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CONTENTS
Introduction 2-Pole 1222MVA Generator
- Specifications - Issues from up-rate - Conceptual design cases - Electrical loadings - Design risks - Main design features
Conclusion
Introduction
Needs: - Ultra Super Critical Power Plant - Increasing Plant Efficiency and Power output - Bigger generator is required. Largest generator design: - High Voltage , High Current , High Flux, High Ampere Turn Loading require the larger machine diameter, longer machine length, more efficient cooling. - Use the existing model for machine reliability. - Adoption of well-evaluated design technology. - All generator component engineering should be performed. - General Electric Companys Experiences for machine reliability.
Design Difficulties Terminal Voltage, Terminal Current, Flux, Armature Reaction, Field Voltage/Current are close to design experience. Design Goal Higher Voltage vs. Larger Current Larger Flux vs. Larger Armature Reaction => Iterative Trade-Off Volume vs. Cost vs. Experience Re-distribution of Electrical vs. Mechanical Vs. Thermal loads
112.4 30 2
112.4 27 3
112.4 18 4
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Electrical loadings
Electrical Loading Comparison : (Case A)
Item
Rated MVA Phi (%) Mar (%) Bar Force (%) Field Voltage (%) Field Current (%) Core Outer Dia. (%) Core Length. (%) Rotor Outer Dia. (%) D2L/kVA (%)
Ref. Model
100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0
1222MVA Model
124.9 120.0 104.1 121.2 107.4 115.4 106.7 112.4 100.9 102.4
Remarks
< Mach. Exp. Similar < Design Guide < Design Guide < Design Guide < Mach. Exp < Mach. Exp Similar/Mach. Exp
Design risks
Up-rating Risk Studies :
Risks Insulation Failure -Due to Coolant Leak & 30kV terminal Voltage. Priority Counterproposal Design Installation of Coolant Leakage Monitor Reduced Brazing Points and Induction Brazing Implement of a first piece qualification plan Stator Bar Prototype Test More reliable Insulation & Gradient System Reduce Field Temperature Modify Bearing Span High Speed Balancing & Factory Running Test 3-D Vibration Analysis Ref. Model Field Operational Data First Unit Verification Test First Unit Verification Test Factory Running Test Reduce bearing span Reduce number of key bars
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Rotor Vibration
Stator Frame Vib. Reliability due to limited factory test Cost Reduction
3 2
Stator Core
10
11
12
13
14
15
16
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Conceptual design
Up-rating Studies :
Item Apparent Power (MVA) Core Diameter (%) Rotor Diameter (%) Core Length (%) Armature Voltage (kV) No. of Circuits
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Electrical loadings
Electrical Loading Comparison :
Item
Rated MVA Phi (%) Mar (%) Bar Force (%) Field Voltage (%) Field Current (%) Core Outer Dia. (%) Core Length. (%) Rotor Outer Dia. (%) D2L/kVA (%)
Ref. Model
100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0
1690MVA Model
110.6 100.0 110.6 114.0 120.2 102.3 100.0 100.0 100.0 90.4
Remarks
Same < Exp. < Exp. < Exp. Similar Same Same Same
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Design risks
Up-rating Risk Studies : Risks
Over Forging Manufacturing Capa. -Weight Over Machining Capacity -Weight Over Turning Machining Capa. & Heat Treatment Facility -Length Over High Speed Balancing Capa. -Weight Close to Crane Handling Capa. -Length & Weight Large Current
Priority 5
Counterproposal Design
Increasing Power Density 5 5 4 4 2 Application of Stub Shaft Design Modification Handling Capacity Test Liquid Cooled Terminal Box, New CT, New HVB
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Thank you
Presenter Chong Whie Cho chongwhie.cho@doosan.com
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