TURBOGENERATORS

TURBOGENERATORS

DAX 2-Pole
Turbogenerators
Equipment supplied to over 130 countries.
Over 120 years of electrical experience.

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TURBOGENERATORS

Corby Power Station, UK, incorporating three BRUSH DAX

turbogenerators.

Introduction
Gas turbine driven DAX generator at Kipevu Power Station, Kenya.

50MW BRUSH DAX turbogenerator in Columbia.

BRUSH DAX cylindrical rotor, air cooled

generators are extensively used in public
utility, cogeneration, CHP, industrial and
offshore applications. These generators
are designed to be driven by both
steam turbines and gas turbines, with
extensive operational experience of both
applications. BRUSH has more experience
of the use of gas turbines than any other
generator manufacturer in the world
and has also supplied machines to a
large number of the major steam turbine
companies.

Stator
The stator frame is a rigid structure,
fabricated from mild steel plate and
designed to withstand the mechanical
stresses imposed during operation and
under accidental short circuit conditions.
Mounting pads are incorporated at
appropriate points on the underside, with
holes in each pad for foundation bolts.
The core is built up from segmented
laminations of low-loss, high permeability,
high silicon content electrical steel.
Radial ventilation ducts are formed at
intervals along the core by H section steel
spacers.
The core is hydraulically pressed at
predetermined stages during the building
operation to ensure uniform compaction,
the pressure being carefully monitored,
and the finished core is clamped between
heavy endplates.

Connecting up the half coils to form the stator

winding of a 100MW DAX
turbogenerator.

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The continued success in both gas turbine

and steam turbine power generation can
be attributed to BRUSHs ability to meet
the demanding interface requirements of
the turbine manufacturers, coupled with
competitive prices and keen deliveries.

The stator winding is of the two layer

diamond type, half coils being used for
ease of handling during manufacture and
winding. The insulation system is based on
a resin rich mica glass tape which, when
processed, results in a high performance
insulation capable of continuous operation
at temperatures up to 155C (Class F).
The half coils are placed in the stator slots
in two layers and wedged securely in
position by polyester glass wedges prior to
connection of the endwinding.
The endwinding is securely braced to
insulated support boards bolted to the
core endplate. Spacer blocks are fitted
between adjacent coil sides to produce a
strong archbound, yet resilient, composite
structure, capable of withstanding the
forces that could arise in the event of an
accidental short circuit.
Finally, the completed stator is heated in
an oven to fully cure the insulation.

Rotor

Cooling

The rotor of a BRUSH DAX turbogenerator

is manufactured from a one-piece forging
of nickel chromium molybdenum alloy
steel which is de-gassed and vacuum
poured to obtain a uniform material which
has excellent tensile properties.

BRUSH DAX turbogenerators are cooled by

air, either in open circuit or closed air circuit
configuration. The generator internal
system is similar in all cases.

Axial slots, to carry the windings and for

ventilation, are milled on the periphery of
the body of the rotor.
The rotor winding conductor material is
high conductivity copper/silver alloy strip.
The pre-formed coils are inserted into the
slots, each turn being insulated from the
next. The class F insulation system is
moisture resistant, shockproof and capable
of withstanding the high mechanical
forces to which it will be subjected.
After completion of the winding, the
conductors are heated electrically and
pressed to the correct depth using pressing
rings.The conductors are held in place by
aluminium alloy retaining wedges, which
are connected together at each end
by copper quarter-rings to form a fully
interconnected damper winding.
The rotor endwinding is braced with
packing blocks between the conductors
and is wrapped with insulation, after which
the rotor endcaps are fitted. The endcaps,
which retain the rotor endwinding, are
maufactured from austenitic non-magnetic
18-18 manganese chromium steel.
All completed rotors are tested in the
Companys rotor overspeed test facility,
which is equipped with comprehensive
monitoring equipment.

Bearings
The main bearings are normally fixed
profile, white metal lined, hydrodynamic
cylindrical or elliptical bearings. Other
profiles, including tilting pad bearings, may
be used for specific applications.
The thrust bearings can be provided where
necessary to suit particular turbine or site
conditions.

Cooling air is forced around the generator

by means of two axial flow fans mounted
on the rotor shaft. Cooling circuits are
designed to cool the windings as uniformly
as possible. Open ventilated generators
are cooled by ambient air drawn into the
machine through filters and exhausted
through an outlet duct connected to the
stator air outlet flange.
Site considerations such as severe desert
conditions, extremely salty atmospheres
or unsuitably contaminated environments
may necessitate the use of a closed air
circuit machine, where the hot exhaust air
is cooled by a secondary coolant before
being returned to the inlet. The secondary
coolant is usually water but, in some cases,
may be air.

A completed BDAX 98-330ER generator for GE LMS 100

gas turbine drive.

Excitation System
The majority of the BRUSH DAX range of
turbogenerators are fitted with brushless
excitation systems.
The brushless exciter consists of a three
phase, rotating armature, alternating
current generator, with a shaft mounted
fused rotating rectifier. The field winding is
stationary. The brushless concept enables
the exciter output to be connected to
the generator field without the use of
commutators, brushgear or sliprings.
Double end drive generators use a
brushless exciter that is capable of
transmitting the full power from one of the
turbines.

Typical rotor of a 55MW DAX generator.

Steam turbine driven DAX generator with water cooled heat

exchangers.

As an alternative, a static excitation system

is available. In this system, power is taken
from the generator output through suitable
transformers and fed back to the main field
via a controlled rectifier, brushgear and
sliprings.

The exciter armature and rotating rectifier of a

typical brushless exciter.

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TURBOGENERATORS
Features

Specification

The BRUSH DAX range of turbogenerators has the following features:

Simple foundation design for economic and speedy civil work.
Minimum number of individual power station components, offering
substantial savings on expensive site time.
All units are fully factory tested, reducing commissioning to proving
interconnections and combined turbine/generator testing.
Modular construction giving a fine balance between flexibility and
standardisation of components for fast economic construction.
Fully developed system readily adapted to any turbine design.
Fully compliant with the provisions of the relevant international standard
specifications, including IEC and IEEE.

Voltage range:
Up to 20kV
Speed:
3000 rev/min for 50Hz operation 3600 rev/min for 60Hz
operation
Excitation:
Brushless or static
Drive:
Single or double end
Output range:
10 to 250MVA - also capable of synchronous compensator
operation.
Cooling:
Open circuit, filter ventilated
Closed air circuit, water cooled
Closed air circuit, air cooled

Experience
BRUSH DAX generators have been supplied for the following turbines/companies:
Industrial
Gas Turbines

Units delivered
up to December 2010

General Electric Frame 5

General Electric Frame 6
General Electric Frame 7
General Electric Frame 9
Siemens Westinghouse W251
Siemens Westinghouse W501
Siemens Westinghouse W701
Mitsubishi MF 111
Alstom Type 11
Siemens SGT-500
Zorya Mashproekt OGT 25000

272
120
129
119
54
45
13
5
3
2
4

Aero Derivative
Units delivered
Gas Turbines up to December 2010

Steam
Turbines

General Electric LM 2000

General Electric LM 2500
General Electric LM 2500+
General Electric LM 2500+G4
General Electric LMS 5000
General Electric 6000
General Electric LMS 100
Pratt & Whitney FT4
Pratt & Whitney FT8
Rolls Royce Avon
Rolls-Royce Spey
Rolls-Royce Olympus
Rolls-Royce RB211
Rolls-Royce Trent

Allen Power

4
232
59
39
59
558
28
54
223
1
6
100
10
30

Units delivered
up to December 2010
1

Alstom Power
Dresser Rand
EKOL Spol
Elliott Company
General Electric
MAN Turbo
Hitachi
Mitsubishi Heavy Industries
Shin Nippon Machinery Co
Siemens
Skoda Power
Toshiba

1
2
1
6
14
6
1
24
14
63
6
1

International Sales and Support Locations

BRUSH Turbogenerators Inc.
15110 Northwest Freeway, Suite 150,
Houston, Texas 77040, USA
Tel: +1281 580 1314
Fax: +1281 580 5801
Service Email: serviceus@brush.eu
Sales Email: salesus@brush.eu

SM0000247M

BRUSH Turbogenerators
P.O. Box 111209, Abu Dhabi,
United Arab Emirates
Tel: +971 4362 6391
Fax: +971 2550 1920
Service Email: serviceme@brush.eu
Sales Email: salesme@brush.eu

BRUSH Turbogenerators
Falcon Works, Nottingham Road,
Loughborough, Leics. LE11 1EX, UK.
Tel: +44 (0) 1509 611511
Fax: +44 (0) 1509 610440
Service Email: serviceuk@brush.eu
Sales Email: salesuk@brush.eu

BRUSH Turbogenerators
Lot PT 5038-5041, Jalan Teluk Datuk 28/40,
Off Persiaran Sepang, Seksyen 28,
40400 Shah Alam, Selangor D.E.Malaysia.
Tel: +60 (0)3 5192 7213
Fax: +60 (0)3 5192 6293
Service Email: servicemy@brush.eu
Sales Email: salesmy@brush.eu

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