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A1-105

CIGRE 2008

POSSIBILITIES TO INCREASE POWER AND EFFICIENCY OF HYDRO GENERATING UNIT D.PETROVI*, S.STOJKOVI University of Belgrade, Faculty of electrical engineering V.VIDAKOVI HPP erdap, Kladovo D.ARNAUTOVI, S.BOGDANOVI, Z.IRI Electrical engineering institute Nikola Tesla, Belgrade M.BENIEK, I.BOI University of Belgrade, Faculty of mechanical engineering SERBIA

SUMMARY Within the scope of preparation and planning the revitalization, efforts are made in order to increase the output power and efficiency of generator and turbine. Thereby, it is necessary to carry on analysis of possible power increase of the whole unit without changing its physical dimensions. Possibilities to increase power one may find at the fact those previous series of generators were designed and built from materials, comparing to nowadays materials, with modest dialectical, magnetic and thermal characteristics. By using modern materials to replace active generators parts, a revitalized generator becomes oversized for former power rating. On a turbines, as well, during the replacement of worn-off active mechanism and parts (of counter flow assembly), a possibility usually arise to, with minor applicable changes, increase flow and/or efficiency without changing physical dimensions. Alongside of efforts to rebuild unit with increased power, a trial to run the old unit on a higher power ratio even before revitalization has been made. Within analysis of possibilities to increase output power, no matter if power increase is before or after revitalization, it is necessary to: - recalculate electromagnetic values and parameters of the generator, its thermal conditions for its designed rated mode and also for 5% to 20% overload; - verify the calculated data experimentally, considering the temperature rises and the vibration conditions of unit during tests for most important data; - confirm the possibility of the turbine to deliver adequate power to the generator. In this paper the methodology of analyzing the power increase possibilities, as some of the results that were achieved over the last few years, has been presented. KEYWORDS Revitalization Electromagnetic calculations Additional losses Overload Calorimetric tests 1. Introduction Most of hydro-units within the Electric power industry of Serbia are operating on the edge or beyond their projected lifetimes. That was the reason to start with preparations for revitalization of old hydrounits, in order to renew resources and extend their operational ability for next 30 years at least.
* epetrovd@etf.bg.ac.yu

During the preparations to revitalize a unit, it is necessary to give an answer on significant number of questions related to its condition, the scope of works and the optimal timing for the revitalization beginning, but the question about possibility to increase installed units power without changing its overall dimensions and construction also arises. For hydro-units that were designed and manufactured a few decades ago that kind of possibility exists in most cases. It is based on the fact that during the revitalization, modern materials will be used that can bear higher mechanic, dielectric, magnetic and thermal tensions compared to originally used materials. Besides that, the results of measuring and monitoring during the exploitation shows that many old units were over-dimensioned due to safety issues and due to calculation methods that were not precise enough. Analysis of power increase possibilities and adequate monitoring were conducted on units in several hydro power plants, most important among others are: HPP erdap I (6x190 MVA), being under initial phase of reconstruction, with a goal to accomplish power increase from 178 to 194 MW for the turbine and 190 to 211 MVA for the generator; HPP Bistrica (2x54 MVA) for suggested power increase up to 10% HPP Zvornik (4x30 MVA) for up to 10% determined power reserve compared to rated power.

In order to analyze the capacity of possible power increase of a unit and start a project of revitalization on time, certain calculations and tests have been conducted, that are required for revitalization. In order to determine degree of continuous overload possibilities of a hydro-unit, an electromagnetic and thermal calculation has been made for several preferable modes of overload. All electrical and magnetic values were calculated, power losses and temperature rise of all active parts of the generator during the operation of unit under increased power mode. Calculation iterated for normal mode as well, to validate input data that were used during the calculation and calculation method itself, and also in order to compare results with data gathered during exploitation, measured at the same or similar generators operating modes. Results obtained from electromagnetic and thermal calculations of generator during overload run, were verified by generator tests [1]. The generators were overloaded in accordance with turbines maximum and after establishing stationary temperature state, the temperatures of generators active parts and cooling liquids were measured. Although direct comparison of temperature rise within generators gathered by calculations and measurements was not possible due to differences of both modes, results from measurements confirmed the conclusion that generators, even before revitalization, do have certain power reserve that could be exploited. Even when the temperature of certain generator parts rose, it did not surpassed limits for applied insulation class. It is a useful idea to exploit old units under increased power even before revitalization in cases when: units are facing revitalization in a short time. For that kind of units, it is necessary to determine maximum power for safe operation, regardless on consequences in accelerated aging and degradation of active parts. This is important especially in a flux power plants with multi-units installed, in which during the revitalization the lack of production capacities is present. units have already experienced replacement of certain equipment during the many years of exploitation. On some units, partial improvements were carried out in order to allow operation under overload (for example, replacement of generators windings with insulation class F instead of B). units are assumed to be over-dimensioned, based on collected data during exploitation.

A problem of eventual data lack or source reliability of certain generators parameters, which were used as input data for power losses calculation, was solved by measurements taken at place, in order to obtain correct values necessary for calculations. Beside obtaining the correct parameter values, the goal of examination was also measuring the particular power losses in generator, as it was to determine its temperature condition.

2. Actions taken to achieve generators power increase 2.1 Recent condition of hydro-generators All generators described in this paper belong to the power plants that are in exploitation for over 30 years. In Table II their rated values were noted. During the years in exploitation, with adequate maintenance, stator windings on some of them were replaced with insulation of higher temperature class (F instead of B), and electromechanical exciting systems were replaced with static ones. Based on exploitation data regarding windings temperature condition, magnetic core, cooling system and bearings, it can be estimated if the reserve exists for load over rated. At the most generators that reserve is significant (approx. 20 K), which is confirmed in every particular case by special measurements at rated load. The results of temperatures measured at rated load are given in Table II. Thereby, all other characteristic values for rated operational load are measured (stator and rotor currents, power factor, flow, air temperature and coolant temperature). For the analysis of generators ability to operate at power over rated value, it is necessary to gather usually unavailable data. Mostly, those are particular losses as well as reliable parameters and characteristics that need to be calculated and measured. Construction data and design values are either incomplete or not confirmed through the experiment on installed machine. Condition and capacity of the turbine should also be examined. The turbine is, in some cases, limiting factor and can be an object of detailed analysis in order to verify existing power reserve [2]. 2.2 Methodologies of possibility of generators power increase calculation Within the scope of examining generators power increase possibilities, overload with 5%, 10%, 15% and 20% applied power above the rated was analyzed. For each mode stator and rotor currents, power loss, efficiency, temperature rise of generators active parts, cooling air and electromagnetic moment are calculated [3]. Based on obtained results conclusions are made about power increase possibility and eventual limitations that should be taken into considerations during the generators revitalization. 2.2.1 Calculation of exciting current Calculation of exciting current can be done by using any of graph-analytical methods, and as most suitable in this case Pothiers method was chosen. Input data for this calculation were characteristics (curve/graph) of idle run, short circuit and reactive load. Due to lack of reactive load characteristic Mordhy`s curve for idle mode was used. By using method of two corresponding components of magneto-exciting forces, one compensating longitudinal reaction of induct and second one, inducting mutual electromotive force, the total magneto-exciting force of rotor is calculated, which corresponds to excitation current. Same algorithm was applied to each of aforementioned overload modes. This method is accurate for as long as three fore mentioned characteristics are correctly measured and precisely created. Considering the complexity of measuring a reactive load characteristic, the Mordhy`s curve was mostly used. Difficulties during the creating of Mordhy`s curves are experienced due to variations of stator voltage from its rated value, so in some cases recalculation of measured values was performed. Besides that, in order to get excitation current value from Mordhy`s curves at overload run, extrapolation was made, considering that it is almost linear in this fragment. Obtained values of exciting current at overload modes are input data for power losses and thermal calculation, as well as to estimate exciting system possibility to provide adequate exciting current at overload modes. 2.2.2 Calculation of power losses The thermal calculation of the generator (for both rated and overload mode) requires, beside the total power losses, the exact values of particular losses in all active generator parts. Input data for the calculation are running mode parameters (voltage, apparent power, power factor and rotor current), generator parameters (active resistance and reactance), construction and dimension data

of all parts and generator details, values of particular magnetic losses at core plates, characteristics of cooling system etc.. The structure of characteristic group of losses affecting the temperature rise at stator and rotor consist from: - constant losses: ventilation losses, bearing losses, magnetic losses at stator core yoke, magnetic losses in core teeth, losses at core and plates due to dissipated flux in axial direction and losses at pole sleeves due to ragged stator. - losses depending on stator current: Joules losses at stator winding, additional losses at stator winding due to skin effect, losses at stator core teeth due to 3rd harmonic of magneto-exciting stator force, losses at pole surface due to higher harmonics of magneto-exciting stator force, losses at pole surface due to stator field tooth frequency and losses at end plates due to dissipated flux in end winding. - losses depending of rotor current are Joules losses at rotor winding. All these losses calculated for rated mode, were recalculated for overload mode by multiplying square value of relative stator current, assuming the voltage and rotation speed constant and equal to their rated values. Beside fore mentioned losses, the calculation of bearing losses and losses in exciting system was performed, in order to determine generator efficiency. In Table I calculated power losses and efficiency of 54 MVA generator at HPP Bistrica is presented. Table I - Power losses and efficiency of 54 MVA generator Power N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Description Stator yoke losses Pa (KW) Stator teeth losses Pz (kW) Additional core losses Ppo (kW) Losses at stators core end teeth Pzkr (kW) Ventilation losses at rotors zone Pvr (kW) Ventilation losses at stators zone Pvs (kW) Bearings losses Stator current I (A) Stator winding losses PCu (kW) Additional stator winding losses PF (kW) Third harmonic magneto exciting force losses P3h (kW) High harmonics magneto exciting force losses Pph (kW) Saw-tooth shape of the filed losses Ppz (kW) Losses at end plates Ped (kW) Rotor current If (A) Rotor winding losses Pf (kW) Thyristor losses Ptir (kW) Brushes losses P (kW) Exciting transformer losses Ptr (kW) Total losses P (kW) Generators active power P (kW) Efficiency = P / (P + P)100 (%) Pn cos=0,95 89,1 51,9 21,4 15,8 72,2 360,7 48,5 2970 140,2 29,4 33,2 1,7 4,1 18,7 850,5 125,1 2,0 1,7 6,5 1022,2 51300 98,05 1,05 Pn cos=0,95 89,1 51,9 21,4 15,8 72,2 360,7 48,5 3118,5 154,6 32,4 36,6 1,9 4,5 19,9 868,3 130.4 2,1 1,74 6,6 1050,3 53865 98,08 1,1 Pn cos=0,95 89,1 51,9 21,4 15,8 72,2 360,7 48,5 3267 169,6 35,6 40,2 2,1 5,0 20,9 884,7 135,4 2,2 1,77 6,7 1079,1 56430 98,12

2.2.3 Thermal calculation The temperature rise calculation of some active components of the generator is a key part of the analysis of the power increase ability. Calculation method is based on concentration of fore mentioned losses by the origin, i.e. at stators core yoke, at stators core teeth, stator windings, rotor windings and pole sleeves and calculations of their flow from the place of origin to machine periphery. Calculations were carried out separately for stator and for rotor and the only mutual value in both calculations was temperature rise of cooling air. Power flows P and temperature rise values in specific parts of stator were determined based on diagram shown on Picture I.

Picture I - Thermal scheme of stator Certain thermal resistances R were determined based on trip distance and surface throughout the heat flows through material, on emitting surface as well as on the heat conduction and/or heat delivery coefficient. Those are: Raa resistance to heat flow through core packages in axial direction and its emitting to cooling channels Rar resistance to delivery of heat from the outer core surface into cooler entry Rzra resistance to heat exchange from core teeth into yoke in radial direction Rza resistance to heat flow through core teeth in axial direction and its delivery into channels Rr resistance to heat delivery from the inner surface of the core into gap Riz resistance to heat flow through the insulation of bars along core Rib resistance to heat flow through bar insulation in sidewise connection area Rab resistance to heat delivery from bares in sidewise connection area Power PI, PII and PIII are losses at yoke, teeth and stator winding. Values of temperature rise of cooling air throughout the cooling system are: 0 gap 1 from gap to entrance to the cooler 2 from gap to the middle of teeth 3 from gap to the middle of yoke The air temperature rise at gap depending of the temperature of entering air 0 is directly proportional to the sum of losses in the rotor zone and specific losses in the stator lost in the gap, and in inverse ratio to air flow. The total air temperature rise in generator is proportional to total losses which heat up air. Assuming that temperature rise throughout ventilation canal is linear leads to air temperatures rises 2 and 3.

Powers at particular branches of thermal scheme (P1 to P7) were determined in a same way as currents at branched electrical circuit. Determination was made by using separate calculations for power losses PI, PII and PIII and by super-positioning obtained results. Temperature rise of some active parts of the generator were calculated by adding the temperature drops on thermal resistances to the temperature rise of air at certain point of cooling system, until observing point is reached. For instance, temperature rise of yoke will be a = 0+3+RaaP1. Rotor temperature rises are calculated in a similar way. 3. Measurement of particular losses During the calculations of particular generator losses, reliable data cannot always we obtained (single losses of stator core plates, airflow and ventilation losses). In order to validate data required to carry out a calculation it is necessary to measure particular losses of generator separately. Particular losses in the generator are measured by using calorimetric method. When using calorimetric tests one has to determine the total losses in generator at specific running states by measuring flow rate of cooling fluid and temperature rise in cooling fluid after thermal stationary state is reached [4]. Generator losses are calculated by multiplying flow rate of cooling fluid, its density, specific heat capacity and temperature rise, taking into account heat rate exchanged with surrounding area, also. Procedures for measurements of generator losses, conditions to be fulfilled for realization of measurements and also conditions concerning measuring equipment are quoted in international technical standards [5]. Generator losses to be measured, operating states at which tests are performed, procedures for calculations and recalculations of losses, operating conditions, reference parameters for recalculation of measured losses are also analysed in same technical standards. Total losses in the generator at specific operating state, quit generally, consist from losses Pi generated inside of reference surface separating generator from surrounding space and from losses Pe generated outside of reference surface. For the goals of our tests it is quite justified to neglect the losses Pe. The losses Pi generated inside of reference surface are determined by measuring losses P1 taken by the cooling fluid and losses P2 exchanged with surrounding area. P i = P1 P 2 (1) Generator losses are measured after thermal stationary state of the generator is reached, at following operating states: - idle running of unexcited generator at rated speed, - idle running of generator at rated speed and rated voltage and - short circuit of the generator at rated speed and rated current. Besides that, losses in the excitation system and also bearings losses have to be measured. Friction and windage losses Pwind are determined from measurements of total losses Pid in the generator operating at idle running with unexcited generator Pwind = Pid = P1,id P2,id (2) Measurements are performed with characteristics of cooling fluid determined after thermal stationary conditions are reached. Core losses PFe are determined having measured losses Pex in the generator operating at idle running at rated voltage Pex = P1,ex P2,ex (3) and taking account of friction and windage losses Pwind,ex at that operating state, then also of rotor losses Pf,ex at that operating state PFe = Pex Pwind,ex Pf,ex. (4)

Short circuit losses in the generator consisting of armature cooper losses Pcu and stray losses Pstray are determined by measuring total losses Psc in the generator operating at short circuit with rated current Psc = P1,sc P2,sc and knowing friction and windage losses Pwind,sc and also rotor losses Pf,sc at that operating state. Pcu + Pstray = Psc Pwind,sc Pf,sc. (6) Separate losses Pwind, PFe, Pcu + Pstray are then recalculated to the conditions at rated speed, rated voltage and rated current of the generator and with reference parameters of the generator and its cooling fluid. For generator efficiency determination it is necessary to know the value of bearings losses. Losses in radial bearing Prb and in thrust bearing Ptb are determined by measuring heat rates taken by cooling fluid of bearings in thermal stationary conditions at rated power of generator. Part of losses in thrust bearing Ptb,gen is taken for calculation of generator efficiency. Scale factor is equal to the ratio of weights of rotating parts of generator and weights of rotating parts of generator and turbine augmented for the force corresponding to axial pressure of water. Total bearing losses Pb,gen taken for calculation of generator efficiency are Pb,gen = Prb + Ptb,gen. (7) Measurements of total losses of the generator at specific operating state Pid, Pex, Psc and of losses in bearings are performed by using calorimetric method. Calorimetric method is applied for measurements of heat rate taken by the secondary cooling fluid, cooling water. 4. Calculation and testing results The results of calculations for possible power increase of generator and temperature rise of some generator parts during continuous operation at overload were evaluated by comparing calculation results and adequate measured values during generators overload up to establishing a stationary thermal state, assuming that the turbine limits are not exceeded. During the testing at the power plant, special attention has to be paid to determine temperature rise of stator windings, rotor windings, magnetic circuit and transformer windings for supplying generators exciting system. Temperature rise should be measured in generators primary and secondary cooling fluid, in generators bearings and also transformer oil temperature rise that links generator into electroenergetic system. Based on experimental results, during the generator operation at overload, practically the value of possible generator power increase is estimated, before the beginning of revitalization. The eventual differences between measured data and calculated values indicate what additional corrections have to be introduced into calculation. Calculation results and data received during the generator testing at all three fore mentioned hydro power plants mostly are presented in Table II. By analyzing data from this table, it can be concluded that generators at these power plants can operate at overload of 10% without making any changes and interventions on generators. During the operation at overload, temperature rise of generators parts stays within the allowed limits and adequate reserve. For the validation of data from Table II on temperature rise, one should acknowledge that insulation of stator windings and rotor windings was of class F. Thus, under advantageous hydrological conditions, these units can operate with increased power for as long as turbine, supplying of exciting system and transformator module hold out. This ability should be especially taken into account during the revitalization, when units that are in operation can significantly compensate loss of energy due to unavailable unit under revitalization. Within the scope of actual activities on revitalization preparations and analysis of possibilities of unit power increase at fore mentioned power plants, following results were obtained: - the completed revitalization of one generator at HPP Bistrica, where power increased from 54 MVA to 58.3 MVA without changing a power factor and without changing generators physical dimensions [6], (5)

under suitable hydrological conditions and with optimal bond unit at HPP Zvornik operates at 10% overload. This type of operation has generated excess of power around 11 GWh in only 18 months [2], old units at HPP erdap I can operate delivering a power projected for revitalized units, even before revitalization. This allows eliminating the losses due to unavailability one of each units, over the next 6 years of revitalization of all units at power plant.
Total losses (kW) Temperature rise (oC) stator rotor air

Table II - Results of calculation and testing

Power plant Operation regime data

S/Sn cos U(kV) I (A) If (A) HEDjerdap I Calculated Sn = 190 MVA U = 15,75 kV Measured 1,0 1,1 1,0 n 1,08 HE Bistrica Calculated 1 1,1 Sn = 54 MVA 0,92 Un = 10,5 kV Measured 1,023 HE Zvornik Calculated 1,0 1,1 Sn = 30 MVA 1,0 Measured Un = 11 kV 1,053 5. Conclusion 0,9 0,9 0,9 0,93 0,95 0,95 0,98 0,93 0,8 0.8 0,8 0,825 15,75 15,75 15,95 15,80 10,5 10,5 9,23 9,76 11,0 11,0 11,0 10,99 6960 7656 6877 7498 2970 3266 2980 3240 1575 1732 1575 1663 1880 1989 1860 1936 850 885 725 875 625 664,8 633 622

qCu qFe 55,4 69,6 53,4 66,1 57,2 67,3 49,0 56,5 49,6 59,6 50,6 52,5 40,1 48,3 41,0 45,2 34,1 35,9 32,0 38,5 45,5 52,0 36,0 41,8

qCu 61,8 68,8 58,6 60,9 62,3 67,8 42,4 59,6 58,3 64,8 55,0 69,3

qv 18,7 20,4 17 19,5 10,6 11,5 7,0 8,5 18,3 21,0 16,9

3216,8 3499,6 3325,7 1022,2 1079,1 733,3 801,1 716,5 -

In this paper, some of the results on analysis of possibilities of power increase are presented, for generators planned for revitalization. On the beginning, calculation of electromagnetic quantities, generator parameters and its thermal condition at overload operation was carried out. Generator tests at power plant provided data necessary to complete calculation, verify model and calculation results. Achieved results consisting in excess of produced energy when unit operated with increased power before the start of revitalization as well as in realization of generator revitalization with increased power are also pointed out. Power increase lied within calculated boundaries and is verified with tests performed before the start and at the end of revitalization. BIBLIOGRAPHY [1] [2] [3] [4] G.B. Pinsky, V.V. Dombrovsky: Hydro-generator calculation, Energoatomizdat, Leningrad, 1984. D.Petrovic and others: An increase of hydro-agregates installed power and efficiency factor before the revitalization phase, Thermal Science, Vol.10 (2006), no.4, pp.17-32. D.Petrovic and others: The possibility of generator's power increase in the process of revitalization, R11-07, JUKOCIGRE, May 2003. S. Bogdanovi, D.Novac, I. Bleier, V. Milosavljevi, V. Vidakovi: Comparision of generator efficiency by measuring losses in cooling air and in cooling water, Rewiew ICEMENRG, Nr.7. pp.11-21, Jyly 2005. IEC 34-2A : Measuring the losses using the calorimetric method, 1974. S.Bogdanovi, D. Depeski, P. Mlaenovi, N. Selakovi: Tests of the generator in hydropowerplant after modernization of the generator, Power Systems Conference 2007, Timisoara, Romania, November 21-23, 2007, pp.

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