TRAINING ON HYDRO TURBINE AND

HYDRO GENERATORS
 Contents

1. Selection and design aspects

of Hydro Turbines

2. Design & construction features

of Hydro Turbines & Valves

3. Operation & Maintenance of Hydro Turbines 3.1 to 3.24

4. Governing Systeni Mechanical portion 4.1 to 4.10

5. Governing Systems Electronics portion 5.1 to 5.11

6. Selection criteria, main construction 6.1 to 6.34

Features, Leveling, Alignment & Boxing off
and O&M of Hydro Generators

7. Control & Protection of Hydro Power Stations 7.1 to 7.20

8. Excitation System. 8.1 to 8.49

1.0 Selection and design aspects of Hydro
Turbines
 SELECTION OF HYDRO TURBINE
BHEL RANGE FOR HYDRO TURBINE

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

In an impulse turbine the water is supplied to the runner at atmospheric pressure,

possessing kinetic energy only. The flow through the runner is entirely at
atmospheric pressure, the force exerted by the water being due to the impulse of
the jet. Whereas in a reaction turbine the water supplied to the runner possesses
energy which is partly kinetic and pai-tly pressure. Both types of energies are
converted into work in the runner, resulting in a drop of pressure and of absolute
velocity of water.

11. CONSTRUCTIONAL DETAILS OF IMPULSE TURBINE

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.

A suitable governing system to synchronise the machine to various load

situations is imperative.

Pelton wheels may be arranged with either vertical or horizontal axis.

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11. CONSTRUCTIOBAL DETAILS OF REACTION TURBINE

Reaction turbines commonly used are of two types :-

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.

TYPE OF HYDRO POWER SCHEMES

1. STORAGE TYPE - Flow from large storage reservoir is supplied to plant.

- Good Peaking Power.

2. RUN O F RIVER - It uses water just as it comes without any storage.

- Dependent upon seasonal variation of flow.

- Base Load Power.

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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

b) HEAD & OUTPUT VARIATION

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

Capacity 1.5 to 300

. . . . .

; Actual

Capacity
i Actual
! KAPLAN
.......................
Capacity
Actual

Capacity
Actual

Size (mm) Head (m)

; 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

BHEL made an e n t r y i n t o t h e h y d r o - e l e c t r i c f i e l d in the

early s i x t i e s when i t s Bhopal p l a n t was s e t up and its
engineers took up d e s i g n o f h y d r o turbines, valves and
a s s o c i a t e d a u x i l i a r i e s w i t h M/s E n g l i s h E l e c t r i c Company o f
U.K., the f i r s t designs o f Kaplan, P e l t o n and F r a n c i s
t u r b i n e s developed by BHEL e n g i n e e r s were f o r Obra i n U . P . ,
Bassi arld Dehar i n H i m a c h a l Pradesh; these t u r b i n e s were
manufactured, erected a n d commissioned i n the early
sevent i e s . To- cope i_ up w i t h i n c r e a s i ng demand f o r hyde I c.
power equipment , a n o t e r BHEL p l a n t was s e t
' up a t Hardwar
i n 1965, i n c o l l a b o r a t t i o n w i t h M/s LMZ o f USSR.

I n the l a t e r years, B H E L 1 s ' c a p a b i I i t i e s were f u r t h e r

enhanced whi I e w o r k i n g o n a number o f joint venture
projects w i t h many r e p u t e d manufactures: e.g .wi t h M/s
Neyrpic, for high-head P e l t o n turbines; with M/s Skoda,
Boving & H i t a c h i , f o r pump t u r b i n e s ; w i t h M/s N e y r p i c &
Fuji, for bulb turbines etc. Recently BHEL had
c o l l a b o r a t i o n w i t h M/s GE, Canada f o r enhancing t h e r a n g e o f
Francis turbines. .

Over t h e y e a r s , g l o b a l l y , c o n t i n u o u s development have t a k e n

p l a c e i n v a r i o u s r e l a t e d a r e a s : h y d r a u l i c d e s i g n s , mechanical
designs, techniques of s t r e s s a n a l y s i s , materials, t e s t i n g
t e c h n i q u e s , g o v e r n i n g & c o n t r o l p h i l o s o p h y , use o f c o m p u t e r .
BHEL, i n i t s p e r p e t c a l endeavour towards u p g r a d a t i o n o f
hydroturbines & valves, has kept i t s e l f abreast w i t h these
advancements and has made u s e o f t h e o p e r a t i o n a l feedback o n
these products.. As a r e s u l t , a number o f new d e s i g n s have
been deve Ioped and s i g n i f i c a n t imp rovemen t s have 'been
made s p e c i a l l y s u i t i n g t o I n d i a n c o n d i t i o n s .

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" ,

performance and h y d r a u l i c r e l i a b i l i t y . A l l these f a c t o r s

results in lower p r o c u r e m e n t c o s t o f equipment .and e a r l ' y '
commissioning. Also from the operational e x p e r i e n c e s o'f
v a r i o u s hydro t u r b i n e , c e r t a i n s p e c i f i c design features a r e
c a l l e d such as l e v e l o f w i s e and v i b r a t i o n s , resistance t o '
suit ere--',. . I ,
lubricated bearings, underneath
a I 5 l i 1 h T 1 1i i CIG ",. ,-,: et c. to suit particular site
conditions. These features t a k e i n t o considerations the
ease i n maintenance, r e m o v a b i l i t y and r e n e w a b i l i t y and to
t h e e x t e n t p o s s i b l e l o n g e r l i f e s p a n . Based on t h e s e f a c t o r s
c e r t a i n s p e c i f i c d e s i g n f e a t u r e s a ' r e b e i n g w i d e l y a d o p t e d by
manufacturers a l l over the w o r l d f o r t h e d e s i g n o f turbine
and v a l v e c o m p o n e n t s .

This i s t h e most important a r e a which c a t e r s n o t o n l y t o the

customer's requirements, b u t a l s o e n a b l e s BHEL t o make its
o f f e r more c o m p e t i t i v e . The d e s i g n i n v o l v e s a n a l y s i s of
complete t u r b i n e from s p i r a l i n l e t t o d r a f t t u b e e x i t with
the h e l p o f computers.

BHEL has numerical design methods aimed at successfully

achieving the following objectives:

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 .

2. Deve l opmen t o f new r u n n e r s u i t i ng t o des i r e d head and

d i s c h a r g e cond i t i o n s .

3. Uprating of an e x i s t i n g machine by increasing

d i s c h a r g e u p t o 1 5 t o 20%. b y r e p l a c i n g t h e o l d runner
w i t h a new n u m e r i c a l l y d e s i g n e d r u n n e r .

4. Altering theoperatngcharacteristicsof a turbine by

suitable runner r e p l a c e m e n t t o meet t h e r e v i s e d head
and d i s c h a r g e w h i c h have c h a n g e d o v e r t h e y e a r .

5. Analysis and s o l u t i o n o f s i t e p r o b l e m s pertaining to

cavitation.

The performance o f a turbine r u n n e r , i n respect of both

e f f i c ~ e n c y a n d power character i s t i c , depends on the
compatibility o f the actual f l o w c o n d i t i o n s w i t h the shape
of i t s blade p r o f i l e . I t s v a l u e i s maximised by minimising
losses. This c a l l s f o r conducting a systematic f l u i d flow
anlaysis and l a b o r a t o r y i n v e s t i g a t i o n . Actual f l o w i n the
turbine i s viscous, t h r e e - d i m e n s i o n a l and u n s t e a d y . The
e q u a t i o n s g o v e r n i n g t h e f l o w a r e n o n l i n e a r i n n a t u r e and t h e
analytical s o l u t i o n o f such a f l o w i s c o m p l e x , while the
experimental v a l i d a t i o n i s a l s o n o t always a v a i l a b l e .

However, with s i m p l i f ~ e d assumptions coupled wlth the

avai lab l e experimental e v i d e n c e s observed dur I n g the
laboratory studies, an e f f e c t i v e n u m e r i c a l s o l u t i o n o f the
flow e q u a t ~ o n shas been made p o s s i b l e . The a b s o l u t e f l o w i s
cons I d e r e d t o b e i n v i s c I d a n d p o t e n t i a l , a n d i t i s assumed
that there a r e axisymmetrlc s t r e a m surfaces i n t h e r e g i o n of
t h e r u n n e r . T h e d e s i g n o f t h e b l a d e p r o f i l e and t h e a n a l y s i s
 of f l o w between t h e two n e i g h b o u r i n g b l a d e s i s c a r r i e d o u t
on these stream s u r f a c e s . The d e s i g n process is
accomp 1 i shed in two s t a g e s : f i r s t l y , by creating a
)
parameteric 3-D geometric shape o f the runner; and
subsequently, b y p e r f o r m i n g f l o w . a n a l y s i s t o generate f l o w
)
parameters l i k e v e l o c i t y and p r e s s u r e i n t h e f l o w passage.

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 . .

D u r i n g the h y d r a u l i c design p r o c e s s , the blade thickness

variation i s assumed.&ased on p a s t similar runners. The
thickness of the blade i n i t i a l l y assumed d u r i n g the
h y d r a u l i c d e s i g n p r o c e s s i s c h e c k e d a l o n g w i t h t h e crown and
band for s t r e s s e s under s t a t i c as we1 l as dynamic
c o n d i t i o n s , e s p e c i a l l y i n t h e a r e a s where h i g h e r s t r e s s e s do
occur, such a s , at t h e j u n c t i o n s between t h e i n l e t o f the
b l a d e and the band, and between t r a i l i n g edge and t h e crown.
The e f f e c t s o f the d e f l e c t i o n s o f the runner a r e a l s o
analysed. All these a n a l y s i s a r e c a r r i e d o u t u s i n g FEA
met hods. Sometimes n a t u r a l frequency o f blades i s a l s o
computed. The s o f t w a r e g e n e r a l l y used a r e IDEAS, ANSYS,
N H S l KAN.

MODEL MANUFACUTRE AND TESTING

For determining t h e b e h a v i o u r o f t h e new r u n n e r h y r a u l i c

model s t u d i e s a r e c a r r i e d o u t i n o u r l a b o r a t o r y a s t a t e of
art equipped with latest instruments and computarised
o p e r a t ~ n gsystems. A f u l l y homologous model o f the t u r b i n e
i s b u i l t f o r c a r r y i n g o u t model t e s t s . The s p ~ r a lc a s i n g and
stay r i n g are c a s t - f a b r i c a t e d i n s t e e l . t h e g u i d e vanes and
r u n n e r b l a d e s a r e N-C machined, w h i l e t h e d r a f t tube i s made
i n glass f i b r e reinforced p l a s t i c . The upper p a r t o f the '
draft tube i s made af transparent acrylic, t o enable
vlsualrzation of c a v i t a t i o n areas.
I
The crown and s k i r t were copy t u r n e d based on NC
.manufactured copying templates. An i n t e g r a t e d CAD-CAM
I
approach i s adopted f o r t h e m a n u f a c t u r e o f t h e templates and
the runner blades, i n o r d e r t o m a i n t a i n t h e accuracy o f the
design. The b l a d e s a r e l o c a t e d on t h e crown through
l o c a t i n g s t u b s on t h e r u n n e r b l a d e s and t h e c o r r e s p o n d i n g
J
holes i n the crown, The t i g h t ' t o l e r a n c e s on these ensures '
)
a h i g h degree o f accuracy o f t h e r u n n e r .
1
I ,
_-- , *
1 Vi:- welding i s c a r r i e d o u t between t h e s k i r t and the
blades, which i s needed f o r a d d i t i o n a l s t i f f e n i n g o f the
1 runner. T h i s ensures m i n i m a l d i s t o r t i o n o f t h e runner.

Inspection of the various model components i s done in

accordance w i t h the p r o v i s i o n s l a i d down i n IEC 193 and IEC
193 A .

The model t e s t o f the new runner i s c o n d u c t e d i n accordance

wi th t h e " l n t e r n a t i o n a l Code f o r Model Acceptance ? e s t s o f
Hydraul i c Turb i nesg'- Pub l i c a t ions 193 & 193A of
I n t e r n a t i o n a l E l e c t r o t e c h n i c a l Commission. The t e s t i n g i s
c a r r i e d o u t a t Hydro Machinery Development Station, BHEL-
Bhopal , where s imu I taneous data lggg i ng o f a l l the test
p a r a m e t e r s ensured an o v e r a l l inaccuracy l e v e l o f less than
0 .'25% i n e f f i c i ency measurement. A c l o s e d l oop feedback
c i r c u i t i s used t o ensure s t a b i l i t y o f t h e t e s t r i g .

Runner i s most important p a r t o f hydro t u r b i n e . I t converts

t h e h y d r a u l i c energy o f w a t e r i n t o m e c h a n i c a l energy. The
e f f i c i ency . o f t u r b i ne depends on e f f i c i ency of energy
c o n v e r s i o n hence a c c u r a t e m a n u f a c t u r i n g w i t h h i g h q u a l i t y o f
finish i s most i m p o r t a n t . A l s o .the r u n n e r i s s u b j e c t e d t o
most s e v e r e s t r e s s e s and hence proper s e l e c t i o n o f m a t e r i a l
and mechanical design i s a l s o o f prime i m p o r t a n c e .

Ti l I the recent past t h e runners o f f r a n c i s t u r b i n e s were

m a n u f a c t u r e d from s t e e l c a s t i n g or s t a i n l e s s s t e e l casting.
The c a s t i n g s were produced as s i n g l e p i e c e c a s t i n g s . Trends
towards s e l e c t i o n o f l a r g e s t p o s s i b l e c a p a c i t y has l e d t o
m a n u f a c t u r e o f large s i z e t u r b i n e h a v i n g l a r g e runner and/or
heavy r u n n e r .

Limitation from the considerations of (1 ) Transport

dimensions. and ( 2 ) C a s t i n g s u p p l i e r ' s c a p a c i t y , has l e d t o
m a n u f a c t u r e o f runner w i t h d i f f e r e n t t e c h n i q u e s .

In case o f transport l imitations the r u n n e r can be

manufactured i n halves w i t h i n t e g r a l f l a n g e s for bolting. -
The crown and bands o f c a s t c o n s t r u c t i o n and blades o f
cast/plate construction a r e welded t o g e t h e r i n the shop.

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.

Dynamic b a l a n c i n g o f runners i n case o f s m a l l s i z e and h i g h

speed runners, have been s p e c i f i e d i n c e r t a i n cases.
However, based on p a s t exper i ence and s i te feed back,
b a l a n c i n g a t a lower s6eed o f 10-15 rpm i s a l s o a c c e p t a b l e .
From t h e o p e r a t i o n a l view p o i n t l a r g e s i z e r u n n e r s w h i c h a r e
o p e r a t i n g a t low speed, a r e s t a t i c a l l y b a l a n c e d .

') 2. INTERCHANGEABLE RVNNERS

) R e p a i r o f e r o d e d r u n n e r s i s a time consuming work, thereby
reduc i ng t h e a v a i l a b i l i t y of t u r b i n e . BHEL p r o v i d e spare
) runners which are interchangeable wi th the shafts.
I n t e r c h a n g e a b i l i t y has been achieved u s i n g j i g s for the
1 coup l i ng ho l e s . T h i s p r o v i s i o n reduces t h e downt ime o f . t h e
machine. The e x i s t i n g runners & s h a f t s o f o l d power s t a t i o n s
c a n a l s o b e made interchangeable, as has been done i n a 4 x
6 0 MW power s t a t i o n r e c e n t l y .
) -.
3. RUNNERREMOVALFAClLlTYWlTHOVTDEIYATERlNGw-UNITS
1
BBEmoPERATION
(FOR PELTON TURBINE)
I

I n the o l d c o n v e n t i o n a l designs, tail r a c e has tg be

dewatered b e f o r e d i s m a n t l i n g o f runner f o r repair.

nc. ' RUNNER REMOVAL ~RRANCEMNT w r r ~ nc. RUNNER REMOVAL ARRANCEh€ENT WKWOlJC
DEWATERl N G OF TmRACE DEWATERINC OFTAJLRACE
 :-

In the new des i g n s , runner i s lowered on a spec i a I I y

) designed p l a t f o r m , w i t h o u t dewatering t h e tailrace. . This
r e s u l t s i n reduced down t i me and qu i c k e r r u n n e r rep I acernen t .
This design has been provided i n a 40 MW p r o j e c t w h i c h has
been operat i n g a t 890 m head f o r more than a decade.
F i g u r e s show t h e c o n v e n t i o n a l and t h e new design scheme
respectively.

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 . ,

Based. on t h i s need, t h e concept o f b o t t o m d i s m a n t l i n g of

r u n n e r s was d e v e l o p e d . . t I n t h i s arrangement, the r u n n e r i s
decoup l e d from t h e s h a f t - and taken o u t f r o m the d r a f t tube
side. B y t h i s p r o v i s i o n , not o n l y t h e runner but even t h e
stationary labyrinths, l i n e r p l a t e s and g u i d e v a n e s become
e a s i l y accessible for repairs. Figureshows a typical
des i gn scheme o f b o t tom d i smant I i ng o f a F r a n c i s r u n n e r .

FIG. BOTTOM D I S \ l A ~ I N COF R U S S E R

The s t a y r i n g c o n s i s t s o f upper r i n g , lower r i n g and a s e t

of s t a y vanes. I t guides the water t o guide vanes and
t r a n s f e r s t h e l o a d o f whole machine t o f o u n d a t i o n . I n past
stay r i n g s were made of cast steel. Now w i t h the
development of w e l d i n g technology, these are b e i ng
manufactured from steel plates by fabr icat ion process;
Advancement in knowledge and analysis of flow pattern, .has
resulted in development of PARALLEL PLATE TYPE stay ring.
The parallel plate type stay ring has following advantages
over conventional contour plate type stay ring.
1. Simple construction
2. Short manufacturing cycle
3. Econom i ca I
4. Overall dimensions of stay ring-spiral casing is
smal ler. This may result in smal ler power house
dimensions.
Large stay ring is fabricated in sections due to transport
limitations. Earlier flanged joints were provided, which
resu I ted in longer manufacturing cycle and higher
manufacturing cost. Presently stay ring sections are
designed without f l a n g ~ sfor final site welding, reducing
manufacturing cylce and less expensive.

I I

RC.. CONMNnONALCGNTOUR TIrE STAY RING nc. PARALLEL-UTE n ~ RING

p STAY

Large size spiral casing is manufactured by using H.T.Steel

Plates. This has resulted in reduction of spiral plate
thickness, overal I weight of spiral casing and cost.
The
distribution piping of peltbn turbines is subjected to
.high water pressure. This was manufactured from cast steel.
Present day practice is to fabricate i t from H.T.Steel.
Even flanges for connecting the individual segments have
been discarded. The segments are welded to each other at
siteafter final levelling andalignment. U s e o f HT Steel
results in lower piping thickness, lower weight, reduction in
manufacturing cyc l e and economical .
1
Guide vanes c o n t r o l t h e q u a n t i t y and d i r e t j o n o f w a t e r to
3 runner. I t i s n o r m a l l y s u p p o r t e d on t h r e e b e a r i n g s . Two i n
t o p c o v e r and one i n b o t t o m r i n g . For small s i z e t u r b i n e s
3 two b e a r i n g s , one i n t o p c o v e r and another i n b o t t o m r i n g
are provided. Present design trend i s t o provide two
? bearings o n l y , one each above a n d below guide vane f e a t h e r .
l h ~ shas been made p o s s i b l e b y a c c u r a t e s t r u c t u r a l analysis
i w i t h t h e h e l p o f computers.

Bushes o f vane t r u n n i o n and b u t t e r f l y v a l v e trunnion

-) were e a r l i e r made o f b r o n z e and l u b r i c a t e d by g r e a s e .

The present trend is t o avoid grease and use

environmentally f r i e n d l r i s e l f - l u b r i c a t i n g bushes. In line
with t h i s trend, t h e new t u r b i n e s b e i n g s u p p l i e d have s e l f -
l ubr i c a t i n g bushes ..

I n the e i g h t i e s , some o r d e s f o r s u p p l y o f smaller size

machines w i t h r u n n e r d i a m e t e r o f 1 t o 1.5 m were received.
To accommodate the conventional design, space was a
constraint.
1 In-house development e f f o r t s o f BHEL l e d t o t h e d e s i g n o f
compact GV l i n k a g e . Machines w i t h t h i s new d e s i g n f e a t u r e
1
have been i n o p e a t i o n f o r n e a r l y a decade.

10. PROViSlQN J N - S I T U BEPLACEMENT QE G U I D E V A N E S E A L S

I n the e a r l i e r desings, r e p l a c e m e n t o f g u i d e vane seals

cal led for dismant I i n g of t u r n i n g mechanism and bush
hous i ng .

Here t o o an improvement has been made, by way o f providing

an arrangement f o r i n - s i t u 'replacement o f t h e s e a l s .

The e a r l i e ' r machines m a n u f a c t u r e d i n t h e 1 9 6 0 ' s and e a r l y

1970's were provided w i t h f i x e d steel liner plates.
However, this design suffered from the f o l lowing
.limitations:

, ,
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 .

ii) I n s i l t - p r o n e zones, wear r a t e i s h i g h e r and t h e t i m e

f o r p u t t i n g a t u r b i n e back t o s e r v i c e i s q u i t e long.
 These deficiencies have been overcome by introducing .the -
replaceable liner plate concept. AS per this concept, the
I i ner p'l ates are made interchangeable and' are fixed by
staln~esssteel fasteners. BHEL machines supplied from late
1970 onwards have this improved features (Refer Fig.)

FIG. REPLACEABLELINER PLATES

The shaft seal design obtained by BHEL from its foreign

collaborators used carbon seal gland. These glands were
very vulnerable in the power stations situated in north
India. The wear rate of the shaft sleeve was faster and i t
needed frequent replacement. Therefore need to develop a
technology to reduce the replacement rate was felt.

Accordingly, rubber flap type shaft sealing was introduced.

This has substaintialy reduced the wear rate, and many
customers have asked BHEL to change the carbon gland seals
to rubber seals. By this design improvement, in a power
station having 6 machines rated at more than 150 MW each,
shaft sleeve replacement frequnency has almost halved.

13. INIET VAIVFS:

The inlet valves serve the purpose of isolating turbine'from

penstock . They are of two types-Butterfly type and
Spherical type. Butterfly valve is used where head is
low/medium. Spherical valve is used where head is high.

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.

Mostly valves are being designed for opening and closing by

oil pressure operated servomotor. However, requirement of
closing by dead weights in emergency, is also being
 - Reducing sol i d content o f water f l o w i n g through t u r b i n e
(customer scope)
- Si I t erosion-resistant material and protective
coatings.
- Designing machinery f o r minimal e r o s i o n , w i t h the
lowest possible r e l a t i v e f l o w v e l o c i t i e s and e a s i l y
r e p l a c e a b l e wearing p a r t s .

BHEL i s working i n the f o l l o w i n g f i e l d s .

(a) ater rial

BHEL a t i t s Corp. R&D, Hyderabad has a f u l l fledged
t e s t - r i g f o r evaluat i n g r a t e o f si lt e r o s i o n where
I various in-house c o a t i n g s a r e t e s t e d . Based on these
test r e s u l t s f i e l d t r i a l s a r e done. I n the past
I different types o f c o a t i n g s were t r i e d on these under
water p a r t s which a r e -
- Chromium b o r i d e plasma sprayed and vacuum heat -
treated coating.
- Boride c o a t i n g .
- High v e l o c i t y o x y - f u e l based c o a t i n g .
- Coating by D e t o n a t i o n gun.

On t h e basis o f f i e l d t r a i . 1 ~ o f these c o a t i n g s hydro

e l e c t r i c schemes prone t o s i l t e r o s i o n have been
d i v i d e d i n three c a t e g o r i e s - A,B,C. L i f e o f components
of p r o j e c t s covered i n 8 & C category .can be
considerably enhanced ,by p r o v i d i n g the coating.
However, f o r A c a t e g o r y h i g h v e l o c i t y p e l t o n machines
work i s s t i l l going on. Coatings o f Tungstun carbide
w i t'h ~ o b lat base a n d Chrom i urn carb i de w i t h N i cke l base
by . d e t o n a t j o n gun a r e under e v a l u a t i o n a t Bhaba HEP.
BHEL.has',recently
. .... p r o c u r e d TAFA 5000 Gun w i t h which a l l
types..:. o f :'coat ings - . can . .be done on h y d r o t u r b i ne
comp'on&n,ts~~~~'c.onven.i e n t I y .:.:Advantage i n .TAFA coat i ng i s
t h a t . ' - temp'e-rafire of ba.se -metal does n o t exceed. 100
degree ' C. :;',~oughhess' and-' bondage o f coat i ngs are v e r y
good. umber..^' of.'.;-'f i e I d t r'ia I s a r e be i ng p I anned w i t h
t h i s HVOF .coat i ng .."..
-.
.. .
. . . . .

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 ,

.
O N h .
. . -- .
&\>,
I

I n t h e b r i e f ispan'of t h e - l a s t t h r e e . decades, contribution

. I made . by BHEL ' i n . . the . f i e l d a f hydro power has been
 considerable. W i t h the experience gained over the years-and
-I developments. made BHEL is now ranked as one of the world's
leading manufacturer in the field of hydro turbines, valves
3 and associated auxiliaries, and is well equipped to develop,
3 design and manufacture all types of turbines (of small as
well as large capacities), to international specifications',
3 meeting the customer's requirements, for both domestic and
overseas markets. These developments, neverthless, are
) mearly a step forward in the long and relentless journey o f
self-development. BHEL is determined to carry on this
) journey unf l inching l y .
3.0 Operation & Maintenance of
Hydro Turbines
IMPORTANT ASPECTS OF OPERATION &
MAINTENANCE OF HYDRAULIC TURBINES
 MAIN AREAS

TURBINES
FRANCIS
KAPLAN
PELTON
OTHERS : Propeller, Bulb, mini-micro etc
INLET VALVES
SPHERICAL TYPE
BUTTERFLY TYPE
PENSTOCK BUTTERFLY VALVES
TURBINE AUXILIARIES
 OPERATION OF TURBINE

OPERATING 'PARAMETERS - HEAD,OUTPUT,TAIL WATER

LEVEL
OPERATING LIMITS FOR DIFFERENT HEAD
CONDITIONS AS PER 0 & M MANUALS TO BE
FOLLOWED
OPERATING CHARACTERISTICS OF DIFFERENT
TYPES OF TURBINE
HIGH TAIL WATER FOR PELTON TURBINES
CREATES PROBLEM'
FOR PELTON TURBINES PERFORMANCE CAN BE
OPTlMlSED BY USING NOZZLE SELECTION BEING
PROVIDED IN MODERN MACHINES
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 CHECKS ON TURBINE

THE CHECKS GIVEN IN OPERATION &

MAINTENANCE MANUALS TO BE FOLLOWED &
DATA LOGGING TO BE DONE
DAILY CHECKS
WEEKLY CHECKS
MONTHLY CHECKS
QUARTERLY / HALF YEARLY CHECKS
ANNUAL CHECKS
PREVENTIVE MAINTENANCE
CAPITAL MAINTENANCE
 SPARE PARTS

INVENTORY OF IMPORTANT SPARE PARTS TO BE

MAINTAINED.
TIMELY PROCUREMENT & ORDERING OF LONG CYCLE
SPARE PARTS.
ALL ITEMS ARE CUSTOM BUILT & SHORT DELIVERY NOT
POSSIBLE.
IMPORTANT COMPONENTS LIKE RUNNERS, GUIDE VANES,
LABYRINTH RINGS, RUNNER BLADES, LINER PLATES,
SPEARS & NOZZLES FOR PELTON, BUSHES1 BEARINGS,
TURBINE GUIDE BEARING PADS1SHELL- SUFFICIENT SPARES
TO BE MAINTAINED.
MORE INVENTORY OF SPARES FOR PROJECTS IN HIGH SILT
AREAS PARTICULARLY FOR WATER WEARING PARTS.
DESIGN FOR EASY REPLACEMENT OF UNDERWATER

PARTS

BOTTOM DISMANTLING OF RUNNERS

(FRANCIS & PELTON)

REPLACEBLE NOZZLE PARTS- EASY IN SlTU REPLACEMENT.

MATERIAL OF ALL WEARING PARTS IS ADOPTED AS

STAINLESS STEEL

MAINTENANCE SEAL FOR MIV FOR REPLACEMENT OF

SERVICE SEAL WITHOUT DEWATERING PENSTOCK.

RUNNER REPLACEMENT AT INSPECTION PLATFORM LEVEL

WITHOUT DEWATERING TAILRACE CHANNEL FOR PELTON
MACHINE.THIS CAN BE ADOPTED FOR SMALLER RUNNERS.
Wcn
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LABYRINTH RINGS
EROSION &WEAR IS MAIN CAUSE OF DAMAGE
TOP COVER PRESSURE INCREASES
LOAD ON THRUST BEARING & HENCE TEMPERATURE
INCREASES
LOSS OF WATER, REDUCTION IN EFFICIENCY & OUTPUT
WEAR RATE MULTIPLIES IF TIMELY REPLACEMENT NOT DONE
NOZZLES(F0R PELTON TURBINES)
VERY HIGH VELOCITY JET WITH SILT LADDEN WATER
CAUSES HIGH DAMAGE
WEAR RATE MULTIPLIES IF TIMELY CORRECTIVE ACTION NOT
TAKEN
EFFICIENCY & OUTPUT REDUCES
EXCESS LEAKAGE IN CLOSED POSITION KEEPS THE MACHINE
RUNNING WHEN STOPPED & DAMAGES GENERATOR
BEARINGS

PREVENTIVE MAINTENANCE & TIMELY REPAIR 1 REPLACEMENT

IS THE KEY FACTOR TO OPTIMISE BENEFITS
 INDEX TESTING

THIS IS A SIMPLE METHOD & CAN BE USED TO ASSESS FALL

IN TURBINE PERFORMANCE OF OLDER MACHINES
BHEL HAS DEVELOPED EXPERTISE & CAN UNDERTAKE
INDEX TESTING OF OLDER MACHINES
DUE TO EROSION OF UNDER WATER PARTS &
DETERIORATION OF TURBINE PERFORMANCE, OUTPUT &
EFFICIENCY REDUCES DRASTICALLY CAUSING BIG REVENUE
LOSS TO OWNER.
BY INDEX TESTING FOLLOWING CAN BE ACHIEVED
PLAN CAPITAL MAINTENANCE & REPLACEMENT OF PARTS
UPRATING THE UNIT BY USE OF NEW HIGH PERFORMANCE
RUNNERS & OTHER MATCHING COMPONENTS
COST INCURRED CAN BE RECOVERED IN A FEW YEARS
 AUXILIARY SYSTEMS

MAIN AUXILIARY SYSTEMS ARE

COOLING WATER SYSTEM
COMPRESSED AIR SYSTEM
OIL PRESSURE SYSTEM
GREASING SYSTEM
COOLING WATER SYSTEM
IN THIS SYSTEM MOST OF OPERATION & MAINTENANCE
PROBLEMS ARE DUE TO SILTY WATER
TYPE OF SYSTEMS
TAPPING FROM PENSTOCK (FOR LOW & MEDIUM HEAD
PROJECTS)
PUMPING FROM TAILRACE ( FOR HIGH HEAD PROJECTS.)
OPEN LOOP SYSTEMS
-CONVENTIONAL SYSTEM FOLLOWED FOR EXISTING / OLD
PROJECTS
CLOSED LOOP SYSTEMS
CLEAN WATER CIRCULATES THROUGH BEARING & AIR
COOLERS & RAW WATER IS USED TO COOL CLEAN
WATER IN SEPARATE HEAT EXCHANGERS
ADVANTAGES OF CLOSED LOOP C.W. SYSTEM

a NO CHOKING OF BEARING & AIR COOLERS DUE TO SILT

REDUCING MAINTENANCE / DOWN TIME
a AUTOMATIC STRAINERS FOR RAW WATER SYSTEM
a LESS SPARES INVENTORY & LONG TERM FINANCIAL
BENEFITS
a FOR OLD POWER STATIONS, UPGRADATION FROM
OPEN LOOP TO CLOSED LOOP MAY BE ADOPTED TO
ACHIEVE OPERATIONAL BENEFITS
 COMPRESSED AIR SYSTEM

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.

GOVERNOR OIL PRESSURE SYSTEM

PROPER DEGREE OF CLEANLINESS FOR OIL IS A MUST FOR
TROUBLE FREE OPERATION OF GOVERNOR
REGULAR CENTRIFUGING & ELECTROSTATIC FILTRATION OF
OIL SHOULD BE CARRIED OUT.
DEBRIS IN PIPING SYSTEM & OIL TANKS TO BE REMOVED
MORE FREQUENTLY.
4.0 Governing System Mechanical portion
 Governing System for Hydro electric Projects

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:

The g w m r must the following requirements as per IEC 6 13 12:

- Steady state
1
- S d l transient
- Large transient
I - Blocked gate

Page 1 o f 6
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.

6. Types of governors developed, manufactured and commissioned:

I . G25M Mechanical Governor

2. G25E Electro Hydraulic Governor
3. G 4 0 Electro
~ Hydraulic governor for francis / Pelton
4. G 40K Electro Hydraulic Governor for Kaplan
5. Compact Electro Hjrdraulic Governor for small (mini-micro) mach~nes
6. Microprocessor based Electro Hydraulic Governor (Digital Type)

7. Special fatures developed in governing system:

..r
.-

- Water level control

- Tandem control
- Pump turbine control
- Optimum control
- Synchronous condenser operation
- Automatic Alfa-Beta relationship according to water aedQad
- Electronic limit
- Individual servomotor control
8. Regulating system of electro hydraulic governor:
It senses the speed of turbine rotation, generates signals proportional to difference between
the turbine speed and governor speed reference and then develops hvdraulic control signals
of sufficient power to position the turbine wicket gate servo motor as required to control the
turbine.

Speed of machine is measured by a speed sensor and converted to a DC voltage which is

proportional to speed. This voltage is compared with a reference voltage set by speed setter.
The error signal so formed is mixed with other signals like speed trim, permanent droop,
temporary droop etc. in the control amplifier, output of which is the control signal which is
further amplified to drive the electro-hydraulic transducer. Electro-hydraulic transducer
converts the electrical sibmal into mechanical movement which is further amplified
hydraulically to effect servomotor movement. This causes change in water flow and machine
output.

Page 2 of .6
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

Elec%ro-- Tmnsdwxr (EMT):

EMT converts electrical signal into mechanical movement of a coil suspended in a magnetic
field. Eh4T converts eIectr~calsignal of +/- 50 mA into a mechanical movement of +I- 2mm
A flapper is attached to the coil assembly and is suspended between two nozzles. A jet of
pressurized oil ~ontinuauslyimpinges on the flapper. Undar steady state condition the
pressure in the nozzles is equal and the oil Nm so formed keeps the flapper in mid position.
Due to change in current in the suspended coil the flapper mwes closer to one of the nozzle,
depending on the polarity of the current signal. This creates pressure in the nozzle to rise.
This pressure unbalance causes mechanical movement.

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.

Page 3 of 6
 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.

Main Distributing Valve:

Main slide valve or MDV regulates oil flow to the main servomotor and allow steady state
operation. Command to open or close servomotor is initiated by change of current signal in
EMT. This movement is further amplified by hydraulic amplifier and passed on to the pilot
d v e through auto rod. Movement of pilot valve is passed on to tbe main slide valve spool.
a s movement uncovers the slots in the sleeve of MDV,thereby allowing oil pressure in the
opening or closing chamber of the servomotor as the case may be. Two trrning nuts are
provided for adjustment of servomotor opening and closing timing.
' r
Feeaback Mechanism:
Feedback mechanism essentially helps in restoring the main slide valve of governor to the
steady state operation. The feedback mechanism consists of steel wire rope drive which
transmits the movement of guide vane servomotor piston rod through a system of pulleys to
the feedback potentiometer and f h k shaft The fdl stroke uf gmde vane Seryomotor is
converted to 200mm feedback stroke for governor. Feedback potentiometer provides
electrical signal for permanent and temporary droop signal derivation in electronic cubicle.
The feedback mechanism also gives mechanical feedback signal to the gate limit and position
mechanism.

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.

Liarit Motor, Hnnd Wheel aid Gear Box:

Gate limiter sets an opening limit for the gates and exercises an over-ridng command and
prevents further gate opening beyond the set limit. Limiter can be operated in manual control
by the hand wheel or by electric motor in case of remote control or auto control. Speed of
limit motor can be adjusted through variable resistance provided.

Limit according to head:

This feature provided helps in operating the machine for optlmum output depending on the
bead available. Tbe net head signal derived f h n head water level and tail water level is fed
to the electric motor whch dictates the position of the servomotor for the required output !
based on net head available.

Page 4 of 6

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.

Emergency Solenoid valve:

Emergency solenoid valve provided in the HMC helps in closing' the machine during any
emergency condition. On operation of emergency solenoid valve, closing chamber of MDV
is pressurized to close the servomotor and opening chamber gets connected to drain for quick
closing.

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.
.-

- Electro-tachometer for measuring the speed of turbine

- BaIance indicator
- ~iimiterandgatepositionindicator
- Pressure gauge
- Speed setting incticator
- Load setting indicator

11. Electronic Cubicle PEG):

This cubicle accommodates the electronic parts of the govemor consisting of regulating rack,
)
speed relay rack, electronic cam rack, motorized pots, power sl~pplyd e s etc. for control
and regulation of the machine.
1
) 12. Hydraulic Overspeed Device:
Hydraulic overspeed device is located at the top of generator shaft. Oil pipeline from
1
hydraulic overspeed device leads to the emergency closing valve. When hydraulic overspeed
)
device operates, it closes the guide vanes through emergency valve bypassing the governor.

I 13. Speed Sensing Device:

A toothed wheel mounted on the generator shaft forms the basis of information, toothed
\
wheel has some number of teeth and some n o m d d~ameterckpedmg upon rotaional
speed of turbine. The magnetic pick-up is mounted near the toothed wheel. The rnagnetrc
pick-up is used to detect the speed of the turb~neand convert rotational speed and Iinear
) movements into electrical signaIs. The parameter to be measured is usually picked-up
without contact from a toothed wheel mounted on the 'shaft of the machine
i
1

Page 5 of 6
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

14. Oil Pressure U&:

Oil unit supplies presswkd oil to governor HMC and servomotor. It consists of an
oil sump tank with two pumpmotor set, idler valves, non-return valves safety valve, pressure
accumulator and instruments for maintaining the required normal working pressure for
operation of govanor and servomotor.
.r
15. 100 Bar Oil Pressure System for Governor:
Higher oil pressure system for governor is the modem trend in Hydro Electric Projects. Due
to high oil pressure system the size of hydraulic components will reduce and also reduce the
cost of material. 100 bar oil pressure system has been developed by B.HE.L. and supplied
for TALA (6X170MW) Pelton Turbine.

The system cornprkx of-

1. Oil Sump Tank with oil cooler
2. Piston Accumulator
3. Safety block
4. Bank of Nitrogen Bottles
5. Charging kit.

Page 6 of 6
 FIRST ANGLE PROJECTION ( A L L DlMENSIONS A R E IN mm.)

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5.0 Governing Systems Electronics portion
- AN OVERVIEW
1.0 EQUIPMENT DATA
7.7 CUBICLE
Dimensions 8 O h WIDE x lOOOmm DEEP x 2280mm HIGH

Welght 450 Kg. approx.

7.2 SUPPLIES
1.2.1 Control supply

I
110\' DC
1.2.2 Electronic circuits:
215V DC regulated supply through either of

- A C D C c o n v w fiom 230V, 14 AC source (fiom auxhary AC)

-
- D C D C converter from llOV/220V D C source (fiom station DC)
1.2.3 Motorised potentiometers
21V DC (derived fiom control supply)
1.2.4 Cubicle lighting and heating
230V, 1$, 50Hz AC

1.3 SPEED REGULATOR

Steady state OmADC
,Ma,. variation under dynamic conditions +60mA D C
Sominal current +30mA DC
Recommended dither signal 2-20mA AC at 50Hz

1.4 CONTROL RANGES

Speed reference
Gate:'Power reference

+ 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

+ Universal amplifier (6DC1017)

0 rD2 (Dither amplitude)

+ Booster amplifier (6DC1006)

3 rH2 (Booster semitkity)
Speed relay rack
+ Speed relays (6DC3002)
0 Speed relay pick-up/drop-off

Limit adjustment and joint control rack

0 Control signal stabhation RV 1
3 Minimum headrace level bias RV2
9 Limit feedback upper range
C Limit feedback lower range

3 + Comparator module (6DC3002)

J O rD2 (Headrace scaler)
I
0 rH2 (Tailrace scaler)
Electronic cam rack
 0 Manual head level setter
+ Level detector (6DC3002)
0 rD2 (Maximurn head level setter)
0 rH2 (Rated head level setter)
+ Universal amplifier (6DC1020)
0 rB2 (GV incremental bias)
0 rD2 (GV fixed bias)
G rL2 (Head bias)

+ Booster amplifier (6DC1006)

G rH2 (Booster sensitivity)
0 Motorised potentiometer tray
0 Speed ref. signal upper range
0 Speed ref. signal lower range
0 Speed ref. indication upper range
0 Power ref. signal upper range
0 Power ref. indication upper range
0 Transducer panel
0 GV position indication upper range
0 GV limit position indication upper range
0 GV limit position indication lower range
2.0 DESCRIPTION
2.1 PRINCIPLE OF OPERA TION
The governor is basically speed sensing type sensitive to speed deviation from a set value of
speed. Temporary droop stabilising technique has been used.
The speed signal is produced with a turbine shaft mounted toothed wheel and magnetic pick up
based on the following equation:
n s p
f = ---------
60

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 :

Where, b, = Percentage of damping signal

Td = Time constant of damping signal

 and s = Laplace operator
The permanent droop signal contributes the gate v/s speed characteristic to the system. By virtue
of this the machine accepts load when the frequency decreases and rejects load when the
frequency increases. The amount of permanent droop, which is adjustable from 0 to 1O0/0,
decides the slope of the characteristic line in relation to the gate position. Ln other words
permanent droop means speed regulation. At 10% droop a machine operating at 50 Hz will
accept fulI load either if the frequcncy decreases by 10% or if the speed reference is raised to 5 5
Hz (50 Hz + 10%) so as to open the gate fully. However, if the grid fiequency iq 48 HI speed
reference p ~ d have
l to be raised to 53 1 % ~(48 + 5) only.
The summing amplifier output is amplified in a booster amplifier and then applied to an electro-
hvdraulic transducer EHT) located in the hydro-mechanical cabinet. It is the W g d a i c e
between the electi-ical and the hydl-o-mechanical sections. The E I f l actuating the hyd~~aulic
amplifier converts the electrical si-rmal into a proportional mechanical movement. The
movement when amphfied hydraulically results in the movement of the main distributing vahe
which in turn imparts oil to the servomotors for controllug the gate movement.
'r
Under steady state conditions, the govenior provides a balance current of OmA to the EHT. In
the event of a frequency raise or a lower command, it provides a proportional negative c w e n r
for closing the gate and in the event of frequency faling or raise command, it provides a
proportional positive current for opening the gate. Once the gate acquires the new position the
output current resets to OmA under action of the permanent droop srgnal. Under & k c
conditions output current can vary in the range of -60 to +60mA. -1Xe relay control circuit
enables the turbine to be started, stopped and protected.

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.

2.3 CONSTRUCTIONAL FEATURES

The equipment is housed in a srngle cubicle as per the outline general arrangement drawing. It is
provided with full h@t fiont and rear lunged doors. The doors have been provided with
lowers for ventilation and rubber sealing strips for vermin protection. The cubicle is fitted with
anti-condensation heater and illuminating lamps. Cable entries are through a removable plate
mounted on the cubicle bottom. Terminal blocks for external connections are accessible from
the fiont door.
The regulator circuits make use of solid state electronic components. The speed regulation,
speed relay, joint control limit adjustment and electronic cam control circuits are contained in
separate control racks. The circuits within the rack are mounted on plug-in printed circuit cards.
The rack is provided with card guides and wire wrapping type female connecton for the cards.
Potentiometers for various controls are fitted on the Eront of the racks. Distribution of the
circuits in the racks is on functional basis. Distribution of components on sub-panels is also on
functional basis.
 MICROPROCESSOR BASED ELECTRO HYDRAULIC GOVERNOR

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.

Performance of a power station mainly depends on :

- The characteristics or parameter set- out.
- Theoperating m d i .
- The healthiness of the equipments.
- The technology adopted.
Later, many new control approaches were developed to enhance the performance of
hydro controls. The three-term PID control with digital technology became the
accepted norm for hydro industry.

The new,digiitaltechnology miarzprocessw g o v e m ~ ~ many advantages wer the

&as
analog technology, such as, flexibility in ofmation, easier cxlibrations, capability of self
diagnosis, long-term stabil~tyof settings, the ability to do the complex control logic in
software instead of in hardware, the abilrty to set up non-linear control functions,
generation of data, information & reports.

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:

[a) CONTROL FUNCTIONS :

Turbine start, stop, Emergency Stop 8 governor parameter control i-e. Permanent
Droop, Temporary Droop & PID Functions etc.

@) GOVERNING FUNCTIONS:
Automatic load Frequency control.

(c) MONITORING FUNCTIONS:

Fault &techon & unit shutdown.

(d) PROCESS INTERFACE:

Connedion to unit & Main Control System

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.

ADVANTAGES Of MlCRePROCESSOR BASED GOVEfWOR:

1. System integration with plant control equipment and higher level control for remate
Contrd / bad frequency conbroletc.
2. Single push button start up and shutdown of turbine.
3. Highly reliable operation due to
a) Minimized wiring in rack panel and oonsiderable reduction of relays in interlock
operation-
b) Supports redundancy in microprocessor modules with hot standby features.
c) Drift free pameter settirtg as the parameter d u e s are digital in nature.
d) Easy modification of application as only software need to be changed.
e) Facilitates up gradation by simple addition of I/O modules to the same local bus
for M u r e requirements.
9 Extensive diagnostic facility available which reduces the fault identifimtion and
red'ification time.
g) High stability of circuits and components and low power consumption.
h) Wide range of adjustments and step less settings.

BHU, has already supplied Microprocessor based Electro-ydmulic hm-nor f o r

steam turbines up to 500 MW and Hydro turbines up t o ,170MW based on the

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

CHAPTER-1 MECHANICAL DESIGN ASPECT OF HYDROGENEKATOKS

CHAPTER-2 LI.3\'ELLliVG, ALICNiVlENT AND hlAGNETIC CENTEIIISC;

CHAPTER-3 ERECTION AND MAINTENANCE ASPECTS OF

HY DROGENERATORS

CHAPTER-4 CLEANING, DRYOUT, 1R MEASUREMENT AND HV

INSULATION TESTING OF HYDRO GENERATORS
 CHAPTER-I
PlECHANlCAL, DESIGN ASPECT OF H\r'lli<O(;ENER.\TORS

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.

2.1 SUSPENDED ROTOR OR CONVENTIONAL ARRANGEMENT

(SEE FIG. 1)

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.

2.2 CLOSE COUPLED SUSPENDED ROTOR ARRGT. (SEE FIG. 2)

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.

This arrgt. is normally adopted for small hish speed machines

2.3 SEMI UMBRELLA ARRGT. (SEE FIG. 3)

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.

The arrangement is normally adopted for the machines where ~~nibrella

armngemcwu
cannot be adopted and suspended rotor arrangement is uneconomical.
 The arrangement is normally adopted for the machines where umbrella arrangement
cannot be adopted and suspended rotor arrangement is uneconomical.

2.4 UMBRELLA ARRGT. (SEE FIG. 4)

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.

3. METHOD OF RIM CONSTRUCTION

3.1 LA-MIKATED RIM:

In large rotors, a laminated rim construc~ionis adopted to overcome transport limitaticns.

The rim is bolted in such a way that it acts as a solid homogeneous mass and is free to expand
elasticity due to centrifugal forces. Only 1.6 to 4 mm thick punchings are used and the
laminations span only 2 to 4 pole pitches. Thick rim end plates are used at the top and bottom as
clamp plates. The clearance bolts, called rim studs are used for clamping and these are tightened
such that clamping force is much higher than centrifugal force.

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.

3.2 SOLID DISC ROTORS:

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.

4.0 THRUST & GUIDE BRG. COYSTRUCTIONS:

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.

6.0 TOP AND BOTTOM BRACKETS

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-

a) The thrust bearing is horizontal.

b) The thrust bearing elevation is set to give correct turbine runner, elevation
during normal operation.
c) The axis of turbine shaft and gsnsrator shafi are in one vertical line.
d) The turbine runner centre and generator rotor centre coincide with centre lines
of stay ring and stator core respectivel~..
e) The guide bearing clearances are set as required in the drawing.

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)

a) Bracket deflection at normal load n

b) Bracket deflection \\.ith rotor and shaft \\,eight alone. h
c j Spring deflection at noni~alload c
d ) Spring deflection with rotor and sliafi \\.ei~llra!onc. d
3.4 Tlie ti~rbineerectors \\.ill ad\ ics rht anioiliii ( T I b! i\Ilicli ~ I I S turbine coul~lingis belo\\.
the normal running position. Tlie generato!- milst then be set at a lieizht nbo\e the ti~rbine
coupling by an amount equal to T plus additional detlection of thrust bearins at f ~ ~load ll .
this is equal to ( T + (a + c) - (b + d ) ) ) mnl.
-
7
I . I t is essential rllat an! ad!usrnlenr of rhc. bcal-ills bl-ackcr shims niadc. ro obtain the cor-rect
coupling gap must be precisel!. the samc ( b ~micro111ete1-
, ~neasurement)ar cacli brncker
feet, otlierwisc. rhe bracket \\.ill be thrown 0111 of le\.el.
 coupling by an amount equal to T plus additional deflection of thrust bearins at full load
this is equal to (T - (a - c ) - ( b * d ) ) ) mm.
3.5 It is essential that an) adjustment of the bearing bracket shims made to obtaln the correcr
coupling gap must be precisely the same (by micrometer measurement) at each bracket
feet. otherwise the bracket will be thrown out of level.

4. LEVELLIKG OF THRUST BEARIKG:

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.

NOTE: (1) The level must be checked for Zero error.

(2) The level. Must be firmly secured to avoid jerks while rotation i s being
given.

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:

Level X axis Y axis

Angle of rotor 0" 90" 180" 270" 360" 0" 90 " 180" 270" 360"

Gen. couplins ( 3 )

Gen. guide brg. (5)

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 COMBINED ROTATIONAL CHECK Oh' GENEARTOR AND TURBINE SHAFTS:

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.

6.7 FORlMAT FOR ALIGKMENT READINGS.

6.7.1 Format for suspended and semi umbrella generators.

Level X axis Y axis

Angle of rotor rotation 0" 90" 180" 270" 360" 0" 90" 180" 270" 360"

Turbine guide bearing (a)

Gen. top guide brg. (c) .

c; = a - c (for suspended m!c.)

d = a - b (for semi-umbrella intc.)

e = b - c (for suspended mlc.)

e = c - b (for semi-umbrella mlc.)

 The note in Para 5.3 will also apply here.

6.7.2 Format for umbrella generators:

Level X axis Y axis

Angle of rotor rotation 0" 90" 180" 270" 360" 0" 90" 180" 270" 360"

Turbine guide bearing (a)

Gen. Lower guide brg. (b)

c = a-b

The note in Para 5.3 will also apply here.

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)

Generator guide brg.(b)

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

'rFIROW CIRCLE D1.-\=6.9xO.O 1 :Q2_0;$n~r~l

I)-.ring erection and operation of hydrogenel-arors. \a~-inusrypes of dit'ticulries may arise, ~vliiclim a '
bt caregorized as belo\\;:

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.

Reasons and Resolutions:

Out of verticality of T-slots in rim.
The out of straightness of poles.
03 To minimize the assembly problem, utmost care is required for building rim properly
vertical in both radial and circumferential directions.
*: Also, the circumferential width of pole keys can be made slightly undersized by
grinding to accommodate circumferential bow of the pole.

ALIGNMENT

I t is a common problem that achieving the throw of guide bearings within stipulated limits becomes
difficult.

Reasons and Resolutions:

*: The axis of either spigot or recess of shafts is not ~nachinedtrue to the shaft axis, or
there may be some burr, thereby preventing proper matcl~ingof the shaft axes.
In such a case, the spigot has to be ground to ~ n a k eroom for proper axis matching.
However, this is a very rare case.
*: The coupling faces of shafts are not perpendicular to the axis.
In this case, either shimming is to be done in the joint, or scraping of coupling face is to
be done. Shimming is preferred as it allows trials to achieve the desired results.
 In this case, either shimming is to be done in the joint, or scraping of coupling face is to
be done. Shimming is preferred as it allows trials to achieve the desired results.

*: 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.

Reasons and Resolutions:

*: Heights of thrust bearing pads may be varying. This may happen if pads of different s ~
get mixed-up by inadvertent mistake. They are to be checked and pads of s a ~ = .
thickness group are to be used in one set.
*: Non-return valves of each pad are to be checked to prevent reverse oil flow.
*: Height of springs may also vary beyond acceptable limits. Their heights are also to :be
checked, segregated and assembled in a definite sequence. Note that this activiq has
to be done during assembly of the springs.
*: Oil flow through each pad shall be of equal order. To check this, dial gauges are to 5=
. . --&3,J
~ sen t the guide ! ~ ~ ?-rhes:
k g 52, :?~AS: bezing, H.S.Lubncatior, haibu ---2 ::-
;-
L--

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.=.' .--

~horoughly.Also. chamkri;:g of iertdir,? t d g t s of :hrust pads to be made p n m i r t r :

Guidc bearing,:
In solme cases, temperatures of pads may vary beyond unacceptable range and may br-; .-L O ~ C
unstable resulting in bearing failure.
I<easons and Resolutions:
 *3 Guide pads arc i:oI cnsagcd pl-opcrl!. \\-i~hjournal. I ' o prcvcnt this. 2uicie pacis arc to hc
bccldcd in p>.;iii,~~i \\-ill1 Journal at'lcr cliccking that they arc sla~idinspropcrly on tlicir
bases.
*: There ma!- be i:lsut'iicicnt oil cil-culation throl~gli the pads. Cliccking is to bc donc
against an!- rrssl;.ictio~ifor oil cil-culation. 1:rce !low is to be cnsurcd hy modifying tight
oil chambcrs crc. li~satticicntpad c\i.::~:it'cring a1 leadings of pads niay also be a roo1
cause for high 1i.rnpc.1-a~urc.
*: In~pedance\.alui.s of some poles nia!. be lo~v.Any polelpoles \\-ith lo\\- Impedance value
will resulr in \.c.;.!. hi& Unbalanced Magnetic Pull and will result in high guide bearing
temperature. Pc~iodicchecking of impednncc values of all poles and replacement by
good poles as required shall be done.

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.

**: The temperature shall be cross-checked by interchanging thermometer or by using a

mercury-in-glass thermometer. Calibrate the defective instrument as required.

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.

TOOLS AXD TACKLES

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.

SLIP-RING & BRESHGEAR

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.

BEARINGS AND OIL

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.

BRAKES & JACKS

The brake jack unit has about 18-20 mm wearing depth which is adequate for about 250-300 braking
operations and hence careful observation should be made for their replacement. In case brake piston
does not retract on its own it may be checked for any sticking of piston or in-effective return air
pressure, requiring proper checking.
OVERSI'EEI) DEVlCE (OSD)

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.

MAINTENANCE DURING L O N G SEIUTDOWN

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.

2.0 STATION EQUIPMENTS, SPARES ETC.

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:

The methods of cleaning various Generators Components & assemblies, Insulation

resistance testing and Dryout and High voItage tests to be conducted on stator and held windings of
Hydro senerators at site are described in this paper. The details are elaborated in the following
Annesures:

ANNEXURE - I CLEANING OF GENERATOR ASSEMBLIES.

ANNEXURE - I1 : INSULATION RESISTANCE TESTING AND DRYOUT.

ANNEXURE - I11 : HIGH VOLTAGE TESTING.

ANNEXURE - I
 CLEANISG OF G E N E I U T O R ASSE>lUI,IES

Clean!i:-sss pi'all current cam;i!~gand magnetic parts of genei21ors such as STATOR

hi-iSDISG. Tf LC; ;\ixDfiG. ST.AT(I!R CORE. BRUSH GEAR. .AXD s x - e n t c q i n g ST?l'OR R
ROTOR LEADS ETC. 111ust be checked and cleaned thoroughly at specified intervals as per
maintenance schedule.

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. Blow off dust etc. by compressed air as above.

2. Remove most of the contamination with an electrical cleaner (GAMLEW SOLVENT 265-B or
CRC LECTRA CLEAN or ZEP FORiiULA 300 or ATOM 3 10 OR any other equivalent as
available.).
This should be applied by brushing, swab, dip or non atomizing spray with a suitable pressured
spray application as per convenience and accessibility. This solvent will evaporate leaving a
dry surface.
3. Finally spray the treated surfaces with insulation resistance improving chemical CRC 2-26.
4. Gamlen 265-B is a product of Sybron Corporation, USA, GAMLEN 265-B is marketed by
GAMLEN SINGAPORE,
15-16, Block-6, Ayer Rajah Industrial Estate,
55, Ayer Rajah Road, SINGAPORE - 05 13
Also available from: Kualalumpur, Bangkok, Hongkong & Tokyo.
5. CRC lectra clean and CRC 2-26 are products of CRC Chemicals and marketed by:
NV CRC CHEMICALS,
B-9140: Zele. Belgium,

Also available at Kualalmlpur, Bangkok & Singapore.

6. ZEP Formula 300 is a product of ZEP manufacturing company, USA marketed b y

ZEP Manufacturing Company,

1310, Sea-board industrial Boulevard, N. W.
P.O. BOX 2015, ATLANTA, GEORGIA 30301,
U.S.A.

Also available at : Bangkok, Kualalumpur & Singapore.

INSULATION RESISTANCE TESTING AND DIiYOUT OF GENERATOR

1.0 IKSULATION RESISTAKCE TESTING

1.1 GENERAL

1.2 SAFETY PRECAUTIONS FOR TESTING

1.3 METHOD OF TEST

1.4 POLARISATION INDEX

1.5 TEST POTENTIAL

1.6 MEGGER

2.0 DRY OUT

2.1 METHOD OF DRYING OUT

2.2 DRYOUT TEMPERATURE

2.3 COMPLETION OF DRYOUT

3.0 REC0,MMENDED MINIMUM INSULATION RESISTAKCE

3.1 STATOR WINDING

3.2 ROTOR WINDING

4.0 GESERAL KOTES

1.1 GESE:KAL,
The insulation resistance of a winding is a f~inctionof the type and assembly of insulating
materials. In general. it \varies directly with the thickness of insulation and in\ersel~\vith the
conductor surface area. The value of insulation resistance also varies in\jersely \\ ith the amount
of moisture in the insulation and the amount of solvent left in the bonding varnish of the
insulating tapes.
. . .
Insulation tests are carried out normally nsing a Ylotorised Ylegger. Where Polznsztior, ir,dex
values are required, then the equipment must be capable of supplying a constant voltage for 10
minutes.
The result obtained using D.C. test methods are affected by the general conditions of the surface
of the windings as well as by the leakage through the main insulation & the surface currents.
Interpretation of the results can be difficult if contamination is present, for this reason before
carrying out the test, the surface of the windings should be examined to make sure that they are
clean and dry, and not contaminated by moisture, oil, salt, carbon & cement dust or other foreign
matter.

1.2 SAFETY PRECAUTIONS FOR TESTING

BEFORE ATTEMPTING ANY INSULATION RESISTAKCE TEST, IT IS ESSENTIAL TO

EARTH THE FRAME OF THE MACHINE AND ANY PARTS OF THE WINDING NOT
BEING TESTED. DRY INSULATION WITH A HIGH INSULATION RESISTANCE IS
CAPABLE OF HOLDING AN ELECTRICAL CHARGE FOR SEVERAL HOURS AFTER
THE REMOVAL OF THE APPLIED VOLTAGE. FOR REASONS OF BOTH SAFETY AND
ACCURACY, IT IS ESSENTIAL THAT THE WINDING, OR SECTION UITDERTEST IS
ADEQUATELY EARTI-IED BEFORE AND AFTER THE APPLICATION OF THE TEST
POTENTIAL. FOR LARGE MACHINES A PERIOD OF 30 MINUTES SHOULD BE
ALLOWED FOR DISCHARGE OF ELECTRIC CHARGE.

1.3 METHOD OF TEST

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.

1.4 POLARISATION ISDEX

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

1.5 TEST POTLENTIAL

Insulation resistance tests are usually made at direct potentials of 500 to 5000 volts. The value of
insulation resistance may decrease somewhat with an increase in applied potential; however for
insulation in good condition and thoroughly dry, substantially the same insulation resistance will
be obtained for any test potential up to the operating potential.
 If' the insulation resistance dccseases significantl~with all incscase in applied potential, it may be
an ii~dicationof fractures of thc irisulatio~~
aggsa~atedh! ti~eprcsence of dirt, dust or moisture, or
may be due to the effects of dirt or moisture alone.

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.

ALL MEASUREMENTS OF IR VALUES SHALL BE TAKEN /

RECORDED AT SAME VOLTAGE. THE FOLLOWING CAKE SHALL
BE TAKEN DURING MEASUREMENTS OF 1R:-

Only flexible insulated leads shall be used.

Megger must be properly leveled before use.
Megger must be earthed.
Megger must be calibrated for 'Zero7 & 'a'value before each use.
Megger should not be disturbed or touched during the measurements.
Megger must be placed away from strong Electric or Magnetic fields.
Live wire to windings (i.e Hipot wire) should be routed such that it is totally in air and should
not touch to any groundlearth surface.
After making connections, remove the lead from winding & calibrate Megger for 'Zero' & 'x'
. Discharge megger, connect to winding and proceed for measurement of IR.

2.0 DRY OUT

2.1 .METI-IOD OF DRYING OUT

2.1.1 SPACE HEATERS

Electric space heaters may be used for drying windings where the moisture is on or close to the
surface of the outer layer of insulation. However, if the moisture has penetrated the winding, then
 the nnethod is unlikely to be succcssfill on its own. If used in conjunction with direct heating. i t
can pro\-c useful in kccping the c)\.erall rempen-atureupto the specified dryout valuc.

2.1.2 SHORT CIRCUIT ZILINIVING

The stator terminals should be short circuitcd b!~ connecting the three main terminals together.
Connections must be made with cable or copper strip of adequate section to carry the full load
current of the machine. Approximately equal current should flow in each phase during the
dryout.
The stator frame must be solid!!, eart!?ed. Ccc!i?.:g \\,ater to Air coolers shall be closed to ficilirat?
. dry out. The machine should be run using the prime-mover. As a first part of the dryout schedule,
the machine should be run without excitation as the windage losses will generate sufficient heat
to raise the temperature of the winding to an acceptable rate.
Initially excitation should be applied to cause approximately 15% of the full load current to flow.
As the temperature goes up the excitation should be varied to follow the heating rate specified
below. In general the circulating current must not be allowed to exceed the full rated value, as
overheating of the stator may occur.

2.1.3 DIRECT CURRENT HEATING

Where the controllable low voltage direct current supply is available from a motor generator
set or rectiformer equipment, then this may be used for dryout of the A.C. stator windings (
with or without the rotor in position) and DC field circuits.

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.

2.2 DRYOUT TEMPERATURE

In general, when using direct heating of the winding by passing current the temperature should
be raised to approximate 80" C as measured by thermometers attached to the end windings or 90
"C when measured by embedded temperature detectors.
The rate of temperature rise for a winding which has been allowed to get damp due to moisture
picked up from highly humid atmosphere should be limited to 5 to 6 "C per hour. Where a
winding has been soaked with water, then the rate of temperature rise should be limited to 2 to 3
" C per hour, otherwise damage to the insulation is likely to occur.
Once the maximum temperature is reached it should be maintained through out the dryout
period. To ensure that the moisture is effectively removed there must be free circulation of air
around the windings. The generator covers must be opened occasionally to allow continuous
interchange of air as otherwise the air may become saturated and thereby slow down the rate at
which moisture comes out from the windings.
A convenient method of following the progress of dryout is to take insulation resistance readings
(R1 and R10) at regular intervals of say 24 to 48 hours and to plot them, along with the
calculated value of polarisation index and winding temperatures.
For damp windings readings should be taken every 24 hours. On grossly contaminated windings
the dlyout will be slower and the intervals may be increased to 72 hours. During the initial
period of the dryout the insulation resistance values tend to decrease appreciably as the
temperature rises but over a period of time they will rise again.
Once the maximum temperature has been reached this should be maintained as constant as
practicable by varying the current, so that the measurcd changes in insulation resistance reflect
accurately the progress of the dryout. The dryout process should be continued beyond the time at
which the insulation resistance has started to increase, and heat should be maintained until the
 insulation resistance is abol-e the minimum acceptable value. Polarisation index is not
substa~itiallyal'l'ected by tcmptsaturt and hcncc a valuc nl' minimum 2.0 should be achie\;ed.
Sillcc thc winding will cool oft'slightly during the time the insulation resistance and polarisation
indcs tests are carried out. follo\\.ins two points should be observed.
-.
(a) \ + h e n individual phases are beins checked, the order in which readings are taken should be
kept the same during each test period.
AND
(b) If the cooling is significant ( e . ~ on
. small machines) then polarisation index value will be
slightly optimistic, unless the insulation resistance values are related to the same temperature.

2.3 COMPLETION OF DRYOUT

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.

3. RECOMMKKDED IMININIU*MISSULATIOS RESISTANCE

3.1 STATOR WINDIKG :
3.1.1 Insulation resistance of stator winding varies considerably for different insulation systems,
atmospheric condition and service life. However, for all practical purposes a recommended
minimum IR of one minute value of entire winding may be obtained from the following
equation to ensure the suitability of the winding for application of high voltage test or
operation, .
IR min = 2 Ft (2 kV + 3) M Ohms
Where kV = line voltage in Kilovolts.
'Ft' is a factor dependent on winding condition and winding temperature at which the test is
carried out.
 Values of 'Ft' are given in the Table below:

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 ~

3.1.2 Polarisation Index

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

PI value is not required or recomn~cndedfor rotor winding circuits. in view of lo~vvoltagc of

rotor winding.

3.2.3 Collector Ring Assembly & Brush gear :

Normal espected value for a new machine is 50 M Ohm. However, a minimum value of 2.0 M
Ohnl can bi: accepted in estrerne casss.

4.0 GENERAL SOTES:

(a) It is recommended that normally dry out shall be carried out irrespective of good IRIPI value
before H.V. Test or building up voltage during commissioning or restarting after prolonged
shutdown.
(b) The IR values recommended are for guidance. It is impractical to specify definite minimum values
of IR or PI of a rotating machine below which the machine cannot be operated. BHEL should be
consulted if lower values of insulation resistance/polarisation index are achieved.
(d) It is recognised that it may be possible to operate machine with values lower than the
recommended minimum value, but it is not considered a good practice in the majority of the cases.
(e) Insulation resistance of a winding is not directly related to its dielectric strength. It is possible to
specify the value of insulation resistance at which a winding will fail electrically.
(0For insulation in good condition, insulation resistance readings of 5 to 10 times the value of
minimum recommended insulation resistance obtained from 3.1.1, are not uncommon.
(g) The insulation resistance of one phase of a three phase stator winding with the other two phases
grounded is approximately twice that of the entire winding. Therefore, when the three phases are
tested separately, the observed insulation resistance of each phase should be divided by two to
obtain a value which, after correction for temperature, may be compared with the recommended
minimum value of insulation resistance obtained from 3.1.1.
(g) After completion of dry out. HV test & Tar: 6 test. the winding must be always covered and
protected for inadvertent damage by proper covers, platforms, etc. till further erection & boxing
UP.
lIIGlI VOLTAGE TESTIXG OF STATOR ABD FIELD \\'IXDISGS OF IIYDRO GEXElUTORS AT
SITE

it. STATOH \VIKl>I3G:

it-1 IIIGII VOI,Tt\GE TESTS OK BAR TYPE SI'ATOR \VINDIKG WIIERE

COMPLETE MACFIINE IS TESTED AT WORKS

SI. STAGE OF TESTlNG MACHINE RATED VOLTAGE (Kv) .

No. 6.6 11.0 13.8 .
Test voltage in kY, 50 Hz, (RMS)

OFFlClAL HV TEST 2U+ 1 2U+ I 2U+ 1

0 1. After placing the balance

Bottom bars in position in
stator slots, test balance
bottom bars.

02. After placing the balance

top bars in position in
stator slots, test balance
top& bottom bars together,

03. Supplementary HV test on

completely wound stator
before commissioning, if
necessary.

A-2 IIIGII VOLTAGE TESTS ON BAR TYPE STATOR WL\QmG WIIERE COlMPLETE
MACIIlKE XOT TO BE WORKS TESTED:

0 1. After placing the balance

bottom bars in position in
stator slots, test balance
bottom bars.

02. After placing the balance

top bars in position in
stator slots, test balance
top & bottom bars together.

03. official HV test after

completing the winding
brazing and stringing etc.

04. SuppIen1e11ta1->I
tIV test on
Completely wound stator
Before conlmissioning, if
necessary.
 - - - - -

SI. STAGE OF TESTING MACHINE RATED VOLTAGE (k7)

Xo. 6.6 11.0 13.5
VOL,TAGE IN KV, 50 HZ, AC (RMS)

OFFICIAL HV TEST 2U+ 1 2U+ 1 2~ i1

01 After placing the bottom bars 17 27 34

in position in stator slots,
Test bottom bars only.

02 After placing the top bar's

in position in stator slots,
test top & bottom bars
together.

03 Official HV test after

Completing winding, brazing
and stringing etc.

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:

01 Joint coils after placing 14 21 27

in position in stator slots
(wedging, bracing and
blocking included.)

02 Rest of the winding after

Reassembly of lifted coils
(all coils together sectors
wise )

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:

S1. STAGE OF TESTING MACHINE RATED VOLTAGE (Kv)

xo. 6.6 11.0 13.8
TEST VOLTAGE IN kV, 50 HZ, AC (RIMS)

OFFICIAL HV TEST 2U+ 1 2U+ 1 2U+ 1

01. Joint barlcoils alter placing

in position in stator
slots (wedging, bracing
and blocking included)

02. Rest of the winding

alter reassembly of
lifted coils (ALL Sector
- wise)

03. Oficial HV Test after

completing stator
winding, brazing and
stringing etc.

04. Suppliemntary HV test

on completely wound
stator befote commissioning
if necessary.

A-6 HIGH VOLTAGE TESTS ON DIAMOND TESTS ON DIAMOND PULLED COIL TYPE
STATOR WINDmTGWHERE COMPLETE WINDING IS DONE AT SITE:

01 After placing the coils

in-position in stator slots 17 27 34
(wedging, bracing and
blocking included).

02. Official HV test after

completing winding,
brazing and stringing etc.

03. Supplementary HV test on

completely wound stator
before commissioning,
if necessary.
 1. -l'lie above tables of tcst \;oltages are the norms tbs 1-1V tests on Hydro generatoss stator
\vindiiigs g sing resifles Insulation systcm.

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:

HIGH VOLTAGE TESTS ON FIELD WINDING

This test shall be conducted by applying following voltage at 5 0 Hz. for 60 seconds as per the
following table:

(Vf = Rated excitation equipment voltage)

SN. Insulation Class 5 kV - 7.5 kV

Vf Volts ~ 401 -500 Above 500

- 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

DISTRIBUTED DIGITAL CONTROL

MONITORING AND INFORMATION SYSTEM

maxDNA DISTRIBUTED .CONTROLSYSTEM

Page 4
 BHARAT HEAVY ELECTRICALS LTD.
ELECTRONICS DIVISION
Bharat Heavy Electricals Ltd. introduces
the maxDNA (erstwhile called as
MAXI 000+PLUS) Distributed Control
System for Plant Automation and. This
product is the latest in a long evolution
of the mission critical systems provided
to the power industry worldwide. This
system includes a modern NT native
Man Machine Interface (maxVIEW,
maxTOOLS), a reliable high-
performance fully redundant network
(maxN ET), high perfarmance Ethernet
resident DPUs, and a field proven, fully
tested I10 system which provides solid,
reliable service to thousands of
customer facilities around the world.,
The MMI system is currently in
operation at plants both in the U.S and
other countries. The latest Distributed
Processing Unit - the DPU4E - was
applied on a recent 30,000 point DCS
system. The I10 subsystem is in use at
plants in the U.S as well as power
stations and process plants around the
world.
Ease of use
The advances and new technology
incorporated in to the maxDNA, place.
the system in the lead in providing a
truly open architecture. This system is
100% native NT software. There are no
crude conversions for UNlX or other
operating systems to mar the simplicity
of operation. The system is designed to
provide a level of simplicity and ease-
of-use that will minimize the time
needed to train personnel in the
operation of this system. Except for
Microsoft Windows NT and CE, all
operating software is designed and
rnaxDNA DISTRIBUTED CONTROL SYSTEM
Page 2 4
produced by Metso Automation.
This ensures consistent operation,
total compa!ability, and
maintainability from a single
source.
The \SJindows Explorer hierarchy
known to every PC user in
organizing files on a computer is
identical to the tree structure ussd
to organize DPUs, I10 modules,
I10 channels and their properties.
Graphics Displays:
Building a graphic is very int~u~tive
and users will find it very similar
to many popular WINDOWS
based drawing I CAD packages.
Significant enchancements include
the ability to add "tool tips" to any
dynamic item on a graphic. Now
the operator is presented with the
most essential data onscreen, and
reminders like a tag ,name or
short descriptiorl are displayed
when the pointing cursor is
passed over the display element.
Trsnd displays can be imbedded in a
process graphic there is no need to
switch' between two disp!ay screen
placing all the process critical data
in one place with a minimum number
of Operator actions. From any alarm
display, the operator has the ability
to 'clicK on the point in alarm and
automatically bring up primary
process graphic associated with that
function.
Most graphics can be drawn with out
any need for programming. A powerful
scripting language (maxSCRIPT ) is
available for the ultimate in power
applications.
 BHARAT HEAVY ELECTRICALS LTD.
i ELECTRONICS DIVISION

Configuration : when associated equipment is out of

service). Alarm color shall change
Building and maintaining the for acknowledged I unacknowledged
configuration is very similar in many alarms. Alarms can be
popular Windows based flowcharting acknowledged either individually or
packages. The standard algorithms collectively.
included with the product come from
over 30 years of power plant experience
utilising digital control techniques. These
algorithms are incorporated as objects The main feature that distinguishes
in a graphical configuration package. In the maxDNA from all others is our
addition, the....objects .can be combinedc,..-., Serverless software Backplana
by the end user and made:. into new (SBP) 'Technology. Our approach to
objects. The principles of object solving the problems with distributed
orientation lead to rapid, error free control communications is a simple,
configurations. reliable, high periormance
communications structures. All
A l a r m Management: primary communications are based
on subscription services whereby a
In addition, the alarm package remains client is connected with the source of
easy t o use. \.Ws provide alarm informstion - wherever it is located.
management capability, including the There are NO SERVERS between
ability to group alarms in a hierarchical clients and sources of information to
alarm presentation scheme. The alarm fail, or become performance
hierarchy cen be used to filter, bottlenecks.
annunciate and organize alarms to
optimize response to abnormal process The SBP resides in every DPU and
conditions. Natural language queries in every maxSTATION. Standard
can filter the data presenteci. to the TCPIIP transactions (CONIM I
engineer to help determine.root causes DCOMM) require cumbersome
of problems to prevent reoccurrence. 'connections' t o be maintaiaed
between any possible Clients and
Audible alarm features a programmable Servers. In a large system, this may
tone for each group Ipriority, as well as result in 10's of thousands of
the ability to play the ability to play a connections to clutter the system.
separate '.wav! file (which allows The SBP utilizes directed UDP
including spoken messages) for any (Universal Datagram Protocol)
individual alarm or group of alarms. This transactions to insure the greatest
can b e set up by the workstation using utilization clf system bandwidth. In
local speakers or could be tied into the addit~onto the function of routing of
plant P A system. The system provides transactions between interested
automatic alarm cutouts to prevent parties, the SB? insures successful
nuisance alarms (or screen clutter completion of transaction through
redundant networks.

-
p
-
-.
p
-.
.
--
p
-p
-
-
p.
.-
.
-
..
-
- ..~
inaxDNA DISTRIBUTED CONTROL SYSTEPJ
Page 3 4
 BHARAT HEAVY ELECTRICALS LTD.
ELECTRONICS DIVISION
SBP Fundamentals:
A 'provider of data' registers a unique
service name on the SBP when it is
started, as in the case of a replacement
DPU inserted in a chassis or a
workstation added to the maxNET.
There is no database to be maintained.
The relationship between names and
addresses is built dynamically and
automatically maintained at all times.
This unique identification can be used
by any client (such as maxVUE) to
obtain information. The SBP acts as a
redundant, distributed sophisticated
name server to route requests directly to
the source of data.
Most requests are subscription based.
That is the client informs the source that
i t is interested in the data. Data'is only
sent when it changes significantly. This
results in great efficiency - and fast
response times.
Interfaces to the SBP are easy to
construct. maxLlNKS provides standard
interfaces to serial devices.
The software back plane currently runs
under both Windows NT and Windows
CE - two operating systems expected to
dominate the process control hardware
platforms. maxAPPS is a SDK
(software development kit) that provides
a "simple to use" custom applications
development tool. Programmers have
the choice of us~ngOCX control in MS
'J~sualEasic or a Mlcrosoft Visual C++
Wrapper. These software tools are
used to link to external MIS, History,
Opt~mizationand other systems. The
system IS truly flexlble
maxDidA DISTRIBUTED CONTROL SYSTEM
Page 4 4
Fully Self Describing DPUs
One feature of the system that will
provide very substantial time savings
for system users both during plant
comrnrssioning and during outages
(when time is shortj is the approach
to placing all the configi~rationdata
in the operating DPU's. There are
no additional configurafion files
necessary to interpret DPU data.
Multiple concurrent access is
provided to the DPU's. MAXTools
actually allows manipulation of the
objects within the DPU - there is no
source code, no object code, or
executable binary code that must be
stored in a central server (or on .
every individual engineering .
workstation and engineering laptop).
For example, a workstaiion loaded
with maxTOOLS with no preloaded
site specific files can tie placed
anywhere on the maxNET, then
access a DPU, and present the full
graphical depiction of the process
and all the objects 1 object's
properties that comprise the
configuration; all connections
between objects will be displayed.
Single points can be added, deleted,
renamed, etc. (given the appropriate
security access) and the changes
will be propagated throughout the
system with no need for additional
work to modify a central system
database.
A Truly Open Architecture
The maxDN,\ system has no
proprietary components at the HMI
level ..NONE!
 BHARAT HEAVY ELECTRICALS LTD.
ELECTRONICS DIVISION
o The HMI operating system is
Windows NT.
o The DPUs are designed around
the Intel industrial compcnent board
level computer used widely in
industrial Machinery, aircraft, etc. and
are bought directly from Inte!. With
future Intel component boards I
processors, this exceptional
performance will be improved and
enhanced but never outdated.
o The DPU operating system is
Windows CE.
The worldwide acceptance - and
growing use - of these hardware
components and operating systems
means that the system will be
supportable for many years to come
.
and through the life of the p!rint.
Fast Switched Ethernet :
The maxNET utilizes comtnercially
available components, standard cabling
(fibre opting and category 5 UTP),
standard managed Ethernet switches,
and standard network interface cards
(NICs).
Between the managed Ethernet
switches, the backbone of maxNET
communication is 1o d ~ b p s Full
, Duplex
Fast Ethernet. The bandwidth provided
meets I exceeds the needs for the
plants even under the worst case
scenario with alarm bursts in the
thousands. Since these are standard,
commercially available components,
they can be migrated to faster (gigabit)
speeds or even different protocols
(FDDI, ATM) should the plant's fbtcre
needs dictate.
rnaxDNA DISTRIBUTED CONTROL SYSTEM
Page 5 4
Full Closed Loop "Soft
Simulation" Capability.
The maxDNA has been designed to
allow users to create multiple virtual
DPG in a Windows IVT workstation.
Logic developed with maxTOOLS
and displays developed with
maxVUE access a virtual DPU just
as if the workstation was connected
to the full DCS.
This allows contr-zctor's engineers to
start their configuration work earlier,
but the real bene.fit comes from
allowing purchasers of the system to
obtain advance copies of the
implemented configuration. This
provides the ability to undertake.
o Reviews of graphics design '
early in the project to ensure
consensus from all parties (plant
operators, company design rep, EPC
project team etc).
..Independent Engineering
checks on the configuration prior to
FAT.
o Independent engineering
checks on the graphics prior to FAT.
o The FAT can use a hardwired
test bench combined with soft
simulation to demonstrate a DCS
response to complex plant upset
scenarios.
o Commissioning and startup
engineers can become familiar with
the control strategy early in the
project and do not have to wait for
the DCS to be fully field wired.
I
'~lwm'
. >
I
BHARAT HEAVY ELECTRICALS LTD.
ELECTRONICS DIVISION
Once the plant is commissioned, the
soft simulation capability also allows
plant engineers to try different control
strategies prior to loading the actual
DPUs in the system. This ensures that
the time taken to make a change during
an outage - when every minute counts
- is not prolonged with troubleshooting a
problem with a control strategy.
Finally, the soft simulation allows
operator familiarization and training with
the DCS, both prior to plant startup as
well as throughout the plant's
operational life.
Should the owner at some point
purchase a simulation package that
provides a process modelling of the
plant, the soft simulation can be
enhanced by interfacing the process
model directly . through . the software
Backplane for the highest performance.
Turbine Control Interface.
maxl-INKS communicates with various
manufacturer's PLCs, RTUs, turbine
- control systems, water purification
systems, and other systsms found in
and around the plant maxLlNKS
provides multip!e ports arid database
tables to link the inaxDNA database to
the data points within these other
devices. Existing protocols include but
are not limited to Modbus RTUt ABt
Conitel RTU, GE Mark V turbine control
via Ethernet. maxLlNKs is a Windows
NT based platform for large data
volumes. It concurrently supports
multiple prctocols: provides
communication, redundancy and a
direct connection to the maxSBP
(Software Backplane).
Note: Most systems with maxDNA
have Turbine Controls as an Integral
part of the DCS
maxDNA DISTRIBUTED CONTROL SYSTEM
Page 6 4
maxLlNKS runs on any Windows NT
based computer such as an
Operator's Workstation, Engineer's
Workstation, maxSTORIAN, or a
dedicated computer if the point count
and channel loading demand it.
maxLlNKS manages the redundant
channel, if used, and the tag name to
data point descriptors between the
maxDNA system and all other
systems. It manages the point
addressing, link retry times and
channel error recovery procedures
necessary to maintain integrity of
the links and data.
Also Data Links can be established
via RS232C serial port of the DPU4E
or via DDE links at the workstation
level.
Sequence of Events.
The maxDNA DCS has an integral
Sequence of Events package that
resolves time stamping to 1
millisecond for any DC powered
digital input (AC powered points can
be timestamped, but the sinusoidal
AC signal introduces inaccuracies of
an order of magnitude).
A digital input can be given a
property that includes it in the SO€
package either (,) when the point is
initially configured, or (2) at any time
thereafter Changing the point's
property requires no reloading of a
DPV, since the system allows a
single point reload.
maxDNA Architecture:
maxDNA incorporates the latest
computer, c~mmunicat~onsand
process control technology io
provide a high performance, secure
 Bharat H e a \ ~Elcctricals Limited (BHEL), Electronics Division,
has entered into a Technical Collaboration Agreement UCA) for the
'manufacture and supply of new generation Distributed control Systems .
.: '\L%YlOOO+PLL.'S', for modern Power Plants & ~ndusthes,wiih
\LLKControl S!..;tems (SICS) Inc. USA, pan of METSO Automatior!
MAX1000+PLUS systems are used in many applications throughou:
the world including electric power generation, co-genention, cemcnt.
glass, ceramics, primary metals, chemicals and petroleurr. R-ntcrax!
waste-water treatnlenr 2nd incineration plants.
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.

32 Bit Intel Processor Surface mount cIei:lon~~j - compact, reliable, eficle~r

\Ylndows CE Operating System. Suppons
off-line simulation and testing
Open architecture
Uses , W V E T Erhemet Data Highway
Object-Oriented Configuration
Surge nithstand 2. i v r IEEE 472-1974
RFI and ESLI as per 5t\L-\33 1
.ADC resolution 15 bib + sign
jOOV peak AC or DC comnlon mode voltage protectlor,
. ',~ 3

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

Open sjsrem arch~recrure

Seamless communsnnon k r n t e n
plant and busmess nemorks
Salable from small prcx-cs5
apphc-iuom ro comple~ep h r control .
On l~neGnphic Monitoring
-
.
On-l~nedocumenting configuration tree na\.ignrion
High speed graphic bullding and dnplay uprintes ( I L W U E )
Po~nrconfigunt~ontools
Centralised Engineering capability
W~ndows-NTbased
-
 Connects applications clients with providers of data
V e n high performance

Simple - RED /\bite / Registei / Subscribe

Setn.ork Independent
Operating System Independent
Kc:-iiion Inticpendent

- --- .- ... .
. .

Pl.o\.cn 1ndus:n Standard, Sn~itclieclFast Ethernet

. Ul:r2 high speed (100 JIbps) redundant netn-ork
a .\Iuitiple siri:ultaneous communication
a Utilises intellipent sxitching
YO ~ ~ l l l i ~ i ~occur.
r . : : Tinffic is never stopped

Interface to enema1 s\srems :

nemorks (Coal Hancirns PI.!
Ash Handl~ngPlnnt e:;)
Suppons mulr~ples~~;:ulr.lnr.~
Historical dat2 collection and communlcarron prorciul~
archiving soir\\.are for l\L-LYITr\UO.\' Suppons data rr.uisfer from oi
"Delta-Sabe' d ~ t storay
a nl.nrnn, i,. sysrems and ncrworks
system data cnpacity All data available ro
Relarional database to simplrfy bWATIONS

.-\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

Plantwide Auromation/Unified Automation Solution -, INDUSTRIAL CONTROLS

.. . .. .,
- Process Indusrry
! Remote diagnostics capability

..
 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 :

, ... - I, Rotating doc. e x c i t e r s ..

C 2, S t a t i c SCR ' e x c ' i t e r s ,
A
.'?
< (~ontd.,,.,Z,)
. . I

L.
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.
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:

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. ,,.:.,.. ......
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.: . : . - . . ' . . ' . .:
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. ..:. . , . , ; ',;;: <': ,;. ;. .
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.-..;,.,. ':;:;:;'. ... .:. . . . . . . r , 1:9.,;;:,;
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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 .-.-
;.......
.....---.
.

.. I\
-. :. -
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. ,

1 i. I n modern e x c i t a t i o n systems s t a t i c e x c i . t e r s a r e used

'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
,

I ( (a) S t r t i c thyristcr e r 7 i t e r s h r s v e r y f ? s t response

( b ) h'o r o t ? . t i n g pzrt; ke3c.e no w e ~ '2nd r no rnechrnical
- losses.
..
( c ) I n s t r l l i t i c n i s i n i e g e n d & n t df g e n q r c t o r s h c f t .
. . .. . ,
.. '

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
.,
,

. . :- .. . . .. . . . . . ? ,

. :::the form 02 o b r i d g e . D i f f e r e n t ' t y p e s sf design used

:
I

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.

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... .
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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
.. .-

3.0 AUTOFATIC VOLTAGE .iCEGULkTOg

--..- -
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 genera-
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 exci1;er o u t p u t v o l t a g e
and h e n c e . t h c g e n e r z 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 value.
AVR i s e s s e n t i a l a h c a r t of e x c i t a t i o n system. D i f f e r e n t
* . t y p e s of
. AVR depending. on m a n u f a c t u r e r s d e s i g n , 4
. used
in . a r e c l a s s i f i e d i n : t o two main
types.
.. . . .

( 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 systems ! i n c o n s i s t s . .'. o t h e r features,

l i k. e -. manual c - n t r o l , f o l l o w up ' u n i t , l i m i t e r s and protec-
r....*..

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
'

value. ~ h e n ' t h t .t .e. r m i n a l v31taged k3rnes t o o r i g i n a l : :

-.
! ' . .
v a l u e , t h. e e r r o r..."si'gnal i s r e d u c e d r e s u l t i n g . i n Geduction
. .

int e r m i n a l , , v o l t a. .g e a g a i n changing t h e e r r o r . s i g n a l . This

. .. . .

p r o c e s s ccmtinu'&'$ till t h e e r r o r s i g n a l snd t e r m i n a l :

v o l t a g e s e t t l e s t o a 'steady s t a t e v a l u e . The ' o s c i l l a t i ~
p r o c e s s . i s s t a b i l i z e d by s e l e c t i n g p r o p e r v a l u e s of g z i n
and t i m e c o n s t ~ k n t sof t h e Am. I n c a s e of v o l t a g @ " r i s e
APR o u t p u t s i g n a l i s such s o as 'Lo r e d u c e e x c i t a t i o n .
I f t h e deviation i n terminal 'voltage i s appreciable
. e x c i t e r output..i s 'foroed by t h e A W t o e i . t h e r m a x i m -

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.
.'

5.2 Follow U p C o n t r 01:

Follow u p - c o n t p o l , continuou.sly compares o u t p u t : of a u t o &
manna1 c h a n n e l s and a d j u s t s e x c i t a t i o n s e t t i n g of manual
c h a n n e l t o match w i t h Auto channel. Thus when t h e r e i s
a u t o m a t i c change-over from "AUTO TO MANUAL" due t o AVK
,
f a i l u r e sudden change i n e x c i t a t i o n i s avoided.
*
.
L i m i t e r s :-.
-

<
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 ,
(

(i) ~ a u i t swhich does n o t r e q u i r e a n y t r i p p i n g o r change.

(ii) F a u l t s , w h f c h r e q u i r e chzngecver t o manual c o n t r o l .

(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 -. .-
--.-.---. ' -' .. ..

umber of v a f i b l e 6 o . f e x c i t a t i o n system ark found i n

p r a c t i c e . The t h r e e t y p i c a l schemes w h i c h are i n most
common u s e f o r BHEL make Hydro ~ e n e r ' a t o r are e x p l a i n e d '
i n following paragraphs.

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

exceeds ' t h a t p r l d u c e d by Auto winding hy an amount s u f f i m t

t o pr-ovide norm21 e x i c i t a t i o n of main e x c i t e r and t h e
g e n e r a t o r . I f t h e gener;:tor v o t l a g e f a l l s o r 'risc-s, t h e AIJR
w i l l c a u s e t h e c ~ r r c n ti n ~ u t of i e l d t o c h a n g e i n a p p r o p r i a -
t e direction s a as t o b r i n ~t e r m i n a l v o l t b e e t o o r i g i n a l
 . . .. . (..--: .
value. . . !:
... . .. . .
I__
. . . . .
'
.
..
.'.
U.nder Hand contrp1l:Generstor e x c i t a t i o n can be s e t t o
d e s i r e d v s l u e by t h e ' ~ a n G a l ' p o t e n t i o m e t e r i n t h e 'HAND'
. control f i e l d o f j t h e amplidyxe, If, t h e g e n e r a t o r under any
c o n d i t i o n bccombs . . .u
. nder-excited beyond s t a b i l i t y l i m i t , , h e
l i m i t e r p r o \ ~ i d e sa d . c. c u r r e n t s i g n a l t o t h e AVR. o a s
t o over-ride t h e , v o l t a g e e r r o r s i g n a l . Under such - c o n d i t i o n
bus b a r v o l t a g e i s allnwed t o r i s c w i t h o u t accdmpanying
.
reduction i n excitation, .

....
.* .
..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 .
'

p u l s e s of th;. t h y r i s t o r convertor a r e ad.vanced o r r e t a r d e d

~b as t o c h a n g e ' t h e e x c i t e r f i e l d c u r r e n t i n r e q u i r e d
d i r e c t i o n . Under 'Kanuall c o n t r o l e x c i t e r f i e l d i s s u p p l i e d .
from an a u t o t r a n s f o r m e r and diode r e c t i f i e r . E x c i t e r f i e i d
c u r r e n t and hence t h e g e n e r a t o r e x c i t a t i o n can be a d j u s t e d
.
by. t h e a u t o t r a n s f o r m e r The l e a d i n g MVAR l i m i t e r d o e s . t h e
same f u n c t i o n a s i n c a s e of p r e v i o u s system: S i n w a l l tEe
c i r c u i t s ir, v c l t a g e r e g u l a t 3 r a r e d e s i g n e d ' w i t h s o l i d s t a t e
e l e c t r o n i c a m p l i f i e r . , t h i s system h a s f a s t e r v o l t a g e
responce thar, t h e conver';ional d . c . e x c i t a t i o n system,
4'
6.z . STATIC EXCITATION
___.-__..C_C ...____ _ SYCTQ!(FIC- .._
...................... j :
-? ,
S t a t i c e x c i t a t i o n scheme c o r p r i s e s o f e x c i t a t i o n t r a n s f o r m e r
v o l t a g e r e g u l a t o r , ' t h y r i s t o r c o n v e r t c r and f i e l d suppress-
i o n and f i e l d f l a s h i n g equipments. .
E x c i t a t i o n power i s tapped of d i r e c t l y f r o m g e n e r a t o r ,

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 ,

f i r i m p u l s e 'posii%ion and hence t h e generator .no l o a d

cxcitstion is set. by e i g h e r " ~ u t oPotentiomcterl' o r "Manual
P9tectiometcrlt. F&ther d e v i a t i o n i n t e r m i n a l v o l t a g e i s
detacted by t h A~ V ~and f i r i n g p u l s e s a r e e i t h e r advanced
. I I

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. . .
, ::

Few i m p r ~ r t a n ts p e c i f i c a t i o n s .of e x c i t a t i o n system a r c

def ized below :

E X C I E R RAT1DIG-NOMI -NAL

It i s the c a p a c i t y : of .. e.x c i t e r expressed i n v o l t , Amp. &

KW. t o sc :ply e x c i t a t i o n power c o n t i n u o u s l y f o r s p e c i f i e d
working c o n d i t i o n s . E x c i t e r rat'ing i s decided by maximum
f i e l d c ~ r : ~ c ; nrdquircment
t cf g e n e r a t o r . a

It i s a cairnurn d.c. v o l t a g e t h a t can be a t t a i n e d w i t h t h e

e x c i t e r loaded w i t h a r e s i s t e r h a v i n g Ohmic value e q u a l t o
t h e r e s i s t a n c e o f t h e g e n e r a t o r f i e l d winding:
'- , a t 7 5 O C f o r f i e l d windings d.esigned t o o p e r a t e a t r a t i n g

with a t e r , p e r o t u r e r i s e of .6OCZo r iess.

.. .
.. . .
. . . . .I . . C
*/8
...
.
<
.. :~''?-
.a , .: .
- -..
' ' '
.
.. .
.. - . -
i (- - a t 100°C f o r f i e l d windinn d r s i n n c d t o oper - - t e a t

1c r a t i c y .with a t e m p e r a t u r e r i s e mord t h a n .60°C.

. . . . . ,,.
,
.c:,,. .
i< 7.3 EXCITATI'ON SYSTEM:VOLTAGE-p _ ~ ~~~.T.J.NcI.
.,--- ---..- --. - ..-.
.-,...-I--- . . . .-.- .--.- - ~ & r ~ ~ ~
.. .L .
.
' I .

The numericzl value .-which i s o b t a i n e d when t h e e x c i t a t i o n

.. . _
system v o l t a r c response . . i n v n l t a n e per .second measured over
a p e r i o d df f i r s t '0:5 second Is devided by r a t e d l o a d f i e I d
volts-e of t h c p e n e r ~ t c r ( ~ e f .Fi.,u. 5)
I
7.4 " .-.---------
VOLTAGE RESPCNSE
--.--- ----- :
TIME
'* '
i.
i.
-
The t i m e i s seconds f o r t h c e x c i t a t i o n v o l t a o e t o r c a c h
93b of ' c e i l i n o v o l t a n c under s p e c i f i c c o n d i t i o n s . E x c i t a t -
t i o n h a v i n e response time o f 0.1 scc: o r l e s s a r e . c a .l l e d
a s " h i g h i n i t i a l response1'. e x c i t a t i o n s y s t e i .

ACCUidCY
------ --..----OR VOLTAGE
. .
"- -.. .-:
.... -.- CONTROL --.

i s t h e deorec of correspondEmce between c o n t r o l l e d

..It
variable and i t s i d e a l v a l h e f o r s p e c i f i e d . l o a d change.
It i s e x p r e s s e d a s r a t i o of t h e d i f f e r e n c e i n t h e c o n t r o l l e d
v a r i a b l e f o r s p e c i f i e d l o a d chanpe t o i t s i d e a l v a l u e . A
...
-p?od -AVR shol.:ldh;ve _t 0.1% t o + 0.5ficcuracy.
. .
'

TRAISFER
--.--..- --.- FUNCTION:.
.-.-..
..-,.,--.. .

. T r a n s f e r f u n c t i o n i s s p e c i f i e d i n terms of ~ a i n sand time

c o n s t a n t s . When e x c i t a t i o n system i s r e p r e s e n t e d i n a form
of t r a n s f e r f u n c t i o n block diaqram, parameter .of i n d i v i d u a l
b l o c k s a r e s p e c i f i e d . Other w i s e t h e , p a r a m e t e r s a r c t o b e
;spccifi;d a s per t h e t y p e s 'cf r e p r c s e n t a t i d n . s p e c i f l e d i n
IEEE s t a n d a r d . . ,

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:

( 8.1 AUTOMATIC VOLTAGE RUI1,D-UP :

_.___._.._.___________._____I_.___ .
.. .
. i'
(.
In all s t a t i c e x c i t a t i o n s y tcms e x c i t a t i o n power i s tapp3d
c. from . e n e r , : t o ~ "-errrinals o n t y . and hence i t i s e s s e n t i a l t o
 Spose . - . F i e l d f l a s h i n s circuit' i n .S.E.E. makes .
J. - .,
e t o.. -i u- i l d u p . t h e volta.ye.i
. ::
I

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... .-.--
...-
, .
.

( ~ 0 i n - t c' o n t r o l of . i - o l t a 7 e arid MVAJ can be provided i n a' :., '"> ,.!

@'." .- >
., -
( . . power h a ~ s ewhere.
. . no. of . e n e r a t o r s o p e r a t e s i n p z r a l l e l .
(
Voltage or M V A R - . ~
a fl l t h e u n i t s i s a d j u s t e d . simultanecusly
by a cormand from one p o i n t only.

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

c a l Power. The s t a b i l i z i q c s i e n a l i s added t o . t h e v o l t a g e

(
. .
. e r r o r s i u n a l of t h e AVR. .
(

c 8.4 -- -*I..- --- - . :

~ G.A T I V EEXCITATION .._--C

c When t h e a e n e r a t o r s a r e connected by v e r y long HV transmi-

s .

s i o n l i n e , t h e p e n e r a t o r s a r e require'd t o absoib "capaci-

t i v e r e a c t i v e power ~ e n e r a t e di n t r a n s m i s s i o n l i n e during
l i ~ h loadt condi-t;ion, . T h i s i s e s s e n t i a l t o .avoid any ov-er
\
v o l t a s e durinl; l i 5 h t l o a d condition. P r o v i s i o n of necatiue
C' e x c i t a t i o n i n c r e a s e s r e a c t i v e power a b s o r p t i o n t a p a c i t y
C of t h e zenerator. For n e g a t i v e e x c i t a t i o n . a s e p a r t e
L t h y r i s t o r b r i d g e of r e q u i r e d r a t i r q i s .connected i n reve- .:

s s e p a r a l i e l with t h e mair: t h y r i s t o r s when neqative

C. - , '. . .
' e x c i t a t i o n i s req..:ired conductiam of p o s s i t i v e main bridge ..:'. .
< i s s t o ~ ~ eand d nelative bridpe s t a r t s co~ducting. .
..
. . .... ..
. ,

.
:::

.:

C 8.5 .. -.- --..-._

JiOTOR . . -___._._-..l__r_
OIm- _..VOLTAGE -
PROTECTION:. __ . .
,.
.'...,i.L
....-. ..
..
.-..
., .
. ......
.;
. . 2. .-. .
c ...
. . .During
. . .

.. -
<.

f a u l t s a t g e n e r a t o r ;..termjinals o r d u r i n z any a s y n . C .@ ... .

.-@.?,=.;,
.
,-
- ,:y-.....
<.-.
....

( chronous operation AC vol*a;:e. i s i n d u c e d ~i n t h e ! f i e l d

.=.:..
....
-:?aLs.:. .
\.
.:
-.:A .
'..Ta.li
- "%
!';*"

< \ winding. The t h y r i s t 9 r e x c. i t e r b l o c k s f l o w o f a c c u r r e n t ~-:-?

........... .
.: . . . - ~ . . ..
..... . . . . ..*., . . .
. . ' .,...> :*?&%!:~.
,.
;; .?.,

C--,, i n n@i-a+.ive h a l f . c. y.o l & r e s u l t i n g in veryihi-gh voltage . . . :;;z;;<:~-=-

:- ., ?,

.
-
. .. .. ,.
. . . 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- . ' . ,
.

:
,... .......
, , . .
'
. ..

(. -. %>, ' . &*.-;

. .
 11 -
. . .
b r c a k e r if due t o ,any f a i l u r e f i e l d suppkession d o e s n o t
t a k e place h i g h v G . t a a e i s i n d u c e d i n t h e - f i e l d windin.?.
.

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
,.

'of nor. l i n e a r s u r g e, suppresson t y p e i s p r o v i d e d f o r p r o t e -

c t i o n of P i e l d wind in^ i n such c a s e s .

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.

In order t o f u r t h e r reduce f i e l d d i s c h a r g e time c o n s t a n t

. -
n o n l i n e r r e s i s t o r s a r e used f o r l a r g e machines. .

Some times i n e x c i t a t i o n s y s t e m s u s i n g d.c. e x c i t e r s

f i e l d s u p p r e s s i o n equipnents ar-e p r o v i d e d for both genera-
t b r f i e l d and e x c i t e r f i e l d .
G
.SEMISTATTC EXCITATION SYSlThd '1
 ---
Ayes A
-../
An I S 0 9001 & 14001 Unit
Typical Static Excitation Equipment
Objectives of
Excitation Control
& Technical Particulars

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.

The operating conditions to be taken into consideration are:

Good response in voltage and reactive power control

Satisfactory steady state and dynamic stability

Transient stability for all stated conditions

Quick voltage recovery after fault clearance

In steady state operation.voltage response is of main importance. In

dynamic stability damping behaviour of small oscillations is of more
importance. Under faulty conditions. the transient stability i.e..abi::?
to return t o the normal operating point is the main objective and
voltage response again plays a secondary role.

Technical particulars for Excitation Equipment

I. Range of voltage control in auto : 90-llO%U,

2. Frequency range of operation : F, +/-5%
3. Transformer drop/droop compensation : Upto 15%

4. Maximum change in generator voltage : +/- I %

when AVR is transferred from
'Auto' to 'Manual' under all
steady state conditions.
5. Range of excitation control in manual : 0-1

6. Accuracy of voltage control : +/-0.5 %U,

Note:

US Nominal gen. voltage

Ifn Nominal field current
F~ Rated Frequency
Excitation System

With large alternators in the power system. excitation control p l a p

a vital role. With ever growing size of alternators, rarious
characteristic parameters also change and the effect of these or,
the system performance has to be taken care of to a certain extenr
by the excitation system. Today it is required to meet more crringenr
specifications than ever before.

In order to maintain system stability i t is necessary to have w r y fa::

response excitation systems for large synchronous machines
operating with the grid. This means thar the field current of z
synchronous machine must be matched extremely fasr to changinc
operational conditions. With the advent of fast microprocasors, ir
is now possible to achieve the matching response in digital zontro:
systems using faster sampling rate. in addition to offering men)- user
friendly features.

A high control speed is achieved by using a n inertia free :ontro'

and power electronic system. Fully controlled thyristor b r i e e s ar?
used to feed the generatorlexciter field for controlling the geIerator
output parameters Any deviation in the generator terminal ~ o l r a g ~
is sensed by an error detector and causes the voltage regc: atc,rI IC

advance or retard the firing angle of the thyristors. lvhich in rurc

controls the field supply of the alternatorlexciter.
Direct
Excitation System
(Static Excitation Equipment)

The BHEL Static Excitation Equipment comprises of the following

main assemblies.

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?

modular form mounted in various racks in the regulation cublcle

The racks are mounted in a s i n g frame in the cubicle. Other item:
pertaining to the control scheme like auxiliary transformers. relays
MCBs, contactors etc. are mounted in the cubicle o n channels.
Various features and working of the controI scheme of digital roltage
regulator are explained separately

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

rectifier bridge and supplied to the generator field through a breaker.

As soon as the generator output builds up, the excitation system
starts working smoothly and the field flashing circuit is then cut off.
Field flashing can also be done by feeding the generator field from a
station battery supply. The battery will be required to deliver
approximately 25% of the no load current for 20 secs.

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.

Over Voltage Protection

An additional over voltage protection circuit is provided across the
field so that duringfaults on the stator side. the induced over-voltages
on rotor side are limited to remain below the insulation level of the
field winding.

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)

The BHEL indirect excitation system normally called as Automatic

Voltage Regulator (AVR) consists of the following. The indirect
excitation refers to both DC exciter and AC exciter (brushless exciter)
machines.

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,

Control Electronics Field Suppression

This feature helps faster decay in the generator terminal voltage after
shutdown. In theevenr of any short circuit at thegenerator rerminals
or at the slip rings of the exciter field. the DC fielddischarge contactor
protects by discharging the field energy through a discharge rssistor
provided for this purpose.
GRID NETWORK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
r
.
UNlT

STATION DC BA'TTERY SUPPLY

I
CONVERTER
415V.3PH.50HzSTN.AUX SUPPLY,
I.
Y

<5 I
I
I OR!
L - ..-- - - - - - - - - -
I
I
ANALOG
INTERFACE
IG,UG
IF
INTERRUPT
GENERATOR d
AUTOMATIC VOLTAGE
REGULATION
+
LIMITERS
'--------
OR:

I STN AUX SUP

-----
(ROTOR CURRENT THYRISTOR THYRISTOR
b
PT
b
LOAD ANGLE,STATOR
CURRENT INDUCTIVE
AND CAPACITIVE
BRIDGE
(AUTO)
BRIDGE
(MANUAL) I
- +
I
AID & D/A
CT

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

FIG 1 : MEASURING THE ACTIVE AND REACTIVE CURRENT

The actual value sensing signals (machine terminal voltage and

current) are taken from the respective CTsIPTs and processed
through an analog interface module. For the voltage regulation.
measurement of the actual parameters such as active & reactive
power, load angle & power factor apart from the voltage and current
are necessary. These are achieved by suitable instantaneous current
measurements based on interrupts. Fig-] shows half a period of R
phase current IR. As R phase voltage UR passes through zero from
positive to negative. the instantaneous value of R phase current In
is given by I sine phi. which corresponds to the value of reactive
current. As the line voltage \Ai,.. passes through zero from negative
to positive the instantaneousvalue of R phase current In correzpnds
to the value of active currenr 1 Cos phi

The control signal is formed by continuous comparison of measured

actual value with the set reference available in digital form. This
control signal for the closed loop operation is taken for generation
of firing pulses by a digital pulse generation unit. Variarion in [he
control signal results in variation of firing angle and subseqcently
the DC output of the thyristor converter.
The transfer function of [he volrage regulator represenrs an
important parameter for the stabiliry of the network. The r-arne
proven transfer function as thar o f a n a l o g controls has 5een
implemented for digital excitarion also, s o as to achieve [he similar
response and stabilirp
 I
I

I MONITORING
j

-(
VOLTAGE
REGULATION

4
-*
4
PULSE
. ,GENERAnON - PULSE
AMPLIFICATION

t
t

FIELD SUPPRESSION

FIG 2 : BLOCK DIAGRAM OF EXCITATIONSYSTEM

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
-

0 FIG 3 W G L E CHANNEL AVR - AUTO CHANNEL WITH C/O TO 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

1 POWER SUPPLY AUTO CHANNEL - I

1
\p,
i
VOLTAGE
REGULATION
> 1
GATE
CONTROL
UNlT
4
PULSE
AMPLIFIER
-
,-(

- 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
When a generator is running in parallel with the power
network, i t is essential to maintain it's synchronism without
exceeding the maximum permissible load o n the machine
and also without tripping by the protection system. Limiter
functions are provided to ensure this by influencing the
voltage regulator function to limit the over excitation and
under excitation. This not only improves the security of
parallel operation but makes the operation of the system
easier. However, it must be made clear that the limiters d o
not replace the protection system but only prevent the
protection system from tripping the machine unnecessarily.
under transient conditions.
The following limiter functions are normally provided : requirements. The software is organized in such a way that
Field current Iimitation
Stator current limitation (for both leading and lagging stator
current)
Load angle Iimitation
Rotor and stator current limiters reduce the excitation in over
excited operation after a time delay to facilitate field forcing
to overcome short lived faults in the network. Under the limit
conditions in the under excited operation of the machine.
the load angle limiter and stator current limiter (capacitive)
increase the excitation without any delay.
Power System Stabilization (PSS)
This function helps to damp-out the low frequency power
oscillations during dynamic conditions to improve system
damping & stability. The PSS signal is treated as a n additional
signal and superimposed with the control signal generated
by the voltage regulation.
Field Current Regulation In Manual Channel
To ensure a stable operating point in the manual channel
inspite of small disturbances, a field current regulation
function is provided in the manual channel of operation.
Follow-up Control
Wherever two operating channels are provided in the Digital
Voltage Regulator, a follow-up control function is also
provided which ensures that the control voltage of the non-
operating channel always tracks the control voltage of the
channel in operation. This helps in a bump free channel
change over when automatic channel change over takes
place. ( eg. Auto to manual change over d u e to a fault in the
auto channel).
Excitation Sequence Control
The s e q u e n c e of logic operation f o r t h e excitation is
performed a s per t h e equipment a n d project specific
alterations can be easily performed at any point of execution
'L!.. .-,Ji-i!:;-,,L:;,~!l.llg.
Excitation Monitoring
Apart from self monitoring of individual electronic unit, the
following monitoring functions are established.
Monitoring of actual value signals of generator voltage a n d
field current
Monitoring of voltage reference for excitation build-up
circuit
Monitoring Vlf (over fluxing)
Protection
From various analog measurements the following protections
can be performed by the software
Over current-instantaneous
. 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
Local Operation
Though the excitation g s t e m is normally operated from a
remote place in the plant, option has been provided for
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

PROTECT.ION & MONITORING

Protection Against Inrush Current (di/dt)

Excitation Transformer Protection &
Monl toring Asuitable copper reactoris provided in series with each thyristor
to protect the same from any surge current (dildt):
* Over Current Protection
Air Flow Monitoring
The protection unit for the excitation transformer is of solid
Since the thyristor bridges are forced air-cooled by fans. the air
state type or can be of the electromagnetic type.
flow is monitored by air flow relays.
It consists of oneltwo stages over current relays (depending
Field Over Voltage Protection
o n the type of relay) with adjustable ranges and tripping time.
An additi~naloveroolta~e
protection circuit is provided across
The current is sensed on the primary side of the excitation
the field so that during faults on the stator side, the induced
transformer with three current transformers. The nominal
over-voltages on rotor side are limited to remain below the
current for the relays can be either 1A or 5A.
insulation level of the field winding. Subsequently it trips the
~emperatureMonitoring machine. ..,

Besides over current protection, the dry type rectifier
transformer is embedded with two temperature dependant
resistors o n each of the low voltage windings. With rise in
temperature the resista.nce value changes sharply after a
certain level. For this one set.of resistors is used for 'warning'
and another for 'tripping'.
Thyristor Bridge Protection & Monitoring
Over Current Protection
Each thyristor in the thyristor bridge is connected with fast
acting semiconductor fuse to protect it in case of over current.
Protection Against Hole Storage
Effect (dv/dt)
RC network across each thyristor is provided for protection
against hole storage effect.
Input Power Supply Protection
AII input power supplies are received at the excitation system
through miniature circuit breakers with thermal over load
release.
INDICATION AND METERING
Excitation fault LED indicationsare provided in the regulation
cubicle. Meters are provided for monitoring various currents
and voltages. These are finalised during detailed designing
to suit the customers requirements.
Duplications in the control desk for these items are done as
per the agreements between BHEL and the customer.
NOTE:
The above Protection & Monitoring a r e generally
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.

For further information please contact:

Bharat Heavy Electricals Limited
Electronics Division
PB. No. 2606, Mysore Road, Bangalor
Phone: 080-6742289; Fax: 080-67401
Emall : rnktg@bheledn.com
 I S 0 9001
QUALITY
A Company Wide Commitment
Digital Excitation Control
Systems

Bharat Heavy Electricals Limited, Bhopal

GENERAL
An excitation control system plays a vital
role in the power system by maintaining
system stab~lityfor synchronous machines
operating with the grid. It also ensures
improved natural damping behavior and
extended stability limits. Basically there
are three types of excitation systems
namely Semistatic, Static and Brushless,
that find application in power plant & indus-
trial application.
BHEL has been manufacturing all three
types of excitation control equipment for
more than last 35 years. Presently about
500 such equipment are operatiqg at no.
of hydro, thermal & nuclear power plants.
Captive power plants in sugar, chemical,
paper and other industries are equipped
with BHEL make excitation systems.
The Digital Excitation Control Equipment
is equipped with fast response continuous
acting digital AVR suitable for both single
and three phase full control thyristorised
power stage. It is suitable for use on both
high and low voltage generators whose
field requirement decides the rating
the regulator. The Digital AVR ensures a
stable, fast and smooth operation of the
synchronous generator in the entire load
range. It ensures a very fast recovery of
generator voltage following any changes
in load demand. The protective features
ensure safe operation of the generator.
The equipment automatically regulates
the output voltage of a synchronous
generator by providing it with a controlled
field supply. The controller is active over
the entire load range with negligible dead
band.
The basic system consists of a digital
controller having two independent channels
AUTO and MANUAL, employing close loop
field voltage and field current regulation
respectively. Occurrence of system problem
like loss of sensing etc. the control mode of
operation changes from AUTO to MANUAL.
In the unlikely event of failure of both auto
& manual channels, an emergency channel
is provided to enhance availability of the
equipment.
PRESENT RANGE O F D I G I T A L
E X C I T A T I O N CONTROL EQPT
DIGITAL AVR VXB22D
Suitable for semi-static i.e. DC exciter and
brushless excitation systems. Provided with
a single phase full controlled thyristorised
power stage.
DIGITAL AVR VXB32D
Suitable for semistatic & brushless systems
Provided with a three phase full controlled
,thyristorised power stage.
DIGITAL STATIC EXCITATION EQUIPMENT
Suitable for static excitation system for both
LT & HT generator used in power plant and
industries.
SALIENT FEATURES O F DIGITAL AVR
VXB22D I VXB32D A N D DIGITAL SEE
1. Four modes of operation are possible :
a) AVR mode : Constant generator
terminal voltage is maintained.
b) FCR mode : Constant field current
is maintained.
c) VAR mode : Constant generator reactive
load is maintained.
d) PF mode : Constant generator terminal
power factor is maintained.
2. Programmable reference setters for
AUTO & MANUAL modes.
3. Compounding for parallel operation
of generator.
4. Auto over fluxing prevention.
5. Auto braking of active mode by non
active modes.
6. Field over voltagelcurrent protection
7. Generator under voltage and over
protection.
8. Loss of sensing protection
9. Over excitation limiter
10. Under excitation lirr~iter
11. Soft start voltage build-up
12. In-built HMI for metering, control &
parameter adjustment.
13. Communication to local PCIlaptop
for parameter setting
14. Comm~~nication to DCSISCADA for
Supervisory Control
15. Field flashing for initial start-up from
station ACIDC
16. Exciter Diode Failure Detection Unit
(for brushless system)
17. Redundancy in stab. power supplies
18. Control supply redundancy
19. Test channel to check healthiness of
of excitation system
20. Redundancy of thyristorised power
stage (for static excitation system)
21. DC field breaker (for static excitation
System)
22. Redundant controller as not standby
(optional)
23. Remote displaylcontrol unit (optional)
SPECIAL FEATURES OF CONTROLLER
The.digital excitation control equipment is
based on latest microprocessor and DSP
controller which combines all the requisite
functions of an excitation control system
in a compact package. Special features of
the. Digital Controller are :
1. Programmable stability (P-I-D) setting
2. One adjustment range or preposition
set. point for each mode.
3. Soft start and voltage build-up with an
adjustable ramp in both AVR and FCR
control modes.
4. Three phase or single phase generator
voltage (RMS) sensing in AVR mode
5. Single phase generator current sensing
for metering and regulators purpose
6. Field voltage and field current sensing
7. Wide range of control -30 to +lo% in
AVR
8. + 0.25% regulation in AVR mode
9. Real time metering
10. Operates from redundant power supply
AC and Ior DC
11. Local control via the LCD screen & key
pad provided on front.
12. Programmable control parameters
13. Minimum hard wares used to ensure
enhanced reliability
14. Temp range of operation -40" to +70°C
15. Shock withstanding capacity 15G in all
the three perpendicular planes
16. Vibration withstand capacity 2G at 10 to
500 Hz
17. Meets lEC60255-22-6 (RF conducted)'
and IEC 60255-22-3 (Radiated electro- +
magnetic field) against RFI
18. Meets IEC 60255-22-4 against fast
transient
19. Meets CISPRI 1lEN55011 Level A for
emissions
Figure 1 :Digital Static Excitation Equipment

Figure 2 . Digital Static Excitatiori Equipment (internal view)

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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

AUTOMATIC VOLTAGE REGULATOR TYPE VXB32D

Figure 4 : Block diagram of digital Automatic Voltage Regulator

 TECHNICAL D A T A .

SENSING SLIPPLY Three phase line voltage, two ranges

- 100V I50 Hz nominal (85V to 127V)
- 200V 150 Hz nominal (170V to 254V)
CT SUPPLY 1A, Phase - Y I5A, Phase - Y

SENSING BURDENS - Voltage - Less than 1 VA IPhase

Current - Less than 1 VA

AUTO CONTROL RANGE: 70 - 110% En from no-load to full load

AUTO CONTROL +0.25%

REG ULATlO N (AVR)

MANUAL CONTROL + 1.O%

(FCR)

VAR MODE + 2.0% of nominal VA rating

PF MODE + 0.02 PF between 10 and 100% of the real power
CORIIMUNICAl'ION Three communications ports, two RS-232 and one RS-485
COMO RS232, 9 pin, sub-D connector located on front panel and
used to communicate with local computers, 1200 to 14200
baud 8N1, full duplex, ASCII commands

COMI RS232, 9 pin, sub-D connector located as rear panel and

used to connect primary and back up controller units or other
devices. 1200 to 19200 baud, 8N1 full duplex, unique ASCII
commands, only used for auto tracking

COM2 RS485 located on rear panel and used to communicate with

local or remote computers or other devices. 1200 to 19200
band, 8N1 half duplex, MODBUS protocol
 ORDERING INFORMATION

1. Generator & Exciter field excitation data

2. PT and CT details
3. Station DC and AC details
4. Requirement of Excitation Transformer and DC field breaker (for digital static excitation
equipment)
5. Special requirement if any

For business information contact

Switchgear Controlgear & Rectifier Commercial Division
Block - IV Western Annexe
BHARAT HEAVY ELECTRICALS LTD.,
BHOPAL - 462 022

Tel : 0755 - 2500947, 5201472

Fax : 0755 - 5201572
Email : rshinqwekar@bhelbpI.co.in
alhardulev@bhelbpl.co.in

BHARAT HEAVY ELECTRlCALS LIMITED

Regd. Office : BHEL House, Siri Fort,
New Delhi - 110 049
Website : littp://~vww.bhel.coin
, ,

DIGITAL STATIC EXCITATION EQUIPMENT TYPE US032

/ - 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)

Weight 1000 Kg. approx.

1.2 EXCITER FIELD RATING

No load as per requirement
Full load as per requirement
Ceiling Output 1.6 times

1.3 INPUT SUPPLIES

1.3.1 EXCITATION SUPPLY
260V, 34, 50Hz AC through 6.6KVl260V dry type transformer connected across the
generator terminals
1.3.2 ELECTRONIC CIRCUITS
DECS300 il 1 1OV, 14, 5OHz AC derived from 230V station auxiliary &

iil 1 10Vl220V DC station battery

Isolation module f12V DC from the DECS300

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

1.4 VOLTAGE REGULATOR

PT supply 1 1 OV, 3 4 , j V A
CT supply 5A. 14. IVA
Auto control range 85%)- 110% of En
'vlanual control range 09;)- 1 10%) or 1 fii
 AVR mode voltage regulation+0.25% (no load to full load at rated power
factor and constant generator frequency)
VlHz characteristic slope = 0 P.U. to 3.0 P.U. is adjustable in
0.1 P.U. increments
Response time < 1 cycle
FCR mode regulation = +1 .O% of the nominal value for 10% of the bridge
input voltage change or 20% of the field resistance change.
Otherwise, +5.0%
PF mode - k0.02 PF of the setpoint PF for the real power between 10 and
100% at the rated frequency. (e.g. - setpoint PF = 0.80, PF
regulation is from 0.78 to 0.82 PF.)
VAR mode - +2.0% of the nominal VA rating at the rated frequency
Internal tracking ?0.5% of the nominal field voltage change when transferring
Compounding 0 - 30%

I.5 FEATURES A VAlLABLE

I
Four control modes (automatic voltage regulation (AVR), manual or field current
regulation (FCR), power factor (PF) regulation, and reactive power (var) regulation).
Two programmable stability setting (PID) groups.
One adjustment range or pre-position setpoint for each mode.
Soft start voltage buildup control in AVR and FCR control modes.
Overexcitation and underexcitation limiting in AVR, var, and PF control modes.
Underfrequency or voltshertz ratio limiting.
Generator paralleling with reactive droop compensation.
Autotracking between modes within the DECS-300 (internal tracking).
Autotransfer (bumpless) between modes.
Five protection functions (field overvoltage, field overcurrent, generator overvoltage,'
generator undervoltage, and loss of sensing).
Real-time metering.
Data logging & event recording
Front RS-232 communication port for PC com~nunication using BESTCOMS
Windows based software for fast, user-friendly, accurate setup, and control.
Rear RS-232 port for dedicated communication with a redundant DECS-300.
Rear RS-485 port supporting the Modbus'cominunication protocol.
Field flashing from either of 4 l j V station ausiliai-y AC or station battery
n - l redundancy in power stage.
COMO RS-232, 9 pin, sub-D connector located on the. front panel and used to
communicate with local computers.
1200 to 19200 baud, 8N1 full duplex, ASCII commands
COM1 RS-232, 9 pin, sub-D connector located on the rear panel and used to connect
primary and back-up DECS-300 units.
1200 to 19200 baud, 8Nl full duplex, unique ASCII commands
COM2. RS-485, located on the rear panel and used to communicate with local or remote
computers or other devices.
1200 to 19200 baud, 8N2 half duplex, Modbus protocol
2. I PRINCIPLE OF OPERATION
The digital Static Excitation Equipment type VSD32, henceforth referred to as the SEE,
ensures stable operation of synchronous generators in the entire load range. It ensures very
fast recovery of generator voltage following changes in load demand. The protective
features ensure safe operation of the generator.
The equipment automatically regulates the output voltage of a synchronous generator by
providing it with a controlled field supply. The equipment is active over the entire load
range with negligible dead band. Other facilities, in addition to generator output voltage
regulation, are as listed in sub-sectibn 2.2 below.
"The basic system consists of two independent channels -- the AUTO CHANNEL with
closed loop generator voltage regulation and the MANUAL CHANNEL with closed loop
field current control. Both the channels employ a common set of three phase fully controlled
thyristor bridges as the output element.
The auto control loop compares the generator voltage (reset signal) with a fixed voltage
(reference signal) to produce the auto control signal, which calls for an increase, or decrease
in excitation, as and when necessary.
When the machine is synchronised to the grid, two more operating modes come into
existence: the PF regulation and the VAR regulation modes, which, as the naines suggest,
control the PF and the VAR respectively at particular levels, as decided by the operator.
When the excitation is being controlled manually, control is switched over from the AUTO
control loop (AVR mode) to the MANUAL control loop (FCR mode) which compares the
generator field current withthe FCR reference to decide the level of excitation.
All the above are achieved through the use of a microprocessor based controller. Front panel
operation and serial communication links using PC software makes the system user friendly
and easy to operate from local or remote locations.
Two three phase fully controlled thyristor bridges forin the output stage for both the control
loops. They are fed from the generator terminals through a suitable excitation transformer.
The output of the converters controls the alternator field current which is determined by the
firing control signal to either of the thyristor bridges.
Further, a potentiometer that directly acts on the control signal input of the firing circuits is
provided to check the healthiness of firing circuits Rr, thyristor bridzes in TEST inode of
operation. This mode can also be used, in the rare event of failure of the DECS300
controller, to continue generation thus ensuring higher availability of the alternator.

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.

Under frequency /Volts per Hertz limit

When the generator frequency drops below the corner frequency for the underfrequency
slope, the voltage setpoint is automatically adjusted by the DECS-300 so that the
generator voltage will follow the underfrequency slope and an underfrequency
annunciation occurs.
The volts per hertz ratio limiter will prevent the regulation setpoint from exceeding the
volts per hertz ratio that is prescribed by the slope setting of the DECS-300.

Under Excitation Limit

The under excitation limiter senses the amount of leading reactive power and limits the
amount of excitation supplied to the field of the generator from dropping below unsafe
operating levels. This prevents the machine from possibly slipping poles and from iron
heating. It limits the amount of VARs being absorbed by the machine, based on user-
definable settings.

Over Excitation Limit

The DECS300 senses the field current level and limits excitation so as to prevent
overheating of the generatorlexciter field.

Stator Current Limit

The stator current limiter senses the generator stator current and limits excitation to avoid
thermal overloading of the srator winding.
 Protections
A number of protections are provided by the DECS300, viz. generator overlunder
voltage, field over voltage 1 over current 1 over temperature, loss of sensing Of these, the
first and the last cause the SEE to trip from auto to manual mode. Changeover occurs in
case of generator voltage exceeding preset and adjustable higher and lower limits or
because of unbalance in the sensing voltage phasors.

n-1 redundancy in power stage

Two thyristor bridges are provided in the SEE, each capable of handling 100% excitation
requirements of the alternator. While under normal circumstances, when both the bridges
are healthy, excitation requirement of the alternator is shared by the two bridges: any
abnormal condition in any one bridge results in that bridge to be blocked by the control
logic in which case, the other bridge handles the full excitation requirement. Off load
isolators provided on either side of both the bridges enable the faulty bridge to be taken
out of service for maintenance while the healthy bridge continues to deliver.

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.

Normal / test mode of operation

As the name suggests, other than the normal SERVICE mode of the SEE, a test mode is
provided that uses a potentiometer RVI (mounted in the switch fuse panel) to set the
control signal level to the firing circuit thus deciding the firing angle of the thyristors and
the output level of the SEE.

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.

2.3 CONSTRUCTIONAL FEATURES

The equipment is housed in a four cubicle suitc as per the outline general arrangement dra\\-ing.
The cubicles for the two nits are al-ranged as mirror image of each other. l'hc two coli\rerte~.
ci~biclesin the middle are complete with cooling fans mounted atop the cubiclcs. A partition
plate separates thc regulating cubiclc fiom thc remainirlg po\\/er cubicles of thc suitc. ;\ll rhc
cubicles are provided with full height front and rear hinged doors. The doors have been provided
with louvers for ventilation and rubber sealing strips for vermin protection. The cubicles are
,fitted with anti-condensation heaters and illuminating lamps.
Cable entries are through removable plates mounted on the cubicle bottom. In order to meet the
cable trench requirements of the power house, the cable entry for control connections in the
regulating cubicle are from the adjoining thyristor bridge panel. Cables pass through the cutout
on the partition plate and are terminated on the terminal block that is accessible from the front
door. Of the power cables, the AC supply from the excitation transformer gets terminated on the
busbars of the second thyristor bridge cubicle while the outgoing DC connections from the SEE
and the DC field flashing input to the SEE are terminated in the fourth cubicle.
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