Motor - Generators

Motor-Generators
Table of Contents
General
Cooling
Bearing
Rotor dynamic
Shaft current
Reference list

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Motor-Generators
General
Two operating modes: Generator mode / Motor (pump) mode
Various starting methods:
Back to back
Starting by pony motor
Starting by turbine
Starting by frequency converter

High number of starts and stops:

Higher material stress
Smaller utilization factor: e.g. rotor rim 50%
Lifespan calculation
Robust design

FE-calculation of rotor
3

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Motor-Generators
Cooling
If two directions of rotation => different types of possible cooling methods:
Radial fans with straight blades mounted directly on the rotor
More losses than conventional radial fans

Rim duct cooling

No fans necessary (except possible small auxiliary fans)
Uniform temperature distribution on pole winding and stator
More losses than conventional fans

Motor driven fans

Possibiliy of speed controlled fans
Higher partial load efficiency
Constant temperature condition during operation

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Motor-Generators
Bearing
Criteria for thrust bearing segments in case of two directions of rotation:
Higher stressed appropriate dimensioned
Oil feed in edge on both sides required
Pivoted on center

Thrust bearings program (Genmat):

Temperature/pressure distribution on a thrust pad

Thrust bearing

L
W

high-pressure oil
supply
white metal
3 mm thick
steel body

pad arc-length
to radial width
ratio: 0,7 max. 1
oil feed in edge on both sides

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Motor-Generators
Rotor Dynamic
High speed units
Typical speed range: 250 to 1000 rpm (28 to 6 poles)

The required safety margin between runaway and 1st critical bending speed is
determined by the client
Hence the stiffness of the shaft and the total bearing support structure has to
be appropriate higher

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Motor-Generators
Rotor Dynamic
The critical speed depends on:
Mass distribution along the axis of the rotation parts
Bending stiffness of the shaft
Distance between guide bearings below and upper the rotor
Rotor design
Dimension of shaft

Total bearing support structure stiffness

Dynamic foundation stiffness
Wehr rotor

Bracket and stator housing stiffness

Bearing component stiffness
Bearing collar stiffness of the shaft
Oil film stiffness

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Motor-Generators
Rotor Dynamic

Radial stiffness calculation

of lower bracket

Radial stiffness calculation of

bearing collar
Radial stiffness calculation of upper
bracket and stator housing

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Motor-Generators
Rotor Dynamic

FE calculation of the rotor

design

Radial stiffness calculation

of bearing component

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Motor-Generators
Shaft Current
If pump-turbine below the generator (conventional):
To prevent shaft current the bearings above the generator have to
be insulated

If pump below and turbine above the generator:

To prevent shaft current special insulation methods have to be
applied, e.g. insulated couplings
Like Kopswerk II

In addition, sandwich insulation can be supplied if

required

Kopswerk II

10

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Motor-Generators
Selected References
Project

Country

Vianden II
Luxembourg
Baixo S.-E. de Jusante Portugal
Baixo S.-E. de Montante Portugal
Limberg II
Austria
Hintermuhr
Austria
Nestil
Switzerland
Kopswerk II
Austria
Lower Olt
Rumania
Lang Ya Shan
China
Cruachan
U.K.
Tong Bai
China

Year

MVA

rpm

2010
2009
2009
2006
2005
2005
2004
2004
2002
2001
2001

1
2
2
2
1
1
3
20
4
2
4

230.0
20.0
85.0
270.0
78.0
175.0
180.0
14.5
180.0
144.4
377.0

333.3
150.0
214.3
428.6
1000.0
600.0
500.0
130.4
230.8
500.0
300.0
Limberg II

11

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Motor-Generators
References 1970 1999

12

Project

Country

Year

MVA

rpm

Goldisthal (synchron)
Goldisthal (asynchron)
Tian Tang
Tian Huang Pin
Shi san Ling
Yang Zhou Yong
Husling
Nassfeld
Oschenik 3
Khtai
Malta HS 2/4
Rodund II

Germany
Germany
China
China
China
China
Austria
Austria
Austria
Austria
Austria
Austria

1998
1998
1998
1994
1992
1992
1981
1980
1979
1977
1973
1973

2
2
2
6
4
4
2
1
1
2
2
1

331.0
340.5
40.0
333.3
222.0
25.0
200.0
36.0
42.0
160.0
220.0
310.0

333.3

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300-346.6

157.9
500.0
500.0
750.0
600.0
1000.0
750.0
600.0
500.0
375.0

Limberg II

Motor-Generators
References Kopswerk II/Austria
Motor-Generator main data:
Year of contract

2004

Number of units

Rated output generator

200 MVA

Rated output motor

180 MW

Max. output

210 MVA

Number of poles

12

Rated power factor generator

0.8

Rated voltage

13 kV +13/-10 %

Rated speed

500 rpm

Runaway speed

925 rpm

First critical speed

1156 rpm (25%)

Rated efficiency generator 98.87 %

13

Type of construction

IM8427

Directions of rotation

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Motor-Generators
References Kopswerk II/Austria
Stator
Frame diameter

6.200 mm

Stator bore

3.930 mm

Core length

2.900 mm

Stator weight

204 t

Rotor
Pole design

Double dovetails

Rotor design

Rotor body

Rotor weight

270 t

Moment of inertia

480 tm

Special
Ternary unit configuration
Joint venture with ALSTOM
14

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Motor-Generators
References Kopswerk II/Austria

15

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