Research progress on mechanism and control strategies of corrosion and plugging in generator stator copper conductors

doi:10.11949/0438-1157.20250679

Abstract

Abstract:

Water-cooled generators are extensively employed in nuclear, thermal, and hydraulic power plants. However, the hollow copper conductors within generator stators are susceptible to corrosion and plugging in the internal cooling water system, which can lead to abnormal system operation and even safety accidents. Uncovering the corrosion and plugging mechanism and developing corrosion and plugging control technologies based on this mechanism is of great significance. This review highlights the unique characteristics of stator internal cooling water systems and outlines the risks associated with corrosion and plugging. It systematically summarizes the underlying mechanisms, including the formation, release, and localized deposition of copper corrosion products, and reviews current water chemistry control strategies aimed at mitigating these issues. The review further re-evaluates the corrosion and plugging tendencies of copper conductors under varying water chemistry conditions, integrating both theoretical insights and field practices. The findings indicate that slightly alkaline water chemistry conditions are more effective in suppressing corrosion and minimizing plugging risks. Finally, the review discusses future research directions from both the aspects of mechanism study and engineering application. To better support the safe and economical operation of water-cooled generators, it is recommended to further investigate the kinetics of corrosion and plugging processes and to develop an integrated system status monitoring and fault diagnosis platform.

Key words: copper conductors, corrosion, plugging, cooling water, water chemistry

摘要：

水冷发电机在核电站、火电厂和水电站应用广泛，但其定子空心铜导线在内冷水中容易发生腐蚀堵塞，进而导致系统运行异常甚至生产安全事故。揭示腐蚀堵塞机理，并基于此发展腐蚀堵塞控制技术具有重要意义。介绍了定子内冷水系统的特点和腐蚀堵塞危害，系统总结了铜腐蚀产物“形成-脱落-局部沉积”的腐蚀堵塞形成机理，探讨了用于控制腐蚀堵塞的水化学调控技术，并结合理论和工程实践重新审视了铜导线在不同水化学条件下的腐蚀堵塞倾向，得出微碱性水化学条件能更有效地抑制腐蚀堵塞的结论。最后从机理研究和工程应用两方面进行了展望，提出进一步揭示腐蚀堵塞的动力学过程以及开发系统状态监测与故障诊断平台，从而更好地为水冷发电机的安全经济运行提供理论依据和技术支撑。

关键词: 铜导线, 腐蚀, 堵塞, 冷却水, 水化学

CLC Number:

TM 62

Tianping WANG, Xuxiang JIA, Yu WANG, Chunsong YE. Research progress on mechanism and control strategies of corrosion and plugging in generator stator copper conductors[J]. CIESC Journal, 2025, 76(11): 5816-5827.

王天平, 贾旭翔, 王宇, 叶春松. 发电机定子铜导线腐蚀堵塞机理及控制技术研究进展[J]. 化工学报, 2025, 76(11): 5816-5827.

Figures/Tables 8

Fig.1 Milestones in the research of corrosion and plugging of generator stator copper conductors

Fig.2 Schematic diagram of the internal cooling water system of generator stators1—cooling water tank; 2—circulating water pump; 3—cooler; 4—filter; 5—water quality monitoring system of mainstream; 6—generator stator with strong current; 7—bypass treatment system; 8—water quality monitoring system of bypass

Fig.3 Typical images of corrosion and plugging in the internal cooling water system of generator stators

Fig.4 Schematic diagram of the corrosion mechanism of hollow copper conductors of generator stators

Fig.5 Schematic diagram of the corrosion and plugging mechanism of internal cooling water system of generator stators

Table 1 Requirements of different water chemistry conditions in the stator internal cooling water system［1， 10-13］

水化学条件	pH_25℃	电导率κ_25℃/(μS/cm)	铜含量/(μg/L)	溶解氧含量/(μg/L)
高氧微碱性	8.0~9.0	≤2.0	≤20	＞2000
低氧中性	约7.0	≤0.2		≤20或30
高氧中性	约7.0	≤0.2		＞2000

Fig.6 Solubility curves of copper oxides under different pH conditions

Fig.7 Locations of different water chemistry conditions in the potential-pH diagram of the Cu-H2O system[63]

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