DEC Pump-Turbine Introduction

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PRESENTATION FOR PUMP-TURBINE
DONGFANG ELECTRIC MACHINERY CO., LTD
Pump-Turbine of DFEM Made PumpPump-Turbine of DFEM Made

Power Station GuangZhou 1st ShiSan Ling XianHongDian HuiZhou HeMiFeng HOHOT Outstanding achievement Main parts Cooperating with VIOTH Self-design Cooperating with ALSTOM and manufacturing 1(one) complete set unit Cooperating with ALSTOM and manufacturing 4(four) complete set units Cooperating with ALSTOM and manufacturing 4(four) complete set units Self-design and manufacturing 4(four) complete set units Operating date 93 95 97 2008 2009 2012
XianYou
2014
Experiences List of DFEM Made Pump-Turbine Experiences List of DFEM Made Pump-Turbine
HuiZhou
1 Turbine condition Unit Power (MW) Turbine output (MW) Maximum head (m) Rated head (m) Minimum head (m) 2 Pump condition Maximum head (m) Minimum head (m) Maximum input (MW) Maximum flow (m3/s) 3 Other Runner Diameter (m) Runner blade Guide vane Rated speed (r/min) 3.82 9 20 500 5.04 9 20 300 3.88 9 20 500 4.158 9 20 428.6 565 529 330 56.02 337.6 275 325 106 595 503 320 55.27 475 421 302 68.1 4300 306 553.7 517 509 4300 306 335 295 270 4300 306 580 521 490 4300 306 475 430 421
HeMiFeng
HOHOT
XianYou
Typical Pump-Turbine Typical Pump-Turbine
DFEM Typical Products XianHongDian 2X40MW HuiZhou 4X300MW HeMiFeng 4X300MW HOHOT 4X300MW XianYou 4X300MW
Principles of Pump-Turbine Design Principles of PumpPump-Turbine Design

The Best CFD tools can be used in pump-turbine hydraulic design. Making full use of the outcomes in key technology research for large Pump-turbines. Fully use of mature and advanced proposal and structure proven by successful operations. Carefully chosen data with certain surplus. Taking the convenience for installation, maintenance, manufacturing and transportation into full consideration . Reliableadvanceddurableeasy-operationnice-looking.
Cooperation with overseas company Cooperation with overseas company
Our company has been cooperating with many famous overseas companies, such as ViothSiemens, Alstom, GE, VA-TECH, ANDRITZ, Toshiba. Among which, we have cooperated with Vioth, Alstom for pump-turbine.
Pump-Turbine Basic Research Hydraulic Design Pump-Turbine Basic Research Hydraulic Design Established test stand specially for pump-turbine Model runner diameter: 350~500 mm Maximum test head: 100 m Maximum Test discharge: 1.5m3/s Test system accuracy: 0.3% The whole system data will be got and processed automatically by computer. Pump-turbine model runner research Technical transfer from the overseas companies Based on overseas advanced runner, making hydraulic design by CFD analyze Machining the blades by 5-axis NC milling and boring machine
Test Stand For Hydraulic Machinery Test Stand For Hydraulic Machinery
DFEM Universal Test Stand For Pump-Turbine
Pump-Turbine Basic Research Hydraulic Design Pump-Turbine Basic Research Hydraulic Design
Whole analyzing Runner and Spiral case and Draft tube
Efficiency
Comparison of experiment results and calculation
l tia en fid n Co
Measurements Calculations
2%
0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5
Q11/Q11 opt
CFD tools to predict performances, and comparison with measurement results
Typical cavitation "bucket" curve
350
300 Required submergence NPSH/NPSHopt (%)
250
200
150
bucket curve submergence
100
50 80 85 90 95 100 Q/Qd (%) 105 110 115 120
a specific tool for entrance cavitation analysis
Softwares for pressure fluctuations prediction
Pump-Turbine Basic Research Rigidity & Strength Calculation Analysis Pump-Turbine Basic Research Rigidity & Strength Calculation Analysis
Pump-turbine integrity rigidity and strength calculation analysis Simulation the true turbines discharge, normal operation, load-rejection and runaway condition. Using ANSYS calculation software to calculate static stress for whole unit and large components. Using ADINA calculation software to calculate the runner and shaft system fem dynamic stress.
Load distribution on obverse surface of blade
Load distribution On water Load distribution way surface of crown on back surface of blade Load distribution On non-waterway nonsurface of band and crow
Load distribution On waterway surface of band
Intensity calculation of runner at any load condition
Combining calculation of spiral case and stay vane
Stress distribution of wicket gate
Stress distribution of head cover
Stress distribution of bottom ring
p5
DIAPHRAG M E ORIFICE PLATE Qtot
R5 Couvercle Anneau flottant Floating ring Ressorts Springs Cover
p1 Q int
p2
p3 Qext
R1 R2 R3 R4
ANSYS calculation of seal ring

Fig 1
Bearing force
Sealing water
Shaft
ANSYS calculation of seal ring distortion Design and calculation of main shaft seal
10
Pump-Turbine Structure Design and manufacture Pump-Turbine Structure Design and manufacture
Runner combination jointing
Typical Pump-Turbine Structure Typical Pump-Turbine Structure
Turbine Cross SectionPump-Turbine

20.500
CIRCULAR RAILWAY 3.5t ? 5904 3.5t ? 7880 ? 1480 18 M100x4 ? 6820 80 - M 105x4 2500 TURBINE PIT ACCES GALLERY
? 5904 Z=20 GUIDE VANES 20
2000
18.300
? 1095 h10
17.750
SERVOMOTOR AXIS
17.800
? 1500 h8 BEARING
SHAFT SEAL ? 1500
15.000
522 DISTRIBUTOR AXIS RUNNER 9 BLADES 9 ? 1480 9 -M110x4 9 -? 150
? 2700 RUNNER OUTLET ( TURBINE MODE )
()
? 5040 RUNNER INLET ( TURBINE MODE )
()
? 7130
40 - M 80x4
2000 DRAFT TUBE CONE ACCES GALLERY
PUMP MODE CLOCKWISE 300 rpm
()
9.500
TURBINE MODE COUNTERCLOCKWISE 300 rpm ()
8.500
DRAFT TUBE ELBOW ? 3596 INLET DIAMETER
11
Gate friction Gate shaft cone sleeve
Transferred wring moment by pin sleeves and connected by bolts between runner and main shaft
Turbine shaft Intermediate collar
Pad
Thin oil ,self-lubricating , segment and ,selfExternal oil circulation guide bearing Adopted to HuiZhou ,HeMiFeng ,HOHOT etc.
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Adapted axial shaft seal
Inflatable maintenance seal
Spring, self-adjusting face-type main shaft seal selffaceseal rings in Carbon material or Cestidur Adopted to HuiZhou ,HeMiFeng ,HOHOT , BaoQuan,Three Gorge,LongTan,XiaoWan,PuBuGou etc.
Spiral case and stay ring: 1 Integer 2 Segmented by transport limit 3 Designing spiral case under maximum water pressure 4 Water pressure test of spiral case at site.
13
Stay ring: Segment Combination at site
Gate operation control mechanism

20
18
2,63
5 47
single gate servomotor
single gate servomotor and control ring
14
DRAINAGE PIPES IN THE PIT DRAINAGE PIPES IN THE PIT
Main Parts Material Table for Pump-Turbine Main Parts Material Table for Pump-Turbine
Item. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 Name of Part Runner Main shaft Spiral case Stay ring Head cover Bottom ring and discharge ring Gate operating ring Guide bearing Main shaft seal Guide vanes Coupling bolt Servomotor cylinder and gate lever Cone and elbow of draft tube Pit liner Wearing ring and seal ring Stay seal ring Material ZG06Cr13Ni4Mo DG20SiMn B610CFADB610D or WDB620 S500Q-Z25 S355J0+N or Q345C S355J0+N or Q345C S355J0+N or Q345C Q235C Q345C ZG06Cr13Ni4Mo 42CrMo ZG20SiMn 16Mn Q235A s135 ZCuAl10FeNi5 GB3274-88 GB3274-88 GB3274-88 GB700 GB3274-88 GB6967 GB3077-88 JB/ZQ4297 GB/T1591-1994 GB700 GB13237-91 GB/T 5231-2001 Standard and Grade (China) GB6967 JB/T6396 CF 62/WCF80 Equality America Standard ASTM A743 CA-6NM ASTM A668 CI.D
G3128-87 EN10025-6 EN10025-2 EN10025-2 EN10025-2 ASTM A36 ASTM A633m ASTM A743 CA-6NM ASTM A304 ASTM A216 WCC ASTM A516-90 Cr70 ASTM A36 ASTM A240-93b ASTM C63200
15
Pump-Turbine Field Test Pump-Turbine Field Test
Water pressure test of Spiral case at site
Pressure cycle
110% 100% 90%
% of pressure
80% 70% 60% 50% 40% 30% 20% 10% 0%

0 1 2 3 4 5 6 7 8 9 10
Design pressure if embedded with partial pressure time in hours
Pump-Turbine Condenser Operation Pump-Turbine Condenser Operation
16
Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare
A) Dismantling PT from middle
1 step: dismantling middle shaft
2 step: dismantling main shaft
17
3 step: dismantling head cover
4 step: dismantling runner
18
B) Dismantling PT from stator
dismantling head cover
C) Dismantling PT from movable cone of Draft tube
19
Inlet spherical valve made by DFEM Inlet spherical valve made by DFEM
Ite m 1 2 3 4 5 6 7 8 9 10 11 12 Diameter (m) 1.75 1.75 1.6 2.5 1.3 2.9 2.0 1.9 1.9 1.6 1.5 2.3 Head (max) Rising head (m) 483 230 390 301 455 335 585 620 620 321 318 479.9 725 300 500 400 550 500 900 793 775 420 393 Units 2 2 1 2 3 2 2 2 2 3 2 4 Operating year 1994 2004 2006 2008 2008 2009 2010 2008 2008 2008 2009 Operating status good good good good good good
Power station ShiSan Ling HuanGuangTan XiaoTianDu WaWuSan ShiZiPing HeMiFeng HOHOT JinWo RenZhongHai LIZhiPing DILuo XianYou
Inlet spherical valve Design Inlet spherical valve Design
Inlet spherical Valve: 1 Two surface seal 2 Two servomotor

11
3 Hydraulic operated seal ring 4 Movable operating seal ring replaces by-pass system by-
20
DFEM IS YOUR BEST CHOICE
THANKS!
HeMiFeng Power station

Type of turbine: HLP()-LJ-504 Runner diameter: 5.04m Rated speed: 300r/min Turbine condition: Maximum head: 335m Rated head: 295m Minimum head: 270m Turbine rated output: 306.0MW Pump condition: Maximum pump head: 337.6m Minimum pump head: 275.0m Max. pump discharge : 106m3/s Max. pump input: 325MW
21
HuiZhou Power Station

Type of turbine: HLP()-LJ-382 Runner diameter: 3.82m Rated speed: 500r/min Turbine condition: Maximum head: 553.7m Rated head: 517m Minimum head: 509m Turbine rated output: 306.0MW Pump condition: Maximum pump head: 565m Minimum pump head: 529m Max. pump discharge : 56.02m3/s Max. pump input: 330MW
22

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PRESENTATION FOR PUMP-TURBINE

DONGFANG ELECTRIC MACHINERY CO., LTD

Pump-Turbine of DFEM Made PumpPump-Turbine of DFEM Made

Typical Pump-Turbine Typical Pump-Turbine

Principles of Pump-Turbine Design Principles of PumpPump-Turbine Design

Cooperation with overseas company Cooperation with overseas company

DFEM Universal Test Stand For Pump-Turbine

Whole analyzing Runner and Spiral case and Draft tube

Comparison of experiment results and calculation

CFD tools to predict performances, and comparison with measurement results

300 Required submergence NPSH/NPSHopt (%)

bucket curve submergence

50 80 85 90 95 100 Q/Qd (%) 105 110 115 120

a specific tool for entrance cavitation analysis

Softwares for pressure fluctuations prediction

Load distribution on obverse surface of blade

Load distribution On waterway surface of band

Intensity calculation of runner at any load condition

Combining calculation of spiral case and stay vane

Stress distribution of wicket gate

Stress distribution of head cover

Stress distribution of bottom ring

DIAPHRAG M E ORIFICE PLATE Qtot

R5 Couvercle Anneau flottant Floating ring Ressorts Springs Cover

ANSYS calculation of seal ring

Runner combination jointing

Typical Pump-Turbine Structure Typical Pump-Turbine Structure

Turbine Cross SectionPump-Turbine

? 5904 Z=20 GUIDE VANES 20

SHAFT SEAL ? 1500

? 2700 RUNNER OUTLET ( TURBINE MODE )

2000 DRAFT TUBE CONE ACCES GALLERY

PUMP MODE CLOCKWISE 300 rpm

TURBINE MODE COUNTERCLOCKWISE 300 rpm ()

DRAFT TUBE ELBOW ? 3596 INLET DIAMETER

Gate friction Gate shaft cone sleeve

Inflatable maintenance seal

Stay ring: Segment Combination at site

Gate operation control mechanism

single gate servomotor

single gate servomotor and control ring

DRAINAGE PIPES IN THE PIT DRAINAGE PIPES IN THE PIT

Pump-Turbine Field Test Pump-Turbine Field Test

Water pressure test of Spiral case at site

80% 70% 60% 50% 40% 30% 20% 10% 0%

Design pressure if embedded with partial pressure time in hours

Pump-Turbine Condenser Operation Pump-Turbine Condenser Operation

Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare

A) Dismantling PT from middle

1 step: dismantling middle shaft

Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare

A) Dismantling PT from middle

2 step: dismantling main shaft

Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare

A) Dismantling PT from middle

3 step: dismantling head cover

Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare

A) Dismantling PT from middle

4 step: dismantling runner

Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare

B) Dismantling PT from stator

dismantling head cover