Basic Electrical

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VOLTAGE V - voltage CURRENT - I Ampere ACTIVE POWER W -watts REACTIVE POWER - VAR - var APPERENT POWER VA - va RESISTOR R - ohms INDUCTOR L - henry CAPACITOR C - farad POWER FACTOR cos FREQUENCY f - hertz
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f = NP/ 120 where N = rotor speed in r.p.m. P = number of rotor poles f = frequency of e.m.f. in Hz The world today is divided between countries generating their power at 50 Hz (e.g. Europe, Africa, Australia, Asia, and South America) and others (e.g., the United States/ North America, parts of Japan & Asia) at 60 Hz., Additional frequencies (e.g., 25 Hz) can still be found in some locations, but they constitute the rare exception.

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Electrical-mechanical equivalence.
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Electrical-mechanical equivalence.
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TURBOGENERATOR
Date 23/07/2009

INDEX

INTRODUCTION BRIEF HISTORY DTPS GENERATOR DETAILS CONSTRUCTION OF GENERATOR COOLING SYSTEM EXCITATION SYSTEM TESTING OF GENERATOR DURING O/H

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INTRODUCTION

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INTRODUCTION

The basic function of the generator is to convert mechanical power, delivered from the shaft of the turbine, into electrical power.

A generator is actually a rotating mechanical energy converter

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INTRODUCTION

In 1831-1832 Michael Faraday (17911867), discovered the operating principle of electromagnetic generators. The principle, later called Faraday's law, is that a potential difference is generated between the ends of an electrical conductor that moves perpendicular to a magnetic field. He also built the first electromagnetic generator, called the 'Faraday disc'
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Faradays Law of Electromagnetic Induction

This basic law, defined by genius of the great English chemist and physicist Michael Faraday, presents itself in two different forms: 1. A moving conductor cutting the lines of force (flux) of a constant magnetic field has a voltage induced in it. 2. A changing magnetic flux inside a loop made from a conductor material will induce a voltage in the loop.

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INTRODUCTION

The hydroelectric generator from Lauffen, Germany . The commercial birth of the alternator (synchronous generator) can be dated back to August 24, 1891
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INTRODUCTION
Principle of operation of Generator

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E M F Equation of Generator

E rms/Phase = 4.44 Kp Kd f T

where T = turns (T) per phase Pitch Factor Kp = emf induced in short pitch coil emf induced in Full pitch coil Distribution Factor Kd = emf with distributed winding emf with concentric winding

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GENERATOR COMPONENTS
The generator must be able to cope with large and fast load changes, which show up inside the machine as changes in mechanical forces and temperatures. The design must therefore incorporate

Electrical current-carrying materials (i.e., copper), Magnetic flux-carrying materials (i.e., highly permeable steels), Insulating materials (i.e., organic or inorganic), Structural members (i.e., steel ), and Cooling media (i.e., gases and liquids),

All working together under the operating conditions of a turbogenerator.

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TYPES OF FORCES EXPERIENCED BY STATOR STATOR - SIGNIFICANT DYNAMIC FORCES IN TERMS OF

VIBRATION TORSIONAL LOADS ELECTROMAGNETIC LOADING, THERMAL LOADING HIGH-VOLTAGE LOADING.

MOST CRITICAL COMPONENT OF STATOR IS STATOR WINDING

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TYPES OF FORCES EXPERIENCED BY ROTOR

ROTOR - THE HIGH SPEED ROTATING MEMBER

SEVERE DYNAMIC MECHANICAL LOADING TORSIONAL LOADS ELECTROMAGNETIC LOADING, THERMAL LOADING HIGH-VOLTAGE LOADING.

THE MOST CRITICAL COMPONENT IN THE GENERATOR ARE THE RETAINING RINGS, MOUNTED ON THE ROTOR. DESIGNED FOR HIGH-STRESS OPERATION

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DEVELOPMENT OF TG

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DEVELOPMENT OF TG

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Development of TG
Global development

First single phase generator of 75 KW First 3 phase generator, salient pole First turbo type 3 phase 25 MW generator CEA, UK made 50 HZ as frequency for Europe First Hydrogen cooled 3 phase 30 MW generator First Hydrogen cooled TG with direct cooling of rotor First generator with water cooled stator winding

1888 1891 1912 1925 1937 1949 1956

First generator with water cooling for stator and rotor wdg 1959

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DEVELOPMENT IN INDIA
IN 1950s: At Bhopal with British collaboration 30 MW & 120 MW Hydrogen Cooled IN 1960s: At Haridwar with Russian Collaboration 100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled IN 1960s: At Hyderabad with CZECH Collaboration 60 MW Air Cooled & 110 MW Hydrogen Cooled

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DTPS GENERATOR DETAILS

Make Type Code Stator winding cooling Rotor Winding cooling MW rating MVA rating Rated terminal voltage Rated Stator current Rated power factor Rated speed / frequency

: : : : : : : : : : :

BHEL THRI 108/44 IS : 5422, IEC - 4 Indirectly hydrogen cooled Directly hydrogen cooled 250 294.1 16.5 KV 10286 amps 0.85 Lag 3000 rpm / 50 Hz

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DTPS GENERATOR DETAILS

Negative sequence current capability (I}t), t-Time in Sec. : 10 Cont. permi. unbalanced load : 8% Efficiency at MCR condition : 98.93 % Short circuit ratio : 0.52 Phase connection : Double Star No. of terminal brought out : 06 Generator Stator winding resistance in phase at 20C U-X : 0.0008994 ohms V-Y : 0.0009091 ohms W-z : 0.0009081 ohms Generator rotor winding resistance at 20C F1-F2 : 0.09421 ohms
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DTPS GENERATOR DETAILS

Short-circuit ratio (SCR) is defined as the ratio of the field current required to produce rated terminal voltage on the open circuit condition, over the field current required to produce rated stator current on sustained threephase short circuit, with the machine operating at rated speed. During operation, to maintain constant voltage for a given change in load, the change in excitation varies inversely as the SCR. This means that a generator with a lower SCR requires a greater change in excitation, than a machine having a higher SCR, for the same load change. The inherent stability of a generator in a power system is partly determined by its short-circuit ratio Short circuit ratio of DTPS generators : 0.52

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DTPS GENERATOR DETAILS

There are two components of negative sequence to consider. The first is the continuous I2 component, which refers to the amount of phase unbalance the generator can tolerate for an infinite operating period

For large steam turbine generators, a typical continuous I2 value of 8 would be normal. This means that the generator could carry a continuous phase unbalance in the stator winding of 8% or 0.08 pu of the rated stator current, without damaging any of the generator components, specifically the rotor.

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DTPS GENERATOR DETAILS

The second is the transient component called I22 t , which refers to the degree of short-term phase unbalance that the generator can withstand. A typical transient value for I22 t would be 10. This means that the generator could withstand 100% or 1 pu phase unbalance for 10 seconds Negative sequence current capability I22 t ,t-Time in Sec. : 10 for DTPS generators

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Negative-sequence inverse time relationship.

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TYPES OF TURBOGENERATOR
Generator Modules :

Air Cooled Turbogenerator - TARI Hydrogen Cooled Turbogenerator - THRI Hydrogen/Water Cooled TG - THDF and THW

Module Nomenclature

THRI 108/44 THDF 115/59

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Rating of TURBOGENERATOR

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GENERATOR MAIN COMPONENTS

STATOR Armature INSULATION ROTOR - Field BUSHING EXCITATION SYSTEM H2 COOLERS

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Advantages of stationary Armature & rotating Field

It is easier to insulate stationary winding for high voltages for which the alternators are usually designed. It is because they are not subjected to centrifugal forces and also extra space is available due to the stationary arrangement of the armature. The stationary 3-phase armature can be directly connected to load without going through large, unreliable slip rings and brushes.. Due to simple and robust construction of the rotor, higher speed of rotating d.c. field is possible. This increases the output obtainable from a machine of given dimensions. Note: All alternators above 5 kVA employ a stationary armature

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STATOR

STATOR FRAME STATOR CORE STATOR WINDING STATOR INSULATION

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STATOR FRAME
THE BASIC PURPOSE OF THE STATOR FRAME IS TO PROVIDE SUPPORT FOR THE STATOR CORE TO ACT AS A PRESSURE VESSEL FOR THE HYDROGEN COOLING GAS IN HYDROGEN-COOLED GENERATOR The type of steel used in the frame is generally highly weldable material with good strength and low-temperature ductility (i.e., mild steel) to contain the internal hydrogen gas pressure. SEGREGATED INTERNALLY TO CREATE A VENTILATION CIRCUIT WITHIN THE GENERATOR

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STATOR FRAME

Totally enclosed fabricated gas tight cylindrical structure. Withstands weight of core & winding, forces & torques during operation

Natural freq. Away from exciting frequencies Provision for H2/CO2 filling Provision for temp measurements Foot plates for supporting on foundation Provision for H2 coolers
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STATOR FRAME
Wrapper Plate H2Cooler Stator winding Rotor Rotor winding

Terminal Bushing

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STATOR FRAME

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Stator Core

The principle function of the stator core is to carry electromagnetic flux. The core must handle magnetic field flux densities in the stator teeth and in the core-back or yoke area.

The stator core is made up of thin sheets of electrical grade, 3% to 4% Radial Ducts at designed intervals for flow of cooling gas Compressed with tension bolts, pressure plate and clamping fingers Stepped arrangement at the end for reduction in eddy current losses

silicon ,CRNO or CRGO, and 0.355 mm or 0.483 mm thick steel

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Stator Core - Laminations

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Stator Core - Laminations

There are numerous terms for these sheets; i.e. coreplate, punchings or laminates. They are segmented, meaning that generally from 10 to 24 laminates are laid side by side to form a full 360 degree ring layer. Each of these layers is staggered relative to the locations of adjacent layers above and below, by the butted radial edges of the adjacent laminates in each ring layer. Staggering advantages 1) has significant effect in increasing the mechanical integrity of the stator core as an assembled unit 2) beneficial effect in reducing shaft voltages on the rotor due to magnetic circuit dissymmetry.

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Stator Core - Laminations

Each lamination is insulated on both sides with an organic or inorganic compound of very thin dimension.

The purpose of the interlaminar insulation is to confine any induced eddy currents

To reduce the eddy-current effect due to axial flux impingement in the core-ends and its subsequent effect of increase in core-end heating, the core teeth are slit, in end core section

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Stator end Cores

SLIT CORE TEETH

Eddy-current activity in the core-ends is increased due to stray and end leakage flux, from axial impingement on the core teeth in the end-region
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SATOR CORE PACKET

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MOUNTING OF CORE IN STATOR FRAME

To keep the laminated ring segments in line with each successive layer, they are fitted onto keybars in a stator frame structure

A large full ring pressing plate at each end of the stator Additional use of through-bolts installed through holes in the core yoke area that extend the full axial length of the stator core and through the pressing plate.

In the area of the core teeth substantially strong fingers are installed on top of the core teeth at the ends

High-pressure loading of up to 250 tons per inch,

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MOUNTING OF CORE IN STATOR FRAME

Stator Core Support bar Pressure Plate Clamping Finger Insulated Through Bolt

Stator Core Locking Key of Stator Core Support bar

high-pressure loading of up to 250 tons per inch

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STATOR CORE SUPPORT BAR

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STATOR CORE SUPPORT BAR & RIB

Circumfer. Rib

Core Support Bar

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STATOR CORE Ventilation spacers

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STATOR WINDING

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STATOR WINDING

Three phase windings in two layers of individual bars Stator winding is divided in three phases Star connected to allow neutral grounding Top and bottom bar displaced by one winding pitch and connected to coil groups

Involute shape at the end of bar helps withstands various forces Micalastic Insulation System (VPI process) - Micalastic good conductor of heat - Low flammability - High resistance to moisture and chemical action - Accommodates thermo-mechanical stresses - Retains properties even after years of operation
VPI- Vacuum Pressure Impregnation
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STATOR WINDING

Armature windings are generally distributed windings Advantages 1) distributed winding generates a voltage wave that is nearly a sine curve.i.e. reduced harmonic content 2) Copper is evenly distributed on the armature surface. Therefore, heating is more uniform and this type of winding is more easily cooled A.C. armature windings may use full-pitch coils or fractional-pitch coils A coil with a span of 180 electrical is called a full-pitch coil. A coil with a span of less than 180 electrical is called a fractional-pitch coil Advantages 1) less copper is required per coil 2) the waveform of the generated voltage is improved
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STATOR WINDING
Distributed, Fractional Pitch , double Layer, Star Connected LAP winding R Y B

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Connection Diagram of Stator Winding

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STATOR SLOT

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STATOR SLOT ripple spring

To ensure good contact between the stator bar and the core, in the slots, a side packing filler is also generally inserted along side both top and bottom stator bars

The side filler is impregnated with semi conducting material to assist with the electrical contact to the stator core.

The base material is usually made up of strong resin-filled glass weave material

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STATOR SLOT ripple spring

Side packing ripple spring with semi conducting impregnation. .

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STATOR SLOT - wedge

Due to the current flowing in the stator bars, there is a reaction force in each slot which varies according to the level of current and direction of flow at any Instant creates forces between bars that are both repulsive and attractive at any give time in the alternating cycle. due to the cross-slot flux produced by the normal load current.

The stator bars tend to vibrate in the slota phenomenon called bar bouncing. Wedges are used in the slot to minimize the relative motion, and avoid fretting damage against themselves and the stator core and bar packing systems

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STATOR SLOT wedge

SINGLE-PIECE FLAT STATOR SLOT WEDGE . .

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CONDUCTOR BAR CONSTRUCTION

To reduce the effect of the eddy currents within each individual stator bar, the conductors are made up of numerous copper strands Due to the difference in the magnetic field from the top to bottom of the slot, additional circulating current could flow from top to bottom strands in a single bar To reduce the effect of the circulating currents, the strands are Roebel Transposed in each bar Roebel transposition of the copper strands refers to the re-positioning of each strand in the stator bar stack such that, it occupies each position in the stack at least once over the full length of the stator bar.

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CONDUCTOR BAR CONSTRUCTION

ROEBEL TRANSPOSITION: 3D VIEW.

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WINDING in Core

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WINDING OVERHANG PORTION

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STATOR END WINDING ASSEMBLY

1. CORE 2. CLAMPING FINGER 3. PRESSURE PLATE 4. TOP BAR 5. BOTTOM BAR 6. PHASE CONNECTOR 7. GAS OUTLET 8. GAS INLET 9. TERMINAL BUSHING

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TERMINAL BUSHING

Tubular construction for gas / water cooling High conductivity copper for taking out electrical power Connection flanges are silver plated to minimise contact resistances Insulated with a porcelain cylinder Differential pressure of gases or forced water for cooling

Construction which is bolted to stator bottom

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TERMINAL BUSHING

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STATOR TERMINAL CONNECTIONS

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Stator Core
Wdg Overhang

Cooler Insert Cover Rotor fan

Oil Catcher

Bearing Shaft Seal

Stator

Rotor

Terminal Bushing

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WINDING INSULATION

The reason for using insulating materials is to separate electrically the conducting parts of equipment from each other and from earthed components.
Thermal class Operating temperature (C)

Y A E B F H 200 220 250

90 105 120 130 155 180 200 220 250

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WINDING INSULATION

MICALASTIC Insulation- High Quality Mica, Selected Epoxy Resin & matching vacuum impregnation process. Extremely dependable insulation system for High voltage(upto 30 kv) turbo generators Why MICALASTIC Insulation ? It has long electrical life It is a good conductor of heat as it has high mica content & void free synthetic resin It is highly resistant to effect of high temp. & temp. changes Its elasticity enables it to accommodate thermo-mechanical stress It does not burn, it provides protection against moisture Highly resistant to chemical action Retains its outstanding properties even after years of operation

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WINDING INSULATION

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CONDUCTOR BAR INSULATION

6 5 4

1 3 2

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STATOR OVERVIEW
Core supporting KEY bar Circumferential ribs Core End Terminals Winding Overhang

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ROTOR

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ROTOR

THE ROTOR CARRIES FIELD WINDINGS. SILVER BEARING COPPER IS USED FOR THE WINDINGS WITH MICA AS A INSULATION BETWEEN CONDUCTORS. MICANITE ,A STRONG INSULATOR IS USED FOR LINING THE SLOT. DURALUMIN WEDGES ARE USED FOR PREVENTING THE LIFT OF WINDING OUT OF THE SLOTS DUE TO CENTRIFUGAL FORCES. THE ROTOR END WINDING OUTSIDE THE SLOTS ARE COVERED BY NON-MAGNETIC STEEL RETAINING RINGS. RETAINING RING IS USED TO TAKE UP THE CENTRIFUGAL FORCE OF ROTOR END WINDINGS, IT IS SHRUNK FITTED AT ONE END

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Salient pole rotor

The individual rotor poles protrude from the center of the rotor, characterized by;

concentrated windings, non-uniform air gap, larger rotor diameters, used in applications requiring low machine speed and a large number of machine poles (example hydroelectric generation). The salient pole rotor does not provide the mechanical strength necessary for these high-speed applications. Also, the salient pole rotor presents too much wind resistance when rotating at high speeds

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Salient pole rotor

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Cylindrical rotor The individual rotor poles are produced using a slotted cylindrical rotor, characterized by:

Winding distributed symmetrically, concentrically in corresponding positions on opposite sides of a pole, nearly-uniform air gap, smaller rotor diameters, used in applications requiring high machine speed and a small number of machine poles, typically 2 or 4 poles (example - steam or gas turbine generators). The cylindrical rotor is typically a solid piece of steel (made from a single forging) for reasons of strength given the high rotational speeds to which the rotor is subjected
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ROTOR -Winding

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ROTOR SLOT
Rotor Wedge Top Slot Liner Conductor

Inter turn Insulation

Slot Liner

Sub Slot
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ROTOR

ROTOR forging 2 pole

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ROTOR POLE

ROTOR forging 4 pole

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ROTOR

High strength alloy steel single forging prepared by vacuum cast steel Slots for housing field windings Strong coupling for withstanding short circuit forces Supported on two journal Bearings Provision of axial fan/compressor for forced ventilation Provision of damper wedges for increasing negative sequence capability of rotor

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ROTOR POLE
Rotor Wedge

Cross Pole Slot

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ROTOR wedges

The wedges that hold the rotor winding in the slots are always highly stressed

The wedges must hold the copper winding and its insulation systems in place at high rotational speeds

Allow cooling gas to pass through them. The wedges do not usually sit tight in the slots. They have a loose fit, relatively speaking, to allow the copper winding underneath to expand axially during operation.

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ARRANGEMENT OF DAMPER WEDGES

1. ROTOR BODY 2. DAMPER BAR 3. SILVER PLATED ROTOR END WEDGE 4. ROTOR WINDING
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5. RETAINING RING 6. SILVER PLATED SHRINK SEAT 7. TRANSVERSE SLOTS 8. ROTOR WEDGE
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Retaining Rings

Required to hold the end-winding copper of the rotor winding against centrifugal loading during operation..

Retaining-rings are generally the most highly stressed component in the generator.

Nonmagnetic materials have been the main choice for retaining-rings because of their electromagnetic high reluctance.

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ROTOR Retaining Ring

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ROTOR Retaining Ring

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ROTOR END WINDING

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COOLING OF ROTOR WINDING

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CONNECTION OF EE COUPLING

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CONNECTION OF EE COUPLING

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ROTOR FAN

1.Baffle ring 2.Fan blade 3.Teflon liner 4.Threaded pin 5.Balancing slot 6.Rotor shaft

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ROTOR General Arrangement

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GENERATOR COOLING SYSTEM.

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GENERATOR COOLING SYSTEM.

The generator losses are dissipated as heat through stator and rotor bodies. This heat should be taken out for safe operation of the generator. The primary cooling medium is hydrogen, which in turn is passed through a water cooled heat exchanger.( 4 nos.) Hydrogen gas density is only 1/14 that of air. Hence windage losses are reduced. Thermal conductivity 7 times that of air. Hence casing size reduced. Only disadvantage is hydrogen and air mixture is explosive mixture.

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COOLING CIRCUIT IN TG

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HYDROGEN COOLER

Hydrogen coolers are provided to cool the hot gas & to maintain cold gas temp. After cooler to @ 40 deg.Cel.The cooling water flows through the tubes & hydrogen gas is passed over the tubes with the help of shaft mounted fans.

Shell & tube type heat exchanger, with coil of copper wire wound on tubes.

Four hydrogen coolers. On load cooler isolation facility ( part load )

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COOLER ISOLATION FACILITY ( PART LOAD )

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COOLING OF TERMINAL BUSHING

1. HYDROGEN SIDE FLANGE 2. TUBULAR COPPER COND. 3. INSULATING CYLINDER 4. MOUNTING FLANGE 5. RUBBER GASKET 6. AIR SIDE TERMINAL BOLT

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END SHIELD

Closes both ends of Stator Frame Fabricated rigid box type structure in

two parts

Supports and houses bearings Provision for mounting Shaft seal body,

Oil catchers, etc

Provision for supply of Bearing Oil,

Seal oil, Thrust oil and its drain

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Synchronizing Procedure

The process of paralleling a synchronous machine onto infinite busbars is known as synchronizing. Before a synchronous generator can be synchronized onto live busbars, the following conditions must be satisfied: the voltage of the generator must be equal to that of the busbars; the frequency of the generator must be equal to that of the busbars; the phase sequence of the generator must be the same as that of the busbars; and at the instant of synchronizing, the voltage phasors of the generator and the busbars must coincide.
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EXCITATION SYSTEM Pilot Exciter

Type Apparent power .Rated current Rated voltage Frequency Speed

: ELP50 /29-30/ 16 : 35 KVA : 105 amps : 220V 22V : 400 Hz : 50 cycles /sec

Stator winding resistance at 20C U-O / V-O / W-O : .0043

ohms

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Make Type

Main Exciter Type : ELR70 /62-30/ 6-10 Active Power : 1350 Kw Rated current : 3200 amps Rated voltage : 420 Volt Frequency : 50 Hz Stator winding resistance F1-F2 : 2.3 ohms (at 20 c) Rotor winding resistance at 20C U-V / U-W / V-W : .00064 ohm Fuse Rating : 750 V / 400 amps Fuse resistance : 350 ohms No of Diodes/rectifi. Wheel : 30 No of fuses blown per bridge arm 2 fuses switch off field forcing 3 fuses shut down
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EXCITATION SYSTEM : BHEL : Brushless Excitation system with Rotating Diodes

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BRUSHLESS EXCITER
FEATURES: High response excitation with fast acting AVR Multi contact electrical connections between exciter and generator field

Stroboscope for fuse failure detection Rotor Earth fault monitoring system RC circuit to avoid over voltages Dehumidifier for use during shut down

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BRUSHLESS EXCITER
PMG Rotor Main Exc. Rotor Rectifier Assembly 3 phase o/p Gen. Rotor Gen. stator

PMG Stator AVR

Main Exc. Stator CT

PT
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BRUSHLESS EXCITATION SYSTEM

ADVANTAGES

Eliminates Slip Rings, Brushgear Eliminates all problems associated with transfer of current via sliding contacts Simple, Reliable and ideally suited for large sets Minimum operating and maintenance cost Self generating excitation unaffected by system fault/disturbances because of shaft mounted pilot exciter

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Rectifier Wheel

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PMG Stator

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Main Exciter Stator

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Exciter Rotor Assembly

Main Exciter Rotor PMG Poles Cooling Fan

Rotating Diode Wheels

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Generator & Exciter

3200 Amps 420 Volts

PMG

MAIN EXCITER

GENERATOR

3, 105 Amps 220 Volts, 400 Hz DIODE WHEELS 26 Amps 60 Volts

AVR
PT

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CT

3 , 10286 Amps 16500 Volts

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BRUSHLESS EXCITATION SYSTEM

The three phase pilot exciter has a revolving field with permanent magnet poles. output of the pilot exciter ( 3 phase ,400 hz ) is fed to automatic voltage regulator- AVR. The controlled rectified D.C.Output from AVR fed to the main exciter field. The induced three phase A.C.Voltage is rectified in the rotating bridge & fed to the generator rotor winding through the D.C. Leads in the shaft. Pilot exciter, main exciter & rotating diodes all are mounted on a single shaft. The rotor is supported on a journal bearing positioned between main & pilot exciter. Lubrication of the bearing is from turbine oil system.
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COOLING OF EXCITER

The exciter is air cooled .The cooling air is circulated in a closed circuit and recooled in the cooler sections. The complete exciter is housed in an enclosure which provides flow paths for circulating of cooling air.

The fan & the rectifier wheel draw the cool air from this main enclosure and expel the warm air to the compartment beneath the base plate. The warm air is then returned to the main enclosure via coolers.

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COOLING OF EXCITER

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PMG ROTOR & FAN

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BRUSHLESS EXCITATION SYSTEM

The three phase pilot exciter has a revolving field with permanent magnet poles. output of the pilot exciter ( 3 phase ,400 hz ) is fed to automatic voltage regulator- AVR.

The controlled rectified D.C.Output from AVR fed to the main exciter field. The induced three phase A.C.Voltage is rectified in the rotating bridge & fed to the generator rotor winding through the D.C. Leads in the shaft. Pilot exciter, main exciter & rotating diodes all are mounted on a single shaft. The rotor is supported on a journal bearing positioned between main & pilot exciter. Lubrication of the bearing is from turbine oil system.
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COOLING OF EXCITER

The exciter is air cooled .The cooling air is circulated in a closed circuit and recooled in the cooler sections. The complete exciter is housed in an enclosure which provides flow paths for circulating of cooling air.

The fan & the rectifier wheel draw the cool air from this main enclosure and expel the warm air to the compartment beneath the base plate. The warm air is then returned to the main enclosure via coolers.

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CASE STUDY - 01

UNIT # 2 Occurrence Date- 07/07/2002

Taken in operation on- 27/08/2002

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CRACK ON SUPPORT BAR

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REPAIRED SUPPORT BAR

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CASE STUDY - 02

UNIT # 2 Occurrence Date- 29/07/2000 Protection operated -Generator Diff. Protection Taken in operation on- 27/08/2000

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Case History

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CASE STUDY - 03

UNIT # 2 Occurrence Date- 25/08/2005 ,07.11 Hrs. Protection operated -95 % Stator E/F, Stator interturn Taken in operation on- 26/09/2005 , 02.05 Hrs

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Thank you
Month DD YYYY

TESTS DURING O/H

TESTS ON STATOR VISUAL INSPECTION STATOR WINDING RESISTANCE IR/PI TEST @ 2.5 kV ON STATOR TAN DELTA & CAPACITANCE MEASUREMENTS NFT,DYNAMIC MECHANICAL RESPONSE OF END-WINDINGS WEDGE TIGHTNESS MAP DIGITAL ELCID TEST TESTS ON ROTOR VISUAL INSPECTIONS AC IMPEDANCE TEST WINDING RESISTANCE RECURRENT SURGE OSCILLOGRAPH DIODE CHECKS
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STATOR CORE

DIGITAL ELCID TEST Electromagnetic core imperfection detection ( ELCID ) test is an alternative test to the Full Flux test. Around 4% flux will be created in the stator core with the help of a "loop" wound torodially around the core. A pick-up coil will be used to access the leakage fluxes that bridge adjacent teeth. Fault currents generated at the sit of "hot spots" or shorted laminations, between the accessed leakage fluxes and the exciting fluxes will be noted, to detect the shorted laminations, using an ELCID kit specially developed for the purpose. Benefits: Identification of core faults such as interlaminar shorts and hot-spots. Timely detection of the core defects helps in prevention of earth faults

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ROTOR

RECURRENT SURGE OSCILLOGRAPH A fast step voltage impulse (12 V) is repeatedly applied using a

Recurrent Surge Oscillograph (R.S.O.) to the rotor winding at one of the leads and the terminal voltage waveform, consisting of reflections from rotor windings, is examined at the other lead. The process is repeated after interchanging the leads and the two waveforms are superimposed to check for rotor winding abnormalities like shorted turns, earth faults, interturn faults or rotor high resistance areas. The method is largely suited for 2 pole machines. Benefits: Effective detection of rotor winding interturn shorts or high resistance joints.

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NFT ( Natural Frequency Test) The operational condition and stresses on the endwindings may loosen the ties and blocks and may cause the coils to vibrate or move. The natural frequency of endwindings should not be matching with the system's natural frequency, which may otherwise cause high amplitude vibrations due to resonance, increasing stresses on the machine. This test is thus conducted to identify the natural frequency of endwindings. The response of the end winding to the tap of a hammer will be recorded using an accelerometer pickup and analyzed to characterize the relevant end winding resonant properties. Benefits: Identifying natural frequency of endwindings Suggesting corrective actions to hold endwinding in place Prevention of resonant condition.

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WEDGE TIGHTNESS MAP

Wedge looseness is a dangerous condition for two reasons, firstly it may foul with rotor causing mechanical damage and secondly the coils are not held tightly in the slots. This may lead to coil surface erosion due to its rubbing with core and eventually partial discharges in slots. wedge mapping is performed to identify which wedges are partially or completely loose/damaged. the wedge deflection test is done by applying pressure on the wedges using a known weight and measuring the deflection of the wedges. Benefits: Map identifying loose wedges Analysis of the severity of wedge looseness

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Capability limiters

synchronous generator capability limiters are as follows 1.MVA or armature current limit of generator: this depends on the cooling system of generator so that temperature rise in generator is limited to safe value. depending on cooling system effectiveness and temperature limit for the insulation used in generator, MVA limit is decided. 2.MW limit: this is determined by the power output capacity of prime mover to which generator is connected. 3.rotor angle limit: this is related to stability of generator which is synchronised to the grid. ideally this could be 90 degree, but in practice this is limited to70 degree so as to have better stability margin in transient and dynamic condition. the generator falls out of synchronism in transient condition if rotor angle is close to 90 degree. 4. rotor current limit: the field winding placed on rotor has got limited current carrying capacity, beyond which it may burn .so this limit is used. all these limiters make capability curve of g generator within which the generators operates safely
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STATOR WINDING

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