May, 2014

Generator Design Team

This document is the informational asset of Doosan Heavy Industries & Construction. Thus, unauthorized access, revision, distribution and copying of this document are strictly prohibited.
Generator Stator
Mechanical Design
Stator
1
Generator Stator Design
1. Generator Stator Component
2. Stator Frame
3. Water Header Assembly
4. Dome & H2 Cooler
5. Key & Spring Bar
6. Stator Core Assembly
7. Foundation Plate
8. Collector housing
Generator Stator Parts
2
Generator Component
Generator Stator Design
1. Generator Stator Component
1
2
3
4 5
6
7
8
9
10
11
1. Rotor
2. Bearing
3. End shields
4. Rotor fan
5. Water header
6. Hydrogen cooler
7. Stator frame
8. Stator core
9. Stator bar
10. High voltage bushing
11. Current transformer
Stator Major Component
1) Stator Frame And Miscellaneous Components(5,6,7)
2) Outer End Shield Assembly(2,3)
3) Stator Core Assembly(8)
3
2. Stator Frame
1) Function :
Component Support :
- Stator Core, Stator Bar, End Shield, Rotor, Cooler & Dome, Lower Frame Extension
Pressure Vessel to Seal Hydrogen Gas(Explosion Pressure, Operation Pressure)
Provide Cooling Gas Passage
2) Design Consideration :
Stress : Hydrogen Gas Pressure, Shipping
Load , Abnormal Torque
Vibration : Natural Frequency, Vibration
Transfer Mechanism
Ventilation : Cooling Matrix
3) FRAME SHAPE TYPE :
Horizontal Mounted Cooler Design Type
Vertical Mounted Cooler Design Type
Twin Dome Horizontal Cooler Design Type
- Duplex Cooler Type (1000MW Nuclear)
- Simplex Cooler Type(Large Thermal Power)
Full Dome Horizontal Cooler Design(1970)
Generator Stator Design
Twin Dome Horizontal Cooler Design
- Large Thermal Power Plant
4
Vertically Mounted Cooler Design
- Thermal Power Plant
Horizontally mounted Cooler Design
- Gas Turbine Plant
Full Dome Horizontal Cooler Design(1970)
Generator Stator Design
5
3. Water Header Assembly
1) Function :
Pipe Line Supply Stator Bar with Cooling Water
2) Design Consideration :
Decision Pipe Size for Necessary
Cooling water Quantity
Pipe Clamping support Vibration and
Water Flow Force
Air Leak Test for Water Leakage
Material : Stainless Steel
3) TYPE :
Single Pass Flow :
Cooling Water Flow supply from CE side
to TE side , then drained Flow Type
Double Pass Flow :
Cooing Water supply and drain TE side, only
CE side water return to TE side
(Old Vertical Cooler Type Design)
Water Header
Generator Stator Design
6
4. Dome & H2 Cooler
1) Function :
Dome (Top Cover) : H2 Cooler Support & Gas Passage
H2 Cooler : Cooling H2 Gas by heating
Generator operation
2) Design Consideration :
Dome (Top Cover) :
- H2 Cooler assembly Space
- Natural Frequency & Stress of Hydrogen Pressure
H2 Gas Cooling Capacity & Material
3) TYPE :
Dome : Vertical Cooler Mounted Type
(Not Applicable)
H2 Cooler :
- Simplex Type : MD1
- Duplex Type : Nuclear Plant
Generator Stator Design
7
W/O Wrapper of Dome
4) Warning Point at installation & Applied material :
Clamp End Assembly To Seal H2 Gas tight
H2 Cooler Material
- Tube : 90-10 Cu. Ni Fin : Aluminum
- Tube Sheet & Water Box : Carbon Steel
H2 Cooler Outline
Generator Stator Design
8
5. Key & Spring Bar
1) Function :
Key Bar : Stator Core Support / Core Stacking
Load Support
Spring Bar : Damp the amplitude of Core to
transfer Stator Frame
2) Design Consideration :
Stator Core Vibration : With Magnetic Flux of the rotors
Core the frequency where the electromagnetic force
corresponds to 2 times of synchronous speed
Radial Force : Magnetic Force
Tangential Force : Torque Force
2 Pole Core amplitude > 4 Pole Core amplitude
3) TYPE :
4 Pole : Welded Key Bar(No Spring Bar)
2 Pole : Bolted Key & Spring Bar Assy
Medium 2 Pole : Welded Key Bar & Spring Bar
Generator Stator Design
9
6. Stator Core Assembly
1) Function :
provide a low reluctance path for the magnetic flux, which is generated
in the rotor and which links the armature winding.
Ventilation passage provision (ISSB, OSSB)
Support Stator Bar Assembly
2) Design Consideration :
Core Tightness - Periodic Pressing
Core Vibration
Core Insulation
3) Import Inspection Fact
Core Insulation Condition & Core Looseness
STATOR FRAME FLANGE
KEY & SPRING BAR ASSY
GAS DUCT(ISSB) PUNCHINGS
OUTSIDE SPACE BLOCK
Step Punching
Generator Stator Design
10
Stator Core Assembly Component
1. Stator Core
2. Copper Facing
3. Inside Space Block
4. Outside Space Block
5. Stator Flange
6. Gas Gap Baffle
7. Shunt Core
1
2
3
4
5
6
7
Generator Stator Design
11
s rnh
Khun dp v men trng
6-1. Tm thp
Generator Stator Design
- Cht liu v mng : Thp xilic, dy 0.35mm
- Phn li thp: S dng l thp s rnh u v khe h hn ch dng in xoy trong li
thp sinh ra nhit.
- B mt : Ph cht cch in C10
12
6-2. Phn khng gian lp rp khi
bn trong
Generator Stator Design
- Vt liu : Thp cc bon, Thp khng r
- Chc nng : Cung cp khong khng gian thng thi kh H2 gia cc li
13
6-3. Phn khng gian lp rp khi
bn ngoi
Generator Stator Design
- Vt liu : Thp khng r bn cao
- Chc nng : Gi p lc ca c inh bch chn p lc v tm chn p lc gia li v
tm chn p lc.
Truyn ti li v thng thi kh H2
14
6-4. Mt bch Stator
Generator Stator Design
- Vt liu : ng st c
- Khng gian bn ngoi tip xc vi b mt c dn bng nng cao kha nng chn.
- Chc nng : Chn, Kt cu b mt ng, Cung cp kt cu dc trc
- Vt liu: ng tinh khit.
- Chc nng: T thng r ngn s gim nhit v cung cp ng x cho kh.
6-5. B mt ng
15
7. Cc bn mng
1) Chc nng :
Cung cp cho my pht gia sn TG v chn.
Hn ch s xe dch dc trc
2) Xem xt thit k:
Chu c i bnh thng cho khi lng my
pht, Momen ti gy ra do ngn mch
3) B phn :
Chn , bu lng, chm, c vt
4) H thng tm FDN
Thit k kiu cht
Thit k kiu keo
Foundation Plate
Generator Stator Design
16
8. Hp c gp
1) Chc nng :
bo v kch thch
ngn nga tai nn in gy ra
2) Xem xt thit k :
n : di 85dBA
Thng thong
Bo v con ngi
C kh nng bo dng chi than
3) Kiu :
Kiu ni thm : Kch thc gn nh
Kiu nh trn tng : C gp t trn tng
(Vi n nh )
Walk In Type
Reach In Type
Generator Stator Design
May, 2014
Turbine Generator BU
This document is the informational asset of Doosan Heavy Industries & Construction. Thus, unauthorized access, revision, distribution and copying of this document are strictly prohibited.
Thit k tm chn
Stator my pht
18
1. Thnh phn ca cc tm chn my pht

2. Phn ngoi ca tm chn

3. Lp t phn chn H2

4. B pht hin du r

5.

6. Quy trnh tho r tm chn

7. Quy trnh lp rp tm chn
Generator End Shield
Generator End Shield Design
19
Generator End Shield Design
1. Thnh phn ca tm chn my pht
20
Generator End Shield Design
1-1. Thnh phn ca tm chn my pht
21
2. Phn bn ngoi ca tm chn
1) Chc nng :
, Pht hin du, chn H2
ng cht kh H2
2) Xem xt thit k :
xe dch v p lc nn theo p lc ca kh
H2
rung :Tn s t nhin
3) Nghim thu thc t lp t v bo dng
Kim loi vi kim loi(Dc v ngang) kh trn
Phn ngoi va khung lp rp da ra tho lun
ng dng ca cc thnh phn trn cho chnh
xc
Kim tra rnh du
chn
Generator End Shield Design
22
3. Lp t phn chn H2
1) Chc nng :
With rotation part the hydrogen gas leak proof
which leads the clearance between of fixation parts
2) Structure :
Seal Oil Shut tightly H2 Gas between Seal Ring
Seal Ring Float by Spring in operation
Seal Casing Assembly Seal H2 Gas by Metal
to Metal Contact
CE Seal Assembly with earth insulation
Seal with Oil Deflector assemblies internal
influx Seal Oil
3) Important inspection fact at installation & maintenance
Metal to Metal Assembly difference
Seal Ring inside Babbitt condition &
Permission Clearance (3000rpm : 1.5 times)
Seal Ring and Casing Hook Fit surface
Contact Condition
Insulation Condition (500 Volt Megger Test : 100K
above in operation)
Generator End Shield Design
23
4. Oil Deflector
1) Function :
Rotor Shaft the generator inside and outside
influx or Outflow prevention
- Inner Oil Deflector : Lubricating oil generator internal
influx prevention
- Outer Oil Deflector : Lubricating oil generator external
influx prevention
2) Design Consideration :
Design for Function
For Oil leakage prevention, Gap between Rotor
diameters and Seal Ring
3) Important inspection fact at installation & maintenance
Check Tooth Damage
Alignment using Height Screw
Generator End Shield Design
24
5. Bearing
1) Bearing Classification by shape :
Tilting Pad Bearing : High Stability
Elliptical Bearing : High load and low-end operation temperature
3) Bearing Insulation :
Double Insulation Design(Large Generator)
Single Insulation Design(Medium Generator)
4) Important inspection fact at installation
& maintenance
Bearing with earth insulation condition (500 Volt
Megger Test : 100K above in operation)
Bearing Fit Contact Condition
Bearing Torque or Pinch Fit
Gap between Bearing and Journal
2) Design Consideration :
Bearing Load to Rotor
Rotor Axial orgin stability
Easy Disassembly & Assembly
Generator End Shield Design
25
Bearing - CE
5) MD1 Bearing Size :
- Turbine End : 23 x 13
- Collector End : 21 x 13

Generator End Shield Design
Bearing - TE
26
6. Procedure for Disassembly of End Shield
Generator End Shield Design
Inspect unit for oil leaks
Inspect Outer Oil Deflector to Bearing Cap
Horizontal Joint gap within a 0.038mm Shim(filler gage)
Remove Bearing Cap
Check Clearance between Shaft &Outer Oil Def. Teeth
Upper Bearing Rings are assembled with Bearing Cap
Inspect horizontal joint for oil tightness.
Remove Outer Oil Deflector
Remove Hydrogen Seal
Nominal Clearance: 1.016~1.143mm
Dia. Clearance : L/S, R/S = 1/2, BOTTOM = 1/3, TOP = 2/3
Inspect teeth damage and inside diameter.
Check Clearance between Shaft & Inner Oil Def. Teeth
Remove the Bearing and Bearing Rings
Nominal Clearance: 1.016~1.143mm
Dia. Clearance : L/S, R/S = 1/2, BOTTOM = 1/3, TOP = 2/3
Check drain back.
Roll out lower half bearing and Bearing Rings
Include Seal Rings and Mid Oil Deflector
27
Generator End Shield Design
Use Upper End Shield Access Covers
6. Procedure for Disassembly of End Shield
Remove Fan Nozzle Ring Segments
Remove Inner Oil Deflector
Inspect teeth damage and inside diameter.
Check drain back.
Remove Upper Half End Shield and Drop Lower Half
End Shield
28
Generator End Shield Design
Inspect End Shield
Assembled the Lower Half End Shield to the Frame
The Field Weight must be removed
Measure the Tight Gaps of the Lower Half Vertical
Joint
Rest the Upper Half End Shield on the Lower Half
and Dowel
Measure the Loose Gap Around the Horizontal Joint
Max. Allowable Gap 0.038mm
When necessary, Check Surface Contact
7. Procedure for Assembly of End Shield
- Clean the Joint Faces
- Any Damage to the Sealing Surface
- Remove High Spots and Burrs
75% contact is desired.
- The Field Weight must be removed
- Max. Allowable Gap 0.038mm
- 0.038mm feeler gauge may not penetrate the joint for
more than 6.35mm.
29
Generator End Shield Design
Tighten the bolts on the Horizontal Joint
Make Tight Gap Checks around the Horizontal Joint
- The Field Weight must be removed
7. Procedure for Assembly of End Shield
Tighten the Bolts on the Upper Half Vertical Joint
Make Tight Gap Checks of the Upper Half Vert. Joint
Inspect for Steps at the Horizontal Joint
Max. Allowable Gap 0.038mm
Inspect for Steps at the Horizontal Joint
Max. Allowable steps 0.038mm.
- Max. Allowable Gap 0.038mm
- 0.038mm feeler gauge may not penetrate the joint for
more than 6.35mm.
Lower Field Weight onto End Shield
Max. Allowable Gap 0.038mm
Max. Allowable Gap 0.038mm
30
Generator End Shield Design
Install Inner Oil Deflector
Install Hydro Seal Casing Assembly
Refer to the O&M manual.
Install the Bearing & Bearing Rings
Install the Bearing Cap
- Check twist & tilt and Pinch per O&M manual
Install Outer Oil Deflector
Install Fan Nozzle Ring Segments
7. Procedure for Assembly of End Shield
- Nominal Clearance between Shaft &Outer Oil Def. Teeth
:1.016~1.143mm
- Dia. Clearance : L/S, R/S = 1/2, BOTTOM = 1/3, TOP = 2/3
- Nominal Clearance between Shaft &Outer Oil Def. Teeth
:1.016~1.143mm
- Dia. Clearance : L/S, R/S = 1/2, BOTTOM = 1/3, TOP = 2/3
Use Upper End Shield Access Covers