dec pump-turbine introduction

wwwwwwwwwwwwwwwwwwwwwwwwwr

1

东方电机有限公司东方电机有限公司DONGFANG ELECTRIC MACHINERY CO., LTDDONGFANG ELECTRIC MACHINERY CO., LTD

PRESENTATION FOR PUMPPRESENTATION FOR PUMP--TURBINETURBINE

Pump-Turbine of DFEM MadePumpPump--Turbine of DFEM MadeTurbine of DFEM Made

2012Cooperating with ALSTOM and manufacturing 4(four) complete set units

HOHOT

2014Self-design and manufacturing 4(four) complete set units

XianYou

2009Cooperating with ALSTOM and manufacturing 4(four) complete set units

HeMiFeng

2008Cooperating with ALSTOM and manufacturing 1(one) complete set unit

HuiZhou97Self-design XianHongDian95Cooperating with VIOTHShiSan Ling93Main partsGuangZhou 1st

Operating date

Outstanding achievementPower Station


2

Experiences List of DFEM Made Pump-TurbineExperiences List of DFEM Made Pump-Turbine

5002093.88

55.27320503595

4905215803064×300

HOHOT

428.6300500Rated speed (r/min)202020Guide vane 999Runner blade 4.1585.043.82Runner Diameter (m)

Other 368.110656.02Maximum flow (m3/s)302325330Maximum input (MW)421275529Minimum head (m)475337.6565Maximum head (m)

Pump condition2421270509Minimum head (m)430295517Rated head (m)475335553.7Maximum head (m)306306306Turbine output (MW)4×3004×3004×300Unit Power (MW)

Turbine condition1

XianYouHeMiFengHuiZhou

Typical Pump-TurbineTypical Pump-Turbine

DFEM Typical ProductsXianHongDian 2X40MW HuiZhou 4X300MWHeMiFeng 4X300MWHOHOT 4X300MWXianYou 4X300MW


3

Principles of Pump-Turbine DesignPrinciples of PumpPrinciples of Pump--Turbine DesignTurbine 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 .

Reliable、advanced、durable、easy-operation、nice-looking.

Our company has been cooperating with many

famous overseas companies, such as Vioth-

Siemens, Alstom, GE, VA-TECH, ANDRITZ, Toshiba.

Among which, we have cooperated with Vioth,

Alstom for pump-turbine.

Cooperation with overseas companyCooperation with overseas company


4

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

Pump-Turbine Basic Research－ Hydraulic DesignPump-Turbine Basic Research－ Hydraulic Design

DFEM Universal Test Stand For Pump-Turbine

Test Stand For Hydraulic Machinery Test Stand For Hydraulic Machinery Test Stand For Hydraulic Machinery


5

Whole analyzing Runner and Spiral case and Draft tube




6




7



0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5

Effic

ienc

y

Measurements Calculations

Q11/Q11 opt

2 %

Comparison of experiment results and calculation

Confidential

Confidential

CFD tools to predict performances, and comparison

with measurement results


8

Typical cavitation "bucket" curve

50

100

150

200

250

300

350

80 85 90 95 100 105 110 115 120

Q/Qd (%)

Req

uire

d su

bmer

genc

e N

PSH

/NPS

Hop

t (%

)

bucket curvesubmergence

a specific tool for entrance cavitation

analysis



Softwares for pressure fluctuations prediction


9

Pump-turbine integrity rigidity and strength calculation analysis

Simulation the true turbine’s 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.

Pump-Turbine Basic Research－ Rigidity & Strength Calculation AnalysisPump-Turbine Basic Research－ Rigidity & Strength Calculation Analysis


Intensity calculation of runner at any load conditionIntensity calculation of runner at any load condition

Load distribution Load distribution on obverse surface of bladeon obverse surface of blade

Load distribution Load distribution on back surface of bladeon back surface of blade

Load distribution On waterLoad distribution On waterway surface of crownway surface of crown

Load Load distribution distribution On On waterway waterway surface of surface of bandband

Load Load distribution On distribution On nonnon--waterway waterway surface of band surface of band and crowand crow


10


Combining calculation of Combining calculation of spiral case and stay vanespiral case and stay vane

Stress distribution of Stress distribution of head coverhead cover

Stress distribution of bottom ringStress distribution of bottom ring

Stress distribution of Stress distribution of wicket gatewicket gate

Design and calculation of main shaft seal Design and calculation of main shaft seal


Floating ring Springs

Cover

ORIFICE PLATE

Ressorts

Couvercle Anneau flottant

DIAPHRAGME

R5

R4

R3 R2

R1

Qtot

Qext Qint

p5

p3 p2 p1

Fig 1

Sealing water

Shaft

Bearing force Bearing force

ANSYS calculation of seal ring ANSYS calculation of seal ring

ANSYS calculation of seal ring distortion ANSYS calculation of seal ring distortion


11

Runner combination jointingRunner combination jointing

Pump-Turbine Structure Design and manufacturePump-Turbine Structure Design and manufacture

Turbine Cross Section—Pump-TurbineTypical Pump-Turbine StructureTypical Pump-Turbine Structure

17.750

SHAFT SEAL ? 1500

CIRCULAR RAILWAY 3.5t ? 5904环形吊车 3.5t

接力器中心线

水导轴承

主轴密封

导水机构中心线

转轮出口(水轮机模式)

转轮进口(水轮机模式)

水泵模式(顺时针)

水轮机模式(逆时针)

尾水管肘管进口内径

尾水管进

人廊

道

20个导叶

机坑进人

廊道

转轮叶片数 9

DISTRIBUTOR AXIS

SERVOMOTOR AXIS

TURBINE MODE COUNTERCLOCKWISE 300 rpm

PUMP MODE CLOCKWISE 300 rpm

8.500

15.000

17.800

18.300

9.500

? 2700 RUNNER OUTLET ( TURBINE MODE )

522

? 1500 h8 BEARING

20.500

? 5904 Z=20 GUIDE VANES

? 7880

? 5040 RUNNER INLET ( TURBINE MODE )

? 1095 h10

? 1480 9-M110x4 9-? 150

? 1480 18 M100x4

2500

TU

RB

INE

PIT

ACC

ES G

ALLE

RY

2000

? 6820 80 - M 105x4

RUNNER 9 BLADES

? 7130 40 - M 80x4拉紧螺杆

2000

DR

AFT

TUBE

CO

NE

AC

CES

GA

LLER

Y

DRAFT TUBE ELBOW ? 3596 INLET DIAMETER


12

Gate shaft cone sleeveGate shaft cone sleeve


Transferred wring moment by pin Transferred wring moment by pin sleeves and connected by bolts sleeves and connected by bolts between runner and main shaftbetween runner and main shaft

Gate frictionGate friction


Thin oil ,selfThin oil ,self--lubricating , segment and lubricating , segment and External oil circulationExternal oil circulation guide bearing guide bearing

Adopted to Adopted to HuiZhouHuiZhou ,,HeMiFengHeMiFeng ,HOHOT etc. ,HOHOT etc.

Pad瓦

Intermediate collar中间轴翎Turbine shaft水机轴


13

Spring, selfSpring, self--adjusting faceadjusting face--type main shaft sealtype main shaft sealseal rings in Carbon material or seal rings in Carbon material or CestidurCestidur


Adopted to Adopted to HuiZhouHuiZhou ,,HeMiFengHeMiFeng ,HOHOT ,,HOHOT ,BaoQuan,ThreeBaoQuan,Three Gorge,LongTan,XiaoWan,PuBuGouGorge,LongTan,XiaoWan,PuBuGou etc. etc.

Inflatablemaintenance seal

Adaptedaxial shaft seal

Spiral case and stay ring:Spiral case and stay ring:

1 Integer1 Integer

2 Segmented by transport limit2 Segmented by transport limit

3 Designing spiral case under 3 Designing spiral case under maximum water pressure maximum water pressure

4 Water pressure test of spiral 4 Water pressure test of spiral case at site.case at site.



14

Stay ring:Stay ring:

SegmentSegment

Combination at siteCombination at site


2,63°18°20°

475


Gate operation control mechanismGate operation control mechanism

single gate servomotorsingle gate servomotor

single gate servomotor single gate servomotor and control ringand control ring


15

DRAINAGE PIPES IN THE PITDRAINAGE PIPES IN THE PIT

15

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

Item.

Stay seal ring

Wearing ring and seal ring

Pit liner

Cone and elbow of draft tube

Servomotor cylinder and gate lever

Coupling bolt

Guide vanes

Main shaft seal

Guide bearing

Gate operating ring

Bottom ring and discharge ring

Head cover

Stay ring

Spiral case

Main shaft

Runner

Name of Part

ZCuAl10FeNi5

s135

Q235A

16Mn

ZG20SiMn

42CrMo

ZG06Cr13Ni4Mo

Q345C

Q235C

S355J0+N or Q345C

S355J0+N or Q345C

S355J0+N or Q345C

S500Q-Z25

B610CF、ADB610D or WDB620

DG20SiMn

ZG06Cr13Ni4Mo

Material

GB/T 5231-2001

GB13237-91

GB700

GB/T1591-1994

JB/ZQ4297

GB3077-88

GB6967

GB3274-88

GB700

GB3274-88

GB3274-88

GB3274-88

CF 62/WCF80

JB/T6396

GB6967

Standard and Grade (China)

ASTM C63200

ASTM A240-93b

ASTM A36

ASTM A516-90 Cr70

ASTM A216 WCC

ASTM A304

ASTM A743 CA-6NM

ASTM A633m

ASTM A36

EN10025-2

EN10025-2

EN10025-2

EN10025-6

G3128-87

ASTM A668 CI.D

ASTM A743 CA-6NM

Equality America Standard

Main Parts Material Table for Pump-TurbineMain Parts Material Table for Pump-Turbine


16

Pressure cycle

0%10%20%30%40%50%60%70%80%90%

100%110%

0 1 2 3 4 5 6 7 8 9 10time in hours

% o

f pre

ssur

e

Design pressure

if embedded with partial pressure

Pump-Turbine Field TestPump-Turbine Field Test

Water pressure test of Water pressure test of Spiral case at siteSpiral case at site

Pump-Turbine Condenser OperationPump-Turbine Condenser Operation


17

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

A) Dismantling PT A) Dismantling PT from middle from middle

1 step: dismantling middle shaft 1 step: dismantling middle shaft



2 step: dismantling main shaft 2 step: dismantling main shaft


18



3 step: dismantling head cover 3 step: dismantling head cover



4 step: dismantling runner 4 step: dismantling runner


19


dismantling head cover dismantling head cover

B) Dismantling PT from B) Dismantling PT from stator stator


C) Dismantling PT from C) Dismantling PT from movable cone of Draft tube movable cone of Draft tube


20

Inlet spherical valve made by DFEMInlet spherical valve made by DFEM

4479.92.3XianYou12

200923933181.5DILuo11

200834203211.6LIZhiPing10

200827756201.9RenZhongHai9

200827936201.9JinWo8

201029005852.0HOHOT7

good200925003352.9HeMiFeng6

good200835504551.3ShiZiPing5

good200824003012.5WaWuSan4

good200615003901.6XiaoTianDu3

good200423002301.75HuanGuangTan2

good199427254831.75ShiSan Ling1

Operating status

Operating year

UnitsRising head (m)

Head (max)Diameter (m)Power stationIte

m

Inlet spherical valve Design Inlet spherical valve Design

下游密封环行程 11

Inlet spherical Valve:Inlet spherical Valve:

1 Two surface seal1 Two surface seal

2 Two servomotor2 Two servomotor

3 Hydraulic operated seal ring 3 Hydraulic operated seal ring

4 Movable operating seal ring 4 Movable operating seal ring replaces byreplaces by--pass system pass system


21

DFEM IS YOUR BEST CHOICEDFEM IS YOUR BEST CHOICE

THANKS!THANKS!

HeMiFeng Power station

Type of turbine: HLP()-LJ-504Runner diameter: 5.04mRated speed: 300r/minTurbine condition:Maximum head: 335mRatedRated head: 295mMinimum head: 270m270mTurbine rated output: 306.0MWPump condition:Maximum pump head: 337.6mMinimum pump head: 275.0mMax. pump discharge : 106m3/sMax. pump input: 325MW


22

HuiZhou Power Station

Type of turbine: HLP()-LJ-382Runner diameter: 3.82mRated speed: 500r/minTurbine condition:Maximum head: 553.7mRatedRated head: 517mMinimum head: 509m509mTurbine rated output: 306.0MWPump condition:Maximum pump head: 565mMinimum pump head: 529mMax. pump discharge : 56.02m3/sMax. pump input: 330MW

dec pump-turbine introduction

Documents