Pelton Turbine Generator Unit
(2X5800KW Pelton Turbine Generator Units)
CJA475-W-110/2×12, SFW5800-8/1730
Pelton Turbine (twin nozzle) with Horizontal Shaft Generator (synchronous, brushless excitation)
Pelton Turbine (twin nozzle) Generator control by Automatic Hydraulic Governor
Electric Control Panels
Outdoor Switch Yard Equipment
1. Main Characteristic Parameter of Turbine and Generator
Table -1
| Gross Head m |
440 |
Generator standard Speed r/min |
750 |
| Design Head m |
416 |
Generator Frequency (Hz) |
50 |
| Design Flow m3/s |
1.65 |
Unit runaway speed r/min |
1576.06 |
| Runner Model |
CJA475 |
Generator runaways Speed r/min |
1600 |
| Designed Unit Speed r/min |
40.44 |
Generator Calculation Pole Number |
8.001 |
| Design Unit Flow m3/s |
0.043 |
Generator Standard Pole Number |
8 |
| Model Efficiency |
0.906 |
Unit center line height over tail-water m |
1.6 |
| Efficiency Revision |
-0.007 |
Calculated Governor Power 10KN |
794.162 |
| Actual Turbine Efficiency |
0.899 |
Round up Governor Power (10Nm) |
600 |
| Generator Efficiency |
0.965 |
Calculated Main Valve Diameter (M) |
0.782 |
| Turbine Output Kw |
6053.49 |
Round Up Main Valve Diameter m |
Q947H-64/DN800 |
| Generator Output ( Kw ) |
5841.61 |
Jet speed m/s |
90.34 |
| m |
9 |
Runner line sped m/s |
43.197 |
| Operation m |
9.16 |
Speed Ratio 0.4-0.485 |
0.478 |
| Number of jets |
2 |
Max. Speed Rise % |
50 |
| Calculation Jet Diameter mm |
110.0 |
Max. Pressure Rise % |
40 |
| Roundup Jet Diameter mm |
120 |
Specific speed m.kw |
126.87 |
| Runner Diameter mm |
990.24 |
Generator power Kw |
5800 |
| Runner Diameter mm |
1100 |
Generator Voltage V |
6600 |
| Design unit Flow m3/s |
0.0795 |
Power factor |
0.8 |
| Single nozzle unit flow m3/s |
0.0397 |
Generator Current A |
634.229 |
| Operation Unit Speed r/min |
40.448 |
Excitation Voltage V |
112 |
| Turbine Max Flow m3/s |
1.9626 |
Excitation Current A |
338 |
| Min. Turbine Flow m3/s |
0.495 |
Turbine Model |
CJA475-W-110/2X120 |
| Max. turbine output Kw |
7200.60 |
Generator Model |
SFW5800-8/1730 |
| Min. turbine output Kw |
1816.04 |
Turbine total weight Ton |
12.1 |
| Max. generator output Kw |
6948.58 |
Runner weight Ton |
1.5 |
| Turbine Calculation Speed r/min |
749.83 |
Turbine max lift weight Ton |
8.4 |
| Turbine standard Speed r/min |
750 |
Generator total weight Ton |
42 |
| Turbine unit runaway speed r/min |
85 |
Generator max lift weight Ton |
20 |
2. Detailed List of Main Items
Table -3 Spare parts for Turbine (per unit)
| No. |
Appell. |
Unit |
Quant. |
| 1 |
hyarulic actuator seal rings |
Set |
1 |
| 2 |
Nozzle tip |
Set |
1 |
| 3 |
Nozzle bush |
Set |
1 |
| 4 |
Pressure gauge |
Set |
6 |
Table -4 Spare parts for Generator (per unit)
| No. |
Appell. |
Unit |
Quant. |
| 1 |
Radial Bearing Shell |
set/unit |
1 |
| 2 |
Thrust pad |
set/unit |
1 |
| 3 |
Brake block, seal ring, spring |
Sets. |
1 |
| 4. |
Diodes |
Set |
1 |
| 5 |
PT 100 sensor |
Set |
1 |
| 6 |
Pressure gauges |
Set |
3 |
| 7 |
Pressure transducer |
Set |
1 |
| 8 |
Flow indicator |
Set |
2 |
| 9 |
Position transducer |
Set |
1 |
Table -5 Spare parts for Control panel
| No. |
Appell. |
Unit |
Quant. |
| 1 |
PLC module with program |
Set |
1 |
| 2 |
Common I/O plugin DCAP-5000 series |
Set |
1 |
| 3 |
Common power plugin DCAP-5000 series |
Set |
1 |
| 4 |
Common CPU plugin DCAP-5000 series |
Set |
1 |
| 5 |
AC/DC power module DCAP-3098 |
Set |
1 |
| 6 |
Indicator lamp, 1 nos for each type |
Set |
1 |
| 7 |
Fuse, 100% for each type |
Set |
1 |
| 8 |
Air breaker, 1 nos for each type |
set |
1 |
| 9 |
Control switch, push button, 1 nos for each type |
Set |
1 |
| 10 |
Output relay, 24V, 1 nos for each type |
Set |
1 |
Table -6 Special Tools for Turbine (per plant)
| No. |
Appell. |
Unit |
Quant. |
| 1 |
Runner dismantle tool |
Set |
1 |
| 2 |
Special Wrenches and Lift eyebolt |
Set |
1 |
Table -7 Special Tools for generator (per plant)
| No. |
Appell. |
Unit |
Quant. |
| 1 |
Runner, dismantle tool |
Set |
1 |
| 2 |
Lift belt 20ton |
Set |
1 |
| 3 |
Lift belt 10Ton |
Set |
2 |
Table -8 Special Tools for panel (per plant)
| No. |
Appell. |
Unit |
Quant. |
| 1 |
Multimer |
Set |
1 |
| 2 |
Tools kit for PCB wire welding |
Set |
1 |
| 3 |
Test pencil |
Set |
1 |
| 4 |
pincers |
Set |
1 |
| 5 |
Paper cutter |
Set |
1 |
| 6 |
Long nose plier |
Set |
1 |
| 7 |
Bent nose plier |
Set |
1 |
Table-9 Integrated Automatic Control Equipments
| No. |
Name of equipment |
Quant. |
Unit |
Note |
|
| I |
Power plant control floor Monitor control equipments |
|
|
|
|
| 1 |
Host & Operator Workstation |
|
|
|
|
| |
Industry control computer |
2 |
unit |
Center Control Room |
|
| LCD displayer |
2 |
set |
|
| 2 |
Laser Printer |
2 |
set |
|
| 3 |
Audio alarm system |
|
set |
|
| 4 |
Inverter |
1 |
set |
|
| 5 |
communication cable |
1 |
set |
|
| 6 |
Smart Comm Management Host |
1 |
set |
|
| 7 |
Internet exchanger |
1 |
set |
|
| 8 |
Computer console |
1 |
set |
|
| 9 |
Monitor system software |
|
|
|
| |
SM-3B computerized system monitor software (English) |
2 |
set |
|
| |
| |
| |
| |
| |
| |
| System Software |
|
| |
| |
| PLC programming software |
|
| II |
UNIT Local monitor& control device |
|
|
|
|
| 1 |
Unit LCU panel |
|
|
|
|
| |
PLC controller |
2 |
set |
Group Panel Installation |
|
| Unit Integrated Monitor Device DCAP-5500A |
2 |
set |
|
| |
| |
| |
| |
| |
| |
| |
| |
| AC/DC duplex power supply |
2 |
set |
|
| Smart Comm Management Host |
2 |
set |
|
| Outlet Relay |
2 |
set |
|
| Operation Switch |
2 |
set |
|
| Cubicle and accessories |
2 |
pcs |
|
| III |
Microcomputer Protection System |
|
|
|
|
| 1 |
Gen-Transformer Protection Measurement Panel |
|
|
|
|
| |
Gen.-tran. Differenctial protection unit |
2 |
set |
Group Panel Installation |
|
| Main transformer backup protection monitor control unit |
2 |
set |
|
| Generator backup protection measurement unit |
2 |
set |
|
| Rotor earthing protection unit |
2 |
set |
|
| Full Digital KWH Meter |
2 |
pcs |
|
| 33KV line protection and measure unit |
1 |
Set |
|
| Cubicle and accessories |
2 |
pcs |
|
| 2 |
Common Synchronization System Panel |
|
|
|
|
| |
Micro-computerized Automatic Quasi-synchronization Device |
1 |
set |
Group Panel Installation |
|
| Manual quasi-synchronizing device |
1 |
set |
|
| 33kV Line protection Measurement Unit |
1 |
set |
|
| Synchronizing Operation Switch |
1 |
set |
|
| Full Digital KWH Meter |
1 |
pcs |
|
| Cubicle and accessories |
1 |
pcs |
|
| IV |
DC system (150AH/DC220V) |
|
|
|
|
| 1 |
DC Recharging control feeding panel |
|
|
|
|
| |
HF power recharging module |
2 |
set |
Group Panel Installation |
|
| Microcomputer monitor module |
1 |
set |
|
| Integrated Measure&control Device |
1 |
set |
|
| AC inlet |
1 |
set |
|
| Lightning protection unit |
1 |
set |
|
| DC distribution disconnector |
1 |
set |
|
| Insulation Monitoring Module |
1 |
set |
|
| Cubicle and accessories |
1 |
pcs |
|
| 2 |
DC System Battery Panel |
|
|
|
|
| |
Lead-acid maintenance-free battery |
1 |
Group |
Group Panel Installation |
|
| Battery logging protection device |
1 |
set |
|
| Cubicle and accessories |
1 |
pcs |
|
| V |
Service AC power system |
|
|
|
|
| 1 |
Service AC power panel |
|
|
|
|
| |
Duel power shift circuit |
1 |
set |
Group Panel Installation |
|
| Normal instruments |
1 |
set |
|
| feed wiring |
1 |
set |
|
| Panel and accessories (incl. busbar) |
1 |
pcs |
|
| VI |
|
|
|
| |
Engineering Service Charge |
1 |
Item |
|
|
| Training and test |
1 |
Item |
|
|
| Transportation packing and insurance |
1 |
Item |
|
|
Table -10 Excitation Panel
| No. |
Item |
Model |
Description |
QTY |
Unit |
| 1 |
Microcomputer Brushless Excitation Panel |
XGN66-12 |
1. TZL-1F Microcomputer excitation regulator, provide stable voltage, stable current, stable reactive power, stable power factor operation model.
2. Three phase full control rectification bridge, shut down auto inverter.
3, ZLC-60KVA dry type excitation transformer |
2 |
set |
Table -11 MV&LV Switchgear Panels
| No. |
Item |
Model / Description |
QTY |
Unit |
| 1 |
Generator outlet vacuum breaker cubicle |
DS/ES/VCB/PT/CT |
2 |
set |
| 2 |
Excitation transformer cubicle |
DS/ES |
2 |
set |
| 3 |
6.3 KV busbar PT cubicle |
DS/ES/PT/LA |
2 |
set |
| 4 |
Generator neutral point Current Transformer |
LZZBJ9-10 800/5A 10P10/10P10 |
6 |
set |
Table -12 HV switchgear
| No. |
Item |
Model / Description |
QTY |
Unit |
| 1 |
Vacuum breaker |
ZW7-40.5/T1250A-25KA vacuum breaker, with in-built current transformer |
1 |
Set |
| 2 |
Vacuum breaker |
ZW7-40.5/T630A-25KA vacuum breaker, with in-built current transformer |
4 |
Set |
| 3 |
Drop Down Lift Off (DDLO) |
RW5-35/100 DDLO |
1 |
Group |
| 4 |
Isolation switch |
GW5-40.5D/630A (single earthing knife switch) |
5 |
Group |
| 5 |
Isolation switch |
GW5-40.5D/1000A (double earthing knife switch) |
2 |
Group |
| 6 |
Potential transformer |
JDJJ2-35 |
3 |
set |
| 7 |
Fuse |
RWXO-35/0.5A |
1 |
Group |
| 8 |
Lightning Arrestor |
YH5WZ-51/127 |
2 |
Group |
Table -13 Automatic Components for turbine (per unit)
| No. |
Appellation |
Model |
QTY. |
Unit |
Note |
| 1 |
Pressure transmitter |
YPM48 |
1 |
pcs |
Penstock Pressure measure |
| 2 |
Electric Contact Pressure Gauge |
Yx-40 |
1 |
pcs |
Penstock Pressure measure |
| 3 |
Needle Stroke Indicator |
ZS-11 |
1 |
pcs |
Needle Stroke |
| 4 |
Needle Stroke Position Switch |
LXW-11 |
2 |
pcs |
Needle Position |
| 5 |
Deflector Stroke position switch |
LXW-11 |
1 |
pcs |
Deflector Position |
| 6 |
Gate valve |
Q941-64/D40 |
1 |
pcs |
Brake Valve, motorized |
Table -14 Automatic Components for generator (per unit)
| No. |
Appell. |
Model |
QTY |
Unit |
Note |
| 1 |
Resistance thermometer |
WZPD-Pt100 |
6 |
pcs |
Stator temperature |
| 2 |
Resistance thermometer |
WZP |
4 |
pcs |
Bearing Oil temperature |
| 3 |
Flow indication signaler |
SLX |
2 |
pcs |
Bearing Cooling water outlet |
| 4 |
Pressure Gauge |
Y-100 |
2 |
pcs |
Bearing Cooling water inlet |
| 5 |
Transistor plunger pump |
QB36-A |
2 |
pcs |
Motored oil pump |
| 6 |
Stroke Switch |
LXW |
2 |
pcs |
brake |
Table -15 Power transformer
| NO. |
Appellation |
Data |
Note |
| 1 |
Step Up Power Transformer |
S11-8000/33-6.6 |
For 6.3KV to 11KV |
| 2 |
Capacity |
8000KVA |
|
| 3 |
Voltage |
33±2*2.5%/6.6 |
|
| 4 |
Frequency |
50Hz |
|
| 5 |
Symbol of vector group |
Yd11 |
|
| 6 |
Empty load current |
0. 3% |
|
| 7 |
Empty Load loss |
7.2KW |
|
| 8 |
With load loss |
20.70KW |
|
| 9 |
Short circuit impendance |
7.5% |
|
| 10 |
Noise level |
60dB |
|
| 11 |
Dimension |
3350*3400*3200 |
|
| 12 |
Mount rail |
1475*1475 |
|
| 13 |
Weight |
15.8Ton |
|
Table -16 Service transformer
| NO. |
Appellation |
Data |
Note |
| 1 |
Service Power Transformer |
S11-M-100/6.6-0.4 |
For 6.3KV to 0.4KV |
| 2 |
Capacity |
100KVA |
|
| 3 |
Voltage |
6.6±5%/0.4 |
|
| 4 |
Frequency |
50Hz |
|
| 5 |
Symbol of vector group |
Dyn11 |
|
| 6 |
Empty load current |
1.1% |
|
| 7 |
Empty Load loss |
0.2KW |
|
| 8 |
With load loss |
1.5KW |
|
| 9 |
Short circuit impendance |
4% |
|
| 10 |
Noise level |
60dB |
|
| 11 |
Dimension |
788*680*955 |
|
| 12 |
Mount rail |
500*500 |
|
| 13 |
Weight |
551Kg |
|
Table -17 M&E workshop equipments
| NO |
Name |
QTY |
Unit |
Note |
| 1 |
Hydraulic jack, plates for mounting and dismantling of flywheel |
1 |
Set |
|
| 2 |
Hydraulic puller for mounting/dismantling or runner. |
1 |
Set |
|
| 3 |
Spanners of size 10 mm to 40 mm |
2 |
Sets |
|
| 4 |
Socket sets |
1 |
No. |
|
| 5 |
Toque wrench |
2 |
set |
|
| 6 |
Plier set |
2 |
set |
|
| 7 |
Allen key set |
1 |
set |
|
| 8 |
Filler gauge |
1 |
No |
|
| 9 |
Adjustable wrench 6 inch |
2 |
Nos |
|
| 10 |
Adjustable wrench 10 inch |
1 |
set |
|
| 11 |
Dial indicator |
3 |
Nos |
|
| 12 |
Iron Hammers ( 1 Kg, 2 Kg, 5 Kg) |
2 |
Nos |
|
| 13 |
Plastic Hammers ( small and large) |
2 |
Nos |
|
| 14 |
Chisel |
1 |
No |
|
| 15 |
Electric drill machine with drill bit set |
1 |
set |
|
| 16 |
Electric grinder |
1 |
No |
|
| 17 |
Spirit level |
1 |
No |
|
| 18 |
Tri square (large size) |
1 |
No |
|
| 19 |
Steel ruler ( 1 meter length) |
1 |
No |
|
| 20 |
Measuring steel tap ( 3m, 5 m) |
2 |
Nos |
|
| 21 |
Screw driver flat/Philips |
1 |
set |
|
| 22 |
File set |
1 |
set |
|
| 23 |
Grease gun |
1 |
No |
|
| 24 |
Scraper (flat & angular) |
2 |
Nos. |
|
| 25 |
Pipe wrenches (small, medium and large) |
3 |
Nos. |
|
| 26 |
Small socket set for diode |
1 |
set |
|
| 27 |
Knife and scissors set |
1 |
set |
|
| 28 |
Special tools for governor |
1 |
set |
|
| 29 |
Multi meter matching with generator capacity |
1 |
No |
|
| 30 |
Clam on mete matching with generator capacity |
1 |
No |
|
| 31 |
Meger 0.500V |
1 |
No |
|
| 32 |
Bench vice |
1 |
No |
|
II. Condition of the Power plant
1. Name: ****** M.H.P, PNG
2. Location: *****, 800 m A.S.L.
3. Type: run of river plant, surface type
4. Operation type: non phase regulation, islanding and Grid connection
5. Water Head: Design head Hr=416 m
6. Flow: design flow: Qr= 2X 1.65 m3/s
III. Turbine introduction
Main parameter Data
1. Model: CJA475-W-110/2X12
2. Runner Diameter: 1100mm
3. Rated Head: Hr=416 m
4. Design Flow: Qr=2X1.65 m3/s
5. Rated output: 2X5841KW
6. Rated Speed: 750 rpm
7. Runaway Speed: 1500r/min
Overall structure
1.1 This unit is horizontal single runner Pelton turbine with two jet nozzles. its runner is mounted on generator shaft, use flat key to transmit torque. Nozzle is supported by casing, bend tube mounted in front of nozzle, and connected with expansion joint and electric gate valve by branch pipe. Deflector is mounted on nozzle. Needle servomotor is connected to needle, needle is controlled action by connection between governor and oil pipe of Φ82 servomotor, and deflector is controlled full-open and full-close by self-governed vertical servomotor and connecting lever mechanism.
Operation oil source of needle servomotor and deflector servomotor is from oil pressure device of governor.
1.2 Main part
1.2.1 Runner
Runner is ZG2OSiMn block cast, bucket molded lines machine and inspect according to IEC standard, and check cast quality by UT and MT, to ensure safety and reliability of operation.
1.2.2 Casing assembly
Casing assembly is made up of casing, big case cover and small casing cover, and all is welded by steel plate, it has enough strength and rigidity.
Blow down pipe is designed on casing, for supply air took by jet, to prevent partial vacuum in casing, and to ensure unblocked drainage.
Matched position between this casing and generator shaft is equipped with baffle. Inspection hole is mounted on casing for observing jet condition. Manhole is equipped for easy maintenance and installation.
1.2.3 Nozzle assembly: it consist of nozzle, jet nozzle, needle, needle lever, deflector and servomotor etc.
Nozzle is made up of Q235A steel, is guide part of Pelton turbine.High pressure water flow pass jet passage consisted of nozzle head and nozzle exit, energy of water flow completely translate into speed energy , form high-speed jet, and toward to bucket, then drive runner rotating.
Needle, nozzle head and nozzle exit have exact geometrical shape and smooth flow channel surface,and long streamline guide blade grid is nearby nozzle entrance, to eliminate effects of elbow on water flow. Thereby, form compact water jet column and make hydraulic efficiency to maintain over 94%.
Needle can move back and forth under controlling of needle servomotor, change flow cross-section, regulate diameter of water jet column, and make it to adapt needs of load regulation. When needle contact with backing ring of nozzle jet , that is at full closing position, it can seal water flow, and act as shut-off function of valve.Backing ring of nozzle jet is made up of ZG1Cr13 stainless steel, and has good anti-cavitation and anti-sand wear performance.
Needle is forged by 2Cr13 stainless steel. Governor control opening and closing time, and is mounted on needle lever. Needle lever is made up of 45 round steel hot shrinking on 1Cr13 balance piston, and it is connecting piece for needle and servomotor piston. Needle can open and close under the controlling of governor. Travel feekback device is mounted on servomotor in order to reflect needle opening. Needle travel pointer is mounted on servomotor, to easily observe needle travel for operating personnel.
1.2.4 Control mechanism: this mechanism consist of Φ80 vertical servomotor, two arms, fork head, connecting rod, lever, upper and lower deflector shaft etc.
This unit is used independent regulating mechanism. When unit is suddenly reject all load, servomotor is controlled at governor .Lower cavity of servomotor fill with pressure oil, piston quickly upward drive two arms to lead connecting rod lever, and make deflector to cut quickly in jet, and make all jet to turning round and diffuse into fan-shaped and directly drain into tail channel, to prevent bucket receiving water, reduce rise value of unit speed rate. When unit is to be started up, upper cavity of servomotor pass through pressure oil, piston quickly do downward, drive two arms, connecting rod and lever, and make deflector to start quickly.In order to measure full opening and full closing of deflector, position switch is mounted outside deflector shaft, and can send signal.
When unit is at normal operation, deflector do not act.
1.2.5 Water diversion pipeline: this part consist of Φ600 valve, Φ600 expansion joint, upper nozzle and lower nozzle, branch pipe, braking pipeline and drain pipeline etc.
Φ600 expansion joint is mounted on branch pipe, one end is connected with branch pipe by bolt, and another end is connected with valve at powerhouse. Branch pipe is respectively connected with upper and lower nozzle, it is designed for easy assembling and disassembling nozzle and other parts.
Branch pipe is made up of Q235A,big flange is connected with Φ600 expansion joint, and small flange is connected with upper and lower nozzle. Pressure gauge is designed at top of branch pipe for measured inlet water pressure, water drain valve is designed at bottom of branch pipe for drained ponding of nozzle, and close the valve when unit is normally operate.
Upper nozzle and lower nozzle is made up of seamless steel pipe and Q235A steel plate, assemble, cooperatively cut and weld according to drawing, and welding seam carry out flaw detection inspection.
Braking pipeline: it is designed for reverse jet braking after unit load-rejection, one end is connected with Φ80 self-holding electromagnetic ball valve mounted on nozzle, and another end is connected with braking nozzle jet on casing.
Drain pipeline: it is designed for drain ponding after valve after closing gate valve. Gate valve is designed at bottom of branch pipe, the valve should be fully closed when unit normally operate. The hydropower station should embed Φ100 steel pipe in gate valve pit, drain water to downstream, and embedded steel pipe should prepared by the hydropower station.
1.2.6 Pipeline and automation system: this machine is designed operating oil pipe of needle servomotor and operating oil pipe of Φ80 vertical servomotor, two ends joint of servomotor operating oil pipe is provided by governor, oil pipe is welded and is mounted when hydraulic station install. Oil pipe of Φ80 vertical servomotor operating is hose joint and is provided by governor, and mounted on. Pay attention to do not make a mistake of assembly position.
Position switch is designed outside of upper deflector shaft for measured whether servomotor is full opened and fully closed. Travel feedback device is designed at top of Φ82 servomotor for measured needle travel.Φ80 self-holding electromagnetic ball valve is mounted on casing for controlled reverse jet braking water source.
1.2.7 All bushing is made up of self-lubricating material, and do not nee to fill lubricating oil.
IV. Generator Introduction
Main parameter data
- Weight of generator main parts
| NO |
Item |
Weight ton |
Note |
| 1 |
Total weight |
42 |
|
| 2 |
Stator assembly |
20 |
|
| 3 |
Rotor assembly |
18 |
|
| 4 |
Base plate |
1.5 |
|
- Generator main parameter
| NO |
Item |
Value |
NO |
item |
Value |
| 1 |
Type of generator
|
SFW5800-8/1730 |
14 |
Short-circuit ratio fko |
1.12 |
| 2 |
Rated power PN(KVA) |
7250 |
15 |
Longitudinal axis synchronous reactance Xd |
1.03 |
| 3 |
Rated voltage UN(V) |
6600 |
16 |
Longitudinal axis transient reactance Xd' |
0.21 |
| 4 |
Rated current IN(A) |
634.2 |
17 |
Longitudinal axis super-transient reactance Xd |
0.148 |
| 5 |
Rated speed nN(r/min) |
750 |
18 |
Transverse axis synchronous reactance Xq |
0.6 |
| 6 |
Runaway speed nY(r/min) |
1500 |
19 |
Transverse axis transient reactance Xq |
0.6 |
| 7 |
Power factor cosφ |
0.8 |
20 |
Transverse axis super-transient reactance Xq |
0.1554 |
| 8 |
Rated frequency fN(HZ) |
50 |
21 |
Zero-sequence reactance X0 |
0.05 |
| 9 |
Length of gap δ(mm) |
8 |
22 |
Inverse sequence reactance X2 |
0.09 |
| 10 |
No-load excitation current Ifo(A) |
137.7 |
23 |
Moment of inertia (T.M2) |
9.5 |
| 11 |
No-load excitation voltage Ufo(V) |
35.5 |
24 |
Calculated efficiencyη(%) |
96.5 |
| 12 |
Rated excitation current If(A) |
112 |
25 |
Mode of connection |
Y |
| 13 |
Rated excitation voltage Uf(V) |
338 |
26 |
Insulation class |
Class F |
Technical conditions
- This condition apply to above 5800KW horizontal hydro generator.
2. Unspecified matter in the condition should conform to related regulations of GB755-2000 "basic technical condition of rotating motor" and GB7894-2001 "basic technical condition of hydro generator"
3. Condition of unit continuous, safe and stable operation:
3.1 Installation site of generator should be lower than 1000m.
3.2 Ambient temperature of station site is not exceed +40ºC.
3.3 Unit operate in covered and masked powerhouse.
3.4 Temperature of bearing cooling water do not exceed +25ºC.
4. When generator is at no-load, line voltage waveform sinusoidal distortion rate is not more than 5%, and line voltage telephone harmonic factor (THF) is not more than 3%.
5. Insulation dielectric strength test of generator had finished at factory according to regulations, so the test can not carry out at station site.If the user insist do the tests, its withstand voltage should be 80% of 2UN+1000 V(that is not less than 1200V).However, whether or not the insulation dielectric strength test is performed, the drying treatment should be carried out, and the insulation resistance measured in the hot state (75ºC) is not less than the value obtained by the following formula:
Re(75)=UN/(1+Po/1000)
Re(75)─insulation resistance(MΩ)
UN─rated voltage(kV)
Po─rated capacity(KVA)
6. Radial bearing of generator and base plate are insulated. If measured by 500V megger, its grounding insulation resistance is not less than 0.5MΩ.
7. Rotating part of generator operate under runaway speed condition, for 2minutes without harmful deformation.
8. Generator can bear no-load current, its no-load current is 105% of rated value which three-phase is suddenly short-circuit impulse current at lead end .
9. Allowable limit value of temperature rise for generator each part are as follows:
| Part |
Measured method |
Limit value of temperature rise (ºC) |
| Stator winding |
Embedding thermometer method |
80 |
| Rotor winding |
Resistance method |
85 |
| Radial bearing |
Thermometer method |
30 |
Note: bearing lubrication is used 30# turbine oil, temperature of cooling water is not exceed +25ºC, ambient temperature is not exceed +40ºC, and maximum temperature of bearing is +70ºC.
10. Supply scope of generator:
a. Generator
b. Spare parts
c. Special tool
d. Drawings and technical document
e. Detailed packing list
11. Generator should be packed properly when generator is deliver. Friction surface and matched surface should carry out rust-proof and mechanical damage, coil should avoid rain, damp and damage.
12. Generator should store in covered and masked warehouse and retain indoor temperature over +5ºC after parts of generator arrived at station site. The users correctly use and store generator according to technical condition, manufacturer shall ensure that generator can well operate within 1 year of putting into operation and do not exceed 2years from shipping date of factory. If within this specific time, generator damage or do not normally work for bad manufacturing quality, manufacturer shall freely repair or replace part for the user.
13. When generator is stored at station site, generator should check for every three months at least.Pay attention to rust-proof, rain-proof and sun block etc. If insulation resistance is unqualified, generator should carry out drying treatment for maintaining integrality.
14. items of acceptance test of generator(that is check test) and type test should perform according to items of GB755-2000 "basic technical requirement of rotating motor".
15. Generator do not carry out three-phase sudden short-circuit test and runaway speed test, it only carry out overspeed test of 1.5-1.6 time of rated speed.
Structure description of generator
This generator is delivered with turbine, in order to its compact structure and shrink plant area, this unit is used coupling method which generator and turbine is same shaft, the while unit is used two pivots structure. in order to make the users knowing structure of generator, its description of structure are as follows:
- Stator
Stator mainly consists of stator core, frame, stator coil and end hoop etc.
-
- Stator core is one of important part of generator magnetic circuit. Stator core is laminated by segment punched by 0.5mm thick high quality cold rolling non-oriented silicon steel sheet. Two sides of segment are coated with 0.02~0.025mm thick insulation varnish for reducing eddy-current loss. Stator core is laminated to several section, interval of each section is 10mm, its interval liner is I-shaped ventilation channel steel, for ventilation and heat dissipation. The whole stator core is fixed on frame by several screws.
- Frame is welded by steel plate Q235, several rectangle hole are opened on frame wall, the external is fixed relevant dimension cover plate by screw. Rectangle hole is not only used for point welding stator core fixed piece, but also is used to regulate temperature of plant.
- Stator coil is wound by dual glass-fibre covered flat copper wire, and carry out stretch forming and shaping, at last execute hot pressing curing forming. Insulation of inter-turn and grounding insulation is used class F 0.14×25mica-paper tape, and is used class F insulation, allowable working temperature is 120ºC or 140ºC.In order to do not produce corona at rated voltage, surface of stator coil carry out anti-corona treatment, make that single coil discharge inception voltage is not less than 9450V.When inserting line, corona treatment should carry out in stator slot, make that discharge inception voltage of whole machine is not less than 6615V. The whole stator winding is stator coil and lead binding thimble, inter-pole connection is three phase star shape, and it has 3 main outgoing lines and 3 main neutral outgoing lines.
- End hoop is mainly bear radial force of stator winding end when generator outlet terminal is short-circuited, to prevent this force causing deformation and damage of stator winding end. End hoope is made up of round ring and supporting plate, fix and connect with screw on frame by nut passed by supporting plate, and is used multi-layer 0.14×25 mica-paper tape continuous insulation.
2. Rotor
Rotor consist of main shaft, yoke and pole etc. Rotor of this generator and rotating part of same shaft coupling, their structure strength is designed according maximum runaway speed. When rotor is at runaway speed, operate 2 minuets, without harmful deformation.
-
- Main shaft is machined by forged steel 20SiMn,it important parts for supporting yoke and transmitting torque.
- Yoke is machined by ZG230-450cast steel, its inner hole and main shaft carry out shrink fit.
- Fan is equipped with two ends of yoke, for increasing radial wind pressure, strengthen cooling.
- Pole core is divided two part, and machined by 45# forged steel.
- Pole coil is wound by oxygen-free copper strip TDR, and inter-turn and grounding insulation is wound by epoxy mica-paper tape, execute hot pressing curing forming, the integrality is good, and is used class F insulation, allowable working temperature is 120ºC or 140ºC.To prevent deformation of pole coil during operation, two groups of inter-pole support block is equipped among each two pole.
3. Base plate and end shield
End shield is steel plate welding structure, it's section is compound for easy assembly and assembly. Base plate is welded by steel plate, and is fixed on foundation by foundation, and mainly bear weight of generator stator, rotor, bearing and rotating part of turbine.
4. Bearing
The whole set unit is used 2 radial bearings, and mainly bearing all kinds of radial force. Bearing pad is that green body of HT20-40 cast iron is poured a layer of ZCHSnSb11-6 bearing alloy, and its abrasive resistance is good. Two ends of bearing end cover is used multi-layer seal, and seal performance is good. Resistance thermometer measured oil temperature and pad temperature is mounted on bearing, and oil level annunciator is monitored oil level of oil slot.
5. Brushless excitor
At the Non driving end of the generator there is a brushless excitor over hang by a flange connection. The excitor is controlled by the excitation panel to feed direct current to the generator rotor. The excitor rotates with the generator rotor on the same shaft.
6. Measuring temperature device
6(2 for each phase) resistance thermometers is measured temperature of core and stator coil, these resistance thermometers is embedded in stator core slot of generator, and lead to terminal by shielded wire, and then lead to monitor screen. Resistance thermometer measured oil temperature and pad temperature is install in every bearing, for monitoring operation temperature of bearing pad.
Installation and operation
Transportation description
Generator is packed according to packing list. During transportation, handle with care, avoid shock, especially not to turn over, and avoid rain, moisture and sun exposure.
2. Installation description
2.1 Foundation of unit shall be firm, and shall avoid resonance phenomenon produced when generator is at normal operation. Foundation bolt fixed base plate shall embed firmly in concrete.
2.2 When installation, firstly lift base plate on foundation(note: when lift stator, put wire rope to cross round steel of frame upper, and then lift), secondly lift bearing of turbine end, after inserted rotor, lift bearing of generator end, align gap of stator and rotor after putting bearing pad of two bearings. Height of stator is regulated by its washer, and then put dowel of each part, at this time bearing pad can carry out fine scraping bearing. If contact area between main shaft and bearing pad is more than 75% and its contact is even, and then can adjust gap between upper half bearing pad and main shaft(according to drawing requirements).
2.3 After above mentioned work complete, installation working of collecting ring and brush carrier etc can carry out, and regulate carbon brush according to 0.16kg/cm2-0.25kg/cm2 pressure requirement.
Note: because turbine and generator is the same shaft, so it require that center line of main shaft is perpendicular to center line of turbine runner is vertical, level of shaft will regulate well, and adjust gap between journal and bearing pad.
3. Instruction for use
3.1 Generator wiring diagram
3.2 Preparation work before operation
All sundries inside and outside generator should be cleaned up, meanwhile check whether each fastening piece and connecting part is firmly or not. Check insulation resistance of stator coil and rotor coil. Afterward check insulation resistance of stator and rotor coil, generally request that insulation resistance of stator winding is about 6MΩat 75ºC, and absorption ratio is more than 1.3.Insulation resistance of rotor winding is above 0.5MΩ.If above equipment cannot BE reached, generator should carry out dry treatment. Generator is generally used short-circuit dry method (also can use other methods).
Short-circuit dry method of generator is that put three phases of stator winding is shortened, rotor winding is used separate excitation, every phase of stator connect to ammeter. Start up prime motor for unit achieving rated speed, then put into excitation, let current increase continuously, but current of every phase do not exceed rated value. Principle for adding each phase current of stator is:
When start dry, temperature rise for every hour do not exceed3ºC,hereafter temperature rise do not exceed 6ºC for every hour. Within starting 10hours, temperature do not exceed 50ºC.During dry, hottest point maximum temperature (measure by alcohol thermometer) of stator coil do not exceed 90ºC, and 20hours can reach after drying.
During dry, note that record temperature for every 30minutes, after reach stable condition, record temperature for every 1hour, meanwhile measure insulation resistance by 1000V megger and record the value. Until temperature and insulation resistance are stable and persist 48hours (during this time, measure insulation resistance for every 2hours), that is consider that dry is complete. Hereafter stator current drop to zero slowly at about 6hours, and then stop unit. When temperature of generator drop to 75ºC,measure its insulation resistance, its value is not less than 6MΩ.
3.3 Commissioning
Generator is passed through careful inspection, after everything is qualified, and then unit can carry out idle (at that time generator is open-circuit, and excitation do not add).When speed rise to 50% of rated speed, check whether generator occur abnormal vibration, crash and friction or not . If these is no abnormal situation, after observe 10minutes, speed can rise to rated value, and maintain a period, check temperature of bearing, monitor and observe whether generator happen abnormal situation. If find abnormal phenomenon, unit shall stop, and find reason and solve the problem. If such condition do not happen, stop the unit after the unit is idle running 4hours at rated speed, check whether each part occur abnormal phenomenon. If everything is normal, and then the unit can carry out second startup and put into normal operation.
V. Governor
Governor Model is CJWT600-2-2, rated operation oil pressure 16Mpa.
Separate performance and operation description attached in governor folder.
VI. Excitation system
see separate description attached in excitation system file folder.
VII. Integrated Automatic Control system
see separate description attached in Integrated Automatic Control system file folder.
VIII. Design and manufacture standard
1.1 Turbine & accessories
1.1.1 Technical standard and code adopted in this tender document
Standard and Issuing Organization Code
International Electrotechnical Commission IEC
International Organization for Standardization ISO
American Society for Testing and Materials ASTM
American Society of Mechanical Engineers ASME
European Industry Association CCH
China National Standard GB
China Electricity Sector Standard DL
China Water Resource Ministry Standard SD
China Machinery Ministry Standard JB
China Oil Ministry Standard SY
China Metallurgy Standard YB
Among above standard, the China national standard, electric industry standard and water and electricity ministry standard has priority. In case absence of National standard, related international standard or other country's standard will be referred to.
The latest published version of the selected standard prevails.
1.1.2 Quoted Standards
Fundamental Technical Requirements for Hydraulic Turbines GB/T 15468-1995
Specifications for Water Passage Components of Hydraulic Turbines GB/T 10969-1996
Specification installation of hydraulic turbine generator units GB8564-88
Turbine Model Acceptance Test Code GB/T15613-1995
Steel pressure vessel GB150-1998
Specification for turbine generator unit packing, transportation and storage JB/T8860-1997
Bend Tube for Power plant DL/T515-93
Cavitation Pitting Evaluation in Reaction Hydraulic Turbines GB/T15469-1995
Hydraulic equipment vibration and pulse on site test specification GB/T17189-1997
General Specification for turbine generator unit ex-factory inspection DL/T443-1991
Middle and small hydraulic turbine Quality classification JB/DQ1428-88
Specifications of governors and pressure oil supply units for hydraulic turbines GB/T9652-1
Hydraulic turbine electric and hydraulic regulation system and hydraulic pressure device technical specification DL/T563-95
Basic Technical Specification for automatic control components and their related systems for Middle and Small hydro-generating sets GB11805-89
Fundamental Technical Requirements for Hydraulic Turbines GB/T 15468-1995
Specifications for Water Passage Components of Hydraulic Turbines GB/T 10969-1996
Specification installation of hydraulic turbine generator units GB8564-88
Turbine Model Acceptance Test Code GB/T15613-1995
Steel pressure vessel GB150-1998
Specification for turbine generator unit packing, transportation and storage JB/T8860-1997
Bend Tube for Power plant DL/T515-93
Cavitation Pitting Evaluation in Reaction Hydraulic Turbines GB/T15469-1995
Hydraulic equipment vibration and pulse on site test specification GB/T17189-1997
General Specification for turbine generator unit ex-factory inspection DL/T443-1991
Middle and small hydraulic turbine Quality classification JB/DQ1428-88
Specifications of governors and pressure oil supply units for hydraulic turbines GB/T9652-1
Hydraulic turbine electric and hydraulic regulation system and hydraulic pressure device technical specification DL/T563-95
Basic Technical Specification for automatic control components and their related systems for Middle and Small hydro-generating sets GB11805-89
IEC related standards
1.1.3 The thread for all bolt, nut, stud, thread bolt and related pipe fittings adopts GB or ISO standard.
1.1.4 Material standard
Gray pig iron GB/T9439-88
Normal cast carbon steel for engineering use GB/T11352-89
Middle High strength stainless steel cast piece for engineering structure GB6969-86
Quality Carbon Structural Steels Technical Specification GB/T699-1999
Carbon Structural Steels GB/T700-2006
High Strength Low Alloy Structural Steels GB/T 1591-1994
Steel plates for Pressure Vessels GB 6654-1996
Hot-rolled quality carbon structural steel plates sheets and strips GB/T711-1988
Hot-rolled sheets and strips of carbon structural steels and high strength low alloy structural steels GB/T 912-1989
Hot-rolled plates, sheets and strips of carbon structural steels and high strength low alloy structural steels GB/T 3274-1988
Alloy structure Steels GB/T 3077-1999
Welded steel pipes for low pressure liquid delivery GB/T 3091-2015
Welded steel pipes for liquid delivery YB(T)44-1986
Spiral submerged arc welded steel pipe for general low pressure fluid transportation SY/T 5037-1992
Spiral submerged high frequency arc welded steel pipe for general low pressure fluid transportation SY/T 5039-1992
Seamless steel pipe GB/T 8162-1999
Seamless steel pipes for liquid service GB/T 8163-1999
Seamless stainless steel pipes for fluid transport GB/T 14976-1994
Nickel and nickel alloys tube GB/T 2882-2013
Drawn tube of copper and copper alloys GB/T 1527-2017
Copper and copper-alloy cold-drawn rod and bar GB/T 4423-1997
Covered electrodes for manual metal arc welding of non-alloy and fine grain steels GB/T5117-1995
Covered electrodes for manual metal arc welding of creep-resisting steels GB/5188-2012
Covered electrodes for manual metal arc welding of stainless and heat-resisting steels GB/T983-2012
Mechanical properties of fasteners -Bolts, screws and studs GB/T 3098.1-2010
Mechanical properties of fasteners -Nuts GB/T 3098-2015
Audited Supplier 
Pelton Turbine (twin nozzle) with Horizontal Shaft Generator (synchronous, brushless excitation)
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