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Confidential. Copyright © Siemens AG 2008. All rights reserved.Generators E F PR GN

CIGRE 2008 CIGRE 2008 Generators > Generators > 1200 MW1200 MW

Lon Montgomery & Lon Montgomery & Klaus SedlazeckKlaus Sedlazeck

27 August 200827 August 2008

Page 2 Generators E F PR GNMontgomery/Sedlazeck27 August 2008Confidential / © Siemens AG All rights reserved

Siemens Energy – Power Generation

ORLANDO – Engineering / Supply Management / Order Management

FT. PAYNE - Component Parts and Assemblies

CHARLOTTE - New Units > 180 MW and Generator Service

ERFURT - New Units < 180 MW and Stator Core Material and Components

ERLANGEN / OFFENBACHApplications & Tendering

SHANGHAI -(SEPG) Joint

Venture

MÜLHEIM - Generator Service and New Units > 180 MW


With over 100 years of experience and over 680,000 MW of installed generator capacity, Siemens Power Generation is one of the major and most experienced suppliers of 50 and 60 Hz generators with ratings between 25 and 2000 MVAworldwide.

Hydrogen/Water-cooled

Hydrogen-cooled

Air-cooled

250 - 600 MVA

25 - 350 MVA

500 – 2222 MVA

500 – 1300 MVA- 1500 MVA

planned

4-pole

2-pole

Turbogenerators4-pole and 2-pole


SGen5-3000W1300 MVA Turbogenerator


SGen5-3000W Overall Design

Cooler head

Terminal box

Multi-stage axial blower

Bearing bracket

Primary water tank

Stator winding

Rotor

Bearing bracket Stator frame


Cooling Gas Circuit


Rotor Winding Design

Rotor end winding with corner brazing

Ready to assemble extruded copper profile

Asymmetric cold gas inlet and outlet in straight portion


Stator Winding Design

1 Stator core2 Slot wedge3 Slide strip4 Top ripple spring5 Top strip6 Low conductive wrapper7 Lateral intermediate strip8 Top bar9 Intermediate strip10 Bottom bar11 Solid strand12 Copper hollow conductor13 Micalastic®- insulation14 Low conductive side ripple spring15 Low conductive equalizing strip

11

Cross over insulation

7

13

Cross over filler

Inner potetial control

Outer corona protection


Turbogenerators – Test Bed


SGen5-3000W Niederaußem KResults of Type Test

(type test result) / (precalculation)

0.000.200.400.600.801.001.20

Field cu

rrent

Subtransie

nt rea

ctance

Transie

nt rea

ctance

Short cir

cuit r

atio

Frictio

n loss

esCore

losses

Short cir

cuit l

osses

Field I2

R loss

es

Electr.

loss

es of e

xcite

rTotal

loss

es1300 MVA, 27 kV, 0.85 Power Factor, 5 Bar H2 Pressure

50 Hz, 50 s-1 Speed

test / calc= 1.00


Turbogenerators – Railway Transport

Niederaußem SGen5-3000W

25.07.2001


Turbogenerators4-pole and 2-pole

With over 100 years of experience and over 680,000 MW of installed generator capacity, Siemens Power Generation is one of the major and most experienced suppliers of 50 and 60 Hz generators with ratings between 25 and 2000 MVAworldwide.

Hydrogen/Water-cooled

Hydrogen-cooled

Air-cooled

250 - 600 MVA

25 - 350 MVA

500 – 2222 MVA

500 - 1300 MVA- 1500 MVA

planned

4-pole

2 - pole


SGen5-4000W 2222 MVA Turbogenerator


SGen5-4000W Components

Frame

Bearing Bracketsand Bearings

Terminal Box

Coolers

Bushings

Core

Blower

Stator Winding

Rotor


Component Cooling

Hydrogen-cooledrotor winding

Water-cooledstator winding


Rotor Winding Cooling (Temperatures < Limits)

Rotor ConductorsTem peratures of Rotor Conductors2200 M VA, 27 kV, 0.90 Power Factor

40

50

60

70

80

90

100

110

120

130

140

-1500 -1000 -500 0 500 1000 1500 2000 2500 3000 3500 4000

Distance Along Conductor from End of Rotor Body [mm ]

Con

duct

or T

empe

ratu

re Top Conductor, End

Top Conductor, Embedded

Bottom Conductor, End

Bottom Conductor, Embedded

130 C

centerline of end arc

centerline of active length

Copper Temperature Limit


Stator Conductors

Stator Winding Cooling (Temperatures < Limits)

Temperatures of Stator Conductors2200 MVA, 27 kV, 0.90 Power Factor

40

50

60

70

80

90

100

0 2000 4000 6000 8000 10000

Distance Along Stator Bar from Water Inlet End [mm]

Con

duct

or a

nd C

oola

nt T

empe

ratu

re

Water in Top BarCopper Strands in Top BarWater in Bottom BarCopper Strands in Bottom BarWater Temperature Limit

Water Temperature Limit


Turbogenerators in Test Field


Sample Test Results for Current Distribution in Main Lead to Bushing Flexible Connector Assembly

Main Leads

BushingsTerminal Box


Main Lead

Bushing

Flexible Connector Assembly



Bushing

Tested & Calculated Current Distribution in Flexible Conductors in Main Lead to Bushing Flexible Connector Assembly

0

0.2

0.4

0.6

0.8

1

1.2

1 2 3 4 5 6 7 8 9 10 11 12Number of Flexible Connectors

Per U

nit C

urre

nt in

Eac

h Fl

exib

le C

onne

ctor

test #1test #2calculated with 3D FEA

7654

Main Lead

83



All design work is controlled by a disciplined Product Development Process

Specific reviews must be passed at ends of defined development steps. Examples include:

Create and review Product Requirements Specification (market requirements and conceptual features)Create and review Product Design Specification(basic technical design features and commercial boundaries)Create and review Basic Design, (major components and the entire generator assemblyDesign components and hold Final Design Reviews

With this Product Development Process, Siemens ensures that the generators meet market requirements and customer expectations for reliable operation during their lifetime.


Siemens Has Designed and Built Giga-watt Class 4-pole and 2-pole Turbine Generators

4-pole: 50 Hz ≥ 2222 MVA, 60 Hz ≥ 1520 MVA

2-pole: 50 Hz ≥ 1300 MVA, 60 Hz ≥ 1200 MVA

2222 MVA 50 Hz 4-pole generator is most recent step

Next step is to develop 2-pole generators ≥ 1500 MVA based upon proven design features and market feedback

Without leaving the range of experience, the capabilities of these designs have been achieved by slight increases in dimensions of active length and diameters and also slight increases in utilization

These designs are evolutionary, not revolutionary


In the most modern of these generator designs the major features include the following:

Stators designed for railway transport by Schnabel car

Stator cores with axial ventilation and “flux trap” core ends

Water-cooled stator windings with anticorrosion features (copper and stainless steel hollow conductors) and robust and reliable electrical and mechanical end turn connections

Hydrogen-cooled rotor windings with axial cooling

High pressure blower mounted on turbine side of rotor


All features in current Siemens generator designs are based upon:

Features that have exhibited good service experience for decades in the Siemens generator fleet

Design analyses based in first principles and calibrated by tests

Component testing

Manufacturing process qualification

Independent design reviews

Assembled generator factory testing


Considerations of grid stability

Stable operation of a grid is less influenced by generator design with respect to reactances and short circuit ratio but more influenced by:

Stiffness and structure of the grid

Sufficiently dimensioned high voltage lines

Sophisticated generator voltage regulator

Confidential. Copyright © Siemens AG 2008. All rights reserved.Generators E F PR GN

Thank you for Thank you for your attention! your attention!

Lon Montgomery & Lon Montgomery & Klaus SedlazeckKlaus Sedlazeck

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