wwwwwwwwwwwwwwwwwwwwwwwwwrPRESENTATION FOR PUMP-TURBINE 东方电机有限公司 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 1 wwwwwwwwwwwwwwwwwwwwwwwwwr 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 4×300 306 553.7 517 509 4×300 306 335 295 270 4×300 306 580 521 490 4×300 306 475 430 421 HeMiFeng HOHOT XianYou Typical Pump-Turbine Typical Pump-Turbine DFEM Typical Products XianHongDian 2X40MW HuiZhou 4X300MW HeMiFeng 4X300MW HOHOT 4X300MW XianYou 4X300MW 2 Among which. Cooperation with overseas company Cooperation with overseas company Our company has been cooperating with many famous overseas companies. ANDRITZ. GE. such as ViothSiemens. Reliable、advanced、durable、easy-operation、nice-looking. maintenance. manufacturing and transportation into full consideration . Alstom for pump-turbine. Fully use of mature and advanced proposal and structure proven by successful operations. Taking the convenience for installation. Alstom. Toshiba. VA-TECH. Carefully chosen data with certain surplus.wwwwwwwwwwwwwwwwwwwwwwwwwr 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. we have cooperated with Vioth. 3 . 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 4 .5m3/s Test system accuracy: ±0.wwwwwwwwwwwwwwwwwwwwwwwwwr 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: 1.3% 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. wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design Whole analyzing Runner and Spiral case and Draft tube Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design 5 . wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design 6 . 5 0.7 0.9 1.5 Q11/Q11 opt CFD tools to predict performances.2 1. and comparison with measurement results 7 .3 1.1 1.4 1.4 0.wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design Efficiency Comparison of experiment results and calculation l tia en fid n Co Measurements Calculations 2% 0.0 1.6 0.8 0. wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design 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 Pump-Turbine Basic Research－ Hydraulic Design Pump-Turbine Basic Research－ Hydraulic Design Softwares for pressure fluctuations prediction 8 . load-rejection and runaway condition. Pump-Turbine Basic Research－ Rigidity & Strength Calculation Analysis Pump-Turbine Basic Research－ Rigidity & Strength Calculation Analysis 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 9 .wwwwwwwwwwwwwwwwwwwwwwwwwr 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 turbine’s discharge. normal operation. 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. wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Basic Research－ Rigidity & Strength Calculation Analysis Pump-Turbine Basic Research－ Rigidity & Strength Calculation Analysis Combining calculation of spiral case and stay vane Stress distribution of wicket gate Stress distribution of head cover Stress distribution of bottom ring Pump-Turbine Basic Research－ Rigidity & Strength Calculation Analysis Pump-Turbine Basic Research－ Rigidity & Strength Calculation Analysis 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 . 5t ? 7880 ? 1480 18 M100x4 ? 6820 80 .M 80x4拉紧螺杆 2000 DRAFT TUBE CONE ACCES GALLERY 尾水管进人廊道 PUMP MODE CLOCKWISE 300 rpm 水泵模式(顺时针) 9.5t ? 5904 环形吊车 3.800 接力器中心线 ? 1500 h8 BEARING 水导轴承 SHAFT SEAL ? 1500 主轴密封 15.500 CIRCULAR RAILWAY 3.750 SERVOMOTOR AXIS 17.300 ? 1095 h10 17.500 DRAFT TUBE ELBOW ? 3596 INLET DIAMETER 尾水管肘管进口内径 11 .500 TURBINE MODE COUNTERCLOCKWISE 300 rpm 水轮机模式(逆时针) 8.000 522 DISTRIBUTOR AXIS RUNNER 9 BLADES 转轮叶片数 9 ? 1480 9 -M110x4 9 -? 150 导水机构中心线 ? 2700 RUNNER OUTLET ( TURBINE MODE ) 转轮出口(水轮机模式) ? 5040 RUNNER INLET ( TURBINE MODE ) 转轮进口(水轮机模式) ? 7130 40 .wwwwwwwwwwwwwwwwwwwwwwwwwr 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 Section—Pump-Turbine 20.M 105x4 2500 TURBINE PIT ACCES GALLERY ? 5904 Z=20 GUIDE VANES 20个导叶 机坑进人廊道 2000 18. self-lubricating .HeMiFeng .HOHOT etc.selfExternal oil circulation guide bearing Adopted to HuiZhou . segment and . 12 .wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Structure Design and manufacture Pump-Turbine Structure Design and manufacture Gate friction Gate shaft cone sleeve Transferred wring moment by pin sleeves and connected by bolts between runner and main shaft Pump-Turbine Structure Design and manufacture Pump-Turbine Structure Design and manufacture Turbine shaft水机轴 Intermediate collar中间轴翎 Pad瓦 Thin oil . BaoQuan.HOHOT . self-adjusting face-type main shaft seal selffaceseal rings in Carbon material or Cestidur Adopted to HuiZhou .LongTan.XiaoWan.PuBuGou etc. Pump-Turbine Structure Design and manufacture Pump-Turbine Structure Design and manufacture 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 .wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Structure Design and manufacture Pump-Turbine Structure Design and manufacture Adapted axial shaft seal Inflatable maintenance seal Spring.Three Gorge.HeMiFeng . wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine Structure Design and manufacture Pump-Turbine Structure Design and manufacture Stay ring: Segment Combination at site Pump-Turbine Structure Design and manufacture Pump-Turbine Structure Design and manufacture Gate operation control mechanism 20° 18° 2.63° 5 47 single gate servomotor single gate servomotor and control ring 14 . wwwwwwwwwwwwwwwwwwwwwwwwwr 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.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 . 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 B610CF、ADB610D 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. wwwwwwwwwwwwwwwwwwwwwwwwwr 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 . wwwwwwwwwwwwwwwwwwwwwwwwwr 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 17 . wwwwwwwwwwwwwwwwwwwwwwwwwr 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 18 . wwwwwwwwwwwwwwwwwwwwwwwwwr Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare B) Dismantling PT from stator dismantling head cover Pump-Turbine maintenance mode compare Pump-Turbine maintenance mode compare C) Dismantling PT from movable cone of Draft tube 19 . 3 Head (max) Rising head (m) 483 230 390 301 455 335 585 620 620 321 318 479.75 1.wwwwwwwwwwwwwwwwwwwwwwwwwr 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) 1.5 1.75 1.0 1.6 2.9 725 300 500 400 550 500 900 793 775 420 393 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 下游密封环行程 11 3 Hydraulic operated seal ring 4 Movable operating seal ring replaces by-pass system by- 20 .9 2.9 1.9 1.6 1.5 2.3 2. wwwwwwwwwwwwwwwwwwwwwwwwwr DFEM IS YOUR BEST CHOICE THANKS! HeMiFeng Power station Type of turbine: HLP()-LJ-504 Runner diameter: 5. pump input: 325MW 21 .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: 337.0m Max. pump discharge : 106m3/s Max.6m Minimum pump head: 275. 0MW Pump condition: Maximum pump head: 565m Minimum pump head: 529m Max.7m Rated head: 517m Minimum head: 509m Turbine rated output: 306. pump discharge : 56.02m3/s Max.82m Rated speed: 500r/min Turbine condition: Maximum head: 553. pump input: 330MW 22 .wwwwwwwwwwwwwwwwwwwwwwwwwr HuiZhou Power Station Type of turbine: HLP()-LJ-382 Runner diameter: 3.