A1-105

CIGRE 2012

http : //www.cigre.org

TYPE TEST AND TORSIONAL VIBRATION MEASUREMENT OF A

GIGATOP 4-POLE GENERATOR FOR AN EPR POWER PLANT
C. PONCOT* / V. LETELLIER
ALSTOM
France

N. PICHOT / L. DAVID
EDF / CNEPE
France

SUMMARY
The GIGATOP 4-pole turbo generators are designed for all types of half-speed turbines for
nuclear power plants (NPP).
For an EPR reactor, the first 1800 MW class turbogenerator designed by Alstom (OEM) is the
Flamanville 3 generator. This machine is a new model, which will be the base of further
derived units for future 50 Hz EPR applications or equivalent.
It has been delivered after comprehensive type tests in factory, which demonstrate and
validates the performances of the generator and of its future evolutions.
The Flamanville 3 generator apparent power output is set at 1944 MVA, which already
represents a substantial step compared to the worlds largest generators in operation in EDF
nuclear fleet, the N4 units operating since the 1990s.
This output has been achieved using proven technologies already used on other nuclear and
fossil units.
The running tests were performed for stator voltages and currents higher than the rated values,
which constitute one of the worldwide largest powers ever running tested. The test stand of
the OEM has been upgraded to enable an increase of the driving power by 40 %.
The evaluation of the test results allows the overall performance of the machine to be
checked. First heat run tests confirm that the temperature rise of the different parts of the
generator are in compliance with the IEC standard criteria and also conform to calculated
values.
In addition to generator standard instrumentation, a large set of temporary test instrumentation
was installed in order to monitor temperatures, currents, vibrations, voltages, flux density, gas
velocities, etc. The temperature of neutral and short-circuit bars were monitored with a
thermal camera.

* clement.poncot@power.alstom.com
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Three heat run tests were performed:

1. Un-excited
2. Stator winding in open-circuit and field winding excited to obtain 110 % of rated
armature voltage.
3. Stator winding short-circuited and field winding excited to obtain 105 % of rated
armature current.
The measured temperatures of stator core, flux shields, stator and rotor windings were
recorded and checked during the tests.
These heat run tests were also used to measure and validate the predicted efficiency, by
measuring the power absorbed by the calibrated driving motors of the test stand. A torque
meter method was also tested during these tests.
In addition to the heat run tests the short-circuit ratio Kc was determined.
Dynamic characteristics were evaluated as well. Sudden short-circuit tests were performed in
order to validate the calculated reactances and time constants.
From a mechanical point of view, special attention was paid to rotor torsional behaviour. The
torsional natural frequencies and responses to sudden and permanent short circuits were
calculated as input to validate the shaft line integrity.
During the spin pit testing of the generator rotor the torsional oscillations were measured
using a telemetry system.
The evaluation provides the torsional natural frequencies during balancing runs in the spin pit.
In addition two modal analyses were performed in order to assess the influence of the driving
shaft line of the running test configuration.
During the rotating type tests (electrical short-circuit tests) the torsional natural frequencies
and time responses due to short circuit were measured. The vibration responses are transient
ones for the sudden short circuit, and are harmonic responses for the permanent two-phases
short circuit. The post-processing delivers vibration time histories and spectral analysis.

KEYWORDS
Turbo generator, Hydrogen-cooling, Water-cooling, Four-pole generator, Design, Development,
Nuclear, Factory test

1.

Main characteristics of the generator

The main characteristics of the generator stick strictly to the original specification for EPR
reactors. The main performance data is summarized in Table 1. The generator has a directly
water-cooled stator winding and a directly hydrogen-cooled rotor winding equipped with the
well-proven forward flow ventilation technology. Figure 1 shows the generator in the test
stand configuration, during insertion of the rotor. A separate excitation source was used.
Figure 2 shows the control room.
Table 1: Main characteristics of the generator type TA 1800-83

Class of insulation
Apparent power
Power factor
Frequency and speed
Rated voltage
Rated current
Excitation

Class 155 (F), with class

130 (B) temperature rise
1944 MVA
0.90
50 Hz, 1500 min-1
23 kV
48.81 kA
Brushless exciter

Figure 1: Test stand overview

Figure 2: Control room during running tests

2.

Temperature of armature and field windings

For such large generators, to determine the temperature rise of the generator at rated output, a
direct method is used for the stator winding and an indirect method for the rotor winding. The
methods are described in IEC 60034-1 and IEC 60034-29 standards.
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The temperature of the stator winding was measured by 168 RTD sensors installed in stator
water outlets and the overall maximum temperature was recorded during heat run test in
short-circuit.
Measured temperatures are lower than calculated ones, which include some safety margin.
These results show that temperatures of the armature winding are within the limit defined for
thermal class 130 (B) operation.
The temperature rise at rated load derived from the type tests is also lower than the calculated
values and will be finally validated during commissioning on site when the generator operates
at rated power. The measured values confirm that the generator can operate within thermal
class 130 (B) temperature limits at 2200 MVA, which is significantly higher than the rated
power of 1944 MVA.
The mean temperature rise of the field winding was determined with the resistance variation
method. The rotor winding temperatures, which were measured during the three heat run tests,
follow a straight line when plotted vs. the excitation power and therefore can be safely
extrapolated to rated current (according to IEC 60034-29).
Results, compared to calculation are shown in Figure 3. The temperature rise is again lower
than calculation, which includes as well some safety margin. The ventilation used for this
rotor, validated on a lot of other models, leads to an improved performance.
100%

Temp. rise above cold hydrogen

(in p.u. of rated temp. rise calculated)

90%
80%
70%
60%
50%
40%
Measured
Calculated

30%
20%
10%
0%
0

1000

2000

3000

4000

5000

Excitation power (in kW)

Figure 3: Temperature rise of the field winding

The generator, which was developed in cooperation with EDF, has a high-performing design
and uses two terminal boxes instead of one. The obvious advantage is the reduction of current
by a factor of two in all the parts, which connect the stator winding to the bushings located in
the terminal boxes, and the possibility to run the generator at 23 kV, which is a moderate
voltage level for this high power.
This solution was successfully validated on the P4 N4 French fleet (1300 1500 MW). As a
consequence the mechanical stress, especially during electrical faults, and the temperature rise
of the conductors are lower. During the heat run test in short-circuit at rated current,
temperatures of the air-cooled neutral bars were checked with a thermal camera (Figure 4 and
Figure 5).

Figure 4: Neutral bar temperature (upper part)

3.

Figure 5: Neutral bar temperature (lower part)

Efficiency

The efficiency was determined indirectly, using the calibrated motor method, which is
preferred according to standard IEC 60034-2-2. The running test configuration (Figure 6 and
Figure 1) was composed of a synchronous motor for tests at rated speed, completed with two
DC motors coupled with a gearbox, which were used to run up the shaft line. These motors
were used to bring extra power when the synchronous motor was at full load (i.e.: during
temperature rise test in short-circuit at 105 % of rated current). For all tests at rated speed,
speed of the shaft line was maintained constant by coupling the synchronous motor directly to
the grid.
The driving shaft line was completely calibrated earlier. Constant losses and on-load losses of
the driving shaft line were determined with specific tests.
The efficiency of the generator was determined higher than 99 % and is better than predicted
by calculation. The measurement of the power transmitted through the coupling during the
tests was confirmed with two other methods:
- Torque meter
- Calorimetric method
Figure 7 gives an overview of the distribution of different losses in efficiency.

Figure 6: Shaft train of the running test configuration

2.8%

26.0%

13.1%

7.7%

Mechanical losses
Core losses at no-load

5.9%

Load losses at 95 C
Additionnal load losses
Rotor copper losses at 95 C

44.5%

Auxiliary & Excitation system

losses

Figure 7: Distribution of the different losses in the generator efficiency

4.

Dynamic electrical characteristics

no-load voltage or short-circuit current (pu)

Each heat run test was completed, when all temperatures had stabilised to reach steady-state
conditions. From this stable state the no-load saturation curve and the three-phase shortcircuit saturation were measured by decreasing values. The short-circuit ratio was determined
using the two curves of Figure 8.
Both curves show a good agreement between measured points and calculated no-load and
short-circuit curves.
1.4
1.2
1.0
0.8
0.6
Measurement
Calculation

0.4
0.2
0.0
0.0

0.5

1.0

1.5

2.0

2.5
Field current (pu)

Figure 8: No-load and short-circuit saturation curves

The generator characteristic quantities were determined, with sudden three-phase short-circuit
tests.
The determined non-saturated reactances are shown in the Figure 9. They show very good
agreement with calculation.
Measured
Calculated

Reactance in pu at 1944 MVA

2.5

2.0

1.5

1.0

0.5

0.0

Xd

X'd

X''d

Figure 9: Non-saturated reactances

5.

Mechanical behaviour

From a mechanical point of view, a special attention was paid to the rotor torsional
characteristics. The aim was to assess the torsional responses to power variations, negative
sequence operation and sub-synchronous resonances. Another aim was to compare the
calculated with measured data.
Two series of measurements were performed. The first one consisted in determining the shaft
torsional natural frequencies in the large spin pit, and the second one in measuring the
torsional response in case of short circuit in the running test configuration (Figure 1).
The torsional measurements in the spin pit (Figure 10 and Figure 11) were performed during
the balancing runs.

Figure 10: Rotor in spin pit with Faradays cage

Figure 11: Rotor in spin pit in Faradays cage

In the spin pit the generator rotor is driven by a driving motor connected with a universal joint
and equipped with a shaft with slip rings on the other end.
The torsional vibrations were measured using a telemetry system. Accelerometers were fixed
on the shaft, and their signals were sent through an antenna to the recorder and spectral
analyzer. Accelerometer system is presented on Figure 12.

Figure 12: Accelerometers measuring in circumferential direction

During the design phase and prior to the measurements, this shaft line had been modelled
according to OEM standards, and calculations were run with OEM in-house software. The
calculations were useful to assess the torsional natural frequencies during design phase, and to
choose the most appropriate accelerometers locations regarding the deformed shapes before
the measurements.
The measurement method is described in Ref [4] and in ISO22266-1.
The correlations between the measurements and the model are given in Table 2.
Table 2: Deviation of measured and calculated torsional frequency

Delta between measurement

and calculation
1st torsional frequency
- 0.1 %
nd
2 torsional frequency
2.1 %

The correlation is excellent for the first 2 torsional frequencies, which are the flexible mode of
the active part and the torsional deflection at DE shaft end.
We have to note that these two modes are the most influential for the torsional behaviour
assessment.
The calculated torsional mode shapes of the generator rotor are shown on Figure 13

Figure 13: torsional mode shapes of the generator rotor

The torsional model is well correlated with the measured torsional frequencies of mode 1 and
2 and validated for further calculations.
Therefore, to model the generator in the shaft line, the brushless exciter was included and the
modal analysis performed. The calculated torsional frequencies with the brushless exciter are
more than 15% away from 50 and 100Hz. As the turbine influence on these two modes is
about 2%, the standard ISO22266-1 in which the largest frequency margin of 6% of the grid
and twice grid frequency e.g. without test verification is respected.
Additionally to the torsional measurement in the spin pit, measurements were carried out in
the running test configuration during permanent two phase short-circuit and two phase and
three phase sudden short-circuit tests at 20% of rated voltage. This gives the possibility to
validate the OEM torsional models for the harmonic response (permanent short-circuit) and
also for the transient response (sudden short-circuit).
The tests have validated the calculation models. This allows better accuracy on the torsional
behaviour to comply with the margins mentioned in standard ISO22266-1.
6.

Supplementary benefits of Testing

During the generator assembly, it was noticed that the alignment of the bearings was difficult
to perform quickly and reliably. Therefore, after the type tests, a new improved alignment
method was developed, implemented and tested.
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Thanks to these type tests, the reliability at site will be improved and maintenance operations
will be optimised.
Among other features, operation at 6-bar hydrogen pressure was validated, as the total leakage
rate during the type tests was very low.

7.
Conclusion
Results from the type tests conducted on the GIGATOP 4-pole generator type TA 1800-83
proved that the generator satisfies completely the EDFs EPR specification and the guaranteed
operating conditions at 1944 MVA/1750 MW. The generator was tested at 105 % of rated
current and 110 % of rated voltage. The rotor ventilation system, which was a well-proven
technology was fully validated for large 4-pole generators. Operation at the rated hydrogen
pressure of 6-bar gauge was successful and led to very low leakage rates.
The generator is fully validated for the specified power, and type tests proved that it could be
exceeded. This validation allows using this generator technology as the base of the platform,
to meet the specificities of various nuclear reactors.
Some customisations are already available, based on the same rotor design.
Among other specificities, future generators of this series will be adapted for higher shortcircuit ratio, different cooling conditions, lower power factor, higher excitation ceilings or
different rated voltages. These adaptations allow compliance with the different grid codes.

Bibliography
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[2]
[3]
[4]

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R. Joho, Y. Sabater, H. Ferretto, D. Abraham, W. Ferens, Hydrogen / Water-cooled
Turbogenerators: a mature technology on the move, CIGRE Session 2008, Paper A1-117
P. Coulon, M. Lichtenberger, M. Berlamont, V. Fernagut, H. Debruyne, L. David, O. Nicolas,
Challenges to test in factory a turbogenerator for an EPR NPP project, CIGRE Session 2010,
Paper A1-208
J. Huster, Dr. L. Eckert, F. Pohle, Calculation and measurement of torsionals in large steam
turbosets. Machine, Plant & System Monitor, March/April 1999, 22-27

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