Water Turbine Generator, Francis Turbine Generator Unit Hl360A-Wj-55, Sfw1000-6/1180

• Warranty: 12 Months
• Output Type: AC Three Phase
• Size: Small
• Type: Horizontal Hydro Generator
• Bearing Support: Pedestal Sliding Bearing
• Speed: Low Speed
• Model NO.: HL360a-WJ-55, SFW1000-6/1180
• Bearing Number: 2
• Standard: Nonstandard
• Hydro Turbine: Water Turbine
• Hydraulic Turbine: Turbine Generator
• Transport Package: Wooden Case
• Specification: CE standard, GB/T standard
• Trademark: Lanzu
• Origin: China
• HS Code: 850239000
• Production Capacity: 100 Sets/Year

Product Description

I. Design and Check Standard
1. Standard and specification the agreement complies:
GB/T15468-1995 Fundamental Technical Requirements for Hydraulic Turbines
GB/T10969-1996  Specifications for Water Passage Components of Middle and Small Hydraulic Turbines
GB7894-2001 Fundamental technical specifications for hydro generators
GB11805-89 Basic Technical Specification for automatic control components and their related systems for Middle and Small hydro generating sets
JB/DQ1554-89   Middle and small hydraulic turbine Quality classification
JB/DQ3467-88   Middle and small hydraulic turbine Generator Quality classification
2. Check and Test
The "supplier" must check, test and pre-assembly the equipments and major components in the factory according related technical standard and specification, to find out the quality and performance index complies with related requirements, properly adjust assembly part clearance, make matching mark or position pin, to ensure correct assembly on the site.
All factory inspection items and ex-factory inspection items will generate inspection report and record.

II. Condition of the Power plant
1. Plant Name:  
2. Type: run off river plant, surface type
3. Operation type: non phase regulation, Grid connection and Islanding operation
4. Water Head: Net head Hr=45 m
5. Flow: design flow 2* 2.67 m³/s
III. Turbine Generator Parameters and Characteristics
1. Model:              HL360a-WJ-55
2. Runner Diameter: 550mm
3. Maximum head: Hmax=48m
4. Rated Head:      Hr=45m         
5. Min. Head:        Hmin=42m           
6.  Design Flow:   Qr=2.67 m³/s 
7. Rated Output    1096 KW
8. Rated Speed:          1000 rpm
9. Runaway Speed:      1731 rpm
10. Allowed Suction height: +1.29 m (guide vane height center line to normal tail water level)
11. Rotation Direction: clockwise direction if viewed from the generator end
12.  Max axial water thrust: 4.9 ton

13.  At design water, design flow and rated speed, the turbine rated output will be no less than 1096KW, turbine efficiency at designed operation point will be no less than 93.7%, max operation efficiency is no less than 94.4%.
14. Efficiency Guaranteed Value is as per the efficiency curve.
15. The Noise level at 1 meter distance from the turbine spiral case does not exceed 85dB(A).
16. Type: Turbine I horizontal Francis turbine, share main shaft with the generator.
17. Cavitation erosion guarantee: during 8000hour operation period (among which less than 45% rated load operation time does not exceed 500 hour, above 100% rated load operation does exceed 100 hour), the weight loss on runner, guide vane, etc, flow contact part will not exceed 0.8kg.
18. Stable Operation Guarantee:
Given operating between minimum and maximum head range and 45% to 100% rated output range, suction head meet the design requirement, the Unit can operation at rated speed stably without causing excessive cavitation erosion.
19. Guide Vane Leakage
With in 8000 hours since commercial operation, under rated water head, the turbine guide vane full close leakage will not exceed 0.3% of rated flow.
20. Regulation Guarantee
In case of dumping 100% load, the Unit maximum speed rise would not exceed 50%, spiral case maximum pressure rise will not exceed 50%, the designed wicket gate closing time does not exceed 8 seconds.
21. Reliability
a. In case of Runaway, if the runaway speed operation does note exceed 5 minutes, the Unit's components will not distorts.
b. The time of turbine's first overhaul is 5 years from commercial operation, whole operation life is 40 years.
22. Runner material is ZG0Cr13Ni4Mo.
23. This turbine is 2-pedestal structure. The turbine does not have its own bearing, and the runner is over hang on the generator shaft.
24. Turbine spiral case water inlet direction is horizontal inlet. Automatic air admission device is provided on the bend tube.
Design Features to notice:


1. Easy to adjust regulation ring mechanism:
Each wicket gate position (opening) can be adjusted separately, to achieve tight closing seal, thus minimize the water leakage.
This design also makes the repairs and maintenance much easier after a long time of operation, so the guide vane can still provide tight water seal.
2. Quick Clean Window:
a quick clean window is provided on the spiral case, so there is no need to remove the front or back cover of the spiral case when foreign objects (stone, tree branches, clothes, etc) are blocking the wicket gate.
Open the window is also simple, a green hand can also do the check and cleaning. For the same purpose, to open and assembly the spiral case front/back cover required very good skilled person and take much longer time.


3. Non-contact Main Shaft Seal:
Our main shaft adopts combined non-contact labyrinth and splash ring seal. The turbine main shaft does not contact with the spiral case cover. The shaft does not need to replace in whole life time. During the operation, there is hardly and water leak out from the main shaft hole.
If using packing seal, the packing need to tighten and replace regularly, and main shaft will wear at the contacting point.

III. Generator Parameters
1. Model:                    SFW1000-6/11800
2. Rated Capacity          1000KW 
3. Rated Voltage:            400V
4. Rated Current:                 1804.3A
Rated Power Factor (lag)   0.8 (lag)
6. Rated Frequency        50Hz
7. Phase NO.:                   3
8. Rated Speed                  1000 rpm
9. Runaway Speed:           1800 rpm
10. Stator winding connection:  Y
11. Stator insulation class:      F/F
12. Rotation Direction: clockwise direction if viewed from the generator collector end
13. generator torque:        as per design
14. Designed Efficiency: 93.5%           
15. Rated excitation voltage: 46.8 V             
16. Rated excitation current: 263 A 

17. Generator Performance
 (1) Temperature Rise, according the GB standard, when cooling media temperature is 40ºC, stator's calculation temperature rise is less than 55K, rotor's calculation temperature is less than 55K.
(2) Vibration and Swing does not exceed specification required value.
(3) Noise: Not more than 85db according standard measuring method.
(4) Ventilation type: enclosed self cycling air cool ventilation type.
18. Electric Characteristics Guarantee:
a. when the stator winding is properly connected according to design method, in case of empty load at rated voltage, linear voltage wave  harmonic distortion is no more than 5%.
b. In case of empty load at rated voltage and rated speed, linear voltage "Telephone Harmonic Factor" (THF) does not exceed 3%.
c. In hot state, generator could withstand 150% rate current for 2 minutes without causing harming distortion and weld crack, etc. The voltage at such point should be as close to rated as possible.
d. In case the Generator is operating in asymmetric system, if non phase exceed rated current value, and negative phase current component vs rate current does not exceed 12%, the generator can long term operate safely. In case of asymmetric fault, in case I₂²·t<40, the generator is allowed to operate in short time, I₂ is the average square root of the negative current in t second time (per unit value).
19. Mechanical Performance Guarantee:
a. Generator should be able to withstand maximum runaway speed for 5 minutes without causing harmful distortion. When the turbine generator unit dumping 100% load, given the governor system operate normally, the Unit is permitted to connect to Grid without any check.
b. Under rated voltage or 105% rate voltage, the generator's mechanical strength could withstand stator terminal suddenly short circuited symmetrically or asymmetrically for 3 seconds without incurring harmful distortion.
20. Structure Features and Technical Requirements
1). Stator
        Stator Iron core adopts low energy loss, non-aging, high quality cool roll thin silicon steel laminated in the factory, the stator design, manufacturing, and test strictly complies with GB7894-2001 Standard.
2). Rotor
The pole winding is made of flat copper belt, longitudinal damping windings are provided on the rotor.
3). The main shaft is made of high quality forge steel in single piece.
4). Collector device
       The generator has a brushless excitor at the generator ND end. There is no carbon brush for excitor.
5) Bearing
The generator and 2 bearings are mounted on same bottom plate, flywheel and runner are overhang on both end of the shaft.
The bearing is water internal cooling, self cycling lubrication structure, cooling water pressure is 0.25 to 0.3Mpa; The radial bearing is babbit alloy bushing, thrusting bearing is babbit alloy pads push against a round collar casted on the shaft.
6). Monitoring Instruments
There is oil level transducer and PT resistance temperature probe, oil water signal, Transistor plunge pump (AC36V), with flow indicator in pump pipeline. Max operation temperature of the bearing should not exceed 65ºC.
  7). Generator insulation class is F class.
  8). The brake is hydraulic pressure type, rated braking oil pressure is 0.7 Mpa.

IV. Governors
Governor Model is YWT-600, rated operation oil pressure 16Mpa.

See separate documents for more details.
V. Excitation Device

It is PGH-2 model brushless excitation controller to provide stable voltage, the core control is done by IGBT control unit.
I. General Instruction
PGH-2 excitation controller is one key start, full automatic excitation control, no need operator running.
-  IGBT excitation control technology solved the problem that silicon controlled excitation is easy to be interfered by high frequency and middle frequency, and instability in low excitation voltage. IGBT (Insulated Gate Bipolar Transistor) excitation control technology is the most advanced DC current control technology. only a few manufacturer in China control this technology and applies it to advanced excitation control system (high voltage excitation control system), the reason is high technology requirement and high manufacture cost. We are the first to use IGBT technology to brushless excitation generator excitation control.
-  There are several version after this type controller was initially launched in 2009.
- The latest 201606 version of GDF series controller solve or rectified the know faults in old version, especially the problem of lose control caused by generator output breaker position contact fault, or electromagnet interference. The latest version GDF series controller had cancelled the breaker contact wiring.
Main Feature Function:
1. IGBT model smart control, free of harmonic interference, can operate stably under 170V excitation voltage.
2. Excitation control circuit manual test function, it is convenient for user to check the controller and charge magnet to the generator.
3. Generator constant voltage function, the generator automatically restore to set voltage when generator is disconnected from the Grid, thus prevent over voltage.
4. Automatic identify shut down procedure and adjust the controlled de-excitation frequency control.
5. "Independent island operation" function, by software setting to achieve this function. it is good for power plant to parallel diesel generator to make a small grid.
6. prevent generator overload
II. TECHNICAL PARAMETERS
1 Application range:
 -  PGH-2 is suitable for brushless excitation generator with excitation less than 12A, excitation voltage between 15V and 170V.
2 Input Signal:
-  Current:  connect generator stator C phase CT current: rated 5A
- Voltage:  generator A, B, N phase voltage: 400V/230V
Grid A, B phase voltage: 400V
-  Grid Connection identify:  generator output breaker position contact: normal open contact
   3: Controller Output:
    Excitation output voltage directly connect to generator excitor.
4. Temperature of environment: -10°C~+50°C    Elevation: less than 2500m a.b.s.l.
5. Dimension: controller unit (W) 305mm X (H) 146mm X (W) 240mm
6. Open hole size: (W) 264mm X (H) 124mm, see outline diagram (same for all GDF series)
III. Installation wiring

1. 1. Read and understand the wiring drawing, and connect the wire according to external terminal drawing.
2. 2. Pay attention to wiring correctness, Grid voltage wire, generator voltage wire, current input should be connected with the right phase.
3. 3. the controller excitation current output serial connect DC current meter (15-20A), and +,- end connects to generator excitor.
4. 4. generator voltage wire connects to A, B phase, current must connect to C phase current transformer (these 2 voltage must not connect to the same phase).

(PGH (GDF)-2 excitation controller external wiring drawing)

VI. Excitation Controller on site test and setting
1. Controller internal setting:
The password for internal setting protection is 341341
-  press and hold for 3 seconds to enter parameter setting, input password: 341341 when "internal setting" lamp flashes.
it is agreed "parameter" is 1, "increase" is 2 , "decrease" is 3 , "change over" is 4.(password enter: press these button in sequence: "decrease", "change over", "parameter", "decrease", "change over", "parameter")
- after entering the parameter set, the nixietube  flash to show parameter label or sequence number, the other position display parameter content.
- parameter 6: Current Transformer conversion ratio (for example, if generator current transformer is 400A/5A, the value is 80).enter 80 into parameter 6
- Parameter 6b: generator rated current vs current transformer prime rated current in percentage.(for example: if generator rated current is 288A, current transformer prime rated current is 400A, then percentage is 72%)enter 72 into parameter 6b.
- the following parameter setting is labeled as internal parameters, because of importance, it is not suggested to change the internal parameter to avoid the controller goes wrong.
-  if no-action for 8 seconds, the setting automatically exit,(or press and hold "parameter" button for 2 seconds) and all changes are save.
2. Excitation controller test on site:
-  after checking all wiring correct, the test can be conducted.
- the generator remains in stand still state, check the controller connected Grid voltage.
-  use the multimeter to measure the Grid A-N, B-N phase voltage, they should be in correct range, turn the "status switch" to "test" position, the controller now shows the control voltage in test, there is excitation voltage and current output.
-  press "increase" or "decrease" button to change excitation voltage.
-  reduce the excitation voltage to minimum.
- increase the generator speed to rated speed, press "increase" button, excitation voltage and current increase gradually, generator voltage slowly increase to rated value 380V. When frequency is 50Hz, turn "Change over" button, to check the control voltage (control voltage lamp on), and noted down this control voltage value.
-  input the password to enter internal parameter setting, and change parameter 2 value as the noted control voltage.
(for example: if the control voltage is 1.8, change parameter 2 as 1.8, method see parameter table, generator start over voltage setting)
- after on site test, turn the "status switch" to "running" position.
- if above steps can not control the excitation voltage and current, please check the wiring and the input voltage with reference to the wiring drawing.

Parameter Setting Table

Parameters	Parameter Mark	Parameter meaning	Default value	value range
00	U	Internal parameter	400	No change
01	CU	Special Parameter	CU6V	No change
02	dU	Internal parameter, automatic control	DuHH	No change
03	HP	Current phase position identify, to identify wired current direction Need/no need HPYY /HPNO	HPYY	HPYY/HPnO
0	0	Power factor at synchronized state	0.85	0.55-0.99
1	1H	De-excitation frequency select	43	30-45
2	2	Generator start over excitation voltage set Prevent start exciting voltage from going too high, the smaller value, the lower generator start voltage.	1.56	0.9-3.6
3	3	Internal parameter	0.3	No need change
4	4	Internal parameter	5.76	No need change
5'	No mark	Internal parameter	400	No change
6	6	Current transformer prime and second current ratio	100	20-900
6'	6b	Generator rated current vs current transformer prime current in percentage	80	30-99
7	7P	Generator Voltage tracking speed before synchronizing, smaller value, slower adjustment, more stable.	3	1-16
8	8I	Adjustment coefficient (integrate)	6	1-16
9	9P	Adjustment coefficient (differential)	5	1-16
10	AC	Synchronized and islanding parallel operation setting. When value is 0, enter island operation (disconnect Grid in island operation), when value is 1-16, enter constant power factor automatic operation, the bigger value, the faster PF adjustment	5	1-16
11	BE	Internal parameter, for master computer control use	01	No meaning for normal user

V. Generator first start up operation
1. turn "status switch" to "running" position.
2. start the generator and increase to rated speed, push the "start up" button, generator build up voltage. if the excitation is not successful, please turn to "Test" position to check the parameter 2, to avoid the parameter 2 setting value is too low or too high, which causing the failure.
3. excitation controller put into operation, automatically adjust the generator voltage to track the Grid voltage. if there is no Grid voltage, the controller will adjust voltage to 400V automatically.
4. Excitation controller first synchronizing operation
-  if all parameter setting is correct, the generator is ready for synchronizing operation.
-  the controller connected to Grid need to pay attention to identify the current and voltage wiring (voltage and current terminal) should be correct.
-  if the power factor wiring is correct, the excitation controller adjust the power factor automatically when the active load increase, and Grid indication lamp is on.
-  if the power factor wiring is wrong, the generator current might go out of control. should stop the generator and inter-change the current wiring or check the wiring.
5. Excitation control in normal operation
-  increase the generator load after synchronizing, when the stator is more than 10%, excitation controller will automatically control the excitation to keep constant power factor according to the active load change, according to the set power factor value. no need human adjusting.
-  if need to change the power factor manually, push the "increase" and "decrease" button. The new power factor value will be saved and operation will be according this new value. It is suggested to make this adjustment when taking up 50% rated active load. If the generator stator current has reached rated value, the controller will not allow increase and decrease operation, thus to prevent wrong operation leads to generator over current or power factor leading.

1. 6. Shut down Operation

-  when shut down the generator, only reduce the active load gradually, the excitation output will automatically reduce.
when the load reduce to generator stator current be 0 or near 0, the generator will disconnect and breaker trips off.
-  after the generator disconnect, if the rotation speed drop to set frequency value, the controller will automatically de-excite.
VI. Faulty trouble shooting

1. 1. De-excitation

   emergency de-excitation, directly cut off the excitation power on the panel. in normal accident, if the generator trip off and stop, generator frequency reduces to set frequency value, automatic de-excits.

1. 2. in case of excitation circuit fault (check the switch, breaker status first)

press excitation "start up" button, no reaction, generator voltage build up failed.
possible reason:
(1) the fuse in the controller burns or the power supply breaker is not closed.
(2) "status switch" position is wrong
(3) generator loss magnet or remaining voltage is too low. in case generator lose magnet, please turn the "status switch" to test position, and press "start up" to excite, when the generator voltage build up, quickly turn the  "status switch" to "running" position.
(4) the "start up" button contact is not well contacted.
(5) if the generator has a neutral knife switch, the test should be done with the switch closed.
3. Controller wiring problem, lose control, current quickly increase un-normally.
  Possible reason: (1) wiring error.
in the first run, if the controller lose control or can not automatically track the power factor, please check the voltage wiring and current wiring are correctly done, by turning the "status switch" to check and contrast the Grid voltage and generator voltage. if the phase position is correct, the generator voltage is higher than the Grid voltage (by about 5V to 15V), this means the terminal phase position is correct. if the generator voltage is lower than the Grid voltage, it means the phase position is wrong.
 (2) after synchronizing, the controller can not automatically track the power factor.
after synchronizing, increase the active load first, when then active current is low, the controller can not accurately calculate and adjust the position, when the controller is in accurate calculation and automatic adjustment, the "Grid indication" lamp is on.
(3) after synchronizing, lose control when increase the active load.
fault description: power factor is in leading area (pointer is at less than 1 position) possible reason: generator is running overload. solution: reduce generator load. When the generator stator current reaches rated value, the controller automatically reduce power factor, push "increase" and "decrease" button but no use, this is a set function of the controller. if need to change the power factor, reduce the active load to half rated value, the controller will be unlocked, then power factor adjustment can be done.
VII. IGBT excitation controller use note:
1. It is prohibited to use external power (rectified) to charge the generator magnet directly. If need to charge the generator magnet with external power, an isolation transformer must be connected and then rectified.
2. It is prohibited to short circuit the controller excitation output terminal. Short circuit the terminal will cause an instant damage to the IGBT transducer.

VI. Valve and Expansion Joint

1. Provided Main Inlet Valve is D971X-10/DN900 model electric /manual open and close butterfly valve with manual bypass valve and expansion joint for easy installation and dismantle.
See separate documents.
VII. Automatic Components
Provision of automatic components will meet the requirement for automatic control.
1. Normal Start up, shut down and increase/decrease load.
2. Instant putting into operation when system is at standby status.
3. Sending signal, alarm, and shut down in case of failure.
VIII. Integrated Automatic Control System
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