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Generator Design Team This document is the informational asset of Doosan Heavy Industries and Construction. Unauthorized access, revision, distribution and copying of this document are strictly prohibited.
Generator Design Team This document is the informational asset of Doosan Heavy Industries and Construction. Unauthorized access, revision, distribution and copying of this document are strictly prohibited.
Generator Design Team This document is the informational asset of Doosan Heavy Industries and Construction. Unauthorized access, revision, distribution and copying of this document are strictly prohibited.
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
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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