HYDRO GENERATORS
Contents
I. INTRODUCTION
Hydraulic turbines are highest efficiency prime movers used for power
production, which utilize the energy of water ways. The hydraulic energy
contained in the streams is converted by such machines to mechanical powel-.
Basically these are of two types :
1. Impulse Turbines
2. Reaction Turbines
Pelton turbine is the most common form of impulse turbine which is named after
Lester Allen Pelton of California, USA (1829-1908) who had patented the split
elliptical bucket runner in 1880. This machine is suited for high heads and low
discharges.
The Pelton turbine consists essentially of a nozzle or nozzles directing jet/ jets of
water into a number of buckets attached to the periphery of the runner which is
keyed to the shaft coupled with the generator. The buckets are symmetrical
relative to the centre line of the jet, having a central splitter edge, which decides
the jet equally. This eliminates side thrust on the runner and a thrust bearing is
consequently not required.
The distribution piping feeds water to all the nozzles at constant flow velocity,
through branch pipes.
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11. CONSTRUCTIOBAL DETAILS OF REACTION TURBINE
1. Kaplan Turbine.
2. Francis Turbine.
Kaplan Turbine
Kaplan turbine is the axial flow reaction machine named in honour of Prof.
Dr.Victer Kaplan of Bruenn, Germany (1 876-1934). This is suited for low hcads
and large quantities of flow and where turbine has to run on part loads too.
Francis Turbine
Francis turbine is the mixed flow type of reaction turbine named after Janles
Richens Francis of England ( I 815-1892). This turbinc is suited for medi~um
heads and medium flow quantities.
The reaction turbine consists fundamentally of four main sections name1)- the
scroll case, the guide apparatus, the runner and the draft tube. The casing
distributes water equally to all parts of the gate apparatus and imparts to it a
whirl. Guide apparatus controls the direction and quantity of water reaching the
runner which abstracts the water whirl converting it into mechanical energy. The
'
draft tube conveys the discharged water from the runner to the tail race and
recovers from it a large proportion of its kinetic energy.
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SELECTION OF TURBINE BASED ON DIFFERENT FACTORS
5. Tubular Below 20 m
6. Reversible Fra~lcis 50 m to 600 m
Pump / Turbine
NOTE :
1. Pelton type of turbine under extremely high head operation very nearly at
constant head and problem of variable head is seldom important.
2. Bulb Type and S-Type tubular turbines although can operate with head and
output variation same as that of Kaplan type, however, usually the head
variation is less.
7
3. 100% output is the output corresponding to 100% guide vane opening at
design head.
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BHEL RANGE OF PRODUCTION
; Actual
Capacity
i Actual
! KAPLAN
.......................
Capacity
Actual
Capacity
Actual
; SPHERICAL VALVE
I Capacity 500 to 4000 200 to 1200
I Actual
1 B.F. VA'VE
Order Commissioned
Pelton
:..................................................
. Francis
. . . . . . . ....
I Kaplan
Reversible Francis
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2.0 Design & construction features of Hydro
Turbines & Valves
DESIGN & COSSTRUCTIOX FTATC1RT.S OF HYDRO TURRISES & VALVES
T h i s a r t i c l e g i v e s a b r i e f a c c o u n t o f t h e advancements made
by BHEL and i t s c a p a b i l i t i e s i n t h e f i e l d o f h y d r o t u r b i n e s &
va l ves .
The l a t e s t d e s i g n t r e n d s o f h y d r o t u r b i n e s a r e l a r g e l y based
.on c u s t o m e r ' s requirements, which predominently f a v o u r s
h i g h e r s p e c i f i c speed, higher turbine efficiency, lower
submergence, wide o p e r a t i n g range, shorter delivery cycle,
mpde l testing ,and field testi-ng for p r e d i c t i'ng" ,
1. Improvement of h y d r a u l i c e f f i c i e n c y o f t u r b i n e through
o p t i m i z a t i o n o f pressure and v e l o c i t y d i s t r i b u t i o n s .
Now a days t o d e v e l o p f l o w e q u a t i o n s a t d i f f e r e n t p o i n t o f
oper' a t i o n s and computing v e l o c i - t y a n d p r e s s u r e d i s t r i b u t i o n
In t he e n t i r e range o f b l a d e i s p o s s i b l e b y u s i n g l a t e s t
hardwares and s o f t w a r e s . BHEL i s us i ng v a r i o u s sof twares
f o r such purpose a r e NISA, TASKFLOW, BLADEGIM e t c . and o t h e r
inhouse developed s o f t w a r e s . T h e s e s o f t w a r e s have a l s o the
c a p a b i l i t i e s t o access t h e p e r f o r m a n c e o f machine a t v a r i o u s
o p e r a t i n g c o n d i t i o n s , w h i c h i n t u r n reduces c o n s i d e r a b l y the
volume o f work o f model t e s t i n g . .
The c a s t f a b r i c a t e d r u n n e r s a r e economical i n m a n u f a c t u r i n g .
Additional advantages a r e t o achieve b e t t e r homologay w i t h
model and s u r f a c e f u r n i s h r e s u l t i n g i n h i g h e r e f f i c i e n c y and
improved c a v i t a t i o n a l p r o p e r t i e s . I n case o f b i g s i z e Kaplan
turbine runners t h e t r u n n i o n s are f o r g e d separately and
b o l t e d t o c a s t s t a i n l e s s s t e e l blades. T h i s f e a t u r e s enables
removal of runner b l a d e w i t h o u t c o m p l e t e dismantling of
runner assembly, r e s u l t i ng i n lower downt ime and i s a l so
economical.
. x.
t h e Pel t o n r u n n e r s a r e t a s t i n t e g r a l ' l y w i t h bucket?.
Mostly
Sometimes f o r g e d r u n n e r s are being asked, i n view o f b e t t e r
grain structure and mechanical properties. T i l l date
s m a I I / m e d ~ u m s i z e runners f o r number o f p r o j e c t s has been
forged. The manufacturing process is s t i l l under
development. It i s worth t o p o i n t o u t t h a t the largest
capacity p e l t o n machine o f the w o r l d - B i e u d r o n HEP, i s
equipped w i t h i n t e g r a l l y c a s t runner o p e r a t i n g a t 1870 m
head and g e n e r a t i n g 423 MW. Runner/Runner b l a d e s m a t e r i a l
most widely used by various s u p p l i e r s a r e 13% Cr-4% Ni
Stainless Steel. Although number o f m a n u f a c t u r e r s supply
stainless s t e e l runners with d i f f e r e n t N i - C r combinations.
Some m a n u f a c t u r e r s p r e f e r t o supply c a s t s t e e l r u n n e r w i t h
stainless o v e r l a y over t h e a r e a prone to cavitation.
However 13-4 s t a i n l e s s s t e e l c a s t r u n n e r / r u n n e r b l a d e s a r e
widely preferred.
nc. ' RUNNER REMOVAL ~RRANCEMNT w r r ~ nc. RUNNER REMOVAL ARRANCEh€ENT WKWOlJC
DEWATERl N G OF TmRACE DEWATERINC OFTAJLRACE
:-
Replacement o f an e r o d e d runner w i t h a s p a r e i n t e r c h a n g e a b l e
r u n n e r a I so consumes cons i derab I e t i me because t u r b i ne
r e g u l a t ing mechan i srn and, generator have t o be d i smant l ed f o r
t h i s purpose. U t i l i t i e s located i n t h e North-East , where
s i I t content i n water i s very h i g h , had indicated a
preference f o r p r o v i s i o n of a f e a t u r e t o reduce the
downt ime f o r ma i n t e n a n c e . ,
I I
, ,
i > Repair o r replacement c o u l d o n l y be done b y t a k i n g t h e
top cover o r p i v o t r i n g t o a major workshop f o r the
w e l d i n g and r e m a c h i n i n g .
Butterfly valve door and spherical valve body and door, were
generally manufactured from cas steel. With the development
of fabrication technology and accurate structural analysis
.these components are now being manufactured from steel
plates by fabrication process. The spherical valve body i s
fabricated in halves, without flanges. Both the halves are
welded in the shop. The design enables the complete assembly
of valve with door in position.
I (b) Design ~ u i d e
. .l .- i n e sf o r S i l t y Water
.. .
Proper I y adApt i ng t h e hydrau I i c design by se I ect i ng
I suitable - design parameters and choosing optimum
o p e r a t i n g . - c o n d i t i o n s , s i l t e r o s i o n can be avoided.
I A l s o mechanica'l d e s i g n o f runner, g u i d e vane s e a l s ,
\I t u r b i n e s h a f t s.eals, main i n l e t v a l v e e t c a r e d i f f e r e n t *
I
f o r s i l t y watec i n cornparision t o c l e a r w a t e r .
1
I
V. CONCLUS ,
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O N h .
. . -- .
&\>,
I
TURBINES
FRANCIS
KAPLAN
PELTON
OTHERS : Propeller, Bulb, mini-micro etc
INLET VALVES
SPHERICAL TYPE
BUTTERFLY TYPE
PENSTOCK BUTTERFLY VALVES
TURBINE AUXILIARIES
OPERATION OF TURBINE
PARTS
NO MAJOR PROBLEMS
FOR NEW DESIGNS 100 BAR OIL PRESSURE SYSTEM IS
BEING USED FOR GOVERNING WHICH USES NITROGEN
BOTTLES & H.P. COMPRESSED AIR SYSTEM HAS BEEN
ELIMINATED.
Hydro electric power plants are mainly used as peaking stations, that is to match generation
to load requirements. Governing system is used at these power plants for control of the
machine, i-e., speed and I
d regulation.
2. Governing System:
Governing system is a combination o f devices and mechanism that detects speed deviation
from a set value and converts it into a change in servo motor or wicket gate position.
It includesthe ..
- Speed sensing elements ' r.
- Governor control actuator
- Hydraulic pressure supply system
- Electro Hydraulic Governor.
- Distributingvalve
.- Turbine control servomotor
3. Governor:
Governor controls the flow of water through the turbine to control its speed during
unsynchronized condition and to control load when the machine is connected to the grid.
4. F m o f G a v m r :
- S p e d control of unit
-A l m m a l i c o p e r d n g o f ~ ~ ~
- Frequency verses gate opening under specified permanent droop setting.
- Load control of machine
- Frequeocy amtrol under isolated grid.
- Normal & emergency shutdown
5. Basic requirement of governor:
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To satisfy IEC 6 13 12 requirements, following feature is essential for the governing system
1 Over laps in thc main distributing valvc for regtrlatcd flow o f o ~through
l
opening/closing ports.
2. Feedback system for swbility duringsmall,transients.
3. Timing device to achieve faster rate of closing and opening to limit speed rise & Y.
pressure rise in water conductor system of hydro power station.
4. Gate limit feature for blocked gate (i.e. blocked load) requirement.
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9. Configuration of Electro-Hydraulic Governing system
It comprises of
- Hydro Mechanical Cubicle (HMC)
- Electronic Cubicle (EHG)
- Hydraulic Over Speed Device
- Speed sensing device
- Oil pressure unit.
10. Hydro-Mechanical Cubicle (IIMC):
It houses hydro-mechanical components like
1 . Electro Magnetic Transducer
2. Hydraulic Amplifier
3. Auto Rod
4. Pilot Distributing Valve
5. Main D~stributingValve
6 . Feedback mechamsm
7. Master Controller
8. Limit motor, Hand wheel and Gear box
9. Limit according to head .,
10. Aut+Manual Solenoid valve
11. Emergency Solenoid valve
12. Duplex Filter
Hydraulic .4rnplifier:
Hydraulic amplifier amplifies the force developed by the coil of EM?' to drive Auto Rod and
control valve. The pressure uribdance created in the node forces the needle of the hydraulic
amplifier to move in one direction, which causes the moving device of the hydraulic
amplifier to operate under any condition of £lapper movement. Hydraulic amplifier operates
at oil pressure of 18-20 KgJsq. cm. Under manual control this hydraulic amplifier is
bypass&.
Auto Rod:
Auto rod transfers the movement of EMT to Pilot valve after mechanical amplification by
hydraulic amplifier Under steady state conditions zero mA flows tbrougb EMT and position '
of the flap is at the centre of the two n o ~ e s Under
. this condtion auto rod length is sci
adjusted that pilot valve spool is maintained in mid position.
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Pilot valve:
The mechanical s~gnalfrom hydraulic transducer moves the floating levev which in turns
operates the pilot valve needle. For opening sequence the pilot valve needle moves up, which
in turn moves the main distributing valve spool upwards. For closing sequence the needle
valve is forced down by the floating lev- which forces the slide valve spool down. The
magnitude of the slide valve movement is cont~olledby the floating lever which acts as
feedback for resetting of the pilot valve needle. For steady state operation the floating leveris
in horizontal position with no signal from hydraulic amplifier.
Master Controller:
Master controller consists of set of cams and limit switches to provide different position of
guide vane for automatic control. These cams are mounted on the same shaft which is rotated
through pulley and wire rope arrangement by the moving counter weight. Guide vane fully
closed, fully open, at no-load positions etc. are derived from this master controller.
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1,
'I,
Auto-Manual solenoid:
Electro-magnetic transducer is provided with an Auto-Manual changeover solenoid valve to
facilitate changing governor mode of operation from Auto control to Manual control and vise
versa.
Duplex Filter:
Electro hydraulic govemor requires clean oil for trouble free operation. One duplex filter is
provided for filtering the oil to the purity of 70 microns. Tbe design of the filter provides for
flushing with oil the filtering element wh~chis in-operative without necessitating the removal
of this element fiom the casing.
Indications:
The following indications are provided on HMC.
.-
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Operating principle:
With the continuous movement of the toothed wheel, following fundamental relationship
between impulse transmitter frequency and speed implies.
NXP
F=
60
Where :
F = Frequency of the sensor's output signal in Hz.
N = The speed ofthe wheel in R.P.M.
P = The number of teeth on the pole wheel
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FIRST ANGLE PROJECTION ( A L L DlMENSIONS A R E IN mm.)
AMPLIFIER
: p
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c ~ n ToY r L 1 --_ >
Y I u ---> C A R O TYPE I > CARD T Y ~ C
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BHARAT H E A V Y ELECTRICALS L T D .
I i ' BHOPAL
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----
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WCIGHT (Q) RV. TO AISY. ma. ITCM n n
WO. -.VC
NIT,".
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1 .8 .TITU 1 1 7 D a A W I M NO. P 1 0 U
7.2 SUPPLIES
1.2.1 Control supply
I
110\' DC
1.2.2 Electronic circuits:
215V DC regulated supply through either of
+ Individual motorised reference setters for speed loop and power loop
+ Redundant stabilised power supply
+ Electronic speed relays
+ Speed slgnal fail monitoring
+
1-t adjustment accordmg to head
+ Joint control
+ Electronic cam
Transducers for SCADA
Start, stop and other control circuits
1.6 ADJUSTMENTS
Regulating rack
G Gate feedback signal rang (upper & lower)
9 Speed trim
S Opening damping limit
: 9 Closing damping limit
0 No load gate limit
0 Dead band (Positive & negative)
3 Phase advance gain .r
0 Permanent droop
0 off line damping time constant
0 Off line damping percentage
0 On line damping time constant
0 On line damping percentage
Where,
f = Frequency of the sensor's output signal in Hz
n = Speed of the toothed wheel in W M
p = Number of teeth on the toothed wheel
Number of teeth is so chosen that at rated speed the SSG produces a 100 Hz signal. This signal
representing the machine speed, is processed in a frequency to voltage converter, which ghcs an
output of 0 to -10 VDC for an input frequency signal of 0 to 200 Hz This signal is compared
with speed setting signal in an amplifier of gain "8" so that at nominal speed and speed setting
the resultant signal is zero volt and varies by + 0.8VA-h depending upon whether the speed is
above or below normal.
The above signal is fed to a control amplifier which comprises of a phase advance amplifier (for
derivative control) and a multi-input summing amplifier. The phase advance amplifier has a
resistivecapacitive feedback and its output varies with the rate of change of input s g d . Thus it
provides "speed error signal and its rate of change", for faster governor action. In the summing
amplifizr the moditied spzed error signal is summed up with permanent droop and t m p o r a q l
droop slgnals. The signal levels and input resistors are so coordinated that output of the
summing amplifier under steady state is zero volt.
The droop signals are derived bv comparing the gate reference signal with the gate feedback
signal (+2 to -13VDC). The resultant srgnal directly applied to the summing amplifier through a
potentiometer is called permanent droop signal, whereas differentiation of the resultant slgnal
with a variable time constant RC network provides the temporary droop signal. ?he temporary
droop signal, also known as the damping signal transiently opposes the gate movement and thus
provides main stabilisation to the speed control loop, which is otherwise highly unstable due to
large inertia of the hydraulic .system. Both the time constant and the percentage of the temporary
droop signal are adjustable.
Transfer function of the temporary droop circuit is :
2.2 FEATURES
Individual motorised reference setters for speed loop and power loop
Individual reference setters for the speed loop and the power loop helps the operator in
getting a true fee& of the quantum of MW load being generated by the machine. The
motorised reference setters help in remote operation of the reference from either the
control desk or the autoqnchroniser.
Electronic speed relays
Logic sgnals are required to be generated at Merent operatmg speeds of the machine to
achieve different types of field device controls for a generating unit. The speed fiedbacl;
signal is compared with a set of reference values in a set of PCBs to achieve the desired
result.
Speed signal fail monitoring
This feature monitors the healthiness of the speed feedback slgnal and initiates a
potential free contact on loss of the signal which may be used for alarm annunciation
and thus prevent abnormal operating conditions of the turbine.
Redundant stabilised power supply
Two stabilised power supply units one powered fiom station DC and the other fiorn the
station awdiaq AC help power the various PCBs used for speed regulation, speed
relays, joint control. limit adjustment and electronic cam circuits. These units are
connected in a hot standby mode through isolating diodes to increase the availability of
the electronic circuits which continue to function even in the case of failure of one lmit
or the failure of the input to the unit.
Limit adjustment according to head
As the name suggests, this feature adjusts the maximum Limit to which the guide vanes
may open according to the available water head. It thus prevents overloading of the
generating set during the monsoon periods by restricting the guide vanes to a lower
opening value.
Joint control
This feature enables uniform loading of multiple generating sets in a power station with
the help of a single joint loading command or joint frequency command from the joint
control desk. The control signal of the individual governor is replaced by a signal as
decided by the joint control circuit, the output setter of the governor panel continuously
tracks the joint controlsignal so as to achieve a bumpless transfer during changeover of
any particular unit fiom joint to individual controi mode.
Electronic cam
The runner blades of a Kaplan turbine need to abgn themselves to a particular position
dependmg on the guide vane position and the operating head of the unit in order that the
turbine operates at maximum effidency. The electronic cam achieves this relationship
between the guide vane and the runner blade at various operating heads known as the a-
p characteristics dispensing with the mechanical cams used in older machines which
involved complicated rnachrnrng durine, manufacture of the governor equipment and
also generation outage for replacing the cams in the hydraulic cabinet.
Transducers for SCADA
In order to achieve master control from a SCADA system, the major analog signals of
the governor, viz speed and output reference settings, operating speed, operating guide
vane position and its limit position, runner blade position, the balance signals of the
guide vane and runner blade, are fed to the SCADA system in the form of standard 4-
20mA signals which are derived from transducers provided in the govemor cabinet.
by
B. L. Singh
ADGM'H7-E
BHEL, Bhopal - * ..,
Introduction:
Governing techndogy for hydro turbine evolved from mechanical control into
electronic control in the early 1960s. This offered some immediate advantages such
as, reduction of moving parts, increased range of compensation adjustment and the
ability to cmb-04 the unit output convenientty using ekcbmic set point signals. These
electronic controls were generally an electronic implementation of the mechanical
temporary droop type governors, and did not offer much advantage.
Description:
The programmable, Microprocessor based Electro Hydraulic Governor provides high
accuracy, resolution and speed of response. It also offers additional advantages such
as stabilrty of set values,
- .
Rexibilrty in designing
. .
and reducing wiring, intelligent
W-W. speed ltamtim spreciselyandmonttonng - The a m b d h is desrgned
using 32 bit processor.
Principle of operation:
The governor IS basically speed sensing type, sensitive to speed devlation from a set
value of speed. It accommodate the micro processor based regulating models and self
~ ~ d e v P c e s ~ b m ~ 3 2 b i 2 m i c
Page 1of 3
It accepts speed signal generated from SSG which is processed to a microprocessor
based measurement and monitoring transducers. The binary and analog output, both
are available from the module. The control and regulation fundiol?s for H i z i n g
function like a d e r a t i o n signal, temporary droop or PID is realized in software using a
function block language.
Speed actual value is compared with set speed value in a comparator module, which
is further differentiated in a differentiator block that outputs a value equal to speed
error and its rate of change. This signal is summed up with permanent droop and
temporary droop signals and the gains are so adjusted that under steady state the out
of the summing amplifier is zero. The selector fundion block does the selection of get
f & d bad< or W feed bad< signal. The ABW/Gate ecror is d d k m t h M to oWain the
.temporary droop signal. Faciltty is provided for selecting regulation algorithm i.e.
temporary droop or PID. The processor are connected to the engineering station
through Ethernet connection.
Se&dion I commands:
Following can be seleded and changed from tbe auto sequencer:
1. LxaURemOfe
2. Gate Mechanical Limit ~ a i s e j ~ a i s e
3. Electronic Limit RaiseILower
4. Speed RaiWLower
5. Power RaiseILower
6. Droopselection
7. Power/Flow/Speed control selection
8. Jet-
Functions:
@) GOVERNING FUNCTIONS:
Automatic load Frequency control.
Page 2 of 3
GENERAL FEATURES:
Hardware:
- Modular bus based architecture which allows for flexibility in hardware configuration.
- Inter modules communication thmugh the bus.
- Signals resulting in high transmission reliabilrty.
- Each max DNA module contains a m i t s for monitoring its m t important fundion.
- If a fault occurs, the type and possible locations are indicated by light emitted diodes
output signals. Modules level self diagnostics is realized in this way.
Software:
- PID/ temporary droop control scheme for regulation.
- Start up and shutdown logic
- Speed relays
- Electronic limit
- Limit axording to M.
- Synchronous condenser operation
- Easy implementationof sofhmre p m g h function block programming language.
Page 3 of 3
6.0 Selection criteria, main construction
Features, Leveling, Alignment &
Boxing off and O&M of
Hydro Generators
HYDROGENERATOR
TABLE OF CONTENTS
1. INTRODUCTION
The design of hydroelectric generators differs in n?an). respects li-om that of other
electrical machines. The output of these generators ma!- range liom a Sew megawatts to hundreds
of megawatts and tlie speed of rotation ma! \-at-!- from about 60 I-pni to 1500 ~ p m The . output.
speed, inertia and other parameters of hydro generators \ar!; widely with site conditions. Even
tlie detail constructions are greatly influenced by such factors as tlie transport facilities available,
niacliine tool capacity, ease in erection and dismantlinz stc. 1-lie result is that cach projzct has its
c;\\.i:zniqur !~?acliines
and the exact duplicate fo: 1:i.o pri:j<c:s ai-2 :are.
Hydro generators are slow speed, large diameter s! nchronous machines and therefore. ths
rotor is normally of salient pole constl-uction. 111this papzr. tlie selection of bearing arrangement.
method of rim construction, construction of bearing and ventilation aspect of hydro senerator
\vill be discussed.
2. BEARING ARRANGEMENTS
In vertical shaft hydro generators, 4 well recognized arrangements as discussed below are
usually adopted.
In this arrangement, the thrust and one guide bearing are above the rotor and one guide
bearing below it. The thrust bearing bracket spans across the stator in this arrangement. The
thrust bearing coolers are more readily accessible. This arrangement results in taller machines
and where the stator diameter is larger, the thrust bearins bracket becomes massi\.e. Bearings are
insulated against circulating shaft currents.
This arrangement is used for higher speed units where stator & rotor diameter are small.
This is similar to suspended rotor arrgt. except ha: the bottom guide bearing is omitted lii
is sometimes possible to extent turbine shaft right up to the generator rotor.
In this arrgt. the thrust bearing is provided belo\\ the rotor. There is one guide bearing
above & one below the rotor. The thrust bearing housing has to span smaller pit, the dimensions
of which are decided by the largest turbine component \vhich has to be lowered into the pit.
In this arrangement, one guide & thrust bearing is below the rotor and there is no guide
bearing at the top of the rotor.
This type of construction is usually preferred where ever possible on account of its
simplicity and economy. It is practicable to have this arrangement for generators with large
diameter and short core length (slow speed machines). Such type rotor is more stable while
revolving than one with a small diameter and iong core.
The rim is built around spider and is free to expand elastically under centrifugal force
without straining the spider. Therefore, spider of little lighter weight and strength can be used for
this construction. Full load torque is transmitted by the spider to rim by five part keys which are
tight fit circumferentially but have radial clearance.
Solid disc rotors are used in case of very high speed machines. The peripheral velocity
considerations at runaway speed and the niaxiniu~nwidth in which rolled steel plates & forgings
are available commercially limit the stator core diameter o f these machines to about 3.75 mersrs.
Number of discs having approx. 200 mm thickness are machined accurately and then assemhied
together to form the disc rotor. The pressure between the discs is s o chosen that the entire rotor
behavior as one mass of steel. Poles are directly mounted on this rotor.
l'he thrust bearing is either o f spring mattress type or pivoted type. The stationary pal: of
the thr~istbearing consists of white nietalled segmental thrust pads supported on a mattress of
spring or on hardened steel pivots. The circumferential movements of the segmental thrust pzds
are restricted by thrust pads stops, \vhich is normally pin type or key t\.pe. Radial in\\.ard 2nd
out\vard ~novementof thrust pads is zisn rssiricted by anchor plates and siops. Ho\\*e\.sr.ali 5 s
thrust pad segnients are free to tilt. The thrust pads are eccentrically supported on spring mattrsss
or pivot, facilities the formation of oil fil~iibetween thrust pad and t h l - ~ ~block.
st
l'he rotating part of thr~istbearing is niirror finished surface of tlirust block. For machines
of fig-l Rr fig-?. runner disc is bollcd to l11c thrust block, to facilitate insulating the thrusr bearing
for preventing flow of current. The insulation is glued to the runner disc and then it is bolted to
the thrust block. The under side of runner is ~nirrorfinished to provide thrust face.
Hydrostatic lubrication system is also provided in the thrust brg. This helps in trouble
free operation of thrust brg. at slow speeds i.e. during starting and stopping. The H.S.
lubrications also helps in almost effortless manual rotation of rotor during alignment 2nd
maintenance. For H.S. Lub. System, the oil from brg. housing is fed at high pressure betwesn
thrust pad and thrust block.
The guide bearing comprised o f white metal lined segmental pads arranged inside a
cylindrical support in the brg. housing and bearing on journal surface machined on the thrust
block or shaft sleeve. A pivot bar is screwed to the back of each pad to enable the pad to rock
slightly to take up a suitable position and to facilitate the formation o f oil film, while running.
The lower part of the pads is immersed in oil for lubrication. The guide brg. clearance is adjusted
by adjusting the shims between guide pads and the pivot bar. The upward & downward
movement o f pad segment is restricted by keep plates at top and bottom. In circumfereniial
direction, a limited freedom is allowed to the guide pad segments by the guide pad stopt to
facilitate its rocking.
5.0 VENTILATION
Axial flow aerofoil / sheet fan or centrifugal fans are mounted on rotor for cooling of rhe
generators. The cooling air passed through interpolar space in the rotor, on to the ventilating
ducts in the stator core and then passes through air to water coolers.
The ventilation of the machine depends mainly on the performance of the fan. Air guides.
air baffle and air splitters are also provided with axial flow fans. These items direct air to f l o ~in
desired directions and also help in efficient performance of the fans. T h e fan blade tip to air
guide clearance is very important because the fan performance largely depends on this
parameter. Measurements on ventilation of various machines have shown that just by accurately
setting this clearance 30 to 50% gain in the ventilation performance can be achieved.
The cooling air in stator follows three paths, through stator core, between fingers 2nd
through end winding. area. The air passages in these three paths. are adjusted such that flou in
each path is sufficient to cool the portion of the slight adjustment in the air passage which is
normally done only after thorough measurement.
Top and bottom brackets are required to house the thrust and guide bearings, iminersec in
oil. In addition, top bracket supports the weight o f generator flooring, casing etc. and the bot?~m
bracker sumorts
. . the weight of the rotor while jackins (in case thrust bearing is at the top of :.he
rotor).
The brackets are o f fabricated steel structures and are designed to give sufficient stiffrzss
against the loads experienced by them.
CLOSED C O U P L E D
S U S P E N D E D ROTOR ARRGT.
FIGURE-2
SESll-UMBRELLA ARRGT
CHAPTER-2
LEVELLING. .ALlGUJ;IEYT A Y D %IAG>ETIC C E N T E R I N G
Levelling and alignment along with centralising are most important operations in the
erection of hydro generators. Trouble free operation of the machine depends on
satisfactory achievement of level, alignment and centralising of the rotor. These
operations must ensure tliat-
For proper erection with respect to levelling. alignment and centralising following
sequence is followed:
2. S T A R T I N G C H E C K :
Tlie turbine shaft will have to be set up truly vertical and central to the stay ring
by the turbine erector. The turbine shaft, however, will be set lower than its normal
running position to clear the coupling spigot when generator shaft is lowered. The
generator erector has to satisfy him self that coupling spigot does not foul with
generator shaft when lowered.
3. S E T T I N G O F T H R U S T BEARING ELEVATION:
3.1 Check that the sole plates and bracket holding do\\,n bolts are all tightened.
3.2 The bracket elevation can be set by adjusting the shims and it is to be ensured that the
turbine runner will be at the desired level under running conditions.
3.3 Allowance must be made for deflection of the bracket and thrust bearing springs under
normal load (i.e. weight of rotating parts and hydraulic thri~st)
4.1 The generator rotor is supported on the thrust bearing but not coupled to the turbine shaft.
4.2 Fit four of the guide bearing pads of generator guide brg. which is nearer to thrust brg.
with alignment pivots at 90" intervals. Close up the clearance to a minimun~:yet allowing
the rotor to rotate. Guide bearing pads are to be coated with molybdenum disulphide
grease.
4.3 Place a precision level (0.020 mm in 1 meter accuracy) on the top face of the thrust collar
in any position. Set the level s o that the bubble is exactly at the centre.
4.4 The rotor is rotated through 90" and the level gauge reading is noted. The same procedure
is repeated for 1 80",270° and 360" rotation.
NOTE: After each rotation through 90°, the guide bearing pads are to be slackened off
before taking readings.
4.5 For a truly horizontal thrust face, the reading of the precision level would be constant. It
is not expected that it will be practicable to achieve precisely the same level readings in
all directions of the shaft and the results can be taken as satisfactory if the maximum
reading is within 1 division of the level with a level accuracy of 1 in 50000.
4.6 To obtain the required level accuracy, the shims under thrust bearing bracket feet are
adjusted. Minimum number of the shims for a given adjustment should be used i.e.
thicker shims are to be used wherever possible.
5. ALIGNMENT OF ROTOR
5.1 Set up two dial gauges each on the journal surface nearest to T.B. and at rhc senerator
coupling in two mutually perpendicular directions X and Y . The mean value of the
readings in X and Y axis is then used.
5.2 Rotate the rotor through 90°, 1 80°, 270" and 360". Record readings of the dial gauges in
the format given below:
5.3 Throw circle s h o \ v i n ~the accuracy of alignment is con~putedfro111the fo!!o\\ in: tahle:
Gen. couplins ( 3 )
NOI'E: The reading at 0 and 160 should be same within the tolerance of reading
accuracy. If these readings consistently show difference, there is a possibilits/ that the
shaft is not freely rotating. The oil retaining sleeve or some such other component may be
touching the rotor. This has to be checked. It is to be checked whether any jerk is
produced while rotating the rotor which affects the initial reading. If so, the initial
reading should be taken after the jerk.
5.4 To find out the throw at Gen coupling plot the co- ordinates of on a graph paper to a
suitable scale. Draw a circle of minimum radius, which passes through any three points
and enclosing the other two. Diameter of such a circle should be in close agreement with
the throw (run out) readings obtained in factory. The throw circle diameter should not
exceed 0. I inm.
6.1 Pull the turbine shaft towards the generator shaft and couple the flanges by permanent
bolts. The force of tightening the bolts should be identical. The diametrically opposite
bolts should be tightened first.
6.2 Remove the turbine guide pads and seals and the turbine support so that the : shaft is
suspended freely from the thrust bearing.
6.3 The gape between the turbine runner and stay ring should agree with the setting obtained
by the turbine erector while centralising the shaft .The generator guide bearings are to be
adjusted if necessary. If this centralising affects the bracket centering by more tan 0.25 mm.
the bracket will also have to be contralised.
6.4 Fit the gauges on the turbine,guide bearing journal level in X end Y-axis.
6.5 The throw at the turbine guide bearing journal level is computed in the same way as
explained in earlier paragraph with appropriate modification on turbines journal in place of
the generator coupling.
6.6 Rotate the rotor through 90°, 1 80",270° and 360°, The dial gauge readings are recorded in
the format given below in clause 6.7. While taking these readings, the guide pads are
slackened.
c = a-b
6.8 Plot the co-ordinates of 'd'in suspended or semi umbrella m/c or 'c' in umbrella m/c. on a
graph paper to a suitable scale. Draw a circle with minimum radius passing through any
three points and enclosing the other two. Diameter of this circle should,be in close
agreement with the throw (run out) obtained in the factory.
6.9 As per N E W standards the maximuin throw circle diameter permitted at the turbine
guide bearing is determined by the formula: -
Where L is the distance between the generator thrust face and turbine guide bearing.
D is the out side diameter of the thrust bearing. If by this standard the permissible throw
exceeds the turbine guide bearing clearance, the throw should be limited to a value of a little
below the turbine guide bearing radial clearances.
6.10 The throw at the bearing journals and flange is corrected if it exceeds the permissible
limit defined above. Small throw may be corrected by differential tightening of the
corresponding bolts of flange connections. If the throw is considerably large, scraping
of end surface o f turbine or generator shaft could be done by stainless steel packing
may be placed between flanges. Packing should be graded with steps covering not less
than 2/3rd radial depth o f flange.
, 6.11 Plot a graph with co-ordinates of point 'e' after the turbine throw has been hrousht
under acceptable iimits. it inay be necessary to change both -e' and -d' tosether. i n such
cases, shims have to be put or scraping may have to be done at the joint surface
between thrust collar and runner disc.
6.12 The collector is now assembled.
6.13 Fit two dial gauges each at one of the collector rings and at generator guidc beafng
nearer to t h r m 'hg. Rotate the rotor ihrough 902.1 802.2702 and 360". The tiai gzsgc
readings are recorded in the format given belo\v:
Level X axis Y axis
Angle of rotor rotation 0" 90" 180" 270" 360" 0" 90" 180" 270" 360"
Collector Ring(a)
c = a-b
6.14 Plot the co-ordinates o f point 'c' on a graph paper. The throw circle diameter as defined
earlier should be limited to NEMA standards or 0.2 mm. whichever is lower.
6.15 The guide bearing pads of both the turbine and the generator are fixed with the
clearances stated in the appropriate drawings.
6.16 The generator stator is centralised with respect to the rotor
6.17 The air gap length is measured both at the top and bottom of the poles. Minimum gap at
the pole centre is to be recorded. The air gap measurement has to be taken at every
pole.
6.1 8 The rotor is now rotated and the air gap at one pole is recorded rotating the pole
through 45",90°, 135",225",270°,3 15" and 360" positions
6.19 The maximum variation of air gap length should be limited to *5 %of the normal value
but a variation of 10% can be allowed at a few places.
6.20 After the bearings have been aligned and levelled, recheck and record final readings.
7 MAGNETIC CENTERING;
For magnetic cantering the centre line of the rotor and stator shall be at the same
elevation during operation. To achieve this following precaution are to be taken during
erection
7.1 During mounting o f pole on rim assembly the centre line of every pole is kept at ihe same
elevation. T o achieve this the pole stop height can be modified to suit on assembl!.
7.2 As mentioned in CI. 3.4 the generator is set at higher elevation. Therefore, at stards ti];
condition the centre line o f rotor shall be at higher elevation than stator centre line by t>e
same amount. To achieve this, shims shall be added or removed from the bottom ~f staIor
sole plates.
T H R O W CIRCLE AT G E N . LOWER G U I D E B E A R I N G - ' e '
! T H R O W C I R C L E D I A = 5 . 2 x 0 . 0 1= 0 . 0 5 2 m m I
THROW CIRCLE AT T U R B I N E G U I D E B E A R I N G - ' d '
I I
I I I I I I I I I I I I I
Usi~allythe core assen~blyis done at the manufacturing plant. However, for high rating machines,
either the core length or the diameter or both beco~nelarge and consequently the weight and dimension
of stator sectors become inconveniently great. As a result, transportation to site in deformed condition
or rip-over of trailers become unavoidable.
TI-.[IS.it is preferred that large cores be built at site with the added advantage that the core can be made
in ring form. It increases the core rigidity tre~nendously against thermal deformations during
eeneration of power.
L
ROTOR
Traditionally and necessarily the wound pole is assembled at works and the rotor assembly is done at
sitz.
While assembling poles on rim in large rotor, it is occasionally observed that assembly of poles
become difficult and also the pole keys become too tight and cannot be fully driven in.
ALIGNMENT
I t is a common problem that achieving the throw of guide bearings within stipulated limits becomes
difficult.
*: Insufficient oil flow through thrust bearing pads during rotating the rotor for alignment.
This can be ascertained by observing movement of dial gauge pointers when H.S.
Lubrication system is just put on without rotor turning.
In case the pointerls move more than 3-4 divisions, it is to be concluded that oil flon- is
insufficient through some thrust pads, thereby lifting the rotor non-uniformly. In one
case, the throw was actually of the order of 20 divisions of dial gauge.
In such case, oil passages are to be checked or oil flow from the pump to be increa=c
as far as possible.
*: For separate thrust collar, thrust collar re-assembly at site may not be the same a s was
done in factory during combined machining of thrust collar with shaft.
Thrust collar assembly should be repeated to ascertain that the reference linzs x e
maintained, and there is no looseness in the assembly.
Mild steel 1 brass shims may have to be introduced in between the thrust collar m c
runner disc insulation.
*: Shims can be judiciously added in other joints also as in case of disc type rotors.
TEMPERATURE
Thrust bearing:
In some cases, temperatures of different pads may vary beyond unacceptable range and may become
unstable.
gauge throws noted without disturbing the machine. The throws should not be mi.??
than 3-4 divisions. This will ensure equal load sharing by all thrust pads.
In case of very high deflection of dial gauge, the oil flow of the H.S. Lubri:cari.>:
equipment shall be maximized, the tlow paths checked for each pad and c:.=ar.=.' .--
If o r e pad (thrustlguide) she\\: abnormal temperature ~vhileother pad temperatures are in a small band,
ii rnay be that the calibration of the thermometer concer~iedhas been disturbed in course of operation.
T?.is can happen in other areas also: e.g., hotlcold air temperature.
Recommendation: It is recommended that all thermometers and RTDs should be checked for
crlibration every year initially, and during major maintenance subsequently.
E=alth of winding needs constant monitoring for continued proper performance. Some suggested
checks are as below:
I. Check for clean air ducts.
!I. Check for cooler performance. Clean cooler tubes as necessary.
I![. Check for water flow through coolers.
IV. Check for proper and uniform fan tip clearance.
V. Periodic checking of IR 1 Impedance of stator 1 rotor winding.
\-I. Health of condition monitoring systems (RTI, Vibration monitor, Temperature recorder etc.)
needs vigilance.
Above precautions will keep the temperature in check and ensure propel- performance.
I~IBIUTIOIVAIVD BALAKCISG
After the machine has been initially balanced and put to operation for some time, the vibration level
n:ay increase gradually after some time.
-Reasons a n d Resolutions:
*: Check the guide bearing pad clearance, this might have changed. Readjust shims and tighten
fasteners fully.
t* Check back surface of the pivot bar. This may have been deformed. Remove the discrepancy
carefully, adjust pad shims and reassemble.
*: Check the rotor level and correct. Any discrepancy will reflect in mal-operation of bearings and
increased vibrations.
*: Check Impedance values of poles and check for rotor earth fault.
*: Rebalance.
Caution: Though generator can run for some time with one rotor earth fault, a second earth fault will
result in catastrophic failure.
*: Check for any looseness of fasteners etc. of the rotating parts and retighten as required.
*: Care must be taken that after balancing has been completed, all balance weights must be
secured with the rotor by welding, boIting and locking them properly.
*? The stator and rotor forms are to be checked and, if requi~ed,corrective measures taken.
It has been experienced that irl case of large number of machines in a power house, say, more than 3,
the tools and tackles get worn out during erection. This is particularly true for hydraulic items, torque
spanners, rim building pins etc.
In view of the above, it is advised that two(2) sets of tools and tackles should be called in scope of
supply during tendering stage.
CLEANLINESS
In most sites, the civil work carries on simultaneously with equipment erection work. This results in
heavy dust problem and life of various items like Stator winding, Rotor coils, various instruments and
electronic equipments will be affected.
Air ducts in stator get choked, low IR values of stator and rotor, shorting of current carrying parts etc.
may take place.
It is strongly recommended to arrange for dust proof working environment by providing proper sealing
arrangements for enhancement of life of the machine.
MAINTENANCE
INTRODUCTION:
Maintenance of generators, auxiliaries, spares and station equipment is of pivotal importance for the
longer life of machines. Although emphasis is laid on periodic maintenance of major components like
stator core, windings and bearings etc., it is equally important to pay attention to smaller items
especially station equipment, spares and auxiliaries. Although detailed maintenance schedules are
made by the power house staff based on the manufacture's recommendations and their own experience
with a particular machine, we mention below a few important maintenance checks alongwith a typical
maintenance schedule.
1.0 GENERATOR.
STATOR
It is recommended that stator core should be periodically checked for proper tightness. For this, the
core studs are to be checked by torque spanner. Generally they are not approachable from top due to
the winding connectors. Hence this is to be done from the bottom of the stator frame by opening the
bottom air guide and heater support plates.
Any type of dirt or dust entering the generators generally goes in the ventilation circuit where it may
get deposited on various stator parts in the form of a paste. Special importance must be given for
-- -
cleaning of the staior ducis which run a risk of getting chocked by the paste, resultiii~in overheating of
tlic core and \\-indins. ?'his pasie some times ma!- even lead to rotor earth fault aficr deposited on polcs
and rim.
Oily deposits on \\.indins can be wiped out \\-it11 a non linting cloth moistened with white spirit
turpentine and cleaned \\-it11 a suitable solvent such as GAMLENE 265B IZ: finally treated with solvent
CRC 2-26 which ii??pro\.t.sthe insulation resistance also. In case of soldered ioints. their health should
be checked periodicail>. for an)- indications of o\-sr'hcaring or looseness and ihe dekcrive joint should
be immediately repaired.
ROTOR
R ~ o uv-indings
r ~hoilici bs checked for r'neii insuiarion resistance \.slues as per manufacrurcr's
recommendations. Field coils and rotor connections should be kept clean from any dirt, dust or oil
particles leaking from vapour seals. These should be cleaned with compressed air and wiped with a
non linting cloth dipped in white spirit or turpentine. For heavy contamination, use chemical cleaner
(such as GAMLET SOLVENT 265 B) and finally spray with the chemical CRC-2-26 for
improvement of insulation resistance value.
Collector & brush gear are generally located such that they are easily accessible for inspection and
maintenance. Although slip-rings should be smooth & glossy but the skin formed on brush track
should not be wiped out since this reduces the brush wear. However, slip-rings should be cleaned of
dust & oil particles if any.
The brush holder should be mounted 2-3 mm away from the slip-rings for better brush stability & it
should be tightly secured with the brush plate. Bnishes should be of appropriate grade and should
move freely in the brush box. Brush pressure should be checked as per recommendations.
To avoid uneven wear of any particular ring, the polarities should be changed periodically by the
changeover link provided in the excitation cubicle. For satisfactory operation, the new brushes shouId
be bedded to fit the slip-ring over their whole thickness.
Levels of oil in .oil pots are to be also monitored to maintain proper oil quantity in the housings.
Periodical testing and centrifuging of oil as required is to be carried out to ensure clean oil for the
bearings, free from impurities and moisture.
In both spring mattress type and pivoted type thrust bearing, it is essential to replace complete set of
pads in case any thrust pad needs replacement.
Guide pads can be replaced one at a time, and when replaced, should be bedded against the journal.
Bearings clearances should be set while the pads are flush with journal & clearance is measured at the
back of pivot bars. Clearance setting should be carried out while shaft has been centralized w.r.t.
turbine runner & turbine bearing.
OSD's are factoiy preset for initial pre-load setting of piston spring. Ho~vever,trial of the overspeed
device for smooth operation (both for the rotating con~ponentsand the static switch box) need be
carried out before start. and finer adjustments for preload of spring or s~vitchbox position are to be
carried out.
Care shall be taken to check that the movement of piston remains free for its reliable operation over a
long period of time.
C O O L I S G I11.4TER .AND C O O L E R S
Care is to be observed for full flow of cooling water for air and oil coolers, but a pressure test of the
coolers should be carried out at periodic intervals to locate any weak point that might develop due to
prolonged use and contaminated water. An overall glance should be cast against any water or oil
leakage in the pipelines to maintain general cleanliness of the unit. Gaskets or seals should be changed
immediately as required.
During long shutdown of a machine, the following checks should be carried out.
A. Remove the carbon brushes from the holders and grease the surfaces of the slip-rings where the
carbon coating is not formed. The coating is never to be removed.
B. All air and oil coolers must be drained of water completely and dried as stagnant water will
have a high tendency to corrode the cooler tubes and may ultimately puncture it.
C. The stator PI and rotor IR values are to be periodically checked. If necessary, the machine
should be run for some time with its stator terminals shorted.
D. All auxiliaries are to be periodically checked for their satisfactory operation.
E. The rotor is to be kept jackedlup on the jacks and mechanical sleeves engaged. Pressurized oil
is then to be released.
Maintenance of station equipments, spare items etc, is also necessary. Once erection of the generator
is completed the slings are rarely used. However, it is a good practice to keep them properly greased
and dust-free. Spare bearing pads (thrust and guide) need utmost attention and must be maintained
ready for immediate use. Proper care should be given to the rolling ball castors of the thrust pad
removal gear so that they do not get jammed.
It is a healthy practice to check the calibration of the measuring .instruments, especially the temperature
measuring devices. Periodic checking of spare brake cylinders also should be carried out for their
satisfactory operation. Various small items like '0' seals etc. need attention. Hand pumps, hydraulic
jacks, high pressure flexible hoses etc which are rarely used after completion of erection, should also
be checked.
In general, it can be said that there are innumerable check points from maintenance point of view and
they should be carried out periodically, frequency of which can be decided by the user after study of
CHAPTER-4
CLEANING, DRYOUT, I I < RIE/\SURERilENT AND
MV INSUL/\TION TESTING OF H I 1)KO GENERATORS
ISTRODUCTION:
ANNEXURE - I
CLEANISG OF G E N E I U T O R ASSE>lUI,IES
Any accumulation of dirt or dust on these parts should be first removed by blowing out with
~ - 2; ~52-5.
compressed air ar a pressure no! ~ X C C P & CP
If the deposit is oily, these parts can be wiped, cleaned using a non-linting cloth dipped in white
spirit or turpentine. Toxic solution like Benzene, Trichloro ethylene or Carbon Tetrachloride should
not be used for this purpose as they remove insulation varnish also.
While this treatment may be satisfactory for the light contamination in easily accessible areas,
the following procedure may be adopted for in accessible areas or when contamination is heavy.
1.1 GENERAL
1.6 MEGGER
Initial test may be carried out without disconnecting the supply cables, but if unsatisfactory
result is obtained, then the windings should be isolated from all external cables and connections
before repeating the measurement of insulation resistance.
Insulation resistance should bc measured between each individual phase and earth with the
remaining phases earthed.
In practice, each test is cal-ried out by connecting 1ii.e lead of megger to the terminal of the
winding under test and the otlie~lead to the frame. The instrument is then switched on and the
resr voirage maintained for one minute at which srage rhe insuIation resistance reading ( R l ) is
noted. The test is continued and an additional reading (R10) after 10 minutes is noted for
calculation of the PI-value.
Test can be made on entire winding at one time under certain conditions, such as when time is
limited; however, this procedure is not the preferred method. One objection to this method is that,
only ground insulation is tested and no test is made of the condition of phase to phase insulation.
The phase to phase insulation is tested when one phase is tested at a time with other phases
eai-thed.
The measured insulation resistance of a winding normally increases with the time of application
of the D.C. test voltage. The increase is usually rapid for the first half minute, and thereafter the
slope of the curve steadies off as the time elapses. The increase is a function of the absorption
characteristics of the insulation and hence of its general condition. The measured insulation
resistance of a dry winding in good condition may continue to increase for hours with constant
test potential applied; however, a final steady value is usually reached in 10 to 15 minutes. On
majority of the windings, the value reached in 10 minutes will be greater than 90% of the final
steady state value. If the winding is wet or dirty, the steady state value will usually be reached in
one or two minutes after the test potential is applied. The slope of the curve is an indication of
insulation conditions.
The polarisation index of a winding is defined as the ratio of the insulation resistance after 10
minutes (R10) to the insulation resistance after 1 minute (Rl).
i.e. Polarisation Index (P.I.) = R1 OR1
1.6 MEGGER
Only precision class Motorized Megger of 1 KV to 5 KV range, of reputed make like
EVERSHED, TINSLEY, etc. shall be used. Megger should have been recently calibrated
before use.
2.1.3.1 AC STATORS
All the phases should be connected in series or parallel using copper strip or cable of adequate
section to carry the full load current. Initially the value of current should be set at
approximately 15% of the full load rating and adjusted as the temperature rises to follow
the heating schedule.
The direct current supply and any external cables must be disconnected before any insulation
resistance readings are taken. L'sually. about 50 - 60% of rated current may be sufficient to
maintain dry out temperature. The end windings must be properly covered by suitable non
hygroscopic covers to contain the heat within, and the direct heating can be supplemented by
use of space heaters located below the winding for quick results.
2.1.3.2 1)C FIELD CIRCUITS
For drying out the DC field windings, all the coils should bc connected ill series and current
passed through the circuit so as to follow the rate of temperature rise specified below. In
general the value of cui-rent used should not exceed the maximum value specified for the
machine field circuit.
As field circuits are inductive, it is essential when breaking the circuit (to take insulation
readings) that the current is brought down to a low value by either having a resistance in series
with the supply or by reducing the voltage to as near zero as practicable.
The dryout should be terminated : and the source of heat removed, after the minimum levels
of insulation resistance and nearly constant (but normally not less than 2 ) polarisation index
have been reached and maintained for at least another 24 hours based on daily readings.
The above conditions ensure the suitability of the winding for application of high voltage test
or operation. However under special circumstances, when the winding is extremely dry and the
initial IR value is very high, or adverse ambient conditions, then PI value of 1.5 can be
accepted, as it may be difficult to achieve PI value of 2.0.
After completion of dry out, measure the IR value at 5 KV for each phase, phase to phase and
all the three phases together. Record the room temperature, winding temperature by RTDs,
humidity & atmospheric conditions.
Value o f 'Ft'
I
1 Winding N e ~ vmachine I Machine after Machine after service of
I
Temperature dry. unaged service, clean and several years with normal
!
"C. and clean uncontaminated industrial contamination ~
The PI value shall be recorded in addition to IR. It is not uncommon on a clean, dry winding to
achieve a PI value of 2.0 & more after proper dryout.
However this may not be achievable in sum cases, due to adverse atmospheric conditions or
when the initial value being very high, under such extreme case, PI value of 1.5 can also be
accepted in consultation with BHEL.
3 . 1 . 3 Tan 6 Measurement
After HV test, Tan 6 measurement shall be carried out on each phase at voltage of 0.6 U and 1.0
u.
3.2 ROTOR WINDIXG :
3.2.1 Insulation Resistance :
The values normally achieved for a new and clean individual pole assembly is 200 1
M Ohm at
room temperatures. The values normally achieved for a new and clean rotor assembly is 50 >1
Oh111 at room temperature. Ilowever. a minimum value of 2.0 M OOhm can be accepted in
A-2 IIIGII VOLTAGE TESTS ON BAR TYPE STATOR WL\QmG WIIERE COlMPLETE
MACIIlKE XOT TO BE WORKS TESTED:
04. SuppIen1e11ta1->I
tIV test on
Completely wound stator
Before conlmissioning, if
necessary.
- - - - -
04 Supplementary HV test on
completely wound stator
before commissioning, if
necessary.
A-4 HIGH VOLTAGE TESTS O N DIAMOND PULLED COIL TYPE WIXDINGS WHERE
COMPLETE MACIIINE T O BE WORKS TESTED:
03 Supplementary HV test
on completely wound
stator before commissioning,
if i;cccssa~-y.
A-5 HIGH VOLTAGE TESTS OX DIAMOhB PULLED COIL TYPE WISDnGS WHERE
CONWLETE MACTTINE IS NOT TESTED AT WORKS:
A-6 HIGH VOLTAGE TESTS ON DIAMOND TESTS ON DIAMOND PULLED COIL TYPE
STATOR WINDmTGWHERE COMPLETE WINDING IS DONE AT SITE:
7
-. Al! t e s ~ sspecified are .AC (RJIS) ar 5 0 Hz. and i b r i m i n u ~ eduration.
3. As per IEC 60034-1, the specified HV test is ( 2 b + 1000V) irrespective of the KW 1 KVA
rating of the machine, up to rated voltage of 24000V.
B. FIELD WINDING:
This test shall be conducted by applying following voltage at 5 0 Hz. for 60 seconds as per the
following table:
- Stage of testing
01 Pole coils afier 2500 10(Vf- 150) + 2500 1 O(Vf- 400) + 5000 6500
mounting on pole
body.
P
02 Pole coils after 2000 10(Vf- 150) + 2000 1 O(Vf- 400) + 4600 6000
mounting on rotor
and after wedging but I
before inter
connection.
03 Polecoilsafier 1500 10Vf 10 Vf 4000 + 2 V,
connection and
connection with rotor
- leads and slip rings -- --
gig4
7.0 Control & Protection of
Hydro Power Stations
BHARAT iiEAiiY E i E Z T R i C A i S LTD.
TECHNICAL LiTERATURE
-
p
-
-.
p
-.
.
--
p
-p
-
-
p.
.-
.
-
..
-
- ..~
inaxDNA DISTRIBUTED CONTROL SYSTEPJ
Page 3 4
BHARAT HEAVY ELECTRICALS LTD.
ELECTRONICS DIVISION
A 'provider of data' registers a unique One feature of the system that will
service name on the SBP when it is provide very substantial time savings
started, as in the case of a replacement for system users both during plant
DPU inserted in a chassis or a comrnrssioning and during outages
workstation added to the maxNET. (when time is shortj is the approach
There is no database to be maintained. to placing all the configi~rationdata
The relationship between names and in the operating DPU's. There are
addresses is built dynamically and no additional configurafion files
automatically maintained at all times. necessary to interpret DPU data.
Should the owner at some point Also Data Links can be established
purchase a simulation package that via RS232C serial port of the DPU4E
provides a process modelling of the or via DDE links at the workstation
plant, the soft simulation can be level.
enhanced by interfacing the process
model directly . through . the software Sequence of Events.
Backplane for the highest performance.
The maxDNA DCS has an integral
Turbine Control Interface. Sequence of Events package that
resolves time stamping to 1
maxl-INKS communicates with various millisecond for any DC powered
manufacturer's PLCs, RTUs, turbine digital input (AC powered points can
- control systems, water purification be timestamped, but the sinusoidal
systems, and other systsms found in AC signal introduces inaccuracies of
and around the plant maxLlNKS an order of magnitude).
provides multip!e ports arid database
A digital input can be given a
tables to link the inaxDNA database to
property that includes it in the SO€
the data points within these other
package either (,) when the point is
devices. Existing protocols include but
initially configured, or (2) at any time
are not limited to Modbus RTUt ABt thereafter Changing the point's
Conitel RTU, GE Mark V turbine control
property requires no reloading of a
via Ethernet. maxLlNKs is a Windows
DPV, since the system allows a
NT based platform for large data
single point reload.
volumes. It concurrently supports
multiple prctocols: provides
maxDNA Architecture:
communication, redundancy and a
direct connection to the maxSBP
maxDNA incorporates the latest
(Software Backplane).
computer, c~mmunicat~onsand
Note: Most systems with maxDNA
process control technology io
have Turbine Controls as an Integral
provide a high performance, secure
part of the DCS
maxDNA DISTRIBUTED CONTROL SYSTEM
Page 6 4
Bharat H e a \ ~Elcctricals Limited (BHEL), Electronics Division, MAX1000+PLUS systems are used in many applications throughou:
has entered into a Technical Collaboration Agreement UCA) for the the world including electric power generation, co-genention, cemcnt.
'manufacture and supply of new generation Distributed control Systems . glass, ceramics, primary metals, chemicals and petroleurr. R-ntcrax!
.: '\L%YlOOO+PLL.'S', for modern Power Plants & ~ndusthes,wiih waste-water treatnlenr 2nd incineration plants.
\LLKControl S!..;tems (SICS) Inc. USA, pan of METSO Automatior!
The >L4X1000+Pl.l;,$ i;CS product line provides reyul3.:'-.. . .-lil~tro,
L
BHEL's Elecri-asi:ics Division has established itself in the area of sequential logic c(,::::-,ii, operator il?ter;~ctionih:o,..::-, ::R;
Controi 3 1nsi:-..:::c;it:iiiti;.: for nea. power plants as well as renovatio;; (~LY<$T.+TIf).\:!'i3ci.i :-,!,,rn:.,tion ma.r?~genlc:lr.
I'hs SL~.~::~l-:!7'i(:!.'.
and moctsrni.<c:ion of existing power plants. A leader in the Intli:~:~ . .
can be configllred n 2: operator station, engineer's static,:. ,!>io~fii.
P o ~ z Sti~or
r ~:~:ket, it h s already supplied and commissioned abr~v.;. ( ~ L ~ Y J ~ O ; SJiY:.
? ~ . ~:. ~ :~r
' ~\iqk
~ ~ s~ e, ~ ~[ >LLV.I.Y;;~:
cr ifi f~i-~!;: \Y->;~I;:
200 se!s o!' DCS ior therxal, combined cycle and hydro sets all ovc; It pro\:ides i9r high-:.::ol~icion graphics l.ltilising a 31-b::sr~pilic::
the coii;:~ snti o \ - e r s e ~ . user interface - ?I.L.:;'.'.'.'E. The M.UlOOO+PLL'S also p:.:\.ides ::
~ 1I ~~ ~CM, syitenls division of ~~~d~and xonhrup, usa4:
s~ , jnller
, ~0mpreheniii.i.set ci :-i~liSli\;TO-OL5jfor the dcvei::.; :iioi o-
is an in!frnztio-3!1! technolop leader in both Power as System application: cb:Bgoration and installation.
as Industria! process control systems, with 70 years of rich experience ALiYYET conn:~!lic::;::g sysiem, based on Sn-itchsd Fnrr Ethec'
in the 5213. Standard operaiing a: :.l'! .\lbps speed, forms the spinal c:?cl:d of t h t
. BHEL ozers v;sriety solutions for poKer plants from system. M.I.\TT intexonnects Remote Processing Cni:s (RPCs.!.
simple systems to
conirol unified automation for Power which include Disiribu:ed Processing Units (DPCS)and 1;O xodules.
Plants of any size. f i e vw o f ~a p ~ e d e~in Power
~ sPlant with hWATI01VS. .%i stations have unlimited access wirhour delay
Controls and cutting-edge technology of >~;U(~~OO+PLVS provides and without the need ;or a traffic director. ,W&\'fl has no limit to
for unified DCS solution for entire Power Plant comprising of Steanl the number ofstationi. in addition. next generation sratior.~csn easii~
Generator. %?am Turbine Generator and Balance of Plant CAI. be added since it is based upon proven industry s:?ndards.
The sixe-of-[hsart control system is also configured for complete
bLiY1000+PL1:S pro\:dcs man!. features and benefis. inii~dingk c
range of Hydro Turbine governing and auto sequence controls.
use of Open systems rrihitecture based upon b ' i n d o ~ sYT. Objec-
The 3Li\;1000APLL'Sallon-s easy integration of third parry doicesand Oriented design and :I revolutionan- approach to faciiirxing ::
comn~unicatic~r~ with estemal s!.stems. The system also allows user "plug and plaf' capabiji: - the Software BackplaneB . SLi'T4T10;Y5
flexibility to o;ente a small stand-alone control system to a me93 btLnrliE and >L-LYF:.,T,LS3ild hLW;\.'KY pro\-ide 3 pen f r suite :.-
conrroi ~ ? ~ r e !n-ith
- - plant-n:ide automation. Its open architecture programs for Pon-c: F..:.:ir :i!lci Indus[:ial 3ppiications. I'Ji ;- 2 ::ls3.--
permiis the ii!::gra[iori of process control, management informatio.:: that the custonier hrs i.~:iiplctcflesibilin- her! it comes rc ?;?nn;
s\stenis. local si:d n-ide a r a nemorks, PLC s!srems and SCADXs!sren~j. the system or linking r,- ~ilirdpan! systems.
8 hlB flash RAb1 and 33 MB SDhM Status indicat~onLED for each channel :I ' 4
Built-in SOE with 1 msec resolution Remote UO and H!I capability; for phnr-wide datribuwn.
Directly accessible' from all ~ K W A T I O I V ~ Redundant configun~lonpoisiblef6fd;both analog ar)d dlg~d.W. I .
P U F T SUB-SYSTEMS
REXiOJT PROCESSIXG USITS
- --- .- ... .
. .
.-\rchr\alstorage to CD-ROM
repom and queries for dnra annlysis
i.---.-.--..--....---..---
Plnnt Sub-Systems i
. \Vindows-NT based
S o b a r e Backplane0
Supporrs interf.1~~
Lo plant rnanaEement ncr\\,orks compatible
. Open architecture that uses Sofrn-are B3ckplaneO and TCPAP POWER PLOT COSTROLS
prorocol Srean? Gc::trnro:- 5 lnrrols
.' 32 011Controllers Heat Recove? Srcin? CTenel-:;ior (H>.(<. controls
On-li!le sin~ulnrionand restins using virrual DPU Stkam Turbine io:::rols
.ill !Lt.L-\TIO.\'S h3i.e free access to ntnvork Indu j[l-i:ii Stt:inl 'i..i.hii;~Cc>~:ii-c)l~
:
Cenrralisetl Engineerins and on-line docllnlenrarion
Builr-in SOE \\.irh 1 msei resolution
.. Balance of plnni i;,r;rrols
Darn ,Q~!:sitlcon :!:xi inforln.irii!n ~::.:.-.:..:zinenr
H!.dro Turbine G;vt~-ningXI?(!.-\i~[;; ~:.;:ICIICC conrr~Is
, S\\~icht.(lI'acr Ethernsr Standard ar 100?Ibps
Genera[@:2nd ';:.::ih!,a~.d ccli:il-oI.<
Full dul~lesoperarion Electrical Systcnl c,.lntrols
lulril~lesirnalr;~neouscommunication for
\ Srarlon independent software rools Fossil poner urili;; plants
,
1
- Kcmore 1/0capability
OI'C co~npliant,proviciing easy integration 10 third party systems
Powerful IMA,WNKS
. . ... . .. . .. -
. .
..- - . . ..
.
. .
Combined cycle po\ver planrs
Captive power pl.i!irs
Simple qcle po\\.sl.plants
. . i i .
- . .. . - Hydel power planrs
tvt.uC.V!T on Elecrrid or Fibre optic media -
+O
..
BHARAT HEAVY ELECTRICALS LIMITED
ELECTRONICS DIVISION
P.B. No. 2606. Mysore Road. Bangalore - 560 026. INDIA
Tel : 080-6742289.6742978 Fax : 080-6746288.6740137 e-mail : mktg@bheledn.com
Regd. Offce : BHEL House. Siri Fort. New Delhi 110 049-
Visil us at : www.bhel.com
./ ,
., .
, .., . . .
Nbre : Duc !ir c ~ n i r ~improvemenrs
nl md changes in rechncl~~g.
[IHEL rcxwes thc. qhr lo updile [he inlonru~ionmentiontxl wilhcur no[ice. . .
8.0 Excitation System.
An e x c i t a t i o r , s y s t e m i s a s o u r c e of f i e l d c u r r e n t
f o r e x c i t a k i o n of synchronous rcachine and i n c l u d e s
an e x c i t e r and a r e g u l a t o r . E x c i t a t i c n c o n t r e l
system i s a f e e d b a c k c o n t r o l system,
. .
.. .
\ T h e , e x c i t e r i s a s o u r c e of e x c i i t a t i b r , power f o r t h e
/ g e n e r z t o ~ . D i f f e r e n t ' types:;? e x c i t e r are:
I , Rotating d o c . exciters. A
2. Static Sm excikers'.
R o t a t i n g d.c. e x c i t e r s a r e c o n v e n t i o n a l s e p a r a t e l y
-. e x c i t e d d.c. g e n e r a t o r s . ' S t a t i c e x c i t e r s a r e t h y r i s -
t o r b r i d g e t y p e r e c t i f i e r s . Depending upon a p p l i c a -
t i o n and ratingzstatic e x c i t e r s a r e s i n g l e phase
f u l l c o n t r o l l e d / h a . l f c o n t r o l l e d o r 'thr::?e phase f u l l
controlled, r l t i i i e r bridges.
Automatic v o l t a g e r e g u l a t o r d e t e c t s d e v i a t i o n
I
\n
g e n e r a t o r t e r m i n a l v o l t a g e .and a d j u s t s e x c i k e r o u t p u t
v o l t a g e and hence t h e g e n e r a t o r e x c i t a t i o n t o t h e
d e s i r e d v a l u e . No.. of t y p e s of AJrR depending an
~ ~ a n u f a c t u r e rdse s i g n , a r e used i n p r a c t i c e .
Two t y p e s of e x c i t e r w h i c h a r e w i d e l y used f o r
hydrogenerators a r e :
L.
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. . . . . > . . .. .. .. . ................
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S -. -
mini-micro h y F r o s e t s . T ~ Ee AC e x c i t e r s ' a r e t h r e e .-.-
;.......
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.
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-. :. -
phase syrchronous g e n e r a t o r s w i t h f i e l d winding on
'
-.-.
, -. .
.
.. . . . . s t a t o r ar,d t h r e e phase a . c . winding on r o t o r - . R e c t i -
. f i e r diodes, a r e rncunte? on t h e same s h a f t and a r e
c o n ~ e c t e dd i r e c t l y t a %e t n r e e a.c,. output terminals.
2 .I .. C.- - ..-
-D. .- EXCITERS :
.---..-.--.
D.C. E x c i t e r r $ a r e c o n v ~ n t i o n a ls e l f e x c i t e d Qr seF.
rately excited exciters, Separately excited exciters
I
a r e w i d e i l y used i n lz;se pcwer s t a t i o n s . E x c i t e r s
o f higher c a p a c i t y a r e e x c i t e d from , a .second e x c i t e r .
. cf smalfle- c a p a c i t y . T t i s s m a l l e x c i t e r i s ' c a l l e d .
a s p i l o t e x c i t e r . S e p a - a t e l y e x c i t e d e x c i t e r s have
e i t h e r s i x g l e f i e l d w.iKding o r t h r e e ' d i f f e r e n t f i e l d
windings. he t h r e e f i 2 l d windings a f e e i t h e r 2s Bis
winding ( b ) Buck windir-; ( c ) b o o i t winding c r ~s B i ~ s
winding ( b ) hrnd c c n t r o l winding ( c ) Auto c o n t r o l
winding, The t y p e of e x c i t e r . u s e d depends on t h e
o t h e r components used i n t h e o v e r a l l scheme. which
v z r i e s from mznufzcture? t o m2nufacturer. ,
'I-. .
i n v a r i a b l y b e c s u s e o f t k e i r f o l l o w i n g advantages
,
S t ~ t i ce x c i t e r s 2 r e S a s l s a l y c o n t r o. .l. k d r e c t i f i e r s i n
.,
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S i n g l e phh& b r i d : r e s o r e used mainly f o r ~ 1 ~ 2 r1a1 tings.
The c&$let& s t a t i c e x c i t e r c o n s i s t of a ' i n p u t r e c t i f i e r
..
, .
t r a n s f dr'mer, . t h y r i s t o r b r i d k e 2nd t h e f i r i n g ! .
Depending: on c u r r e n t r ~ t i n g .number. s of t h y r i s t o r b r i d g e s
2 r e connected i n p n r a l i e l . For h i g h e r r p t i n g s normally
a d d i t i o n 2 1 one or t w n b r i d g e s m e provided a s r e d u n d ~ n t s ,
s o t h a t even i f one :?r 4.x3 b r i d g e s f a i l , norr-pal o p e r c t i o n
of e x c i t a t i o n system i s n o t o f f e c t e d . The t h y r i s t o r s a r e
I. ' forced cooled and z r e of modular c o n s t r u c t i o n , 3utput
voltage of s t z t i c e x c i t e r i s c o n t r o l l e d 5y varying i t s
,:- '
f i r i n g a n g l e e e F i r i n g c i r c u i t pf t h y r i s t o r bridge genera-
t e s f i r i n g p u l s e s cnd c o n t r o l e s f i r i n g a n g l e depending
. .
on i n p u t c o n t r o l s i g n a l from Automatic v o l t a g e r e g u l a t o r .
. . . --4
.. .-
( a ) Non c o n t i n ~ o ~ ~ l . y i c t , i , " ~ ~
One t h a t r e q u i r e s a s u s t a i n e d f i n i t e change i n t h e
controlled varizble (input voltage signal) t o i n i t i o t e
corrective action:
( b ) -.--.
Continuously -
--- .-.-----. A c t i n s
The one t h a t : ' i n i t i a t e s a c o.. r r c c t i v c ac.tion f o r n
s'lstained i n f i n i t e s i n a l change i n t h e c o n t r o l l e d ,
. . ..
variable.
AW:s of a l l t h e p r c s c n t day e x c i t a t i o n system a r e
c o n t i n u ~ u s l ya c t i n g type.
. .
I n a d d i t i o n t o a b ~ v erneritioned b a s i c components, e x c i t a -
.
t i o n s u n i t s . These a r e u s u a l l y c o n s i d e r e d as p a r t i of
voltage reg:ulator. ..
- ----..-.O F. -.AUTOMATIC
-- -...- - .- .-VOLTAGE
. - .- --- - --- - -. - . .
EIAC-IPLE , <.-
REGULATION:
,-< v
' .
, . , ..
I n a n i s o l a.. t. e d. operafSicn
. o f ' a s i n g l e o r a g r 5 u p of genera-
. < .
t o s s i f f i i i d . c .u r r e n t i s c o n s t a n t , t e r m i n a l v o l t a g e of t h e
1:
g e n e r a t o r drops'. .w i t h i n c r e a s e i n l o a d . The d r o p i n
vciltage
. .
depends upon n a t u r e and magnitude of t h e l o a l .
a ..
R e a c t i v e l o a d 'predominantly' a f f e c t ' s t e r m i n a l v o l t a g e . I n
c a s e of h y d r o & n c r & t o r s connected .by l o n g t r , a n s m i s s i o n
l i n e s t o . a l a r g e power g r i d , b o t h t e r m i n a l v o l t a g e and
power f a c t o r w i l l v a r y w i t h t h e change i n r e a c t i v e l o a d , '
Whether v n r i a ~ i o ni n t e r m i n a l v o l t a g e w i l l be- predominant
o r w.hether power f a c t o r w i l l v a r y over 'a .wide r a n g e . ,
depends upon l e n g t h of t h e ' t r a n s m i s s i o n l i n e and s i z e of t h e
trsnsmission: line, and s i i e of .the -genei2-tor a& Gmpared.
t o g r i d c a p a c i t y .. .However i n both c a s...e s f t i s n e c e s s a r y
.
t o r d j u s t power f a c t o r v a r i a t i o n o r t o m a i n t z i n t e r m i n a l
-voltage, constant.
During t r a n s i e n t l o a d c o n d i t i o n s , such a s f a u l t , t e r m i n a l
v ~ l t a g ed r o p s suddenly. E x c i t a t i o n , under' such c o n d i t i o n s
has t o be f o r c e d t o r n a x i k p o i s i b l e e v a l u e as fast as
p o s s i b l e . , i n o r d e r t o reduce- a c c e l e r a t i n g power and hence
t o help i n maintaining ' ..
t r a n s i e n t s t a b i l i t y of t h e g e n e r a t o r ,
F u r t h e r when t h e ~ y d r o ~ e n e r o t o w r si t h a l o n g t r a n s m i s s i o n
l i n e s o p e r a t e under l i g h t l o a d c o n d i t i o n s o r g e t s loaded by
l o n g t r a n s m i s s i o n l i n e , t e r m i n a l and r e c e i v i n g end v o l t a g e s
r i s e t o a v e r y high vhlue and e x c i t a t i o n h a s t o be reduced
..
suddenly t o l i m i t shch o.ver' .vbltage.s. .
. *
The above r e q u i r e m e n t has t o be met by an e x c i t a t i o n
' system. A s shcwn i n Fig.1 , g e n e r z t j r t e r m i n a l v o l t a g e
s i n g a l , t h r o u g h p o t e n t i a l , t r a n s f o r m e r . (PT) .is f e d t o t h e
AVR.'AVR c'gmprises'error det.ector and one o r more s t a g e s of
I hb
a m p l i f i e r s . I n t h e e r r o r d e t e c t o r voltage[, 4 error
voltage i s g i v e n t o t h e h i g h g a i n a m p l i f i e r . Ampli-
f i e r o u t p u t (AVR o u t p u t s i g n a l ) c o n t r o l s e x c i b r o u t p u t
L e t t h e l o a d on t h e g e n o r c t o r i s i n c r e a s e d . There w i l l
be momentory drop i n tcrminal ... v o l t a g e which i s d e t e c t e d
. .
by e r r o r d e t e c t o r and a n e r r o r v o l t a g e b i s produced. ,
TUS s i g n a l, . a f...t e r 'amplif i c a t i b n w i l l i n o r e a s e e x c .i t e r
.
.
. .....
, f i e l d c u r.r e.n. t an?. i n t u r n e x c i t e r o u t p u t . v o l t a g e . i his
w i l l b r i n g t. h e t.f.&
. . n i n r . l v o l t & e b ~ c kt o t h e o r i g i n a l
'
o r ainimw. value.
5.e
, .
OTFR FEATURES
_-_--__.- C-._______.._
OF EXCITATION
.
_.
SYSTEM:
.
. .
. .. -
. . ,
. ..
- . .. -. . .
5.1 Manual
---_._-__-.--__ c o n t r o l Channel: .
~ s n u a cl h a n n e l i s a n &en l o o p c o n t r o l 'and . i s : p r o v i d e d t o
k i v e f i x e d e x c i t a t i o n . *This is used mainly f o r t e s t i n g .
P
rA i r p p s e oi when a u t o m a t i c v o l t a g e r e g u l a t o r . . i s n o t working.
.'
<
L i ~ i t e r sa r e p r ~ v i d e dt o l i m i t g e n e r a t o r e x c i t a t i o n with-
i n s a f e t h r r *.a1 znd s t a b l e o p e r a t i n g limits. of t h e genera-
t o r , when i t i s under c o n t r o l of Am. L i m i t e r h e l p s i n a-
v o i d i n g unnecessry t r i p p i n g of g e n e r a t o r due t o p r o t e c t i v e
r e l a y s , D i f f e r e n t l i ~ i t e r sused i n p r a c t i c e a r e , rnaximuc
. r o t o r c u r r e n t l i m i t e r , under e x c i t a t i o n , maximum r o t o r
a n g l e o r l e a d i n g MVAR l i m i t e r and s t a t o r c u r r e n t l i m i t e r .
. .
. . . :I. I ..
(. 5-4 PROTECTIONS
--.- ..- .- : - -:.; . ..
I
i
The p r o t e c t i o n f k d t u r e s i n e x c i t a t i o n s y s t e m depends
I
upon t h e t y p e of e q u i p n e n t s used and n o r m a l l y i n c l u d e
( e x c i t e r o v e r c u r r e n t , g e n e r a t o r h i g h v o l t a g e , low v o l t a g e ,
( ,
s t a b i l i z e d power Supply f a i l u r e c o n t r o l shpply f a i l u r e ,
I t h y r i s t o r b r j d , e f a i l u r e , e t c . The f a u l t s i n n o d e r n
e x c i t a t i o n system a r e grouped i n t h r e e g r o u p s ,
(
(iii) F a u b t s which r e q u i r e t r i p p i n g of f i e l d c i 5 c u i t
breaker .
6. 0 .TYPICAL
-._-__ EXCITATION -.SYSTEMS:
CX-..C--I-----.IL -. .-
--.-.---. ' -' .. ..
6 .I CONVENTIONAL
_._.-._._.._-r.
_. .....---- ._.C..l_.-._
U.C, EXCITATION
_--___r_..- ._.- (
.SYSTEN: ,
- 2 ) .i..
~ ~ ..
. This system . .
c o n s i s t s of D.C. e x c i t e r d i r e c t l y coupled
.. t o t h e g e n e r a t o r s h a f t , an amplidyne w i t h t h r e e d i r e c t
a x i s c o n t r o l f i e l d w i n d i n g s , a F'MG and a M a g n e t i c Amplifi-
e r t y p e v o l t a g e R e g u l ~ t o ru n i t . .The M a g n e t i c ~ r n ~ i i f i et yr p ~
v o l t a g e R e g u l a t o r , d e s i g n a t e d a s .,VM21t y p e v o l t a g e r e g u l a -
t o r s , c o m p r i s e s of e r r o r d e t e c t o r , -2 s t a g e s of magnetic -
amplif i e r , s t a b i l i z i n g f e e d back c i r c u i t s , f s l l o u - u p
c o n t r o l , u n d e r - e x c i t e d KVAR l i r n i t e - and r n i s c e l i a n e o u s
c o n t r o l o p e r a t i n g f e a t u r e s . Amplidyne and PMS a r e d r i v e n
by a s e p a r a t e i n d u c t l o n not.or. During A u t o C o n t r o l b i a s
. .
f i e l d winding of a m p l i d y ~ ei s a p o s i t i v e b i . a s f i e l d and
A : ~ t of. i e l d winding i s a r.egative c o n t r o l , f i e l d . Under
Normal c o n d i t i o ~ st h e e x c i t a t i o q produced b y b i a s windinge' r
....
.* .
..3
6.2 . ._ _.-.
___...._.__
-- .__..._._ ___.._...EXCITATION
~EMISTATIC SYSTEM ._-_._ )
___(FIG- l _i_.__._._
.- .
T h i s system c o n s i s t s of 3 . C . e x c i t e r and a s s l i d s t a t e
e l e c t r o. n i c ver s i e n of volt.agc r e g u l a t o r . The v c l t a g e r e g a l a -
t c r comprises of AVR ~ n y r i s t o r / D - .. ,.
iodebridge, gate control
r e .c t i f i e r t r a ~ sormer
.
f l e a d i n g MVAii l i m. i t e. r . , . follow-up
doAtrpl ...and o t h e r m i s c e l l a n e o u s componentq. . . AC v o l t a g e
e i t h e r ' f rorn g e n e r a t o r t e r m i n a l s . or f r o m . . ~ u x i l i a r ysupply.
i s r e c t i f i e d hy t h e r e c t i f . i e r , and g i v e n t o t h e e x c i t e r
f i k l d . The AVR t h r o u g h t h e g a t e k o n t r 9 l u n i t c o n t r o l s , ti-.*
o u t p u t v o l t a g e of t h k t k y r i s t o r Any d e v i a t i o n i& t e r m i n a l .
v b l t a g e i s d e t e c t e d by t h e i ~ w " a n d accof d i n g l y t h e f i r i n g .
'
t e r m i n a l s and f e d t.o t h e t h y r i s t o r c o n v e r t o r t h r r u g h an
. . .
, ..
. ,
. . .
(~,ontd. .....8. )
e x c i t e t i o n t r a n s f o r m e r . Output of t h y r i s t o r c o n v e r t o r ' i s
. c o n t r o l l e d by . t h e AVK through g a t e c o n t r o l u n i t . I n i t i a l ,
or retarded t o a d j h s t e x c i t a t i o n t o match w i t h
t h e new l o a d c o n d i t i o n . The scheme i ~ . ~ r.?. v i d ewdi t h r o t o r
aygle l i m i t e r , f i e l d c u r r e n t - l i m i t e r , follow-up c o n t r o l and
' M a n ~ d . c~o n t r o l . The scheme f o r l a r g e Hydro G e n e r a t o r s a r e
usua11~-pr0vide.d ,*..
, w i t h redundancy i n t h y r i s t o r c o n v e r t o r
a d g o t ? c 3 n t r d f u n i t s . Nclrmally t h r e e , or four ._
bridges .. .
operate i n p i r a l l e l and i n case -any o i e bridge f a i l s ,
'nominal and c c a l i n. g. c a p a, c.i t y of t h e e x c i t a t i c n equipment i s not
: -.
'nct . r e d ? ~ c e d .
I . .
A t t h e Lime of . s t a r t i n g , , s o 1 t a g e : i s b u i l t ,up w i t h e x c i t a t i o n
. f r o m s e p a r a t e d.c. o r a.c. s o u r c e through t h e f i & l d f l a s h i n g
c i r c u i 6 . when t h e v o l t a g e i s b u i l t - p up t o 7396 of r a t e d
value f i e l d f l a s h i n g c i r c u i t disconnected and c o n t r o l i s
taken over by t h e t h y r i s t o r c o n v e r t o r .completely,
-
static
. e x c i t a t i o n system i s a high i n i t i a l . response system and i s
capable of o p e r a t i q ~t h e g e n e r a t o r w i t h negative e x c i t a t i o n
also. . .
, ::
E X C I E R RAT1DIG-NOMI -NAL
ACCUidCY
------ --..----OR VOLTAGE
. .
"- -.. .-:
.... -.- CONTROL --.
TRAISFER
--.--..- --.- FUNCTION:.
.-.-..
..-,.,--.. .
hrlcclr
A t y p i c a l s t a t i c c x c i t a t i o f i system i s described - A
- .-
i n t h e preccediny .poraqraphs. Numbers of s p e c i e l s f e a t u r ~ s .
a r e a v a i l a b l e and are, normaly provided i n . s t a t i c e x c i t a t i o n
system. Some i n p o r t a n t f c a t u r e r a r c described below:
station b e t t e r ~
. ;om
o r AC scpply .-
and dhan.?eover a u t o m a t i c a l l y t o t h e n a i n
,
. . -. :. . . ..1.
:
circuit, . .I
. .. .
*
8.2 ---...... T..---V ~,-.-..L T.-A G-..-.-E. ~ ...
JOIN MVCONTROL:
~ R... .-.--
...-
, .
.
8 3 ...
PO',iER, SYSTEM
. _.--- __ ........... -- :-
............... STABILIZER
-.
( Power
- II
system s t a b i l i z e r i s provided f o r :dampi% of p w e r
( o s c i l l a t i o n - nenerated due t o .any l o a d chiiqce or = i t c h i @
o p e r a t i i n . -The p o w e r s l ~ t e r ns.t a b i l i z e r produces a s i e n a l
p r o p o r t i o n a l t o a c c e l e r a t i o n o r r a t e cf chance
- .
of e l e c t r i -
<
I
.
:::
.:
.. -
<.
.
-
. .. .. ,.
. . . I . ;
,--.
-. . . .. -a: ?
.. -
. -
a c ..... r ~ ~..s ~ . f.,.i e l d.,. ~. . .. .w~. ii~ rd in~i~ l_ .a k. l . ~
,;. .:..'A::. . -:.,
: . .. d ~ i o~f .field~.=-:~~~
. ~ ~ $ ~ ~ i
c, '.i: ...
.?
.
.. . ,. :<..
:..~ *.... :
y5
.. . .... . . . . .
- . &;: t?:. . . . . .
, . ;
. .
: c ..........
. . .
m g g ; .j: -- L- . ' . ,
.
:
,... .......
, , . .
'
. ..
R o t o r over v o l t a y e, . . p r o t e c t i o n u s i n e t h y r i s t a r s w i t c h e s o r of
,.
Main components of f i e l d s u p p r e s s i o n e q u i p a e n t a r e f i e l d
c i r c u i t b r e a k e r and f i e l d d i s c h a r g e r e s s i t o r . ' F i e l d c i r c u i t
I
b r e o k e r i s provided f o r s e p e r a t i o p of s o u r c e of e x c i t a t i o n P
i .e. e x c i t e r and g e n e r a t o r f i e l d , ,
1
!
In case of i n t e r n a l f a u l t s it i s n e c e s s a r y t o r a p i d l y
d i s c h s r g e t h e e n e r g y i n n a g n e t i c f i e l d of g e n e r a t o r i c o r d e r I
t o avc:d damage l i k e i r o n b u r n i n g o r i n s u l a t i o n f a i l u r e of +
t
s t a t o r winding. F i e l d s u p p r e s s i o n i s a c h e i v e d 'by connec- t
qcms s
f i e l d winding as shown i n
' tine a d i s c h a r g e r e s i s t c r
k - 1
Fig.6'. ,
I
The f i e l d b r e a k e r h a s main c o n t a c t s ( a ,
b):- and a d i s c h a r g e
.
c o n t a c t (c) During norma.1 o p e r a t i o n main c o n t a c t s a r e
c l o s e d and d i s c h a r p e c o n t a c t i s open. F i e l d d i s c h a r g e i s .
i n i t i a t e d by " E x c i t a t i o n OFF" oruF.B. T r i p " command. The
d i s c h a r e e c o n t a c t c l o s e s f i r s t and c p n n e c t t h e f i e l d d i s c h -
a r g e r c s i s t o r a c r .?ss f i e l d w i n d i n g , The main . c o n k c t s
b e g i n s t o b r e a k immediately, Energy s t o r e d i n t h e f i e l d
windine, i n d u c t a ~ c ei s d i s c h a r g e d t h r o u c h t h e r e s i s t r r
q u i c k l y ; The d i s c h a r g e time c o n t a c t i s d e c i d e d by f i e l d
windir?. i n d u c t a n c e and r e s i s t a n c e and. d i s c h a r g e r e s i s t o r
resistsnce.
OBJECTIVES
Besides maintaining the field current and steady state operating point.
the excitation system is required to improve the natural damping
behaviour and extend the stability limits.
Note:
Rectifier Trans:ormer
The power transformer normally gets input supply from the generator
output terminals. The secondary is connected to the thyristor bridge
which delivers a variable DC output to the generator field. The
transformer is housed in a ventilated cubicle. Normally. dry type
transformer is provided with protective devices.
Thyristor Bridges
The thyristor bridge is assembled in one or more number of cubicles.
depending o n the number of thyristor bridges connected in parallel.
Control Electronics The number of bridges are so designed that in case one bridge fails
during operation. the remaining bridges wiII have adequate capacirr
to feed the generator field for full load output. Under such (n-11
operation. where 'n' specifies the total number of thyristor bridges.
the converter is capable of meeting the field forcing conditions.
The thyristor bridges are cooled by fans mounted on the top of the
cubicle. Adequate protection and monitoring is provided for the
thyristors and cooling fans.
Control Electronics
The control circuits contain carious electronic sub-assembfies ir?
Field Flashing
Since it is not possible to start rhe excitation system with the residual
Fidd Suppression Equipment
voltage at nominal speed. a field flashing circuit is proviczd to
overcome this problem. Initially the station auxiliary supply of 41 5
Thyristor Bridge Cubicles
Note: Cooling fans are mounted on top, at site. AC is stepped down by a small transformer, then rectified in a
'(7
Blocking diodes are provided to prevent any backfeed from the field
to the battery when the generator voltage rises under excitation
control by thyristors. Field flashing cubicle contains the field flashing
contactor. diode bridge, dropping resistors etc.
Field Suppression
For rapid de-excitation of the synchronous machine and complete
isolation of the field from the thyristor bridge, a field breaker is
provided. 'In case of severe internaI faults or a three phase short
circuit at the generator terminals or short circuit on the slip rings.
the field breaker provides protection by isolating the DC source from
the field. The field energy is dissipated through a field discharge
resistance, which gets connected across the field under such
operation.
Installation
The sratic excitation equipment should be normally mounted in a dust
free atmosphere on a floor. free from vibration and heat source.
. -, --.
i?:~ii;i .seati,: E.xcitation Equipment)
Rectifier Transformer
The AVR equipment receives the input power supply from the
permaneci magnet generator (PMG) terminals or from generator
terminals through a step down transformer o r from the station
auxiliary supply, as the case may be. This supply is connected to the
thyristor bridge which delivers the variable DC output to the main
exciter field. Normally dry type excitation transformer ( if required)
is provi'ded.
Thyristor Bridge
The thyristor bridge (natural cooled) is configured in a three phase
full-wave connection having individual snubber circuit a n d
protective fuses. Redundant configurationsdepending on the project
requirements c a n be a d a p t e d to increase the reliability a n d
availability.
Control Electronics
The controls using microprocessor based digital voltage regulation
are same as that of Static Excitation Equipment explained separately,
<5 I
I
I OR!
L - ..-- - - - - - - - - -
I
I
ANALOG
INTERFACE
IG,UG
IF
INTERRUPT
GENERATOR d
AUTOMATIC VOLTAGE
REGULATION
+
LIMITERS
'--------
OR:
I
b CONVERTER V/f LIMITER
+
SPECIAL FEATURES
GATE
CONTROL UNIT (AUTO) --b
PULSE
FINAL
STAGE
I
(PSSetc.) (AUTO) U
IF
+ + --- I
I USYNC -+ REFERENCE VALUE
USYNC A
I I
DIGITAL PROGRAMMABLE
GATE CONTROL
I
I/O LOGIC
MANUAL REF VALUE
INTERFACE CONTROLLER
I
IF
USYNC
I
:..P.i - . - . - . - . - . - . . - . , . . . . . . . . , . , . - .
It1 O( It l)l i(vllAh1 0 1 l N l ) l l { l ( I I \( II A I I O N \l\l i hl
Diaital Excitation
ntrol Scheme
Control Philosophy
SIN 0
I MONITORING
j
-(
VOLTAGE
REGULATION
4
-*
4
PULSE
. ,GENERAnON - PULSE
AMPLIFICATION
t
t
FIELD SUPPRESSION
Block Diagram
The digital excitation control using microprocessorsis used in both static excitation and
AVR equipment. The blockdiagram (Fig- 2) represents a typical excitation system and
the functions highlighted represent digital voltage regulation
All the functions shown such as voltage regulation. logic controls etc are carriedout by
the Central Processing Unit (CPU)connected to various peripheral units (analog and
digital VO) through, address bus and a control bus. The data processing is synchronized
by clock pulses derived from internal clock generator. The electrical measuredwlues
obtained from CTsPTs etc for machinevoltage & current, field current are conditioned
in the analog interface module (for field signals) before being taken for active/reactive
measurement. Similarly the binary control signals after getting processed in digital
interface unit (for field signal) are taken to CPU through its digital 110 unit (peripheral.
device to CPU connected to the bus). The binary output data from the CPU after
processing is also communicated through thesedigital VO units.
By means of a separate processor the digital firing and control module generates pulses
at variable firing angles linear to the control signal obtained from the CPU. The control
signal also gets compensated for frequency and commutation etc. before it is used for
pulse generation.
Depending on the customer's requirements. operating control channels can be provided
as eitherautomatic/rnanual channels or automatic/automatic (Dual Auto) channels.
Engineering is done for automatic/manuaI change overs from one channel to another
when more than o n e control channels are provided (Refer iig 3 .
fig 4 & fig. 5 for different configurations)
Power supply for the electronics is provided from two sources (station .AC & kttery
supplies).These two sources are coupled in a power supply unit which concer:s i t to
a common DC bus. From this bus. supply inputs are taken by indicidual DC/DC
converters. ~rhichgive stabilized output to various electronic circuits.
POWER SUPPLY AUTO CHANNEL
J
- . 4
-b GATE
OR 3 w w
VOLTAGE
REGULATION - CONTROL
UNIT
PULSE
AMPLIFIER
0 -
4
MANUAL
CONTROL
-
1 1
+
POWER SUPPLY AUTO CHANNEL
4 4
b GATE b
VOLTAGE PULSE
CONTROL
REGULATION AMPLIFIER
UNlT
0 *-
b
GATE ---4
MANUAL C PULSE '
c
CONTROL
CONTROL AMPLIFIER
UNlT
t I
POWER SUPPLY MANUAL CHANNEL
I
FIG 4 DUAL CHANNEL AVQ - AUTO & MANUAL CONTROL
- w
VOLTAGE + GATE
+. PULSE
CONTROL
REGULATION AMPLIFIER
UNIT
/C - -- - --- -
t t I
I POWER SUPPLY AUTO CHANNEL - II
I
FIG 5 IW_HANNEL AVR - TWO AUTO CHANNEL (MAIN & STANDBY)
CENTRAL PROCESSING UNIT &
ASSOCIATED SOFTWARE
Voltage Regulation
The digital voltage regulator is capable o f performing wide
ranging functions depending o n application requirements for
the projects. However, the important functions apart from
voltage regulation are as below;
Limiters
Follow-up Control
When a generator is running in parallel with the power
network, i t is essential to maintain it's synchronism without Wherever two operating channels are provided in the Digital
exceeding the maximum permissible load o n the machine Voltage Regulator, a follow-up control function is also
and also without tripping by the protection system. Limiter provided which ensures that the control voltage of the non-
functions are provided to ensure this by influencing the operating channel always tracks the control voltage of the
voltage regulator function to limit the over excitation and channel in operation. This helps in a bump free channel
under excitation. This not only improves the security of change over when automatic channel change over takes
parallel operation but makes the operation of the system place. ( eg. Auto to manual change over d u e to a fault in the
easier. However, it must be made clear that the limiters d o auto channel).
not replace the protection system but only prevent the Excitation Sequence Control
protection system from tripping the machine unnecessarily.
The s e q u e n c e of logic operation f o r t h e excitation is
under transient conditions.
performed a s per t h e equipment a n d project specific
The following limiter functions are normally provided : requirements. The software is organized in such a way that
Field current Iimitation alterations can be easily performed at any point of execution
'L!.. .-,Ji-i!:;-,,L:;,~!l.llg.
Stator current limitation (for both leading and lagging stator
current) Excitation Monitoring
Load angle Iimitation Apart from self monitoring of individual electronic unit, the
following monitoring functions are established.
Rotor and stator current limiters reduce the excitation in over
excited operation after a time delay to facilitate field forcing Monitoring of actual value signals of generator voltage a n d
to overcome short lived faults in the network. Under the limit field current
conditions in the under excited operation of the machine. Monitoring of voltage reference for excitation build-up
the load angle limiter and stator current limiter (capacitive) circuit
increase the excitation without any delay.
Monitoring Vlf (over fluxing)
Power System Stabilization (PSS) Protection
This function helps to damp-out the low frequency power From various analog measurements the following protections
oscillations during dynamic conditions to improve system can be performed by the software
damping & stability. The PSS signal is treated as a n additional
Over current-instantaneous
signal and superimposed with the control signal generated
by the voltage regulation. . O v e r c u r r e n t - t i m e delayed from a n inverse t i m e
characteristics
Field Current Regulation In Manual Channel
Local Operation
To ensure a stable operating point in the manual channel
Though the excitation g s t e m is normally operated from a
inspite of small disturbances, a field current regulation
remote place in the plant, option has been provided for
function is provided in the manual channel of operation.
possible local operation. This can be selected for either
normal operation o r for testing & commissioning. All the
desired parameters can be set for optimizing the controls or
normal setting requirements. The parameters o r memory
locations can be displayed as designed for the information
of the operator. This facility eases the effort of the operating
engineer during testing, trouble shooting and commissioning.
Additional functions such as rotor temperature calculation
can be performed by sensing the field voltage and current.
Protection,
Monitoring, Indication
and Metering
Besides over current protection, the dry type rectifier Input Power Supply Protection
transformer is embedded with two temperature dependant
AII input power supplies are received at the excitation system
resistors o n each of the low voltage windings. With rise in
through miniature circuit breakers with thermal over load
temperature the resista.nce value changes sharply after a
release.
certain level. For this one set.of resistors is used for 'warning'
and another for 'tripping'. INDICATION AND METERING
Thyristor Bridge Protection & Monitoring Excitation fault LED indicationsare provided in the regulation
cubicle. Meters are provided for monitoring various currents
Over Current Protection
and voltages. These are finalised during detailed designing
Each thyristor in the thyristor bridge is connected with fast to suit the customers requirements.
acting semiconductor fuse to protect it in case of over current.
Duplications in the control desk for these items are done as
Protection Against Hole Storage per the agreements between BHEL and the customer.
Effect (dv/dt)
RC network across each thyristor is provided for protection
NOTE:
The above Protection & Monitoring a r e generally
against hole storage effect.
recommended for Static Excitation System. However.
protection for thyristor bridges against over current, hole
storage effect and si~pplyprotection are also applicable for
indirect excitation system (Automatic Voltage Regulator
Equipment). Scope of supply shall always be referred with
regard to the actual equipment.
Note:
1. Due to constant improvements and changes in technology,
BHEL reserves the right to update the system mentioned
without notice.
2. The features mentioned are for information only and actual
scope will be as per contracts.
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IIFF F I E L D FLASHING
59/27G GENERATOR HV/LV
834 E X C I T A T I O N SUPPLY ( T E S T MODE)
B3G E X C I T R T I O N SUPPLY ( S E R V I C E MODE)
90VI I S O L A T I O N MODULE
90VR AVR CONTROLLER
BR I THYRISTOR BRIDGE - I
CSSl SERVICE/TEST SELECTOR
CTI COHPOUNDING CT
FA E X C I T E R F I E L D AMMETER
I'C I IRING C l R C U l l
FV E X C I T E R F I E L D VOLIHETER
G ALTERNATOR
GV GENERATOR VOLIMETER V l l H
SELECTOR S V I TCH
PSI, PS2 S l R B l L l S E D POWER SUPPLY
PS3. P S 4
RE F I E L D F L A S l i I N G DROPPING RESISTOR
RV I SEE O/P REF UNDER T E S l MODE
SHI SHUNT
TI EXCIT/\TION TRANSFORMER
T2 SYNCHRONISING TRANSFORMER
73. 7 4 CONTROL SUPPLY B4CKUP TRANSFORMER
/ - AN OVERVIEW
1.0 E Q U I P M E N T DATA
1.1 CUBICLE
Dimensions 800+700+700+800mm WIDE x lOOOmm DEEP x 2350mm HIGH
(quad cubicle suite)
Firing circuits +15V DC & 24V DC regulated supply through either of A C D C &
DCIDC converters connected across the station AC & station DC input
feeders
1.3.3 CONTROL CIRCUIT & ALARM ANNUNCIATION
1 10Vl220V DC from station battery
1.3.4 FIELD FLASHING
il 1 10Vl220V DC from station battery, or
iil4 15V, 34, 50Hz AC from station auxiliary
1.3.5 CUBICLE LIGHTING & HEATING
230V, 14, 50Hz AC
2.2 FEATURES
Compounding
The reactive component of the generator output current is measured and a signal is
'
introduced into the voltage control loop changing the excitation as determined by the
load condition. thereby providing drooping characteristic to the generator voltage with
respect to reacrive loading. This makes the parallel operation of the generator possible.
Setpoint Control
Adjustment of the reference value of the active mode of operation is available either
through contact inputs, auxiliary voltage or current input or communications with a PC or
PLC.
External set point adjustment is provided for controlling the reference value of the active
mode of operation. This eliminates the need for additional equipment like motor operated
potentiometers for remote control or multiple point control for the excitation system. The
operating mode's set point may be directly controlled by raisellower contact inputs,
auxiliary inputs of 4-20mA or *IOVdc. The auxiliary input adjusts the operating mode
across its predetermined adjustment range. These devices modify the operation of the
DECS-300 controller ti meet specific operating characteristics and requirements for the
machine under DECS-300 control. Two more methods of set point control may be
achieved via the RS-232 communication port by using the Windows based PC sofhvare
or by the RS-485 port using Modbus protocol. Regardless of which method of set point is
used (contact inputs, auxiliary input or communications with a PC or PLC), traverse rates
of all modes of operation are independently adjustable. This means an operator can
customise the rate of adjustment and "feel" to meet hisher needs.
Internal Tracking
The control signal levels of the non-active modes are automatically adjusted so as to
match the level of the active mode thereby ensuring a bumpless transfer during mode
changeover.
Field flashing
In the absence of any excitation power to the thyristor bridges when the machine is
started, field flashing is employed for initial voltage build-up. Provision is made for
either AC field flashing through a suitable step-down transformer and three phase
rectifier bridge fed from the station AC or DC field flashing from the station battery
through a dropping resistor and blocking diode arrangement.
Softstart buildup
This feature allows the generator voltage to build up at a predetermined speed over a pre-
determined range so that damaging overshoots of field voltage and stator voltage are
eliminated.
NOTE : Typical applications of this niode would be for testing the healthiness of the
firing circuits and the thyristor bridges independent of the DECS300
con/roller and for tests like the OCC and /he SCC of the genei-n/or or for
drying out the windings of the generator during first run or oflei- n rrrnjor
shutdown.
Indications pertaining to excitation statzrs and auto/nianual stcr/l/s 11103: be
ignored while oj~eratingzmder /he lest n7ode.