大型水轮发电机损耗、发热与通风问题研究
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摘要
随着电机设计与制造技术的进步,大型水轮发电机的容量不断提高,功率体密度不断增加。但与此同时,其损耗、发热与通风的问题也变得越来越严重。为了保证大型水轮发电机的可靠运行和使用寿命,有必要对其降低损耗与发热、改善通风效果的方法进行系统而深入的研究。针对大型水轮发电机设计与制造中的这些关键技术问题,本文采用电路、风路、热路和电磁场、温度场的分析计算方法,对大型水轮发电机的定子线棒换位问题、空载电压波形问题、转子阻尼系统损耗和温升问题、混合通风问题和定子温升问题进行了研究,其主要工作与取得的成果如下。
首先,针对大型水轮发电机的结构特点,对其定子线棒的换位方法及其减损效果进行了研究,分析了360o全换位、360o空换位、不足360o换位、360o延长换位等4种不同方法的优缺点,推导并提出了完整的股线漏感电势简明计算公式,为股线环流及其附加损耗的分析计算奠定了理论基础。在Windows平台上研发了1套大型水轮发电机定子线棒换位优化设计软件,并结合4台不同机组,对上述4种不同换位方法的减损效果进行了对比研究。在此基础上,提出了混合换位的思想与“不足360o+延长”换位、“不足360o+空段”换位、“360o延长+空段”换位等3种新方法。结果表明,与传统的Roebel线棒360o全换位方法相比,各种改进换位方法的最佳可减损效果可达95%以上,其中360o延长换位方法的减损效果最好,3种新的混合换位方法为大型水轮发电机定子线棒优化设计提供了更为丰富、灵活的选择方案。
其次,分析并建立了“二维非线性稳态电磁场有限元结合解析公式计算损耗”、“二维非线性时变运动电磁场有限元及其损耗计算”、“二维非线性时变运动电磁场场路耦合有限元及其损耗计算”等3种不同的电磁场和转子损耗计算模型以及转子三维各向异性稳态温度场有限元计算模型,为大型水轮发电机的电磁场、温度场综合分析以及转子涡流、损耗、温升的计算奠定了理论基础。与试验数据的对比表明,“模型3”的计算精度更高。
第三,利用本文建立的二维非线性时变运动电磁场场路耦合有限元及其损耗计算模型,针对大型水轮发电机不对称磁极结构设计方案,首次对其改善空载电压波形的效果进行了研究。结果表明,采用极靴偏心和阻尼条偏心的结构设计方案,对削弱齿谐波、改善发电机空载电压波形、提高电能质量具有明显效果,可以替代定子铁心斜槽等传统设计方法,具有制造工艺简单等优点。
第四,利用本文建立的二维非线性时变运动电磁场有限元及其损耗计算模型、转子三维各向异性稳态温度场有限元计算模型,针对大型贯流式水轮发电机的不同运行工况、不同转子结构和不同材料,对电磁场和温度场进行了大量的计算与分析。结果表明,在额定运行工况和12%负序运行工况时,每根阻尼条的涡流和损耗不等,背风面阻尼条的损耗与温升明显大于迎风面阻尼条的损耗与温升,转子最高温度出现在阻尼绕组上。
最后,针对大型贯流式水轮发电机的结构特点,对其轴向与径向混合通风系统和二次冷却循环系统进行了研究,分别建立了混合通风系统的等效风路模型和定子等效热路模型,推导并提出了具有良好收敛性的复杂风网通用迭代算法,为大型水轮发电机的通风发热计算奠定了理论基础。在此基础上,在Windows平台上研发了1套大型水轮发电机通风发热计算软件,并针对新型的定子铁心叠片不等距分段结构设计,对发电机的混合通风系统与定子温升进行了分析与计算。结果表明,在以轴向通风为主的混合通风系统中,定子铁心叠片采用不等距分段结构设计方案,对改善各支路风量的分配、降低定子铁心和绕组的温升发热具有良好效果,发电机的温升较低,即使在超发10%工况下也可以长期安全运行。
With the technologic development of electric machine design and manufacture, the power and the power density of hydro-generators are becoming larger and larger. At the same time, the problems due to loss, temperature rise and ventilation become more and more serious. To ensure the steady operation and lifespan of large hydro-generators, it is necessary to study the ways of decreasing loss and heat and improving ventilation effect thoroughly. Focus on the key technologies of design and manufacture for large hydro-generators, the problems of stator bar transposition, no-load voltage waveform, loss and temperature rise of rotor damper system, mixed ventilation system, temperature rise of stator are researched by the methods of electric circuit, wind circuit, thermal path, electromagnetic field and temperature field in this thesis. The main studies and achievements are as follows.
Firstly, various transposition methods of stator bars and their effects on loss reduction are researched according to the structure feature of large hydro-generators. The advantages and disadvantages of 4 different transposition methods, including 360o full transposition, 360o void transposition, deficient 360o transposition and 360o extended transposition, are analyzed respectively. To calculate the strand circulating currents and their additional losses, the simplified formulae of leakage induction e.m.f. in the strands of 4 different transposition methods are derived and presented completely. And then, an optimal design software for stator bar transposition of large hydro-generators is developed on the platform of Microsoft WINDOWS. The effects on loss reduction of 4 different transposition methods are compared and discussed for 4 hydro-generators. Furthermore, a new idea of mixed transposition and 3 methods, including deficient 360o extended transposition, deficient 360o void transposition and 360o void extended transposition, are proposed respectively. The results show that all of the improved methods can reduce the additional losses by more than 95%, among them the 360o extended transposition method is the best, comparing with the traditional Roebel bar which uses 360o full transposition method. The 3 new mixed transposition methods provide more flexible options for the stator bar transposition optimization of large hydro-generators.
Secondly, 3 different models for the computation of electromagnetic field and rotor losses, including 2D nonlinear steady-state electromagnetic field finite element coupling with the analytic formulae of losses, 2D nonlinear time-varying moving electromagnetic field finite element and 2D nonlinear time-varying moving electromagnetic field finite element coupling with circuits, are established respectively. At the same time, a model of 3D anisotropic steady-state temperature field finite element for the computation of rotor temperature is built up. These models provide the foundations for the comprehensive analysis of electromagnetic fields and temperature field, and the calculation of rotor eddy current, losses and temperature rise. The results show that the model of 2D nonlinear time-varying moving electromagnetic field finite element coupling with circuits is more accurate by comparison with the test data.
Thirdly, by applying the model of 2D nonlinear time-varying moving electromagnetic field finite element coupling with circuits, the effects on improving no-load voltage waveform are researched for the first time according to the asymmetric magnetic pole structure design of large hydro-generators. The results show that eccentricities of pole shoe and damper bars have obvious effects on weakening tooth harmonic, improving generator no-load voltage waveform and power quality. The asymmetric magnetic pole structure design is a good alteration of traditional methods such as skew slots of stator core, and has advantages of the simpler structure and cheaper manufacture.
Fourthly, by combining the finite element models of 2D nonlinear time-varying moving electromagnetic field and 3D anisotropic steady-state temperature field, a series of computation and analysis are carried out for different operation conditions, different rotor structures and materials of large bulb hydro-generators. The results show that the eddy current and loss of each damp bar are different, the loss and temperature rise of the damp bar at the windward are larger than that at the lee side. The highest temperature of the rotor occurs on the damper winding at the conditions of rated operation and 12% negative sequence operation.
Finally, axis- and radial mixed ventilation system and the second recurrent cooling system are researched according to the structure feature of large bulb hydro-generators. The models of equivalent wind circuit and stator equivalent thermal path are established respectively, and a general iterative algorithm with good convergence is deduced and proposed for the calculation of complex wind network. Furthermore, a software for ventilation and heat calculation of large hydro-generators is developed on the platform of Microsoft WINDOWS. The mixed ventilation system and the stator temperature rise are analyzed and calculated based on the new structure design of the uneven section of the generator stator core lamination. The results show that the uneven section structure design of stator core lamination has obvious effects on improving the distribution of branch wind quantity, decreasing the temperature rise and heat of stator core and winding. The temperature rise of the generator is quite low and the generator can operate continually and safely even though overloaded 10%.
首先,针对大型水轮发电机的结构特点,对其定子线棒的换位方法及其减损效果进行了研究,分析了360o全换位、360o空换位、不足360o换位、360o延长换位等4种不同方法的优缺点,推导并提出了完整的股线漏感电势简明计算公式,为股线环流及其附加损耗的分析计算奠定了理论基础。在Windows平台上研发了1套大型水轮发电机定子线棒换位优化设计软件,并结合4台不同机组,对上述4种不同换位方法的减损效果进行了对比研究。在此基础上,提出了混合换位的思想与“不足360o+延长”换位、“不足360o+空段”换位、“360o延长+空段”换位等3种新方法。结果表明,与传统的Roebel线棒360o全换位方法相比,各种改进换位方法的最佳可减损效果可达95%以上,其中360o延长换位方法的减损效果最好,3种新的混合换位方法为大型水轮发电机定子线棒优化设计提供了更为丰富、灵活的选择方案。
其次,分析并建立了“二维非线性稳态电磁场有限元结合解析公式计算损耗”、“二维非线性时变运动电磁场有限元及其损耗计算”、“二维非线性时变运动电磁场场路耦合有限元及其损耗计算”等3种不同的电磁场和转子损耗计算模型以及转子三维各向异性稳态温度场有限元计算模型,为大型水轮发电机的电磁场、温度场综合分析以及转子涡流、损耗、温升的计算奠定了理论基础。与试验数据的对比表明,“模型3”的计算精度更高。
第三,利用本文建立的二维非线性时变运动电磁场场路耦合有限元及其损耗计算模型,针对大型水轮发电机不对称磁极结构设计方案,首次对其改善空载电压波形的效果进行了研究。结果表明,采用极靴偏心和阻尼条偏心的结构设计方案,对削弱齿谐波、改善发电机空载电压波形、提高电能质量具有明显效果,可以替代定子铁心斜槽等传统设计方法,具有制造工艺简单等优点。
第四,利用本文建立的二维非线性时变运动电磁场有限元及其损耗计算模型、转子三维各向异性稳态温度场有限元计算模型,针对大型贯流式水轮发电机的不同运行工况、不同转子结构和不同材料,对电磁场和温度场进行了大量的计算与分析。结果表明,在额定运行工况和12%负序运行工况时,每根阻尼条的涡流和损耗不等,背风面阻尼条的损耗与温升明显大于迎风面阻尼条的损耗与温升,转子最高温度出现在阻尼绕组上。
最后,针对大型贯流式水轮发电机的结构特点,对其轴向与径向混合通风系统和二次冷却循环系统进行了研究,分别建立了混合通风系统的等效风路模型和定子等效热路模型,推导并提出了具有良好收敛性的复杂风网通用迭代算法,为大型水轮发电机的通风发热计算奠定了理论基础。在此基础上,在Windows平台上研发了1套大型水轮发电机通风发热计算软件,并针对新型的定子铁心叠片不等距分段结构设计,对发电机的混合通风系统与定子温升进行了分析与计算。结果表明,在以轴向通风为主的混合通风系统中,定子铁心叠片采用不等距分段结构设计方案,对改善各支路风量的分配、降低定子铁心和绕组的温升发热具有良好效果,发电机的温升较低,即使在超发10%工况下也可以长期安全运行。
With the technologic development of electric machine design and manufacture, the power and the power density of hydro-generators are becoming larger and larger. At the same time, the problems due to loss, temperature rise and ventilation become more and more serious. To ensure the steady operation and lifespan of large hydro-generators, it is necessary to study the ways of decreasing loss and heat and improving ventilation effect thoroughly. Focus on the key technologies of design and manufacture for large hydro-generators, the problems of stator bar transposition, no-load voltage waveform, loss and temperature rise of rotor damper system, mixed ventilation system, temperature rise of stator are researched by the methods of electric circuit, wind circuit, thermal path, electromagnetic field and temperature field in this thesis. The main studies and achievements are as follows.
Firstly, various transposition methods of stator bars and their effects on loss reduction are researched according to the structure feature of large hydro-generators. The advantages and disadvantages of 4 different transposition methods, including 360o full transposition, 360o void transposition, deficient 360o transposition and 360o extended transposition, are analyzed respectively. To calculate the strand circulating currents and their additional losses, the simplified formulae of leakage induction e.m.f. in the strands of 4 different transposition methods are derived and presented completely. And then, an optimal design software for stator bar transposition of large hydro-generators is developed on the platform of Microsoft WINDOWS. The effects on loss reduction of 4 different transposition methods are compared and discussed for 4 hydro-generators. Furthermore, a new idea of mixed transposition and 3 methods, including deficient 360o extended transposition, deficient 360o void transposition and 360o void extended transposition, are proposed respectively. The results show that all of the improved methods can reduce the additional losses by more than 95%, among them the 360o extended transposition method is the best, comparing with the traditional Roebel bar which uses 360o full transposition method. The 3 new mixed transposition methods provide more flexible options for the stator bar transposition optimization of large hydro-generators.
Secondly, 3 different models for the computation of electromagnetic field and rotor losses, including 2D nonlinear steady-state electromagnetic field finite element coupling with the analytic formulae of losses, 2D nonlinear time-varying moving electromagnetic field finite element and 2D nonlinear time-varying moving electromagnetic field finite element coupling with circuits, are established respectively. At the same time, a model of 3D anisotropic steady-state temperature field finite element for the computation of rotor temperature is built up. These models provide the foundations for the comprehensive analysis of electromagnetic fields and temperature field, and the calculation of rotor eddy current, losses and temperature rise. The results show that the model of 2D nonlinear time-varying moving electromagnetic field finite element coupling with circuits is more accurate by comparison with the test data.
Thirdly, by applying the model of 2D nonlinear time-varying moving electromagnetic field finite element coupling with circuits, the effects on improving no-load voltage waveform are researched for the first time according to the asymmetric magnetic pole structure design of large hydro-generators. The results show that eccentricities of pole shoe and damper bars have obvious effects on weakening tooth harmonic, improving generator no-load voltage waveform and power quality. The asymmetric magnetic pole structure design is a good alteration of traditional methods such as skew slots of stator core, and has advantages of the simpler structure and cheaper manufacture.
Fourthly, by combining the finite element models of 2D nonlinear time-varying moving electromagnetic field and 3D anisotropic steady-state temperature field, a series of computation and analysis are carried out for different operation conditions, different rotor structures and materials of large bulb hydro-generators. The results show that the eddy current and loss of each damp bar are different, the loss and temperature rise of the damp bar at the windward are larger than that at the lee side. The highest temperature of the rotor occurs on the damper winding at the conditions of rated operation and 12% negative sequence operation.
Finally, axis- and radial mixed ventilation system and the second recurrent cooling system are researched according to the structure feature of large bulb hydro-generators. The models of equivalent wind circuit and stator equivalent thermal path are established respectively, and a general iterative algorithm with good convergence is deduced and proposed for the calculation of complex wind network. Furthermore, a software for ventilation and heat calculation of large hydro-generators is developed on the platform of Microsoft WINDOWS. The mixed ventilation system and the stator temperature rise are analyzed and calculated based on the new structure design of the uneven section of the generator stator core lamination. The results show that the uneven section structure design of stator core lamination has obvious effects on improving the distribution of branch wind quantity, decreasing the temperature rise and heat of stator core and winding. The temperature rise of the generator is quite low and the generator can operate continually and safely even though overloaded 10%.
引文
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