oe lest INSTRUCTION BOOK HYDROGEN WATER-COOLED TURBINE GENERATOR 2. DESCRIPTION OF CONSTRUCTION 2-1 GENERATOR CONSTRUCTION FEATURE CONTENTS 1. Cooling(Stator Coil) 2. Cooling(Stator Core) 3. Cooling(Rotor Straight Part)----~ 4. Cooling(Rotr End Part) 5. Stator Frame: 6. 7. 8. . Stator Lamination: Stator Core End- . Flexible Mounting: 9. Stator Coil 10. Dialastic Insulation 14. Stator Coil Header Part ~~ 42. Support of stator Coil End Part 13, Bushing 14, Rotor Shaft ~ 15. Rotor Coil 16. Coil Retaining Ring 17. Blower 18, Bearing Bracket 19, Bearing 20. Jacking Oil System 24. Protection for Shaft Current 22. Gland Seal- 23. Gas Cooler 24, Slip tinge 25. Brush and brush holder GENERATOR 24 ABZ-0440she, MTSuBISHH ELECTRIC 4. COOLING (STATOR COIL) ‘The generator stator coil is water-cooled. The cooling water is fed from the generator turbine side of the manifold (A), then is supplied to the stator coil via insulated hose. The cooling water supplied to the stator coil is discharged via manifold (B) of the generator exciter side. Therefore, the stator coil's temperature is lowest on the turbine side, and highest on the exciter side. Therefore the stator coil temperature is monitored by embedding a search coil between the upper coil and the lower coil of the stator coil, and also by mounting a thermocouple for measuring the outlet cooling water temperature of each coil to the exciter side manifold. Exciter Side Turbine Side Generator Insulation Hose \, iy a = 1 Manifold (A) Manifold (B) Stator Coit Fig.1_ Cooling for Stator Coil GENERATOR 24-2 ABZ-0440he MITSUBISHI ELECTRIC 2. COOLING (STATOR CORE) A high-pressure blower is mounted near the shaft end of the exciter side; the hydrogen gas, whose pressure is boosted up here, passes through the gas cooler provided on the stator frame exciter side to be led to the turbine side end through the passage between the stator core and the stator frame. Part of hydrogen gas enters the ventilation hole of the stator core, moves in the axial direction to be discharged to the exciter side end, then is once again sucked in by the blower. Exciter Side Turbine Side Gas Cooler Blower Stator Core Fig.2. Cooling for Stator Core GENERATOR 24-3 ABZ-0440% MITSUBISHI ELECTRIC 3. COOLING (ROTOR STRAIGHT PART) The ventilation of the rotor coil consists of two systems, one wherein gas enters from the both ends of the turbine side and exciter side and is discharged from the straight part center into the air gap and the other wherein gas is discharged into the air gap after cooling only the coil end part and passing along the lower part from the central part, and it forms altogether a four- parallel circuit. ‘The below illustration shows the ventilation of the straight part of the rotor coll, A part of the gas that reached the turbine side enters the gas channel inside the rotor coil in such a process as shown in the illustration from the circular space formed by the end cover of the coil retaining ring and shaft, and proceeds to the center part in the axial direction, then to the exciter side, after being discharged into the air gap, and to be drawn in by the blower, On the exciter side, the low temperature gas enters the circular space formed by the end cover of the coil retaining ring and shaft after passing through the passage provided in the blower hub, then in the same way as the turbine side, cools the coil and is discharged into the air gap from the hole in the center of the straight part. Fig.3 Cooling for Rotor Coil (straight parts) GENERATOR 21-4 ABZ-04409 MITSUBISHI ELECTRIC 4, COOLING (ROTOR END PART) A part of the gas that enters the circular space formed by the end cover of the coil retaining ring and shaft proceeds, as shown in the above illustration, in the peripheral direction along the curved part of the coil end and is discharged again into the lower side from the hole in the center of the end part. This chamber is partitioned with a separate board as shown in the illustration from the intake of gas, and the gas discharged here goes out into the air gap through the notch provided in the pole center of the shaft to be united with other gas, and proceeds through the air gap in the axial direction to be draw in by the blower. The idea of cooling the straight part and end parts of the rotor coil separately with four parallel Circuit, as illustrated below, is to reduce the length of gas passage and enhance the cooling effect. GENERATOR 24-5 ABZ-0440(MITSUBISHI Saves 5. STATOR FRAME ‘The stator frame is of special pressure-proof design that can withstand pressure of 10Bar-g, twice the maximum gas pressure, 5.0Bar-g. The material used is: No.1 SM 400 AP, of JIS G 3106 Rolled Stee! for Welded Construction or its equivalent. The stator frame is formed by materials of huge size to minimize the welding parts, of the outer frame, in order to provide explosion safe gas-tight housing. Besides, meticulous care is given the welding. A thorough gas leakage test is also given after welding to the spaces between the base materials of the outer frame and between the side walls of the outer frame and both ends. GENERATOR 241-6 ABZ-0440(MITSUBISHI oa lieee 6. STATOR LAMINATION To form a stator core, high quality silicon steel plates of litle core loss are used and punch them with a die in such segments as shown in the illustration. After giving them varnish treatment, pile them up in a stator frame. In the segments at the end parts of the core, provide slits at the tooth part as shown in the left segment of the above illustration, whereby to prevent the increase of end stray load loss. Fig.6 Stator Core GENERATOR 217 ABZ-0440% MITSUBISHI ELECTRIC 7. STATOR CORE END In the case of water-cooled generator which has a large capacity, it is necessary to reduce stray load loss as much as possible. To this end, at the stator core end part non-magnetic finger plate is used and, as shown in the illustration, an end core structure wherein silicon steel plates are piled up is adopted to shield the end flux. For coil supports, non-metalic material is used to the most to reduce eddy current loss. Fig.7 Stator Core End GENERATOR 241-8 ABZ-0440MITSUBISHI oats 8. FLEXIBLE MOUNTING In a two-pole turbine generator, the magnetic pull caused by rotor and stator flux makes a big difference between the pole center and its midway, producing double frequency vibrations wherein the stator core becomes oval or returns. Efforts are made to design the core and stator frame in such a manner as to minimize this vibration, but furthermore a flexible support is provided, as shown in the illustration, in order to prevent the transmission of vibrations from ‘the core to the stator frame. This suspends the entire stator core from the stator frame by many spring plates provided in the peripheral direction as well as axial direction, and the stator core is rigidly supported by the stator frame in the gravitational direction, but it can be comparatively freely changed in the radial direction, and so it prevents the transmission of the double frequency vibrations to the stator frame. Fig.8 Flexible Support (between Stator Core and Stator Frame) GENERATOR 241-9 ABZ-0440MITSUBISHI ELECTRIC 9. STATOR COIL The stator coil consists of a hollow strand and solid strand which are combined as shown in the drawing. This structure features superior cooling effect, and is suited to the large- capacity generator with reduced vortex loss. The cooling water runs inside the hollow strand, and snatches the heat generated to the stator coil, thus preventing temperature from rising. A special transposition, which is designed to minimize the circulating current due to the end magnetic flux by means of 1-turn coil, is used in order to keep current balance between strands. ‘Two pairs of strands are integrally molded, then main insulation is applied to the outside. Solid Strand Hollow Strand Ground Insulation Fig.9 Stator Coil (section view, typical) 24-10 ABZ-04409 MITSUBISHI ELECTRIC 10. DIALASTIC INSULATION (1) Having been impregnated with solventless, heatcuring epoxy resin (diaresin), the mica tape is thoroughly filled with resin to the extent that no void is left. (2) Since diaresin is epoxy resin, it can withstand high voltage. (3) Because of high tensile strength, elasticity and coefficient of expansion approximate that of copper, it can be free from cracks resulting from the expansion and contraction of the conductor due to long time operation. (4) Moisture-proof, chemical-proof and oil proof. (5) Since tand(delta) is small, the increase or decrease of tana(delta) due to changes of temperatures and voltage is also negligible. (6) Thermally stable, long life is assured. Fig.10 Stator Coil GENERATOR 24-11 ABZ-0440ae ELECTRIC 414. STATOR COIL END CONSTRUCTION The stator coil end part consists of the header for branching the cooling water to the hollow strand, the header cap, and the hose joint; and, each part, including the strand, is soldered so as to completely prevent leakage of water. The hose joint is for connecting the manifold to the insulated hose through which the cooling water passes through stator coils; and, it is made of non-magnetic steel. Fig.11 Stator Coil (Header Parts) GENERATOR 24-12 ABZ-0440g MITSUBISHI ELECTRIC 42, SUPPORT OF STATOR COIL END PART The coil end part, where large electromagnetic force is applied during short-circuit, is made into an integral structure of a resin cone, segment plate, and tightening bolts. ‘The axial-direction slide mechanism is provided for absorbing the heat expansion difference between the stator coil and the stator core. Non-magnetic Bolt ‘Segment Plate Insulated Bolt Resin Cone Axial-direction Slide Mechanism Resin Cone Support Fig.12 Stator Coil (End Parts) GENERATOR 24-13 ABZ-04409 MITSUBISHI ELECTRIC 13. BUSHING At the lower part of the turbine side of the stator frame is provided a lead box, which has six lead bushings, three on the line side and three on the neutral side. The generator armature current is fed to the transformer through the lead bushing after passing through the phase ring from the coil part on the turbine side. The lead bushing is also provided with a gas passage for inner cooling, to allow the low ‘temperature gas that enters from the gas intake of the main lead to directly cool the conductor of the lead bushing, to be discharged into the airtight lead box in the return way to the stator frame. For the insulation of the bushing, a dry type insulation free from oil leak is adopted, To eliminate stray load loss and overheating, nonmagnetic steel is used for the lead box. Fig.13 Lead Bushing GENERATOR 24-14 ABZ-04409 MITSUBISHI ELECTRIC 14. ROTOR SHAFT As shaft material, solid forging of Ni-Cr-Mo-V steel is used. This is equivalent to the requirements of the seven items for the shaft material standard of the ASTM Turbine Generator On the pole surface, cross slots are machined to have uniform rigidity and crescent-shaped slots for supersonic tests are also provided so that the reliability of the shaft material may be tested even after inserting rotor coils. Ross VENTILATING PASSAGES: ‘SLOTS (OF ROTOR ENO TURNS coNpucTOR SLOT mcL42022 Fig.14 Rotor Shaft GENERATOR 24-15 ABZ-0440Be MTSUBSHI 45. ROTOR COIL Made of cold worked silver bearing copper, the rotor conductor is of a structure wherein two U- shaped strands are composed to have a vent duct in the center. In the case of inner-cooled rotor coil wherein trapezoidal slots are adopted in order to increase the exciting capacity, itis impossible to coil edgewise as in the conventional type machines and allow them to insert one by one into the slots. Therefore, the coils are manufactured in parts, as in the lower illustration, so that they may be let into the slots to get their joints welded by means of high frequency induction heating individually. In the upper part of the field coil, a damper winding consisting of high tensile copper alloy, copper and retaining ring is provided to allow it to absorb negative phase sequence current. Fig.15 Rotor Coil GENERATOR 21-16 ABZ-0440g MITSUBISHI ELECTRIC 46. RETAINING RING In order to support the rotor coil end, thin cylindrical coil retaining rings are force fitted to both ends of the rotor body. The coil retaining ring is located at such a position where it is lable to receive during operation a large hoop stress and repeated elliptical deformation in the radial direction and to converge the end flux, so that high-tensile and non-magnetic austenite stee! is used. Further, in order to prevent the lowering of the mechanical strength due to notches, a unique ventilation system that does not require vent duct in the radial direction has been adopted. In force fiting the coil retaining ring to the rotor body, enough fit clearance has been taken to prevent the ring from loosing even in the standard over-speed condition, and rings are inserted for locking to prevent any movement in the axial direction. Fig.16 Retaining Ring GENERATOR 2AAT ABZ-0440fe MITSUBISHI 417. BLOWER In water-cooled machine, a multi-stage axial blower is installed only at the exciter side. In order to feed cooling gas (cold gas) into a long and narrow vent duct in the axial direction ventilation, a high pressure blower of little volume is required, and so the blade of low height is not inconvenient but it is important that a multi-stage blower(s) be adopted. Both the stator blade and rotor blade are made of Ni-Cr-Mo steel and 13 Cr steel of precision casting, and are fixed to the blower shroud and hub with dovetails separably. Their construction is easy in assembly and disassembly. To prevent the increase of stray load loss, the Ni contents of the stator blade are increased and make non-magnetic. Fig.17 Blower GENERATOR 21-18 ABZ0440MITSUBISHI ELECTRIC 18. BEARING BRACKET The bearing bracket is of welded construction and is directly fixed to the stator frame. It is divided into two parts both at the turbine side and the slip ring side, having sufficient mechanical strength by means of many ribs. In the bracket are included bearings, gland seal ring and oil seal and the lower section of the lower bracket constitutes a defoaming tank. To fix the stator frame, gasket and sealing compounds are used and the construction is such that gas leakage is kept to the minimum. Fig.18 Bearing Bracket GENERATOR 24-19 ABZ-0440MITSUBISHI Ae 19. BEARING Tilting pad type bearings are used in order to keep high stability of rotor and low metal temperature during operation. The bottom half of the bearing consists of a shell with spherical seat, containing two pivoted ‘pads with center lines located 45 degrees each side of the vertical center line. Spherical seat keeps the bearing and shaft free from undue stress due to the deflection of shaft or misalignment. The bottom pads consist of babbitt lined copper "shoes" held mechanically to steel backup pads. The top half with a viscosity pump groove is identical to that of a conventional sleeve bearing. Equipped precisely with a slinger device, they are protected against oil leakage. ‘The shaft journal is machined by super finish, to increase the allowable bearing pressure and maintain satisfactory lubrication. ‘The bearings may be inspected even with the generator filled with gas by removing the keeper (bearing insulation) at the top. Fig.19 Bearing (titing pad type) GENERATOR 24-20 ABZ-0440% MITSUBISHI ELECTRIC 20. JACKING OIL SYSTEM The purpose of the Jacking Oil System is to supply high-pressure oil to the oll pocket in the lower part of the bearing of generator, so that the oil film established in the clearance between the bearing and shaft makes the generator rotor rotate smoothly during low speed turing operation. The high-pressure is required to lift the generator shaft with oil pressure from the bearing when the shaft is contacting with the bearing. However, after the shaff is once lifted from the bearing with the high-pressure oil, the required pressure to keep lifting the shaft becomes relatively low because of increase of lifting area. As the lifting quantity of shaft depends on the oil flow quantity, it is required to maintain the oil flow quantity at constant value so as to obtain the stabilized rotation of the generator shaft at low turning speed. ‘The common Jacking Oil System is adopted for turbine and generator. The Jacking Oil System has the functions in response to these requirements, and in addition, it has the features of safety in operation. (1) To supply oil with appropriate pressure and flow quantity to each bearing of turbine side and slip ring side (2) To prevent the excess oil pressure in related piping and equipments even if the piping is blockade. (3) To prevent the back flow of oil film established in the clearance between shaft and bearing through the oil lift piping in condition of high-speed operation of generator at which the oil lift is not required. In high-speed condition of the generator, as the sufficient oil film is established, the operation of Jacking Oil System is not required. Therefore, the operation of Jacking Oil System is limited between 0 to 600 min and the 600 min” is enough speed that sufficient oil film is established. ‘The Jacking Oil System mainly consists of Generator Bearing portion, Jacking Oil Pump Unit and associated piping. GENERATOR 24-21 ABZ-04409 MITSUBISHI ELECTRIC 21. PROTECTION FOR SHAFT CURRENT For the protection of shaft current, the bearing and bracket are insulated at the top, as shown in the above (upper) illustration, with a bearing keeper, while their lower side is assembled by using insulated bolts after inserting an insulating sheet into the bearing ring and the bearing fitting surface. Besides them, insulation materials are inserted into all possible parts which may be exposed to the flow of the shaft current between gland seal bracket and bearing bracket, between the gland seal and oil piping, between oil seal and bracket. The construction is such that has sufficient creepage distance, free from leakage current. Fig.20 Bearing Keeper and Bearing Ring GENERATOR 24-22 ABZ-04409 MITSUBISHI ELECTRIC 22. GLAND SEAL ‘As shown in the below illustration, the gland seal is provided with two oil lines, the inside of the machine is called the hydrogen side and the outside, the air side, each with independent circuits. The two circuits have at the entrance of the sealed parts pressure equolizing valves 0 as to control the pressure at the entrance for equalization, so that there is no mutual exchange of oil between the two circuits in gland seal. The hydrogen side seal oil is saturated with hydrogen, and the air side seal oil with air. However, due to absence of mutual exchange between them, there is no possibility of the hydrogen leakage outside the machine or the air defusion inside. In order to prevent the ring from impossible to operate smoothly due to lateral thrust that works on the seal ring because of the high gas pressure, such a construction as to give a float oil pressure to the seal ring from the outside of the machine, to press the ring inside the machine to equalize it with the thrust by gas pressure, as shown in the above illustration is adopted. Fig.21 Gland Seal GENERATOR 21-23 ABZ-0440MITSUBISHI SoMeRe 23, GAS COOLER ‘Two gas coolers are each arranged vertically both on the right and the left side at the exciter side in the generator. Cooling tubes with spiral copper fins are used as shown in the lower illustration, but the material for the cooling tubes themselves ranges from two to four kinds of seamless copper alloy tubes for condenser. : ‘The cold gas temperature is designed fo maintain below [MFC when the cooling water temperature isc. Fig.22_Gas Cooler GENERATOR 24-24 ABZ-04409 MITSUBISHI ELECTRIC 24, SLIP RING The slip ring is made of tool steel and its slide surface is spirally grooved so as to ensure a uniform contact of the brush with the slip ring. This groove also helps the air to escape so that the high air pressures generated on the ring surface due to its revolution at high speed do not prevent the good contact between the brush and the ring. ‘Around the slip ring and in the housing, ventilation and cooling are performed by a fan. The slip ring is mounted to the rotating shaft through an insulating material. The slip ring and the field coil are connected each other with two sets of riser leads and the axial lead provided in the axial center hole. The riser lead has a taper screw at its joint with the axial lead and is tightened by being screwed into the axial lead. The two sets of riser leads are sealed tight by a synthetic rubber gasket so that it can structurally prevent a leak of gas from inside the machine to the center hole. The center hole of the rotor is plugged up at both ends but a test hole is provided on the slip fing side. So, you can a leak test with the riser leads, Fig.23 Slip Ring GENERATOR 24-25 ABZ0440MITSUBISHI ELECTRIC 25. BRUSH AND BRUSH HOLDER The brush is housed in a magazine-type brush holder. The brush holder is so structured that it can be attached to and detached from the brush arm by one touch concentrically with the slip ring. The brush requires no special adjustment of its pressure, because a constant- pressure spring that ensures a normal brush pressure of 120 g/cm’is used. GENERATOR 21-26 ABZ-0440