Finite Element Analysis of the 500 MVA Hydro-Generators at the Bieudron Power Plant

Erich Schmidt, Member, IEEE

Vienna University of Technology, Institute of Electrical Drives and Machines Gusshausstrasse 25-29, A-1040 Vienna, Austria, Email: erich.schmidtQtuwien.ac.at

Christian Grabner
Graz University of Technology, Institute of Electrical Machines and Drives +Kopernikusgasse24, A-8010 Graz, Austria Email: grabner@ema.tu-grazac. at

Georg Traxler-Samek
ALSTOM Power Ltd. , Hydro Generator Technology Center CH-5242 Birr, Switzerland Email: georg.traxler@power.alstom.com

Abstract -For an implementation of the finite element analysis in the design optimization of large synchronous machines, the efficiency of modeling and analysis methods is of great importance. The presented modeling and analysis methods utilize only one finite element model for all angular rotor positions without any remeshing. These methods are applied to the nonlinear finite element analysis of the salient-pole hydro-generatorsat the Bieudron power plant in Switzerland. The comparison with measurements of the steady-state,parametersshows an excellent agreement and validates the proposed methods. Keywords - Space vector calculus, Reactance calculation, Synchronous machine, Domain decamp+ sition, Finite element analysis

calculations, whereby only one independent finite element model of both the stator part as well as the rotor part is necessary [3]. The two distinct pari:s of the model are connected with a sliding surface, which has an equidistant discretization in moving direction. The finite element mesh, in particular within the air-. gap, remains completely unchanged for all rotor positions without any remeshing. Consequently, different numerical errors with respect to the rotor position are avoided. Moreover, the domain decomposition establishes a significantly reduced calculation time! of successive rotor positions. These modeling and analysis methods are applied
to the nonlinear finite element analysis of the salientpole synchronous generators as described in [4], 151.

1. INTRODUCTION
The finite element analysis of large synchronous generators provides a significant improvement in the accuracy of the predicted performance. Therefore, the finite element method is increasingly utilized not only for the verification of contractual values of existing machines, but also for the design optimization of new machines [l], [2]. In the case of fractional slot stator windings, the inclusion of more than one or two pole pitches is necessary for the consideration of a precise model of the synchronous machine. These large finite el<ment models require highly efficient modeling and analysis methods for an implementation in the design optimization. Tho proposed analysis method uses a domain decomposition algorithm in the nonlinear finite element

The main characteristics of the machines with a frwtional slot stator winding are summarized in Table I. The presented results are focused on the evaluation of the steady-state parameters from the analysis resur!ts using space vector calculus. Comparisons are given r o m measmements. with the reactances obtained f
TABLE I GENERATOR CHARACTEIUSTICS
Rated power Rated voltage Rated current Rated power factor Nominal freqliency Nominal speed Runaway speed Number of stator slots Stator bore diameter Stator stacking height

500 MVA 21000v 13745 A

0.9 50 Hz 428 rpm 800 rpm 138 5350 mm 2900 mm

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11. FINITE ELEMENT MODELING

Due to the fractional slot stator winding with 23/7 slots per pole and phase, the 2D finite element model has to consider one half of the synchronous generator. The periodicity is obtained by using anti-periodic boundary conditions along the two boundaries being seven pole pitches apart. Fig. 1 depicts the mesh of one pole pitch in the iron and the winding regions. The data of the complete model are summarized in Table 11.

The complete finite element model is solved with the nonlinear magnetostatic analysis of the EMAS solver [7]. Within the solver, a domain decomposition algorithm based on 181 and fully described in [3] is utilized for the analysis of different rotor positions. This algorithm reduces the number of unknown potentials in the analysis of each rotor position as listed in Table 11. Thus, a significant reduction of the calculation time for successive rotor positions is established.
TABLE I1 FINITE ELEMENT MODEL DATA Number of elements Number of nodes Unknown potentials Residual potentials 102296 89935 87806 2268
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111. ANALYSIS RESULTS

A . Field Results
Fig. 2 shows the distribution of the magnetic flux density in the airgap and the fundamental harmonic with a field current excitation of I f = 1.5 kA. As expected, the stator slots cause ripple components of a p proximately 30% of the fundamental magnitude. Due to the fractional number of slots per pole and phase, these higher harmonics do not cause any equivalent higher harmonics in the sinusoidal induced generator voltage.

Fig. 1: Finite element model of one pole pitch

For the purpose of the intended domain decomposition, the complete 2D model is divided into two distinct parts. The stator part consists of 69 stator slots with 138 stator bars representing the fractional slot stator winding according to the winding diagram. The rotor part holds seven poles including the damper windings, the field windings and the rotor yoke. As shown in Fig. 1, additional 1D elements consider the airgap between the poles and the rotor yoke due to the construction.
Both model parts have an equidistant discretization in moving direction on the cylindrical sliding surface inside the airgap. This sliding surface between the independent stator and rotor parts facilitates the analysis of different rotor positions without any remeshing of the airgap regions [3], [6].

-1.51

2r

3r
1p

In

5s

6r

7s

(W

Fig. 2: Magnetic flux density Br(v) in the airgap versus angular position, field current excitation of Zf = 1.5kA

Fig. 3 and Fig. 4 show the distribution of the magnetic flux density in the airgap with rated stator current excitation. In both pictures, the fundamental harmonic and the third harmonic are drawn,additionally. This harmonic component in the fluk density d i s tribution arises from the saturation and the saliency

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of the synchronous generator, in particular in case of a stator current space vector in quadrature axis.
E.(+) (T)
I

-0.75

c (4

-1.5

2r

3n
p (rad)

4r

5~

e.*

I rr

Fig. 5: Magnetic flux density Br(v)in the airgap versus angular position, idealized short circuit condition, field current excitation of 1, = 1.5 kA

Fig. 3: Magnetic flux density B r ( q ) in the airgap versus angular position, rated stator current excitation in direct axis

which is obtained directly from the EMAS solver. Referring to the base quantities (7) 1 9 1 , the magnetic energy (1) can be written in a normalized form i t s
w,=ia~a+ib$b+ic$c

(2)

As the stator is star-connected, zero-sequence stator currents are impossible. Thus, the transformation to the dq rotor fixed reference frame as described in [9], [lo) yields

Due to the fractional slot stator winding, the cztlculated total magnetic energy has nearly no dependency on the rotor position. Therefore, the evaluation of both reactances X d , x q from the magnetic energy (3) is straightforward for the current injection according to id = 0 . . .1.4 and iq = 0 . . .1.4. As depicted in Fig. 7, the saturation gains influence with stator (current magnitudes of i s > 0.6. Finally, Fig. 5 shows the distribution of the magnetic flux density in the airgap in the idealized short circuit condition with a field current excitation of 1 , = 1.5kA. With this condition, the fundamental harmonic vanishes. Due to the fractional slot stator winding, the local compensation of the field and stator current excitations differs among the several poles. This can be seen with the additionally drawn third harmonic. Fig. 6 shows the magnetic flux distribution in the stator slots and teeth, the airgap and the rotor poles according to this short circuit condition. The splitting of the synchronous reactances as
Zd Zq

= XU =2s

+ Zdh + Zqh

(44 (4b)

allows for the evaluation of the stator leakage mactance zo from the distribution of the magnetic ihx density within the airgap. The magnitudes Bid, .B1, obtained from a Fourier analysis of the magnetic h x density distributions can be used a s

- $qhli,=l
Bld $dhlid=l

- -x.q h
xdh

(5)

B. Steady-state Reactances
The reactance calculation of the synchronous machine utilizes the total magnetic energy of the three stator phases in steady state,

Therefore, the stator leakage reactance x u is evaluated by using (4) as

xq - xqh -

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Fig. 6: Magnetic flux distribution in the idealized short circuit condition, field current excitation of If = 1.5kA

The calculated value as listed in Table I11 shows almost no dependency on the current excitation in the range of is < 1.2.

C. No-load Voltage and Short Circuit Current

Fig. 8 shows both the evaluated no-load voltage and the short circuit current characteristics of the synchronous generator, The stator values are given with regard to the base quantities (7)[9]. Both the unsaturated and the saturated short circuit ratios agree very well with the values obtained from measurements.

id

vir(])

Fig. 7: SynchronousReactancesz d ( i d ) , z q ( i q ) versus stator current excitation

Table I11 lists the calculated reactances in comparison with the measured reactances. There is an excellent agreement between the various calculated and the measured, values.

Fig. 8: No-load voltage %l and short circuit current i., versus field current If

TABLE I11
COMPARISON OF STEADY-STATE REACTANCES
Reactance Leakage reactance adaxis, unsaturated adaxis, saturated q-axis, unsaturated q-axis,saturated Calculated value Measured value

IV. CONCLUSIONS The 500 MVA hydro-generators at the Bieudron power plant are analyzed using nonlinear finite element calculations. Due to the large finite element model caused by the fractional slot stator winding, optimized modeling and analysis methods are consid-

zo
Zdu
zd

zpu

zg

0.104 1.122 1.076 0.795 0.767

0.105 1.120 1.070 0.800 0.780

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ered. The nonlinear analysis uses a domain decomposition algorithm with fully independent stator and rcitor model parts. This analysis method facilitates a finite element mesh which remains completely unchanged for all rotor positions without .any remeshing. Moreover, the domain decomposition within the nonlinear analysis provides a significant reduction of the calculation time for successive rotor positions. The comparison with measurements shows the high suitability of the proposed methods for an application in the integrated design optimization of large synchronous generators.

REFERENCES
Zhou P., McDermott T.E., Cendes Z.J., Rahman MA.: "Steady State Analysis of Synchronous Generators by a Coupled Field-Circuit Method". Proceedings of the IEEE International Electric &fachines and Drives Conference, IEMDC, Milwaukee (WI, USA), 1997. Ramirez C., ' h Xuan M., Simond J.J., Schafer D., Stephan C.E.: "Synchronous Machines Parameter:, Determination using Finite.Elements Method". Proceedings of the International Conference on Electrical Macliines, ICEM, Espoo (Finland), 2000. Schmidt E.: "Electromagnetic Finite Element Aniilysis of Electrical Machines using Domain Decomposition and Floating Potentials". Proceedings of the 13th Conference on the Computation of Electromagnetic Fields, COMPUMAG, Evian (France), 2001. Howald W., Stijckli F.: "Generatoren fur daa weltgrhsste Hochdruck-Wasserkraftwerk". ABB Technik, 10/1994. Howald W.: "Die Generatoren fur das Hochdruck-Wasserkraftwerk Bieudron". ABB Technik, 02/1998. Zhou P., Stanton S., Cendes Z.J.: "Dynamic Modeling of Electric Machines". Proceedingsof the 2nd Naval Syrnpe sium on Electric Machines, Annapolis (MD, USA), 1998. Brauer J.R., MacNeal B.E.: MSC/EMAS User Mariual. MacNeal-Schwendler Corporation, Los Angeles, 1994.

APPENDIX
As proposed in [9], base quantities using the effective rated phase current I N , the effective rated phase voltage UN and the rated frequency f N are defined as
base current
Ib=fiIN
1

base flux linkage

$b

4U N =2rfN

N.N.: MSC/NASTRAN Superelement Analysis, Seminar Notes. MacNeal-Schwendler Corporation, Los Ange-

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les, 1997.
Kovacs, P.K.: Tbansient Phenomena in Electrical Machines. Elsevier, Amsterdam, 1984. Nabeta S . I . : &tude des Regimes Ttansitoires des ,Machines Synchrones par la Mkthode des filkrnents Finis. Dissertation, Institut National Polytechnique de Grenoble, 1994.

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