CIGRE SC A1 2008 Panel Session

State-of-the-art Technology for

Large Turbine Generators

Hitachi, Ltd. Power Systems

August, 2008
Kenichi Hattori*, Kazuhiko Takahashi,
Shigeki Tohnosu, and Kado Miyakawa
Hitachi, Ltd.

Hitachi Ltd.2008 All Rights

Reserved.

CIGRE SC A1 2008 Panel Session

Hitachi Turbine Generator Development History

1800

Generator Capacity (MVA)

Hitachi, Ltd. Power Systems

1600

Two-Pole Generator
Four-Pole Generator
Air-Cooled Machine

1400

1570 MVA ABWR

1570

1300 MVA

1200

Current
MVA 4 pole

1120 (1230) MVA 2 pole

1120 MVA
940 MVA

1000

800 MVA

800

670 MVA

600

520 MVA

320 MVA

200
70 MVA

0
1950

Near future

626 MVA
408 MVA

400

778 MVA

1960

1970

1980

250 MVA
230 MVA
165 MVA
217 MVA

1990

2000

2000 MVA ?

2010

Year

Hitachi Ltd.2008 All Rights

Reserved.

CIGRE SC A1 2008 Panel Session

Current

Hitachi, Ltd. Power Systems

Largest Units for Nuclear Power Plants (4 poles)

1,300-MVA (1,500 rpm) Turbine Generator 1,570-MVA (1,800 rpm) Turbine Generator
at Fukushima Nuclear Power Station No.
at Hamaoka Nuclear Power Station
2 (Japan)
No. 5 (Japan)

Hitachi Ltd.2008 All Rights

Reserved.

CIGRE SC A1 2008 Panel Session

Current

Hitachi, Ltd. Power Systems

Replacement of Generators for Nuclear Power Plants

749 MVA 1,800 rpm 60 Hz

Turbine Generator at Kori
Nuclear Power Plant No.1
(Korea)
Hitachi Ltd.2008 All Rights
Reserved.

CIGRE SC A1 2008 Panel Session

Typical Structure of 1,000 MVA Class Generator

Stator Coil End Support

Generator components

Stator Winding

Stator Core

Collector Rings

W/O Suspension (4pole)

With Suspension (2pole)

Brush Holders

Hydrogen Coolers

Ventilation Fans
Field Winding

Radial Fans (4-pole)

Axial Fans (2-pole)

Bearings
Retaining Rings

Rotor
Hitachi, Ltd. Power Systems

Radial Flow (4-pole)

Bushing CTs

GPU Flow(2-pole)

High Voltage Bushings

Hydrogen Control System

Stator Cooling Water System

Seal Oil System

Hitachi Ltd.2008 All Rights
Reserved.

CIGRE SC A1 2008 Panel Session

Stator Core - Clamping Structure Stator

core
Clamping
plate

Reinforcement
ring

Hitachi, Ltd. Power Systems

Wrapper plate

Clamping
fingers
Horizontal spring bars
(for 2-pole only)
Key bars

Hitachi Ltd.2008 All Rights

Reserved.

CIGRE SC A1 2008 Panel Session

Ventilation of Generator Rotor (4-pole*)

Rotor (Radial Flow Ventilation)
Discharge Gas

Wedge

Hitachi, Ltd. Power Systems

Creepage
Block
Conductor
Turn
Insulator
Slot Armor
Ventilation
Hole
Insulating
Filler

Radial Flow
Inlet Gas

Sub-Slot

* Used also for 2-pole generators of smaller output

Hitachi Ltd.2008 All Rights
Reserved.

CIGRE SC A1 2008 Panel Session

Ventilation of Generator Rotor (2-pole only)

Hitachi, Ltd. Power Systems

Rotor (Gap Pick-up Ventilation)

Baffle
for zone separation

Stator

Rotor
Direction of
Rotation

Exhaust Suction
Suction
gas zone gas zone gas zone

Exhaust
zone

Suction
zone

Directly cooled
Gap pick up flow
(Diagonal flow)
Hitachi Ltd.2008 All Rights
Reserved.

CIGRE SC A1 2008 Panel Session

Ventilation of Generator Rotor (Gap pick-up)

Rotation
H2 Out

H2 In

Rotation
Discharge Gas

Hitachi, Ltd. Power Systems

Inlet Gas

Direction of Rotation

GAS FLOW

Hitachi Ltd.2008 All Rights

Reserved.

CIGRE SC A1 2008 Panel Session

Example of Rotor Temperature Analysis

Ventilation
network

Stator
Rotor

Stator

Rotor

Transition

Inlet

Outlet

Inlet

Result of ventilation analysis

We
Investigate interaction of
stator and rotor
Control both hot spot and
average temperature

End portion
End and transition
portion

Slot portion
Repetitive portion

60
Temperature rise (K)

Hitachi, Ltd. Power Systems

End

Top
5th
4th
3rd
2nd
Bottom

50
40
30
20
10

Cooling gas inlet

0
- 6000
- 5000

Cooling gas inlet

- 4000
- 3000
- 2000
Axial position from rotor center (mm)

- 1000

0
Rotor Center

Hitachi Ltd.2008 All Rights

Reserved.

10

CIGRE SC A1 2008 Panel Session

Stator Coil

- Strand -

Stator Coil and Cooling System

Cross Section of Stator Slot

Strands and Transposition

Hollow Strand

Bottom Coil

Solid Strand

Hitachi, Ltd. Power Systems

Center Filler
(RTD)

540Roebel Transposition

Temperature Analysis

Top Coil

Cooling Water Flow

Coil Center
Top Ripple Spring

Wedge

Slot Region

end

Hitachi Ltd.2008 All Rights

Reserved.

11

CIGRE SC A1 2008 Panel Session

Example of Stator Coil Temperature Analysis

End
Bottom coil

Slot region

End

Stator core

Top coil
Sec.3
Sec.3

Sec.1

Total

Total

Sec.3

Sec.2

Sec.1

Cooling water flow

Bottom coil

Total

Sec.2

Coil Center
Top coil

Hitachi, Ltd. Power Systems

Eddy Circulatig
current
+ DC

Linkage flux

Sec.2 Sec.1

High

Slot Region

End

Low

Loss distribution

Temperature distribution
Hitachi Ltd.2008 All Rights
Reserved.

12

CIGRE SC A1 2008 Panel Session

Stator Coil

- Coil End Support System -

Sliding support
Permanent
ring
Support arm

Hitachi, Ltd. Power Systems

Slide bearing

Support arm
Slide bearing
Permanent
Sliding
ring

Nose ring

End winding

Binding Band

Stator core

End winding
Stator core
Nose ring

Secured from radial and

circumferential movement
Free for axial movement
Hitachi Ltd.2008 All Rights
Reserved.

13

CIGRE SC A1 2008 Panel Session

Stator Core - Measures against Overheating Stator core

Stepped Teeth

End Duct

Teeth Cut Slits

Bottom coil

Hitachi, Ltd. Power Systems

End duct
Top coil

Duct piece

Arrangement of the stator core end is designed to reduce detrimental

heating effect (eddy current loss) due to axial leakage magnetic flux.

Hitachi Ltd.2008 All Rights

Reserved.

14

CIGRE SC A1 2008 Panel Session

Advanced Technology for Optimum Design

Hitachi, Ltd. Power Systems

Electro-Magnetic Force and Vibration Analysis on Stator End Windings

Mechanical Analysis of Rotor Shaft Fan Characteristics Analysis

Vibration Analysis of Stator Casing

Ventilation Analysis

Hitachi Ltd.2008 All Rights

Reserved.

15

CIGRE SC A1 2008 Panel Session

Advanced Technology for Optimum Design

Magnetic filed analysis

at stator core end plate

Magnetic field analysis at

stator core end

End portion

Slot portion

60

Cooling water flow

Stator coil temperature distribution

Temperature rise (K)

Hitachi, Ltd. Power Systems

Generator magnetic flux analysis

Top
5th
4th
3rd
2nd
Bottom

50
40
30
20
10

Cooling gas inlet

0
- 6000
- 5000

Cooling gas inlet

- 4000
- 3000
- 2000
Axial position from rotor center (mm)

- 1000

0
Rotor Center

Rotor coil temperature distribution

Hitachi Ltd.2008 All Rights
Reserved.

16

CIGRE SC A1 2008 Panel Session

Hitachi, Ltd. Power Systems

Quality Assurance and Tests for Development

Stator Inspection

Stator End Winding Vibration

Test Equipment

Clean Room for Stator/Rotor Assembly

Quality control and

inspection of components

Spinning Burst Test Using Full -Size Rotor

Hitachi Ltd.2008 All Rights
Reserved.

17

CIGRE SC A1 2008 Panel Session

Quality Assurance and Tests for Development

Hitachi, Ltd. Power Systems

Stator coil (Insulation for Class F)

High performance of the insulation system confirmed from

thermal cyclic endurance test
Hitachi Ltd.2008 All Rights
Reserved.

18

CIGRE SC A1 2008 Panel Session

Proven Technology for High-performance

Generator
2,000-MVA Class Generator for ESBWR

Tetra-lock type
stator coil end
support

Stator bars

Stator frame

Hitachi, Ltd. Power Systems

Round-type
cooler box
Top-dometype cooler box

F-class
Insulation
System

d
Ra

F
ial

Movable to
axial direction
Rigid to radial
and
circumferential
direction

low

Stator core
Terminal box
Retaining ring

Shaft

18Mn-18Cr
Anti-corrosion
Material

High-Strength
Forging
Material

Twin terminal
boxes for
4 star
connection

Reduction of
stator core end
loss

Hitachi Ltd.2008 All Rights

Reserved.

19

CIGRE SC A1 2008 Panel Session

Future Design Philosophy

Hitachi, Ltd. Power Systems

Comparison of Parameters
Item

Country

China

Japan

ESBWR

Capacity

MVA

1,120 (Max 1,230)

1,570

App. 1,900 2,000

Output

MW

1,000 (Max 1,083.5)

1,413

App. 1,700 1,800

Power factor

0.9

0.9

0.9

SCR

NLT 0.50

NLT 0.58

NLT 0.35 (*1)

Voltage

kV

27

22

24 - 27

Current

23,949 (Max 26,302)

41,202

App. 44,000 - 38,000

Connection

2Y

4Y

4Y

H2 Pressure

MPag

0.52

0.52

0.52 0.62

Rotating speed

rpm

3,000

1,800

1,800

No. of Poles

Stator cooling

Water Direct

Water Direct

Water Direct

Rotor cooling

H2 Direct
(GPU Flow)

H2 Direct
(Radial Flow)

H2 Direct
(Radial Flow)

Exciter

Static

Static

Static

* 1: According to IEEE C50.13 - 2005

Hitachi Ltd.2008 All Rights
Reserved.

20

CIGRE SC A1 2008 Panel Session

Features of Large Turbine Generators

Difference between 4 and 2-pole generator discussed
The main technique that characterize our generator is the
minute temperature analysis where the rotor and the stator
interaction was fully incorporated.
The stator strand loss and temperature are examined full 3-D
Hitachi, Ltd. Power Systems

scale while physically considering transposition.

From the above, the current maximum rating is 1,570 MVA (4pole) and 1,230 MVA (2-pole). We foresee future 2,000 MVA in
the future.

Hitachi Ltd.2008 All Rights

Reserved.

21

CIGRE SC A1 2008 Panel Session

Hitachi, Ltd. Power Systems

Thank you

Hitachi Ltd.2008 All Rights

Reserved.

22

CIGRE SC A1 2008 Panel Session

Current - 4 pole generators Current 4-pole generator for NPP including AVR

Hitachi, Ltd. Power Systems

Country
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Korea
Korea

Capacity(MVA)
1570
1540
1530
1300
1300
1300
1300
1280
1280
1222
1222

RPM

Voltage(KV)

1800
1800
1800
1500
1500
1500
1500
1800
1800
1800
1800

22
24
22
19
19
19
19
22
22
22
22

Service Year
2005
2006
2011
1984
1987
1990
1994
1993
1987
2009
2009

Hitachi Ltd.2008 All Rights

Reserved.

23

CIGRE SC A1 2008 Panel Session

Current - 2 pole machine Current 2-pole generator (latest upgrade)

Hitachi, Ltd. Power Systems

Country
China
Korea
Korea
USA
USA
Germany
Germany
Netherland
Germany
USA
USA
USA
Japan

Capacity(MVA)

RPM

Voltage(KV)

1230
1028
1028
1025
986
962
962
962
962
828
825
825
800

3000
3600
3600
3600
3600
3000
3000
3000
3000
3600
3600
3600
3600

27
25
25
24
24
21
21
21
21
25
25
25
25

Service Year
2006
2008
2009
2007
2010
2009
2012
2012
2013
2009
2008
2009
1992

Hitachi Ltd.2008 All Rights

Reserved.

24

CIGRE SC A1 2008 Panel Session

Example of Stator Coil Loss Analysis

End

Slot region

Bottom coil

End

Stator core

Top coil
Sec.3

High

Linkage flux

Sec.2 Sec.1

Low
Eddy Circulatig
current
+ DC

Eddy Circulatig
current
+ DC
Bottom coil
Top coil

Total

Bottom coil

Total

Top coil

Bottom coil
Top coil

Hitachi, Ltd. Power Systems

Eddy Circulatig
current
+ DC

Total

Loss distribution
Hitachi Ltd.2008 All Rights
Reserved.

25