUT TEMPERATURE
QUALITY LIMITS

ERECTION TRANSPORT
LIMITATION LIMITATION

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Design Approach

DESIGN

ELECTRICAL VENTILATION THERMAL MECHANICAL

GENERATOR
FAILURE
MODE

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Generator Failure Mode
Main Problems Affecting Generator Performance

THERMAL

ELECTRICAL

AMBIENT

MECHANICAL

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Generator Failure Mode
Main Problems Affecting Generator Performance

THERMAL FAILURE MODE AND AGENTS

INSULATION BEARING BRUSHES CORE

BREAKDOWN BURNING WEAR MELTING

DEFOR- PROPERTY LIFE

MATIONS CHANGE REDUCTION

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Generator Failure Mode
Main Problems Affecting Generator Performance

ELECTRICAL FAILURE MODE AND AGENTS

TRI-PHASE BI-PHASE HALF POLES

SYNCHRON.
SHORT- SHORT- SHOR-
ERROR
CIRCUIT CIRCUIT CIRCUIT

CORONA ELECTRICAL
BAR SHAFT
PARTIAL FIELD IN THE
VIBRATION CURRENT
DISCHARGE ROEBEL BAR

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Generator Failure Mode
Main Problems Affecting Generator Performance

MECHANICAL FAILURE MODE AND AGENTS

ELECTRICAL MECHANICAL HYDRAULIC

VIBRATION VIBRATION VIBRATION

DEFORMATION
CRACKS
BUCKLING

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Generator Failure Mode
Main Problems Affecting Generator Performance

Mechanical Vibration – Main sources

• Mechanical Unbalance
• Misalignment
• Bearing wear and Geometry
• Shear pin failure
• Coupling defects
• Shaft bow
• Rubs

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Generator Failure Mode
Main Problems Affecting Generator Performance

Electrical Vibration – Main sources

• Magnetic unbalance
• Non concentric generator rotor
• Winding problem

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Generator Failure Mode
Main Problems Affecting Generator Performance

Hydraulic Vibration – Main sources

• Vortex interaction
• Hydraulic unbalance
• Cavitation
• Hydraulically induced axial vibration
• Runner blade vibration

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Generator Failure Mode
Main Problems Affecting Generator Performance

AMBIENTAL FAILURE MODE AND AGENTS

OXIDATION
GOLDEN
CORROSION INSECTS NOISE
MUSSEL
EROSION

OIL/WATER
BURN DUST MOISTURE
LEAKEGE

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Generator Failure Mode
Main Problems Affecting Generator Performance

ALTOGETHER

DEFORMA- CONTAMINA-
WEAR CORROSION
TION TION

AVAILABILITY
CHANGE SAFETY
LIFE
RELIABILITY
PROPOERTY REDUCTION
COSTS

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 Generator Technology
TURBINE TECHNOLOGY vs GENERATOR TECHNOLOGY

Bulb turbine Kaplan turbine Francis turbine Pump-turbine Pelton turbine

Low-speed Low-speed Medium-speed Motor-generator High-speed

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Maintenance
Inspections, Tests, Service, Repairs
Maintenance
Inspections & Tests

TESTS BEFORE AND AFTER MAINTENANCE

HEAT RUN AIR-FLOW VIBRATION NOISE

SLIP RING
SHAFT BRAKING LEAKAGE
SPARKS AND
CURRENT OPERATION OIL/WATER
PATINA

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Maintenance
Inspections & Tests

TESTS AT STANDSTILL

INSULATION PARTIAL CORONA DUST

RESISTANCE DISCHARGE SIGNS MOISTURE

RUN-OUT
CORROSION CRACKS TIGHTNESS CIRCULARITY
VERTICALITY

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Maintenance
Inspections & Tests

REPAIRS

CORE
CORONA WEDGING LOSE BOLTS
LAMINATION

BEARING POLE DAMPER

SLIP RING
PADS CONEXIONS WINDING

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Maintenance
Inspections & Tests

REPLACE

BOLTS
SEALS WEDGES JOINTS
WASHERS

OIL BARS POLE

BRUSHES
ADICTIVES COILS CONEXIONS

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Maintenance
Inspections & Tests

CLEANING AND PROTECTION

STATOR COOLERS PIPING

AIR-DUCTS SHAFT

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Maintenance
Stator Frame and Foundation

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Maintenance
Stator Core Lamination

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Maintenance
Stator Back and Key-Bar

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Maintenance
Stator Core Fingers

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Maintenance
Stator Core Press Plate and Fingers

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Maintenance
Stator Core Pressing System

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Maintenance
Stator Core and Winding

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Maintenance
Stator Bar Wedging System

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 Maintenance
Stator Bar section
Slot Wedge
Ripple Spring

Round
Packer Packing

Main
Insulation

Separator

Corona
Shield
Roebel
Transposition
Conductor

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Maintenance
Roebel Bar

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Maintenance
Stator Winding Conection

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Maintenance
Lower Bracket

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Maintenance
Combined Bearing

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Maintenance
Oil Sump

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Maintenance
Shaft

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Maintenance
Shaft

3.1 Number and diameter of studs

3.2 Number and diameter of pins
3.3 Diameter of slot

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Maintenance
Thrust Block

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Maintenance
Rotor Spider

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Maintenance
Rotor Rim

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Maintenance
Pole

Top Pressure Plate Pole Block #1 Pole Block #2

Damper Winding Connection Special Nut Cilindrical Pin

Anchor
Pole Block #3 Bottom Pressure Plate

Pole Core
Damper Key
Damper Bar
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Maintenance
Pole Coil

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Maintenance
Pole Claw

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Maintenance
Pole Connection

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Maintenance
Complete Rotor

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Maintenance
Braking System

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Maintenance
Dust Exhauster

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Maintenance
Auxiliary Shaft

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Maintenance
Collar

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Maintenance
Guide Bearing

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Maintenance
Combined Bearing

1.2

Combined Bearing
Load and Strength
1.1

Size / Dimensions of
Generator Spider rotor

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Maintenance
Upper Bracket

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Maintenance
Slip Ring

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Maintenance
Slip Ring

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Maintenance
Brushes

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Maintenance
Cover

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Maintenance
Excitation System

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Maintenance
Ventilation

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Maintenance
Air Guide

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Maintenance
Water Cooler

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Interfaces
Interfaces Systems
7. TERMINALS OUTPUT: PHASE AND NEUTRAL /
1. COMBINED BEARING
EXCITATION
2. CLOSING PIT
8. AIR/WATER COOLING SYSTEM
3. COUPLING SHAFT TURBINE and GENERATOR
9. OIL COOLING SYSTEM FOR BEARING
ROTOR
10. AUXILIARY SYSTEMS
4. TURBINE KAPLAN DRIVE HEAD
11. WIRING and INSTRUMENTATION
5. OIL PIPING FOR KAPLAN DRIVE / AIR VALVE FOR
FRANCIS TURBINE 12. FIRE FIGHTING SYSTEM
6. BASES IN THE CONCRETE / LAY OUT / LIFTING PLAN 13. GROUND PROTECTION
of big components
(HOUSING, UPPER BRACKET, FLOORS, PASSAGES
AND ACCESS)

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