Modernizarea Instalațiilor Electro-

Energetice

1. Dezvoltarea și modernizarea mașinilor

electrice
2. Modernizarea generatoarelor electrice
•turbogeneratoare
sursă:
•hidrogeneratoare https://www.wholesalesolar.com/wind-
generator-turbines
•generatoare eoliene
3. Modernizarea turbomașinilor (turbine)
4. Modernizarea liniilor electrice de înaltă
tensiune

2 GW generator with test field exciter

slip rings in the test bay
sursă, Siemens, Germany
Overview

• Turbogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
• Hydrogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
Manufacturing of Turbogenerators
Manufacturing of Turbogenerators
Overview

• Turbogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
• Hydrogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
Stator Manufacturing and Refurbishment

Stator core assembly with Stator coil winding insulation Support system of stator
bonded stator core packs system in the resin oven winding overhang
Source: Siemens AG, Mülheim/Ruhr, Germany
 Stator Winding
Developed” view of a two-pole stator

source: G. Klempner, I. Kerszenbaum, Handbook of Large Turbo-generator Operation and Maintenance

Completed stator with three-phase winding
and coil connections

Source:
Siemens AG,
Mülheim/Ruhr,
Germany
Stator end zone of a turbogenerator

Press plates

Stepped
end-packets

Source: Siemens AG, Mülheim/Ruhr, Germany Source: Bohn, T (Ed.), TÜV Rheinland
Stator Coil with Water Cooling
Bars of Stator Winding

Cross section of a stator bar Water cooling circuit Teflon hoses

Stainless steel cooling tubes

Stainless steel
water boxes

De-ionized water is supplied by a manifold

2 parallel Roebel bars
on the driven side of the generator. Hot
water is collected by another manifold on
High voltage insulation
the non driven end.
Bar connections
Old method

Current method
Electrical Insulation - Components
Corona Protection
Main Insulation
Electrical Insulation
Big generators:

Only one turn per coil.

Coil is split into 2
halves = 2 bars.
Here visible: Insulating
one bar for a 2-pole
turbine generator with
glass-fibre band with
mica layer for high
voltage insulation.

Source:
Andritz Hydro,
Austria
Resin impregnated coils are heated in the oven

Source:
Andritz Hydro,
Austria
Stress Grading
Stator Core
(grounded)
Corona Protection
Stator of Air-Cooled Turbogenerator

Source:
Alstom Power
Generation,
Mannheim
Stator Core Suspenssion

Source:
ABB,
Mannheim
Big Four-Pole Turbine Generator
Stator: water, Rotor: hydrogen gas cooling Source: Alstom, Switzerland
High Voltage Terminal Box with Bushings
and Winding Main Leads

Terminal box

Flexible
conductor

Bushing

Source: Alstom, Switzerland

Manufacturing of stator housing

Sealing Shaft

Source:
Alstom Power
Generation,
Mannheim
Transportation of a turbogenerator stator via
the road

Source:
Siemens AG,
Mülheim/Ruhr,
Germany
Fully assembled turbine generator for easy
installation on-site

Railway transportation Car transportation

Source:
Siemens AG, Mülheim/Ruhr, Germany
Four-pole rotor

1500 MVA,
60 Hz, 1800/min,
for a nuclear power
plant

Source:
Alstom Power Generation, Birr,
Switzerland (former BBC)
Overview

• Turbogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
• Hydrogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
Two-pole Rotor
Manufacturing of Gas-cooled Two-Pole Rotor

Before the
mounting of the
stainless steel
end caps

Source:
Alstom Power
Generation,
Mannheim
 Axial Cooling of Rotor Winding
Axial Cooling Slot wedges
Rotor end-winding
Retaining ring

H2 flow

The rotor itself operates as a radial fan.

Different gas inlet- and outlet-diameters
develop centrifugal forces providing
nearly the same pressure across each
individual hollow conductor.
Axial Cooling of Rotor Winding
Rotor centre
Source:
Sequenz, H. (Ed.), Springer-Verlag

Slot cross
Gas outlet section

Gas inlet
Gas outlet
Gas inlet

Direct AXIAL cooling of rotor conductors

Radial Cooling of Rotor Winding

Radial gas flow

Rotor centre
Slot bottom duct
Radial gas outlet
Gas inlet
slot
Source:
Sequenz, H. (Ed.), Springer-Verlag

Direct RADIAL cooling of rotor conductors (Air or hydrogen gas)

Pick-up Cooling of Rotor Winding
Testing of a turbine generator in the
manufacturers test rig

Source:
Alstom Power
Generation,
Mannheim
Completed steam-turbine and two-pole
generator group in the nuclear power plant

Leibstadt, Switzerland,
1230 MVA, 3000/min, 50 Hz
Big 2-pole water/hydrogen cooled turogenerators

Low pressure stage of

steam turbine

Cooler unit
Exciter slip
ring housing

Generator Source: Alstom, Switzerland

Rated data: SN = 950 MVA, Thermal Class F (155°C), utilized acc. to Class B
(130°C), 700 MW, 50 Hz, 30000/min, coal power plant Manjung
 Completed steam-turbine and two-pole
generator group in the nuclear power plant
Low
pressure
stage of
steam
Exciter Generator turbine
slip ring
Source: Alstom,
housing Belfort

Rated data: SN = 1722 MVA, 1500 MW, nuclear power plant Oskarshamn,
Sweden
Overview

• Turbogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
• Hydrogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
Hydropower Generator
source: Karl Arstrom,
Vertical synchronous
generators, http://uu.diva-
portal.org/smash/get/diva2:
736932/FULLTEXT01.pdf

source:
www.el.angstrom.uu.se/for
skningsprojekt/vattenkraft.
html
Manufacturing the stator of a hydrogenerator
Welded stator housing of
synchronous hydro generator

The stator frame consists of horizontal steel plates

shaped as rings,vertical steel plates for support, vertical
Source:
dovetail bars and outer shell plates that are welded
Andritz Hydro,
together to a complete structure Austria
Stacking of stator iron sheets of hydrogenerators

Source:
Andritz Hydro,
Austria
Stacking of stator iron sheets of a hydrogenerator
Stator Winding

Wedges of non-metallic
material are used to secure
the windings in the radial
direction and a tight fit is
ensured by ripple springs.
source: https://www.voith.com
 Inserting of impregnated form wound coils
Ventilation
duct
Tooth
Slot
Massive
iron
clamping
finger
Pressing
plate
1st layer
2nd layer

Source: Andritz Hydro, Austria

High voltage form wound stator coil

Winding overhang

coil side, inserted in

slot

Source:
coil terminals Andritz Hydro, Austria
Pressing of winding bars in the slots

Source:
Andritz Hydro,
Austria
Time required for stator assembly sequences and
processes
Example for a hydropower
generator with an outer diameter
of 8000 mm and a core length of
1000 mm. The pack thickness is
45 mm.
source: Karl Arstrom, Vertical synchronous generators
Overview

• Turbogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
• Hydrogenerators
- Stator Manufacturing and Refurbishment
- Rotor Manufacturing and Refurbishment
Stator assembly process
Stator assembly process
Upper spider for the bracket of a vertically mounted
salient pole hydro generator

Skewed spider
to equalize
better the
thermal
expansion

Source:
Alstom power
(former BBC,
Switzerland)
Rotor spider during milling before mounting of rotor
yoke
Manufacturing
of bulb type
hydro generator
for Freudenau
power plant

Source:
VATech Hydro, Austria
(now Andritz Hydro)
Upper spider for the bracket of a vertically mounted
salient pole hydro generator

source: Karl Arstrom, Vertical synchronous generators

Manufacturing of poles for high pole count low speed
ring generator
Pole shoes, built as laminated
iron stack to suppress eddy
currents, which are induced by
slot ripple magnetic air gap field
due to stator slot openings
Slots for damper bars

Source: VATech Hydro, Austria

(now Andritz Hydro)
Manufacturing of poles for high pole count low speed
ring generator

Source:
VATech Hydro, Austria
(now Andritz Hydro)
Drilling holes into massive pole shaft to fix them to
rotor yoke ring with screws
Welding
machine

Welding of
massive
pole shaft o
laminated
pole shoes

Source:
VATech Hydro,
Austria
(now Andritz Hydro)
Rotor poles
Damper ring
segment
pole press
plate
pole joint
bolts

three-fold
hammer
head fixation

Source:
VATech Hydro, Austria
(now Andritz Hydro)
 Field winding
Non-insulated
flat copper
winding
provides good
heat transfer
to cooling air
at front sides
Inter-turn
insulation

“Cooling fins”
by increased
copper width

Source:
VATech Hydro, Austria
(now Andritz Hydro)
Completed salient pole before mounting
Pump storage
hydro power plant
Vianden/Belgium

Three-fold hammer
head fixation
“Cooling fins” by
increased copper
width
Damper ring
segments

Source:
VATech Hydro, Austria
(now Andritz Hydro)
Completed salient pole before mounting
Dove tail
fixation of rotor
poles
“Cooling fins”
by increased
copper width
Damper ring
Damper
retaining bolts
Rotor back
iron
Rotor spider

Source:
VATech Hydro, Austria
(now Andritz Hydro)
 Balancing & over-speed test

4 pole rotor
Exciter
generator
3-phase
winding

Rotating
diode
rectifier
Balancing
bearing Source:
(Schenck
VATech Hydro, Austria
Company, (now Andritz Hydro)
Darmstadt)