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Necessity of Cooling System
- Relative motion between two parts / mediums generates
heat due to °
.
- Similarly electric current flowing in a conducting medium/
material, generates heat due to
(I2R)
.
- Unless heat so generated is effectively removed from the
affected parts/ medium, temperature of these parts/ medium
may rise beyond
.
- Hence the necessity of having proper cooling arrangements
which essentially involves °
°
°
°°
which could be gaseous,
liquid or solid form.
aptimizing Cooling Requirements /
Arrangements
Cooling Process has to be tackled in following three distinct stages:
: Minimization of Losses,
: Using Materials which can withstand higher temperatures µ
: Deploying effective and efficient cooling arrangements.
!
Î Superconductivity is a phenomenon occurring in certain materials at
extremely low temperatures, characterized by exactly zero electrical
resistance and the exclusion of the interior magnetic field.The use of
such superconducting materials as conductors in machines would result
large savings in size of equipment, amount of conductor use, heating
losses and energy required for cooling.
Î The Iron Losses in the Generator Stator and Rotor Core is reduced by
selecting material with low reluctance.
The eddy currents formed by the changing magnetic flux in the core is
also minimized by fabricating the core with stampings coated with
insulating varnish etc.
ane of the commonly used material for stampings is Silicon Steel.
aptimizing Cooling Requirements /
Arrangements
!
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- Iron Losses.
°
The hollow conductors used for cooling are fully integrated
into the bars and run parallel to the copper conductors.
Chemically clean water is used as coolant, which as we know
is electrically non-conductive.
Cooling of Generators
V
PTFE w j
" #
is being used widely in
bearing surfaces in Russia and China, as it has high thermal
capability, lower coefficient of friction and longer life.
Thrust Bearing Section
Cooling Tubes in Bearings
Cooling in Turbine Parts
!
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Similar to the Generator Guide Bearing, the Turbine
Guide Bearing also serves the purpose of guiding the
shaft in a pre-desired axis.
°
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In case of Reaction Turbines, Shaft Seals are
provided to prevent water leakages from the Turbine
Pit. Shaft Seals are provided with clean water under
pressure, which in turn prevents leakage of water
from Turbine to Top Cover / Turbine Guide Bearing.
Material of Shell & Tube Heat Exchangers
Carbon Steel, Stainless Steel, Cu-Ni 90:10, Titanium, incoloy
and others.
Generator Coolers w Material CS, SS, Cu-Ni, Brass/ Tubes
can be of Copper, Cu-Ni, SS, titanium and others.
Bearing ail Coolers w Tube, fittings and headers can be of
Cu-Ni, SS, admiralty brass, CS, Copper or any other as
required.
Cooling of Transformers
AN Air Natural Cooled a
aNAN ail Natural and Air Natural
aFAF Coolers comes complete
With motor and fan assembly mounted and wired
in a fan cabinet.
aFWF (Shell & tube type design)
aNAF (Normal convection design/ Tubes of Copper or
Cupro-Nickel (Cu-Ni) etc.
HVAC
Equipment that are air cooled e.g.
aa
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Single Loop Cooling Water Scheme
Double Loop Cooling Water Scheme
Cooling Water Scheme adopted for Malana II
HEP
apen Loop Cooling Water Scheme
In this scheme, the Cooling Water consists of a single
Loop of Circulating CW.
Water from the Source is pumped into the heat
exchangers, and thereafter, the hot water is disposed in
the tail race or river.
Advantages:
- Simple Scheme with Least Components.
Disadvantages:
- Erosion due to silt present in the water reduces the life of
equipment.
Closed Loop Cooling Water Scheme
In this scheme, the Cooling Water consists of two Circuits
of Circulating CW.
1. j
w The water from the penstock or
tail race is fed to a heat exchanger (which cools
the Secondary Circuit Water) and is disposed in
the tail race.
2.
w De-mineralized Water, is the
working fluid of this system which is fed to the
heat exchangers of Generator, Unit Bearings and
Transformers and its cooling is done by the
Primary Circuit.
Closed Loop Cooling Water Scheme
- The Scheme provides higher reliability from silt damage,
as Primary Circuits are made redundant by connecting
multiple unit Tail Race.
- Higher aperational Costs, as pumps for both the circuits
are required.
- Make up water tank is required to compensate the loss of
DM Water due to leakage etc.
- averall System Efficiency is Lower.
Silt Removal through
Cyclone separators are devices that utilize centrifugal forces
and low pressure caused by spinning motion to separate
materials of differing density, size, and shape.
Axial & Tangential Cyclone Separators
Heat Exchangers for Cooling Water System
Malana w II HEP
Pumps for Cooling Water System
Malana w II HEP
Drainage System
Drainage System comprise of two types:
ë
w The Leakage water from the
bushings of guide vanes, Shaft seals, MIV flanges, CW
System etc. has to be evacuated out of the Powerhouse.
w This is the seepage water from
rocks / soil which enters the cavities such as an
underground powerhouse due to gravity and high
pressure of rock mass.
Drainage System
The Drainage System comprises of the following
components:
1. Drainage Water Sump/ Pit w May be located at different
Levels.
2. Drainage Water Pumps (Vertical Turbine or
Submersible) with Starters.
3. Valves
4. Pipes and Fittings
5. Level Sensors.
Leakages in Turbine Pit
Three Methods of removing leaked water from Shaft Seal,
Guide Vane Bushes etc in Turbine Pit:
ë
: Leakage water is lead through
embedded pipes by gravity drainage sump. This water is
then pumped out to the tail race.
@
: The water is made to pass through a
nozzle, which creates a low pressure area, thereby
sucking the leaked water to Drainage sump, from where,
it is pumped to the tail race.
!
j
"
: In case leakage water is not
controllable with above said means, submersible pump
sets are sometimes deployed for draining Turbine Top
Cover.
Reaction Turbine Cross Section
Dewatering System
is of very high importance in respect to
the Powerhouses equipped with
% as the
Runner Centerline is below the Tail Water Level.
The Water present in the draft tube is removed by directing
the water into a Dewatering Pit, from where it is pumped out
to the downstream of the Tail Race Gate, to avoid back flow.
Dewatering System
The Dewatering System comprises of the following
components:
1. Dewatering Sump/ Pit w Is located at the lower most
level of the draft tube/ turbine pit.
2. Dewatering Pumps (Choice as per Silt Content in Water)
3. Hand aperated Valves
4. Pipes and Fittings
5. Level Sensors.
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