Pressurized Air Cooled Generators - Siemens Energy · PDF filePressurized Air Cooled Generators ... H2O. 25-370 MVA . Cooling . ... • Fewer plant interfaces compared to hydrogen

Pressurized Air Cooled Generators

Mike Zborovsky New App Generator Portfolio Owner

siemens.com © Siemens AG / Siemens Energy, Inc. 2016 All rights reserved.

PGI Orlando

Dec. 13, 2016

PowerGen International, December 2016 Page 2 Mike Zborovsky / Power and Gas

© Siemens AG / Siemens Energy, Inc. 2016 All rights reserved.

Pressurized Air-Cooled Generator (SGenX-2000P) Table of content

• Introduction 3

• Portfolio Overview

• SGen-2000P Air Cooled Generator 7

• 2000H vs. 2000P

• Overview & Benefits

• Design Features & Components

• Auxiliary System

• Operational Flexibility & Interfaces

• Access & Serviceability

• Summary 20



Generators Product Overview

SGen-2000H series Preferred choice for large outputs

SGen-100A series Customized for use on smaller gas and steam turbines,

most economical and efficient design for multi-shaft applications

SGen-3000W / 4000W series Optimized for extreme outputs and designed for steam power plants



Generators Product Overview

25-65 MVA

Size

Indu

s.

Nuc

Air

H2

Foss

il

Segment H

2 / H

2O

Cooling

1000-2235 MVA (4P)

560-1280 MVA

370-565 MVA

H2O

25-370 MVA

Cooling

550-850 MVA

Size

Air

165-370 MVA

850-1280 MVA

370-550 MVA

Existing

1000-2235 MVA (4P)

Future

Air /

H2O

H

2O /

H2

Air

Generator Development Focus

Simplified portfolio with lower complexity and increased sameness across products; product development focus up to ~850MVA

300 MVA



25-65 MVA

Size

Indu

s.

Nuc

Air

H2

Foss

il

Segment H

2 / H

2O

Cooling

1000-2235 MVA (4P)

560-1280 MVA

370-565 MVA

H2O

25-370 MVA

Cooling

550-850 MVA

Size

Air

165-370 MVA

850-1280 MVA

370-550 MVA

Existing

1000-2235 MVA (4P)

Future

Air /

H2O

H

2O /

H2

Air

300 MVA

Future Generator Portfolio with SGen-2000P Air-Cooled Machine with Water Cooled Stator

SGenX-2000P replaces traditional indirectly cooled hydrogen generators

SGenX-2000P




• Introduction 3



• 2000H vs. 2000P






• Summary 20



SGen-2000P – Side by Side Comparison Hydrogen Cooled vs Pressurized Air-Cooled

SGen-2000H Technical data: Hydrogen-cooled

Apparent power 370-565 MVA

Terminal voltage up to 22 kV

Stator insulation GVPI; Class IEC B

Shaft sealing Performance plus TM

Ventilation 1-stage axisymmetric radial-cooled rotor & stator

Coolers 2 x Omega coolers

Total weight 350 t

Rotor overall length 12.2 m

Generator dimensions Length: Width: Height:

10.3 m 3.9 m 4.0 m

SGen-2000P Technical data: Pressurized air-cooled

Apparent power 370-550 MVA

Terminal voltage up to 22 kV

Stator insulation GVPI; Class IEC B

Shaft sealing Brush seal

Ventilation 1-stage axisymmetric radial-cooled rotor & stator

Coolers 3 x horizontal / transverse

Total weight 339 t

Rotor overall length 11.2 m

Generator dimensions Length: Width: Height:

9.6 m 3.9 m 4.3 m

SGen-2000H Hydrogen-Cooled

SGen-2000P Pressurized Air-Cooled

Hours as reported to Siemens; rated values; unit-specific values may vary



SGen-2000P – Overview & Benefits Market Differentiator with Innovative mix of Siemens Technology

~940 units in fleet > 30,909k operation hours

99.2% Availability; 99.7% Reliability

100A: Air-Cooled Technology

• Water-Cooled Stator • Stator water manifolds • Aluminum end plate

(w/o shield) • Stator water skid ~550MVA up to ~900MVA

3000W: Water-Cooled Technology

~140 units in fleet > 8,409k operation hours

98.1% Availability; 99.3% Reliability

>300MVA up to ~370MVA

2000P: Pressurized Air With Water Cooled Stator Winding Up to ~550MVA

• Verified extended cooling technology with air (no hydrogen) • Water-cooled stator winding for maximum operating flexibility –

ramp rates, start stops • Efficiency comparable to hydrogen (H2) technology • Low OPEX with fewer auxiliaries • Stainless steel tubes – less sensitive to water chemistry • Product line use of common components improves availability of

spare parts.

Owner/Operator Benefits

New design features • Air supply skid • Directly air cooled

parallel rings

Hours as reported to Siemens; rated values; unit-specific values may vary

• GVPI stator • Radially cooled rotor • Symmetrical single stage blower • Simple frame & interfaces • Pedestal bearings • Integral collector



SGen-2000P Design Features

Man Access

Lifting Trunnion

Integral Collector

Water Manifold Outlet

IPB Support

Coolers

Bushings

Stator Frame

Stator Core

Core to Frame Attachment

Lead Box

Stator End Winding Bed Plate

Bearing Pedestal

Water Cooled Stator Coils

Verified component from 3000W series

Verified component from 1000A & 2000H series

from 1000A

Conceptual illustration; not to scale

Legend:

from 2000H

New Arrangement



1

2

3

4 4 4

4

2

SGen-2000P – Verified Components Added to Base Air-Cooled Generator

SGenX-2000P generator design consists of verified components & manufacturing technology with long history of successful field operation

Component Basis Experience Water Cooled Stator

Coils (GVPI) 3000W

>140 units* >20yrs fleet exp. >8M OH

Water Manifolds

Parallel Rings

1

2

3

* Based on # units reporting to Siemens. Manufactured fleet significantly higher.

Component Basis Experience

Coolers (internal to frame)

100A 2000H 3000W


Stator Frame, Stator Core, Core-to-Frame, End Windings,

Rotor, Bearings, Excitation

100A 2000H 3000W


*Conceptual illustration; not to scale

4



Generator Auxiliary Interfaces SGen-2000P vs. Traditional Hydrogen Cooled Unit

SGen-2000P eliminates potential issues related to hydrogen gas

Waste Gas System

Gas Supply System Air Supply System

Eliminated

Additional

Stator Water System

Seal Oil System

Lower plant complexity, with operational flexibility

Waste Gas System



SGen-2000P – Air Supply Skid User Friendly and Reliable

• 2 self controlled screw compressors

• 2 automatic air dryer

• Simple and modular skid layout with verified industry standard components

• Overall control & monitoring by plant I&C

*Conceptual illustration; not to scale

Filtering, Compression

Storage, Control Drying



SGen-2000P Operational Flexibility & Interfaces

Operational Flexibility • Pressurized - Air at atmospheric or positive pressures (up to 1bar

gauge); controlled leakage rates within limits of auxiliary air system

• Extended Output - Variable pressurization enables flexible operation in extended capability range; rotor temperature control logic.

• Market Flexibility - Water cooled stator for thermal cyclic loading of stator due to high start / stops and ramp rates

Air System

Variable Air System

1

2

3

Operation at nominal active power output PN at PF ~1 and leading PF does not require pressurization

Rotor Temp Control

1

2

Variable pressure

PN

Reduced potential for unit shut down solely due to loss of pressurization



SGen-2000P – Pressure & Sealing Simplified I&C and Sealing

Load dependent air pressure control • Generator designed to maintain slight overpressure to

avoid contamination (semi-closed system comparable to hydrogen cooled generators)

• Pressure control by rotor winding temperature • Pressurizing only at high excitation current, lagging power

factor • Continuous fresh air supply, intended air

exchange to maintain low dew point Shaft seal design • Brush seal attached to bearing pedestal vapor seal • Reference from steam turbine design • Brush seal expected design life ~ 30 years (max. leakage

rates for worn brush seals considered in design)

Conceptual illustration; not to scale



no access for operators

(A) – Lead box (B) – Before blower (C) – ID stator end winding (D) – OD stator end winding (E) – Cooler area

EE

A

B C

D E

D

C B TE

SGen-2000P Accessibility for Assembly & Service Activities



SGen-2000P provides total cost of ownership benefit as compared to traditional hydrogen cooled (2000H)

- 63% installation effort

2000H

2000P

Generator auxiliaries incl. piping

- 68% commissioning effort

2000H

2000P

Generator auxiliaries incl. piping

- 220K € operational costs*

2000H 2000P

Argon consumption H2 consumption H2 refill 0

Serviceability

Major Inspection

outage duration man hours

-21%

-58%

Minor Inspection

-44% -53%


Medium Inspection

-17% -46%


2000H 2000P

~30% LTP cost savings No rotor disassembly over entire lifecycle Maintenance free stator due to GVPI technology



SGenX-2000P: Validation Plan

Tests and test conditions Measurements • Rotor balance • Ventilation test • Short circuit and open circuit characteristics • Short circuit and open circuit heat runs • 3 phase sudden short circuit • Determination of efficiency • Modal test • Determination of reactances • Rotor moment of inertia • Bearing performance

• Rotor vibration and critical speed • Air flow and blower capability • Short circuit and open circuit characteristic curves • Winding temperatures • Frame, core and winding vibration • Generator losses • Component natural frequencies • Noise level • Stator winding operation deflection shape

Planning of Validation

Basic Design Final Design Purchasing & Manufacturing Factory Test Validation In Service

• Electrical (incl. insulation • Mechanical • Thermal (cooling)

R3 R5 R7 R8 R9 Ex

• Implementation of concept design

• QA mechanical & electrical tests during manufacturing

• PPQ’s & IPPQ’s

• Verification of design requirements, validation of concept design

• Commissioning, test operation until PAC



>27 years of fleet operation experience

Siemens GVPI Technology (Global Vacuum Pressure Impregnation)

Excellent operational experience of more than 1650 generators with > 25 Mio. OH’s

More than 1650 generators Rating 25 - 870 MVA 10 – 22 kV

Location MLH CLT

Num

ber o

f Gen

erat

ors

in G

VPI-T

echn

olog

y




• Introduction 3



• 2000H vs. 2000P






• Summary 20



Summary SGen-2000P Generator Product Line

• Overview & benefits • Verified cooling technology in Air • No hydrogen • Maximum operating flexibility

• Generator design features • Verified components and manufacturing technology • Long history of successful field operation

• Interfaces & operation • No added potential for shut down solely due to loss of pressurization • Efficiency of pressurized air (SGen-2000P) comparable to hydrogen cooled (SGen-2000H) technology

• Auxiliary systems • Fewer plant interfaces compared to hydrogen cooled generators • Less installation time, lower maintenance cost and lower total cost of ownership

• Serviceability • Full serviceability is confirmed with less effort than traditional hydrogen cooled generator products



Turbine Generator Product Introduction; Dec’16 Pressurized Air-Cooled Generator (SGen-2000P)

Q&A

Generator Portfolio Strategy & R&D Mike Zborovsky [email protected]



Disclaimer

This document contains statements related to our future business and financial performance and future events or developments involving Siemens that may constitute forward-looking statements. These statements may be identified by words such as “expect,” “look forward to,” “anticipate” “intend,” “plan,” “believe,” “seek,” “estimate,” “will,” “project” or words of similar meaning. We may also make forward-looking statements in other reports, in presentations, in material delivered to shareholders and in press releases. In addition, our representatives may from time to time make oral forward-looking statements. Such statements are based on the current expectations and certain assumptions of Siemens’ management, of which many are beyond Siemens’ control. These are subject to a number of risks, uncertainties and factors, including, but not limited to those described in disclosures, in particular in the chapter Risks in the Annual Report. Should one or more of these risks or uncertainties materialize, or should underlying expectations not occur or assumptions prove incorrect, actual results, performance or achievements of Siemens may (negatively or positively) vary materially from those described explicitly or implicitly in the relevant forward-looking statement. Siemens neither intends, nor assumes any obligation, to update or revise these forward-looking statements in light of developments which differ from those anticipated.

Trademarks mentioned in this document are the property of Siemens AG, its affiliates or their respective owners. TRENT® and RB211® are registered trade marks of and used under license from Rolls-Royce plc. Trent, RB211, 501 and Avon are trade marks of and used under license of Rolls-Royce plc.

Pressurized Air Cooled Generators - Siemens Energy · PDF filePressurized Air Cooled Generators ... H2O. 25-370 MVA . Cooling . ... • Fewer plant interfaces compared to hydrogen

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