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A1-109

CIGRE 2008

Application of Electromagnetic Numerical Analyses for Large Indirectly Hydrogen Cooled Turbine Generators Haruyuki Kometani, Susumu Maeda and Kazuichi Suzuki Mitsubishi Electric Corporation Japan

SUMMARY
Awareness about the global environment has grown markedly around the world in recent years. This has led to a public push to make electric power generation system more efficient. One of the main ways adopted for improving the efficiency of the generation systems is the adoption of high-efficiency combined cycle power plants. The indirectly hydrogen-cooled turbine generators used in these kinds of plants are now available in capacities up to 550 MVA class and there is still an urgent need to reduce the energy losses of the turbine generators used in such systems. In this study, we focused on the iron loss and stray load loss in turbine generators, and clarified the mechanism by which losses were generated that had been understood only vaguely up to now. In addition, we quantified the losses in each part of the generator where these losses generated and examined effective counter measures to reduce the losses. Furthermore, we described electromagnetic field analysis techniques suitable for large-scale system, in order to calculate these kinds of losses. The main iron losses in case of oriented and non-oriented electrical steel sheets were calculated by 3dimensional numerical analysis method considering the ventilation ducts. From the analysis of the vicinity of ventilation ducts, we found that the losses were reduced to 10% by using the nonmagnetized vent finger and by decreasing the width of the ventilation ducts. And eddy current loss at frame end region was calculated by the 3-dimensional numerical analysis method, loss density distribution is clarified and we obtained the results that the total loss was reduced by 20 in the case where end bells and covers were made of non-magnetized material. And as for the core end region, we obtained the results that the losses were concentrated at the angular parts of the inner diameter of the magnetic end shield and end sheets of stator core in the iron core end parts. We also showed the 3dimensional numerical analysis method for calculating the local eddy current loss in stator coil strands and showed the numerical analysis combined with the circuit equations for calculating the circulating current loss. Using these analyses, loss distribution in the stator coil strands was clarified. We applied these electromagnetic field analysis techniques to a 550MVA class indirectly hydrogencooled turbine generator, and compared the values of losses obtained by these analyses with the results of the iron loss and stray load loss measurements. The small difference in values confirmed the validity of our analysis methods. In addition, we confirmed ways to reduce these losses by a total of 20% by means of optimizing the materials of stator core, vent finger and frame end and the design of stator core end structure.

KEYWORDS
Turbine Generators, Iron Loss, Stray Load Loss, Electromagnetic Numerical Analysis Kometani.Haruyuki@cw.MitsubishiElectric.co.jp

1. Introduction
Awareness about the global environment has grown markedly around the world in recent years. This has led to a public push to make electric power generation systems more efficient and environmentfriendly. Improving the efficiency and reliability of generators has thus become an important challenge. Corresponding to this move, a majority of electric power plants are now utilizing high-efficiency combined cycle power plants (CCPP), and plant capacities per shaft have increased to 500 MW class. The indirectly hydrogen-cooled turbine generators used in these kinds of plants are now available in capacities up to 550 MVA class, with capacities expected to increase further to 650 MVA[1-3]. Currently we are producing generators up to around 550 MVA class. The history of electromagnetic numerical analysis for turbine generators dates back to the finite difference method-based 2-dimensional and quasi-3-dimensional analysis methods of the 1960s and 1970s, which evolved in the 1980s into 2-dimensional analysis techniques based on the finite element method (FEM). Since 2-dimensional analysis techniques cannot take into account leakage flux from rotor and stator end windings, these effects needed to be determined separately, and improved computation accuracy was also necessary. Even in quasi-3-dimensional analysis of generator ends, infinite series approximations were used to compute the distribution of MMF in end windings. The development of FEM-based 3-dimensional analysis techniques emerged in the 1990s[4], and evolved progressively as the processing power of computers increased. Three-dimensional analysis enables the structure, MMF distribution, and magnetic saturation characteristics to be accurately taken into account, thereby enabling very precise analysis. It has been used partially for analysis of turbine generators[5-7]. Authors have been challenging in the development of 3-dimensional electromagnetic field analysis, making practicable large-scale analyses for the evaluation of characteristics, including rotor current under load, synchronous and transient reactance, electromagnetic forces on stator end windings, rotor surface losses due to negative-sequence current, iron loss, stray load loss, and shaft voltage. Especially, investigating the effective way for high efficiency, the 3-D analysis has been applied to the loss calculations for the most part of the turbine generator. In this report, we will present a method for calculating the losses generated in an turbine generator, utilizing a detailed electromagnetic field analysis, for the purpose of increasing generator efficiency, and we confirmed ways to reduce these losses by a total of 20% by means of optimizing the materials of stator core, vent finger and frame end and the design of stator core end structure.

2. 550 MVA class generator

Appearance of an indirectly hydrogen-cooled 550 MVA class generator is shown in Figure 1.

3. Loss separation
The losses in turbine generators can be classified into stator copper loss, rotor copper loss, mechanical loss, iron loss, stray load loss and excitation loss. Figure 2 breaks down the typical losses in an indirectly hydrogen-cooled turbine generator. The diagram shows that iron loss accounts for 10 to 20% of total losses, while stray load loss accounts for another 15 to 25% of total loss. Iron loss and stray load loss correspond to the total of the eddy current loss and hysteresis loss generated in each of the components inside the generator, which can be evaluated using electromagnetic numerical analysis. Table 1 and Table 2 show the generator parts that produce iron loss and stray load loss, and the magnetic flux and magnetic field responsible for the losses. The major part of the iron loss is accounted for by the loss resulting from the main flux in the stator laminated core (Loss (a)). The rest of the iron loss is made up largely of the loss generated in iron core structural parts due to end windings leakage flux

Fig. 1. Appearance of 550MVA class generator

Mechanical Loss Stator Copper Loss Rotor Copper Loss Iron Loss Stray Load Loss Excitation Loss

Fig. 2. Example breakdown of generator losses (indirectly hydrogen-cooled turbine generator)

(Loss (b)); the loss generated in stator windings due to slot leakage flux and end windings leakage flux (Loss (c)); and the loss generated in vent fingers within iron cores by main flux (Loss (e)). Stray load loss can be broadly divided into the losses generated around the iron core, in the stator windings, and the rotor surfaces. Two kinds of loss are generated around the iron core: the loss in the iron core teeth due to slot leakage flux (Loss (a)), and the losses at the iron core end structural parts and the end frames due to end windings leakage flux (Loss (b)). Table 1 Generator parts where iron loss is generated Kinds of losses Parts of generator Linkaged flux and field (a)Main iron loss (Eddy current Hysteresis Laminated core plate Main flux loss) (b)Eddy current loss in end End surface of laminated Leakage flux of rotor windings region core plate (c)Eddy current loss in stator Strand of stator coil (Local Leakage flux of rotor windings windings eddy current loss) (d)Eddy current loss at rotor Pole Wedge Damper bar Harmonic field by stator slots surface etc. Vent finger, Core plate Main flux (e)Other losses Leakage flux at outer surface of Core bolt, Core support stator core Table 2. Generator parts where stray load loss is generated Kinds of losses Parts of generator Linkaged lux and ield (a)Additional iron loss Laminated core plate Stator slot leakage flux (Eddy currentHysteresis loss) (Mainly teeth portion) End surface of laminated Leakage flux of rotor and stator (b)Eddy current loss in end core windings region Magnetic end shield Leakage flux of parallel rings End frame etc. Stator slot leakage flux Strand of stator coil Series connection at coil-end Leakage flux of rotor and stator windings Parallel ring etc. (c)Eddy current loss in stator Leakage flux of parallel rings (Local eddy current loss) windings Stator slot leakage flux Strands of stator coil Leakage flux of rotor and stator (Circulating eddy current) windings (d)Eddy current loss at rotor Pole, Wedge, Damper bar Harmonic field by stator windings surface (e)Other losses Lead box, bushing Leakage flux of main lead Local eddy current loss and circulating current loss are generated in the stator windings due to slot leakage flux and end windings leakage flux (Loss (c)). The losses at the rotor surfaces are generated due to magnetic field harmonics of stator windings (Loss (d)). These are the main kinds of losses. We calculated these losses principally by means of 3-dimensional electromagnetic numerical analysis, to clarify the mechanism by which iron loss and stray load loss occurpreviously understood only vaguelyand examine ways in which these losses can be reduced.

4. Analysis methods and analysis results

In this chapter, we demonstrate a method for electromagnetic field analysis of the losses generated in each part of the generator that contribute to the iron loss and stray load loss, as shown in Table 1 and Table 2. We also present the parameter study results of these analyses. Since we cannot present the all analyses due to limitations of space, we focus on the main losses. Figure 3 shows the 3-dimensional mesh division representing the example of generator model. The mesh consists of hundreds of thousands of elements.

Stator core

Stator coil end

Clamper

Rotor Magnetic end shield

Fig. 3. Mesh divisions (overall model)

4.1 Main iron loss

(1) Calculation method and modeling The loss generated in the stator laminated core is calculated[8] by determining the flux density hysteresis of each element, using a model of the entire generator, based on measurement data on flux density and iron loss in the core material. If the mesh created were to take into account all the ventilation ducts, the number of mesh divisions would be extremely large, and the calculation process would become impracticable. For this reason, we ignored ventilation ducts in our model. We simulated the magnetization characteristics of the iron core using Eq. (1), which makes use of (as a parameter) the stacking factor, p, of the iron core. We then calculated the main iron loss after converting the flux intensity obtained from this model into a value of in-core flux intensity.

Bmod (H ) = 0 (1 p )H + pB(H ) (1 p )B + pH (B ) Lamination direction: H mod (B ) =

In-plane direction:

(1)

Here Bmod(H) and Hmod(B) are the magnetization characteristics used in the calculation, 0 is permeability of a vacuum, and B(H) and H(B) are measured magnetization characteristics of the iron core.

(a) 0.5mm non-oriented electrical steel sheet

(b) 0.35mm non-oriented (c) 0.35mm oriented electrical steel sheet electrical steel sheet Fig. 4. Main iron loss distribution

(2) Analysis results Figure 4 shows the main iron loss distribution in an open circuit test when using non-oriented electrical steel sheets of 0.5 mm and 0.35 (loss reduced type) mm thickness for the iron core in comparison with the case of using oriented electrical steel sheets of 0.35 mm thickness. From the figure of oriented steel sheets, because the loss at the teeth is high (along the hard axis of magnetization), resulting overall iron loss of oriented steel sheets was not so small compared with the 0.35mm non-oriented steel sheets (loss reduced type). The ratio of main loss in the three cases was approximately 1 : 0.76 : 0.62 (non-oriented (0.5 mm) : non-oriented (0.35mm) : oriented). Though we applied oriented steel sheets in case of the 550MVA class generator, non-oriented sheets is to be used in the future, because of the small difference of losses.

4.2 Loss around ventilation ducts

(1) Calculation method and modeling We conducted a 3-dimensional analysis based on a model of a half-pack between ventilation ducts, and then calculated eddy current losses generated in the vent fingers and the surface of the laminated iron core. For cases where vent fingers are made of magnetized materials we also calculated the hysteresis losses generated. To calculate the eddy current losses at the surface of the laminated iron core we used a homogenization method[9], utilizing conductivity anisotropy, setting the conductivity in the lamination direction as zero. (2) Analysis results Figure 5 shows the loss density distribution in an open circuit test in the case of magnetized vent fingers. The configuration of the vent fingers of core back area has been simplified because the loss of the duct finger is mainly generated at the tip of the stator teeth portion. Figure 6 shows the loss separation around the ventilation ducts in the open circuit test. We then compared the results with the case of vent fingers made of magnetized materials, and the case of magnetized materials at ventilation duct widths of 5 mm and 7 mm. Figure 6 clearly shows that losses in vent fingers are extremely low when vent fingers are made of non-magnetized materials. And when vent fingers are made of magnetized materials the loss increases approximately in proportion to the cube of duct width.
eddy current on laminated core eddy current on vent finger hysteresis on vent finger

Vent finger
Loss (%)

300 250 200 150 100 50

Surface of laminated core Fig. 5. Loss density distribution around ventilation ducts Frame Bracket Cover

0 7mmmagnetized 5mmmagnetized 5mmnonmagnetized

Fig. 6. Loss separation around ventilation ducts

Endbell

Fan guide Fig. 7 Loss density distribution in end components Fig. 8 Loss density distribution in end components due to flux leakage from coil ends due to flux leakage from parallel rings

4.3 Losses at frame end and iron core end parts 4.3.1 Frame end parts (frames, brackets, covers, fan guides, endbells)
(1) Calculation method and modeling We replaced coil ends and parallel rings in reduced potential regions with coil elements, and

conducted a 3-dimensional analysis of the eddy current losses generated due to flux leakage at each of the components of the generator ends. (2) Analysis results Figure 7 and Figure 8 show the loss density distribution in a 3-phase short circuit test due to flux leakage from coil ends and parallel rings. These results are for calculations in the case where covers and endbells are made of non-magnetized materials. Figure 9 shows the comparison of losses between magnetized / non-magnetized covers and endbells. In the case where covers and endbells are made of magnetized materials, the leakage of flux to frames and brackets is lower, but the losses at covers and endbells are higher, resulting in an overall increase in losses.

Cover 120 100 80

Loss (%)

Frame

Bracket

Endbell

Fan guide

60 40 20 0

magnetized

nonmagnetized

4.3.2 Iron core end parts (finger plates, clampers, magnetic end shields, and shield clampers)

Fig. 9 Comparison between magnetized/nonmagnetized covers and endbells

(1) Calculation method and modeling We calculated the eddy current and hysteresis losses due to leakage flux from stator windings and rotor windings, by creating a 3-dimensional mesh defining non-magnetized finger plates, magnetized clampers, laminated inner-tapered magnetic end shields, and non-magnetized shield clampers. (2) Analysis results Figure 10 shows the loss density distribution in the magnetic end shield. This figure is based on the results of 3-phase short circuit tests. This figure makes it clear that losses are concentrated at the angular parts of the inner diameter of the magnetic end shields. Outer side Slits Inner side Stator teeth

Fig. 10 Loss density distribution in the magnetic end shield

Fig. 11 Loss density distribution in the stator iron core ends

4.4 Losses in the stator core ends

(1) Analysis method and modeling We calculated the eddy current losses generated in the stator core ends due to leakage flux from the stator windings and rotor windings, utilizing conductivity anisotropy by means of a homogenization method, as in section 4.2 above. (2) Analysis results Figure 11 shows the eddy current loss density distribution in a open circuit test. The figure clearly demonstrates that the loss is high at the edge of teeth. This finding can be used to reduce loss by designing slits in the teeth edges.

4.5 Loss in stator windings

(1) Calculation method and modeling There are two kinds of losses here: local eddy loss generated within the strands of the stator windings, and circulating current loss due to the eddy currents circulating between individual strands of the

stator windings. To calculate the loss within slots (a part of the local eddy loss), we conducted a simplified calculation based on a 2-dimensional analysis using a mesh consisting of elements corresponding to individual strands. The coil end loss was calculated using a 3-dimensional analysis that took into account the full MMF of winding ends, in which a single coil of the top coil and bottom coil were divided into a finely partitioned mesh. Circulating current was calculated according to the following procedure. a) The induced voltage (external induced voltage E) generated in each strand due to flux leakage from stator windings and rotor windings was calculated using a 2-dimensional analysis, considering the calculated circulating current, while coil ends were calculated using a 3-dimensional analysis. b) The reactance between strands was calculated within slots and at coil ends, and an impedance matrix Z was created by adding strand resistance to a diagonal matrix. c) Circulating current I are calculated by solving the following circuit equations so that the voltages of all strands in the coil are equal to voltage between coil ends V. V is a value which exclude the voltage drop by resistance. (2) I=0 (3) (2) Analysis results Figure 12 shows the distribution of local eddy current loss density at coil end parts in a 3-phase short circuit test. The local eddy current loss becomes large to the involute portions near the stator core. Figure 13 shows the distribution of circulating current loss for each strand in a 3-phase short circuit test. This figure shows that circulating current loss exists even when a Roebel transposition is conducted, and that loss is highest in the strands located on the air gap side at the coil end. Each strand consists of two lines in slots, and by using the strand located on the right-line and air gap side at the coil end of the turbine side as a reference, we show the right-line and slot bottom side, left-line and slot bottom side, and left-line and air gap side, in this order.
T op coil Bottom coil

300

Involute portion
Strand loss (%)

250 200 150 100 50 0 air gap side bottom of slot side air gap side

Fig. 12 Distribution of local eddy loss density

Fig. 13 Strand losses by distribution of circulating current

5. Comparison with measurements of 550MVA class generator

We calculated the iron loss and stray load loss by separately calculating and adding the losses described in sections 4.1 to 4.5 above, as well as rotor surface loss, bushing loss, and losses at series connectors, parallel rings, and stator iron core back parts. We also examined counter measures to reduce these losses. We selected the most effective loss reduction measures, those are Oriented steel sheets for stator core, Non magnetic vent finger, Non magnetic cover and end bell and Optimum slit and shield core configuration for stator core end, and applied them to one of our 550 MVA class generator. Figure 14 shows the results of measurements of iron loss and stray load loss for the 550 MVA class generator, along with some analysis. The figure clearly shows that the difference between the measured and computed results was only 5%, confirming the validity of the applied analysis methods. The figure also shows loss measurement results obtained before considering efficiency enhancement measures. It is clear that total iron loss and stray load loss can be reduced by

20%.

6. Conclusion
In this study, we identified the main factors behind iron loss and stray load loss in turbine generators, and discussed methods for computing these quantities using detailed electromagnetic field analysis. In addition, we analyzed and computed iron loss and stray load loss for a 550 MVA class indirectly hydrogen-cooled turbine generator and compared the results obtained with measurements. The difference between computed and measured results was only 5%, confirming the high precision of the computation method. By applying effective loss reduction measures based on these kinds of computations, it was possible to reduce the total of iron loss and stray load loss by a total of approximately 20%. Including the loss reduction in iron loss and stray load loss, generator efficiency has been improved by approximately 0.2%.

Laminated core Vicinity of ducts Iron loss

140 120 100 Loss (%) 80

End region Rotor surface Stray load loss

Armature coil Others

Stray load loss

60 40 20 0 Analyses Measurement Original design

No-load Iron loss

Fig. 14 Comparison of iron loss and stray load loss values obtained by analysis and measurement, and examples of efficiency enhancements

BIBLIOGRAPHY
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