Beruflich Dokumente
Kultur Dokumente
Energetice
• 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:
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
Stainless steel
water boxes
Current method
Electrical Insulation - Components
Corona Protection
Main Insulation
Electrical Insulation
Big generators:
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
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
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
Slot cross
Gas outlet section
Gas inlet
Gas outlet
Gas inlet
Rotor centre
Slot bottom duct
Radial gas outlet
Gas inlet
slot
Source:
Sequenz, H. (Ed.), Springer-Verlag
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
Cooler unit
Exciter slip
ring housing
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
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
Winding overhang
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:
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)