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Article(id=1210577181743387305, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1210560429043085661, articleNumber=null, orderNo=null, doi=10.16790/j.cnki.1009-9239.im.2024.07.009, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1692028800000, receivedDateStr=2023-08-15, revisedDate=1696608000000, revisedDateStr=2023-10-07, acceptedDate=null, acceptedDateStr=null, onlineDate=1766553691564, onlineDateStr=2025-12-24, pubDate=1721404800000, pubDateStr=2024-07-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1766553691564, onlineIssueDateStr=2025-12-24, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1766553691564, creator=13701087609, updateTime=1766553691564, updator=13701087609, issue=Issue{id=1210560429043085661, tenantId=1146029695717560320, journalId=1149653034449285133, year='2024', volume='57', issue='7', pageStart='1', pageEnd='142', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1766549697408, creator=13701087609, updateTime=1766563951127, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1210620213532430860, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1210560429043085661, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1210620213532430861, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1210560429043085661, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=68, endPage=75, ext={EN=ArticleExt(id=1210577182905209515, articleId=1210577181743387305, tenantId=1146029695717560320, journalId=1149653034449285133, language=EN, title=Research on stress grading technology of stator winding overhang for 18 kV hydro-generator in high altitude area, columnId=1190369198472794288, journalTitle=Insulating Materials, columnName=Insulation Technology, runingTitle=null, highlight=null, articleAbstract=

In order to meet the stress grading requirements of the 18 kV hydro-generator in a large hydropower station with an altitude of 2 500 m, the air breakdown field strength and its influencing factors at the target altitude were analyzed theoretically, and the overhang electric field characteristics was evaluated by establishing a three-dimensional simulation model of stator winding overhang, the influences of the clearance distance and binding structure on the electric field at overhang hypotenuse were analyzed, the scheme of controlling the minimum clearance distance at the overhang hypotenuse of the stator winding to 15 mm was determined. Finally, the stress grading performance of 18 kV hydro-generator stator coil and winding was tested and verified in a large high-altitude environmental simulation laboratory. The results show that the stress grading performance of the 18 kV hydro-generator is good and can meet the stress grading requirements at an altitude of 2 500 m.

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为满足海拔高度为2 500 m的某大型水电站18 kV水轮发电机的防晕要求，本文从理论方面分析了目标海拔高度下的空气击穿场强及影响因素，并通过建立定子绕组端部三维仿真模型评估了端部电场特性，分析了间隙距离与绑扎结构对端部斜边电场的影响，确定了定子绕组端部斜边最小间隙距离控制在15 mm的方案。最后，在构建的大型高海拔环境模拟试验室完成了18 kV水轮发电机定子线圈和绕组的防晕性能进行测试验证。结果表明：该18 kV水轮发电机的防晕性能良好，满足在2 500 m海拔高度下的防晕要求。

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刘学忠（1962-），男（汉族），陕西西安人，教授，主要从事电力设备电磁场计算分析优化和变频电机绝缘状态评估、检测与研究。
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张鹏（1982-），男（锡伯族），山东青岛人，高级工程师，主要从事绝缘技术和电气工艺的研发工作。

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张鹏（1982-），男（锡伯族），山东青岛人，高级工程师，主要从事绝缘技术和电气工艺的研发工作。

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张鹏（1982-），男（锡伯族），山东青岛人，高级工程师，主要从事绝缘技术和电气工艺的研发工作。

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Large Electric Machine and Hydraulic Turbine,2018(2):32-35., articleTitle=Study on the influencing factors of UV corona imaging detection of stator bar and winding for high voltage rotating machine, refAbstract=null)], funds=null, companyList=[AuthorCompany(id=1218111620576887753, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, xref=1, ext=[AuthorCompanyExt(id=1218111620585276362, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, companyId=1218111620576887753, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=1Zhejiang Fuchunjiang Hydropower Equipment Co., Ltd., Hangzhou 311504, China), AuthorCompanyExt(id=1218111620597859276, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, companyId=1218111620576887753, language=CN, country=null, province=null, city=null, postcode=null, companyName=null, 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journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Fig.1, caption=The stress grading structure of stator winding overhang, figureFileSmall=q26nGwVHkwEKnIP121HYDA==, figureFileBig=fwGdsZwRaNxRSo+CSzNCMg==, tableContent=null), ArticleFig(id=1218111624787968125, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=图1, caption=定子线圈端部防晕结构, figureFileSmall=q26nGwVHkwEKnIP121HYDA==, figureFileBig=fwGdsZwRaNxRSo+CSzNCMg==, tableContent=null), ArticleFig(id=1218111624968323206, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Fig.2, caption=The relationship between the uniform electric field gap breakdown field strength and gap distance at different altitudes, figureFileSmall=zd/5MBxb0ejlTslaEBwoXw==, figureFileBig=Vph/PcysRUZDFuuFI0/Sfw==, tableContent=null), ArticleFig(id=1218111625060597899, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=图2, caption=不同海拔高度下均匀电场间隙击穿场强与间隙距离的关系, figureFileSmall=zd/5MBxb0ejlTslaEBwoXw==, figureFileBig=Vph/PcysRUZDFuuFI0/Sfw==, tableContent=null), ArticleFig(id=1218111625144483986, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Fig.3, caption=Basic simulation model of the stator winding overhang, figureFileSmall=3CksZlU5AQnO8kzTGULNSA==, figureFileBig=fheFuqVwKHJxcWkdLzKDzQ==, tableContent=null), ArticleFig(id=1218111625240952980, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=图3, caption=定子绕组端部基础仿真模型, figureFileSmall=3CksZlU5AQnO8kzTGULNSA==, figureFileBig=fheFuqVwKHJxcWkdLzKDzQ==, tableContent=null), ArticleFig(id=1218111625366782105, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Fig.4, caption=Tangential electric field and loss density of inner stress grading coating under withstand voltage, figureFileSmall=zoTtiuTina2bmvBItPwB/g==, figureFileBig=E6sXZZ2pYl0xkT/W7q/uKw==, tableContent=null), ArticleFig(id=1218111626708959391, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=图4, caption=耐压试验电压下内层防晕层切向电场和损耗密度, figureFileSmall=zoTtiuTina2bmvBItPwB/g==, figureFileBig=E6sXZZ2pYl0xkT/W7q/uKw==, tableContent=null), ArticleFig(id=1218111626851565733, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Fig.5, caption=Electric field distribution of stator winding overhang section in different directions, figureFileSmall=2qkAZ3oiho/U3MfQCS0a6Q==, figureFileBig=5Z1AsRv2sNew7UKxQcczDQ==, tableContent=null), ArticleFig(id=1218111626931257508, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=图5, caption=不同方向定子绕组端部截面的电场分布, 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figureFileBig=W4cxL1i57JhM+i0ApdGtdA==, tableContent=null), ArticleFig(id=1218111627765924028, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Fig.9, caption=Large-scale test chamber for simulating the environment in high altitude area, figureFileSmall=fKI2l/1XK2sN/PIMLWBltA==, figureFileBig=Ypbn4kyLBUMLMTpr0hcTUg==, tableContent=null), ArticleFig(id=1218111627895947456, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=图9, caption=大型高海拔环境模拟试验室, figureFileSmall=fKI2l/1XK2sN/PIMLWBltA==, figureFileBig=Ypbn4kyLBUMLMTpr0hcTUg==, tableContent=null), ArticleFig(id=1218111628004999366, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Fig.10, caption=Diagram of the stator coil and stator winding for test, figureFileSmall=gOV4T3cfVLofqJeqWaPncQ==, figureFileBig=Yfe/A4PZumXa7ZAxqQJcOQ==, tableContent=null), ArticleFig(id=1218111628101468361, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=图10, caption=试验用定子线圈与绕组示意图, figureFileSmall=gOV4T3cfVLofqJeqWaPncQ==, figureFileBig=Yfe/A4PZumXa7ZAxqQJcOQ==, tableContent=null), ArticleFig(id=1218111628172771534, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Table 1, caption=Altitude correction factor specified by different standards, figureFileSmall=null, figureFileBig=null, tableContent=
海拔高度/m1 0002 0002 5003 0004 0005 000
GB 311.11.001.131.201.281.451.63
JB/T 84391.111.251.331.431.662.00
), ArticleFig(id=1218111628248269010, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=表1, caption=

不同标准要求的海拔修正因数

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海拔高度/m1 0002 0002 5003 0004 0005 000
GB 311.11.001.131.201.281.451.63
JB/T 84391.111.251.331.431.662.00
), ArticleFig(id=1218111628332155094, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Table 2, caption=Maximum electric field strength in different regions of stator winding overhang, figureFileSmall=null, figureFileBig=null, tableContent=
部位垫块绑扎垫块绑扎垫块(圆角2 mm)
绝缘表面1.731.711.56
径向截面1.931.811.80
轴向截面1.611.771.81
), ArticleFig(id=1218111628457984217, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=表2, caption=

定子绕组端部不同区域最大电场强度

, figureFileSmall=null, figureFileBig=null, tableContent=
部位垫块绑扎垫块绑扎垫块(圆角2 mm)
绝缘表面1.731.711.56
径向截面1.931.811.80
轴向截面1.611.771.81
), ArticleFig(id=1218111628617367776, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Table 3, caption=Measured data of the hypotenuse clearance distance at end of stator winding mm, figureFileSmall=null, figureFileBig=null, tableContent=
方位12345678
左侧15.014.815.014.815.015.015.215.1
右侧15.016.015.015.015.516.016.015.5
), ArticleFig(id=1218111628718031074, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=表3, caption=

定子绕组端部斜边间隙距离实测数据

, figureFileSmall=null, figureFileBig=null, tableContent=
方位12345678
左侧15.014.815.014.815.015.015.215.1
右侧15.016.015.015.015.516.016.015.5
), ArticleFig(id=1218111628806111462, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Table 4, caption=Corona inception voltage of stator coil under different ambient humidity at an altitude of 2 500 m, figureFileSmall=null, figureFileBig=null, tableContent=
空气湿度/%405060
起晕电压/kV>50>5050
), ArticleFig(id=1218111628948717802, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=表4, caption=

2 500 m海拔高度不同湿度下定子线圈起晕电压

, figureFileSmall=null, figureFileBig=null, tableContent=
空气湿度/%405060
起晕电压/kV>50>5050
), ArticleFig(id=1218111629028409581, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Table 5, caption=Corona inception voltage of the stator winding under different ambient humidity at an altitude of 2 500 m, figureFileSmall=null, figureFileBig=null, tableContent=
空气湿度/%10203040506070
起晕电压/kV212224252223.523
), ArticleFig(id=1218111629116489969, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=CN, label=表5, caption=

2 500 m海拔高度不同湿度下定子绕组起晕电压

, figureFileSmall=null, figureFileBig=null, tableContent=
空气湿度/%10203040506070
起晕电压/kV212224252223.523
), ArticleFig(id=1218111629221347572, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1210577181743387305, language=EN, label=Table 6, caption=Corona inception voltage of the stator winding under different air pressure at an altitude of 2 500 m, figureFileSmall=null, figureFileBig=null, tableContent=
气压/kPa89.685.681.579.377.574.5
起晕电压/kV282725242220
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2 500 m海拔高度不同气压下定子绕组起晕电压

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气压/kPa89.685.681.579.377.574.5
起晕电压/kV282725242220
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高海拔地区18 kV水轮发电机定子绕组端部防晕技术研究
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张鹏 1 , 刘枰 2 , 刘学忠 2 , 毛继业 1 , 黄亿良 1
绝缘材料 | 绝缘技术 2024,57(7): 68-75
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绝缘材料 | 绝缘技术 2024, 57(7): 68-75
高海拔地区18 kV水轮发电机定子绕组端部防晕技术研究
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张鹏1, 刘枰2, 刘学忠2, 毛继业1, 黄亿良1
作者信息
  • 1浙江富春江水电设备有限公司,浙江 杭州 311504
  • 2西安交通大学 电工材料电气绝缘全国重点实验室,陕西 西安 710049

    • 张鹏（1982-），男（锡伯族），山东青岛人，高级工程师，主要从事绝缘技术和电气工艺的研发工作。

通讯作者:

刘学忠（1962-），男（汉族），陕西西安人，教授，主要从事电力设备电磁场计算分析优化和变频电机绝缘状态评估、检测与研究。
Research on stress grading technology of stator winding overhang for 18 kV hydro-generator in high altitude area
Peng ZHANG1, Ping LIU2, Xuezhong LIU2, Jiye MAO1, Yiliang HUANG1
Affiliations
  • 1Zhejiang Fuchunjiang Hydropower Equipment Co., Ltd., Hangzhou 311504, China
  • 2State Key Laboratory of Electrical Insulation and Power Equipment, Xi′an Jiaotong University, Xi′an 710049, China
出版时间: 2024-07-20 doi: 10.16790/j.cnki.1009-9239.im.2024.07.009
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摘要
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为满足海拔高度为2 500 m的某大型水电站18 kV水轮发电机的防晕要求，本文从理论方面分析了目标海拔高度下的空气击穿场强及影响因素，并通过建立定子绕组端部三维仿真模型评估了端部电场特性，分析了间隙距离与绑扎结构对端部斜边电场的影响，确定了定子绕组端部斜边最小间隙距离控制在15 mm的方案。最后，在构建的大型高海拔环境模拟试验室完成了18 kV水轮发电机定子线圈和绕组的防晕性能进行测试验证。结果表明：该18 kV水轮发电机的防晕性能良好，满足在2 500 m海拔高度下的防晕要求。

高海拔  /  水轮发电机  /  防晕  /  端部电场仿真  /  起晕电压

In order to meet the stress grading requirements of the 18 kV hydro-generator in a large hydropower station with an altitude of 2 500 m, the air breakdown field strength and its influencing factors at the target altitude were analyzed theoretically, and the overhang electric field characteristics was evaluated by establishing a three-dimensional simulation model of stator winding overhang, the influences of the clearance distance and binding structure on the electric field at overhang hypotenuse were analyzed, the scheme of controlling the minimum clearance distance at the overhang hypotenuse of the stator winding to 15 mm was determined. Finally, the stress grading performance of 18 kV hydro-generator stator coil and winding was tested and verified in a large high-altitude environmental simulation laboratory. The results show that the stress grading performance of the 18 kV hydro-generator is good and can meet the stress grading requirements at an altitude of 2 500 m.

high altitude  /  hydro-generator  /  stress grading  /  overhang electric field simulation  /  inception corona voltage
张鹏, 刘枰, 刘学忠, 毛继业, 黄亿良. 高海拔地区18 kV水轮发电机定子绕组端部防晕技术研究. 绝缘材料, 2024 , 57 (7) : 68 -75 . DOI: 10.16790/j.cnki.1009-9239.im.2024.07.009
Peng ZHANG, Ping LIU, Xuezhong LIU, Jiye MAO, Yiliang HUANG. Research on stress grading technology of stator winding overhang for 18 kV hydro-generator in high altitude area[J]. Insulating Materials, 2024 , 57 (7) : 68 -75 . DOI: 10.16790/j.cnki.1009-9239.im.2024.07.009
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0 引言
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在“双碳”政策实施的发展背景下，开发和利用可再生能源的重要性愈发凸显，而水力发电作为绿色资源开发的典范，相关关键技术的研究备受关注。我国的水电资源非常丰富，自2014年起，水电装机容量与发电量稳居世界第一。截至2022年，我国水电发电机总容量已达41 350万千瓦[1]，且总装机容量仍逐年持续增加。正在建设的单机容量500 MW某大型水电站是国家电力“十三五”规划的重点项目，电站正常蓄水位为2 500 m，空冷发电机组安装的海拔高度为2 236.8 m。电机在如此高海拔环境下运行，其定子绕组防晕结构的性能与稳定性相当关键。
电机定子端部防晕结构是将SiC防晕带材包绕浸渍漆料或将漆料直接涂刷在定子线圈端部之后固化形成的具有非线性电阻特性的薄层结构，通常会在6 kV及以上工频大电机定子线圈上增设，以均化端部表面电场，确保电机定子在出厂试验考核或机组运行过程中不出现电晕放电[2]。经过数十年的发展，我国在防晕材料和结构设计等方面取得了显著进展[3-5]，但在电机电压等级逐步提高和投运环境复杂的发展背景下，防晕技术仍需全面深入的研究。
近年来，诸多学者围绕电机定子绕组端部放电、防晕结构优化方面进行了大量研究。李寅伟等[6]研究了绝缘参数对定子线棒端部电场的影响；孙永鑫等[7]以定子相邻线圈端部二维模型为研究对象，研究了斜边间隙与绕组间介质属性对斜边电场的影响；康爱亮等[8]研究了环境湿度对定子端部放电特性的影响规律；胡建林等[9]研究了海拔高度和湿度对电机定子绕组相间起晕电压的影响；T UMEOTO等[10]通过仿真优化了大电机定子线圈防晕结构；王有元等[11]和刘雁等[12]评估了海拔高度对端部电晕放电和定子线圈绝缘性能的影响。但上述研究均未考虑电机定子绕组端部的三维电场分布特性、绕组绑扎结构的影响和高海拔下的防晕设计方法。本文以某大型水电站18 kV空冷式水轮发电机为研究对象，在仿真设计单个线圈防晕结构的基础上，进一步通过仿真深入研究端部间隙和绑扎结构对定子绕组端部三维电场的影响，确定在高海拔下影响定子绕组防晕性能的关键因素，最后在大型环境试验箱内对单个定子线圈和真机绕组端部防晕性能进行验证测试，以期为运行于高海拔地区的水电机组的定子防晕结构设计提供技术参考。
1 定子线圈结构与考核要求
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1.1 定子线圈防晕结构
本文使用的18 kV空冷式水轮发电机定子线圈采用155级（F）绝缘，经真空压力浸渍工艺处理[13]，采用经附加绝缘隔开的双层防晕结构，内层防晕根据所用带材阻值不同分为3段，从低阻末端依次被命名为中阻防晕层、中高阻防晕层和高阻防晕层，外层防晕为一段式并延伸至距绝缘末端100 mm处，定子线圈端部防晕结构如图1所示。
1.2 高海拔下的气体放电特性
空冷式水轮发电机绕组绝缘外表面直接与空气接触，其线圈表面或绕组间的气体放电特性满足巴申定律，均匀电场中气体的击穿电压可由式（1）计算[14]。
Ub=BpdlnApdln(1+1/γ)
式（1）中：Ub为间隙击穿电压峰值；A和B为电子碰撞电离系数中的常数，分别取值为8.5 cm-1·mmHg-1和250 V·cm-1·mmHg-1；p为气压；d为间隙距离；γ为阴极二次电子发射系数，试验表明γ与电场强度关系不大，同时假定其不依赖于气压值，因此γ可取值为0.025。
根据GB/T 16927.1—2011，不同海拔高度对应气压可由式（2）计算。
p=101.3×e-(H/8150)
式（2）中，H为海拔高度。
间隙击穿场强平均值E¯b可由式（3）计算。
E¯b=Ubd
结合式（1）～（3）可计算得到不同海拔高度下不同间隙距离对应均匀电场的击穿场强，然而式（1）是在假设温度不变的情况下给出的，实际环境中温度升高，空气密度会减小，所以式（1）更普遍的形式应是空气相对密度和间隙距离的函数。有试验研究了间隙距离为0.01～10 cm的均匀电场的击穿电压[15]，得出间隙击穿电压峰值满足式（4）。
Ub=24.22δd+6.08δd
式（4）中，δ是相对空气密度。
又根据GB/T 16927.1—2011，当环境温度t和标准大气条件下的温度t0以℃表示，大气压力p和标准大气压力p0的单位相同时，相对空气密度可由式（5）计算。
δ=pp0×273+t0273+t
式（5）中：t0为20℃；p0为101.3 kPa。
根据GB/T 755—2019可知，低海拔地区最高环境温度限值为40℃，海拔高于1 000 m的地区每升高100 m降低1%温升限值，因此选择20℃和40℃代入式（5），结合式（3）和式（4）可以得到不同海拔高度下不同均匀电场间隙的击穿场强理论计算值，如图2所示。从图2可以看出，击穿场强不会随着间隙距离增大而线性减小，具体表现为在间隙距离为0.1～1.0 cm范围内击穿场强急剧减小，而在间隙距离为1.0～3.0 cm范围内减小幅度明显变小，若以1.0 cm为基础值计算，间隙距离每增加0.5 cm，击穿场强下降幅度约为0.1 kV/mm。因此，间隙距离并非越大越好。事实上，对于大容量高电压等级的发电机，斜边间隙距离选择通常不会超过图示范围。
1.3 考核标准与方法
在常态环境下，定子线圈防晕性能一般是直接通过试验考核，要求在1.5倍额定电压下无明显晕带和无连续金黄色亮点，且在1 min耐压试验过程中防晕结构不烧蚀击穿、不闪络。对于高海拔地区，一般根据现行标准中规定的海拔校正因数来定义设备外绝缘水平，其中根据GB 311.1—2012和JB/T 8439—2008计算得到的海拔校正因数如表1所示。从表1可看出，JB/T 8439—2008对高海拔下电机的绝缘强度要求更高。
发电机实际安装地点海拔高度为2 236.8 m，计算评估时以2 500 m作为设计海拔高度，按表1修正系数可以计算得到，常态试验环境下该电机定子绕组的电晕起始电压有效值，即相邻异相定子线圈间理论最大电压差应不低于18 kV，在后续定子绕组端部电场特性仿真中以此电压作为导体激励。
2 定子线圈与绕组端部电场仿真分析
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2.1 仿真配置
改变海拔高度会引起气压、温度和湿度的变化，但对空气介电属性的影响可忽略不计。因此，为评估定子绕组端部是否存在放电风险，仅需分析考核电压下定子线圈端部防晕结构沿面电场和绕组端部斜边间隙电场在目标海拔高度下是否超过1.2节所述临界场强。
定子绕组端部基础仿真模型如图3所示，该模型包含3个同层相邻线圈、间隔垫块以及绑扎结构，后续仿真研究则根据评估目的，分别调整间隙距离和绑扎结构。为便于分析，规定垂直线圈斜边宽面方向为径向，与斜边窄面平行方向为轴向。
所有仿真场域控制方程如式（6）所示。
-∇⋅(σ∇V+jωε0εr∇V)=0
式（6）中：V为电位；σ为材料的电导率；ω为角频率；ε0为真空介电常数；εr为材料的相对介电常数。
对于单个线圈，导体以1 min耐压试验电压2.75Un+6.5 kV作为激励，低阻接地；定子绕组则是在中间线圈导体上施加工频电压18 kV，两侧相邻线圈导体以及3个线圈的低阻区域设置为零电位。
2.2 防晕结构沿面切向电场和损耗
在耐压试验电压下，单个定子线圈防晕结构沿面切向电场（Et）和损耗密度（Q）如图4所示。从图4可以看出，防晕结构沿面有效均压区域已延伸至高阻区域中段，损耗则主要分布在中阻段与中高阻段。从数值来看，防晕结构沿面最大切向电场为0.78 kV/mm，最大损耗密度为0.5 W/cm2，均满足设计指标要求[16]，表明防晕结构长度足够且阻值选择相对合理。
2.3 定子绕组端部电场
2.3.1 电场分布特性
本文的发电机定子线圈端部斜边直线长度约为0.5 m，鉴于斜边间隔垫块数量理论上不会影响间隙电场，但绕组安装复杂，且经人工完成的绑扎结构数量增加可能会导致毛刺等缺陷出现概率增大[17]，经综合受力分析后，确定该发电机定子绕组端部斜边间隔布置两个垫块。同时，为了确定端部电场分布特性，以斜边间隙仅分布两个高度为11 mm的环氧垫块的定子绕组端部模型为例，仿真提取了不同方向定子绕组端部截面的电场分布，如图5所示。从图5可以看出，径向截面最大电场主要分布在线圈圆角附近的空气域内，轴向截面电场分布显示斜边间隙最大电场出现在环氧垫块与线圈表面交界处，而两种截面上环氧垫块与空气间隙内部电场都相对均匀，分别统计其空气间隙电场不均匀系数，结果均不到1.2，表明发电机定子绕组端部电场属于稍不均匀场，起晕情况理论上与均匀电场相似，这也说明采用1.2节不同间隙在不同海拔高度下的空气击穿场强计算值作为判定依据的合理性。
2.3.2 间隙距离对斜边电场的影响
大型空冷式水轮发电机定子绕组端部相邻线圈间应设计合适的间隙距离，一方面确保有足够的冷却风量流过来限制绕组温升，另一方面确保有足够的间隙距离避免产生局部放电。本文以不含绑扎结构的两个垫块定子绕组模型为基础，通过改变环氧垫块高度来调整斜边间隙距离在11.0～20.7 mm内变化，仿真获取了绕组斜边间隙电场强度随间隙距离的变化曲线，结果如图6所示。由2.3.1节可知，空气间隙内部电场近似均匀，数值即为实际平均场强，为取一定设计裕度，统一将截面最大场强以不均匀系数1.25定义。从图6可以看出，间隙距离为11 mm时的气隙内部场强小于图2中2 500 m海拔高度下温度为40℃时的临界场强，且随间隙距离增大与临界场强的差值更大。考虑电场不均匀性，约在13 mm间隙时，截面最大电场达到临界场强，进一步增加间隙距离，最大电场愈发小于临界场强，说明具有更高的安全裕度。由此可知，电机定子绕组斜边间隙距离需选择合理的安全裕度，以避免间隙过大造成电机功率密度下降。本文通过对电机定子绕组的接线进行优化，将同层异相相邻线圈间设计承受的最大电压有效值降为10.7 kV，更低的工作电压也为机组在高海拔环境下的长期安全运行提供了更大的安全裕度。综合上述因素，该发电机斜边间隙拟按15 mm控制。
2.3.3 绑扎结构对斜边电场的影响
空冷式水轮发电机组定子绕组端部斜边间隙由环氧垫块和浸渍适形材料控制，并采用玻璃纤维编织带叠包绑扎后涂刷环氧树脂胶形成刚性结构。为了明确绑扎结构的影响，在15 mm斜边间隙距离且分布两个垫块的定子绕组模型上增加浸渍绑扎结构，仿真得到增加绑扎结构前后的定子绕组端部表面电场如图7所示。从图7可以看出，绕组表面电场分布无明显变化，且最大电场非常接近，说明绑扎结构对定子绕组端部表面电场几乎没有影响。进一步，提取得到绑扎前后定子绕组端部径向截面上的电场分布如图8所示。从图8可以看出，绑扎结构会导致相邻空气间隙距离轻微减小，且绑扎后间隙内部场强轻微增大。
2.3.1节提到无绑扎结构时环氧垫块与定子线圈宽面交界处会出现最大场强，事实上，绑扎后垫块与线圈交界位置不再是直角状态，因此在前述有绑扎结构的仿真模型中，对线圈宽面与绑扎垫块接触边缘增加了圆角过渡，半径为2 mm。统计了上述3种情况下定子绕组端部不同区域的最大电场强度，如表2所示。从表2可以看出，垫块到线圈边缘增加圆角过渡会明显降低绝缘表面电场至1.56 kV/mm，但不论是轴向表面还是径向截面，绑扎后或继续增加圆角处理，气隙内部最大电场没有明显变化，最大电场为1.81 kV/mm，结合图6可知，仍与2.3.2节所选的安全裕度保持一致。
3 高海拔下18 kV发电机定子线圈与绕组验证试验
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3.1 试验装置与方法
为直接考核该大型水电站18 kV发电机真机定子线圈端部防晕结构和绕组端部斜边区域在不同气候环境中的实际起始电晕放电特性，委托相关生厂商设计制造了图9所示的大型高海拔环境模拟试验室，试验室内部环境温度为10～85℃、湿度为10%～95%、气压为54～101 kPa，箱体顶部可接入最高50 kV电压，两侧壁对称分布多个观察窗，开窗位置配置磁吸式盖板和遮光布，以满足任意时间进行电晕起始电压测试的需要。
高海拔环境试验室中单根定子线圈和模拟试验绕组布置如图10所示，其中模拟试验绕组采用6根均已通过起晕电压测试与1 min耐压试验考核的定子线圈布置，上下层各3根，其中各有2根定子线圈同槽放置，试验时给上下层处于中间位置的定子线圈铜导体施加交流高压，剩余4根线圈的铜导体与模拟铁心接地。
结合本文仿真研究结果，将图10所示模拟定子绕组同层相邻线圈斜边间隔布置2个垫块，间隙距离为15 mm，绑扎完成后，对模拟定子绕组左右两侧端部共计16个斜边垫块处的实际间隙距离进行测量，结果如表3所示。因端部防晕结构厚度变化，实际间隙分布在14.8～16.0 mm范围内，满足公差要求。
试验验证依据JB/T 8439—2008进行，采用暗室环境下多人目测的方法判定起晕，尽管日盲型紫外成像仪可直接观测起晕现象，但因起晕时光子数的判定未有统一标准，且实际试验中光子计数易受观测距离、软件设置和标定方法等因素影响[18]，因此本文试验过程中仅借助日盲型紫外成像仪进行辅助定位。试验过程中发现，模拟实验室内空气湿度较大时，内部箱壁开始出现水汽凝结并形成水滴，如在试验过程中滴落在定子线圈和绕组端部任意区域，会畸变局部电场，可能使定子线圈或绕组电晕起始电压显著降低，干扰测试。因此，试验前后需注意检查线圈或绕组的表面状态，确保无水滴出现。
3.2 结果与分析
在常态环境下，定子线圈在耐压试验电压下均不起晕、不烧蚀，进一步抽取线圈在海拔为2 500 m环境下进行起晕电压测试，环境温度为70℃，测试结果如表4所示。从表4可以看出，单只线圈的电晕起始电压仍不低于50 kV。显然，不论是对常态环境下的测试结果进行修正，还是直接在目标海拔高度对应的低气压下进行测试，电机定子线圈的起晕电压均远高于1.3节所述标准要求。
表5和表6分别为单一环境因素变化即不同湿度和不同气压下电机定子模拟绕组的起晕电压测试结果。从表5和表6可以看出，空气相对湿度增加，定子绕组起晕电压先增大后略有减小，但波动范围有限；随着气压降低，定子绕组起晕电压逐渐减小，但均不低于20 kV，满足1.3节所述起晕电压考核标准。需要说明的是，一般认为湿度对均匀电场间隙的击穿电压影响很小，但对极不均匀场来说，湿度在一定范围内增大，空气中水分会吸附电子使起击穿电压增大，本文在模拟绕组验证试验过程观测到的起晕位置主要在下层线圈与圆柱形端箍绑扎区域，此处电场不均匀性更大，因此会受湿度变化影响。
综合上述研究，该18 kV空冷水轮电机定子线圈与绕组端部防晕性能满足2 500 m海拔高度下的运行要求。
4 结论
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（1）单个定子线圈的防晕性能基本不受海拔高度变化的影响，绕组端部结构设计对高海拔下电机防晕性能起决定作用。
（2）定子绕组端部斜边电场属稍不均匀场，空气间隙内部最大电场出现在垫块与线圈交界边缘，其余区域电场分布均匀，绑扎结构不会改变间隙的电场分布特性。
（3）绕组端部斜边间隙距离增大，最大电场线性减小，与空气临界场强在1～30 mm范围内随间隙距离变化趋势对比表明，间隙距离越大，绕组防晕设计的理论安全裕度越大，但需合理选择以避免浪费电机端部设计空间。
（4）环境湿度增加，定子绕组起晕电压呈现先增大后略微减小的趋势；而随海拔增加即气压降低，定子绕组起晕电压单调减小。
（5）该18 kV水轮发电机定子端部斜边间隙距离控制在15 mm时，在2 500 m高湿环境下绕组起晕电压不低于20 kV，满足标准要求。
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doi: 10.16790/j.cnki.1009-9239.im.2024.07.009
  • 接收时间：2023-08-15
  • 首发时间：2025-12-24
  • 出版时间：2024-07-20
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  • 收稿日期：2023-08-15
  • 修回日期：2023-10-07
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    1浙江富春江水电设备有限公司,浙江 杭州 311504
    2西安交通大学 电工材料电气绝缘全国重点实验室,陕西 西安 710049

通讯作者:

刘学忠（1962-），男（汉族），陕西西安人，教授，主要从事电力设备电磁场计算分析优化和变频电机绝缘状态评估、检测与研究。
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