P.D.P.

Alternator Training
Date : 28.02.07

Place : C.E.S.C.
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Alternators
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Alternators
PRINCIPLE OF OPERATION OF SELF EXCITED, SELF REGULATED MACHINES

OUTPUT
Reference

Sensing
AVR Output of AVR
Power

MAIN STATOR EXCITER

STATOR

EXCITER
MAIN ROTOR ROTOR

ROTATING
CLOCKWISE RECTIFIER
ROTATION ASSEMBLY EXCITER
MAIN STATOR
FROM DRIVE STATOR
END
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Alternators

Principle of working
If a conductor is moved in a magnetic field so that it cuts the
magnetic lines of force (flux), a voltage is induced in the conductor
by Faradays law.
The same effect is achieved if the conductor is stationary and the
magnetic field is moving.
The induced e.m.f. (voltage ) can be increased by
Increasing the strength of the magnetic field.
Increasing the rate of cutting the magnetic flux.
Increasing no of conductors and connecting them in series.
Current capacity can be increased by increasing no. of conductors
and connecting them in series.
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Alternators

Major components
Rotor
Made of silicon steel.
Carries electromagnetic poles and windings.
The rotor coils are made from dual coated,class H copper wire.
Stator
Made of fabricated steel.
Designed to ensure correct air flow over the stator core and
windings.
The stator coils are made from dual coated,class H copper wire
and wound with a 2/3 pitch.
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Alternators

AVR
Regulates the output voltage by adjusting the excitation current
as per changes in load.
Rotating rectifier assembly
Consists of 06 nos. Diodes and 01 no. Surge Suppressor .
Excitor stator
D.C winding providing excitation for excitation generator.
Excitor rotor
Three phase A.C. winding supplying to main field through
the rotating rectifier.
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Alternators
ROTATING RECTIFIER ASSEMBLY
Aluminium Plate + ve

Forward
Diodes
+ ve
To Main Rotor
Exciter - ve
Rotor

Reverse Surge
Diodes Suppressor

Aluminium Plate - ve
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Alternators

Rating

Output KVA
Power factor
Frequency

KW (output ) = KVA (output) x P.F.

KW (input) = KW (output) / alternator efficiency

HP (input) = KW ( input) / 0.746

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Alternators

Factors affecting selection of alternator

Steady state load condition.

Transient state load condition.

A rating sufficient for steady state load condition may not be

large enough to meet motor starting or voltage dip condition.

Type of load

Linear load.
Non linear load.
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Alternators

Types of load

Linear load

Constant load impedance regardless of applied voltage.

Load current increases proportionately as the voltage increases
and decreases as the voltage decreases.

Examples = Motor, Incandescent lighting, Heating loads etc.

Alternator capacity = Total linear load + 15 to 20 %

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Alternators

Non linear loads

Load current is not proportional to the instantaneous voltage.

Load current may not be continuous.

Examples = Essentially Electronic loads such as Computers.

UPS equipments, variable speed motors etc.
Gas discharge lighting loads.

Semi conductor Thyristor / Rectifier loads.

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Alternators

Effects of Non Linear load

Generate harmonics in their current waveform, which in turn

leads to distortion of alternators output waveform.

Harmonics also cause overloading of neutral conductors.

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Alternators

Motor loads

Method of starting Starting current

Direct on line 6 x full load current.

Star / Delta 3.5 x full load current.

Rotor resistance 1.5 to 2 x full load current.

Auto transformer
65 % tapping 4 x full load current.
80 % tapping 4.8 x full load current.
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Alternators

Data required regarding motor loads

Rating of motor ( HP).

Type of motor ( slip ring / squirrel cage ).
Method of starting.
Rated full load current.
Starting power factor.
Restriction on transient voltage dip, if any.
Frequency of starting.
Base load at the time of starting the motor.
Any other loads apart from motor loads.
Sequence of starting motors.
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Alternators
Derating on Alternators
Load
Fluorescent lighting
UPS & Telecom load controlled
by 12 pulse thyristor bridge + filter
UPS & Telecom load controlled
12 pulse thyristor bridge + filter
UPS & Telecom load controlled
12 pulse thyristor bridge + filter
Variable speed 6 pulse thyristor
bridge controlled drive.
Deration factor
None
None
Non linear loads should by
not exceed 66 % of full load.
Non linear loads should by
not exceed 35 % of full load.
Non linear loads should not
exceed 50 % of full load.
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Alternators

Data required on Non Linear loads

Number of system pulses.

Level of current distortion produced by non linear loads.
The distortion filters fitted.
What is the maximum acceptable level of voltage distortion for
the non linear loads.
Operating voltage and frequency.
Operating power factor and system efficiency.
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Alternators

Parallel Operation
To increase capacity of existing system.
Allows non-interruption of supply when servicing is required.
Size and weight may preclude the use of one large unit.
Conditions
The terminal voltages of all alternators must be the same.
The output frequency of all alternators must be the same.
The phase sequence of all alternators must be the same.
The impedance drop per phase should be the same for all
alternators.
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Alternators

Instrumentation Required for Parallel Operation

Volt meter
Ammeter
Watt meter
Frequency meter
Synchroscope
Reverse Power relay
Neutral contactor
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Alternators
Parallel Operation
Engine Engine
governor governor
and speed ENGINE and speed ENGINE
adjust 1 adjust 2

Power
(kW)
Sharing

AVR and AVR and

voltage voltage
adjust GENERATOR adjust GENERATOR
1 2
Reactive
(Ampere)
Sharing

To
Busbars Load
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Alternators
Parallel Operation

V A Hz

kW
p.f.

DG SET CONTROL PANEL

12 O'CLOCK POSITION

S F

SYNCHROSCOPE LAMPS

SYNCHRONIZING PANEL
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Alternators

Load Sharing

Engine governor decides the KW sharing. Equal Speed droops

ensure equal (or proportional to the rating ) KW sharing.

Alternator voltage regulation decides the current sharing.

Equal voltage droops ensure equal ( or proportional to the rating)

current sharing.
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Alternators
Parallel Operation Difficulties
Oscillating kW meter, ammeter and voltmeter.
Cause: Engine governing.
Unbalance ammeter readings, kW meters balanced and stable.
Cause: Circulating current through incorrect voltage setting, droop
kit connections reversed or insufficient droop.
Unbalanced ammeter reading on no load or rapidly rising currents
as soon as breaker is closed
Cause: Incorrect voltage setting or droop kit connections reversed.
Unbalanced kW and ammeter reading as load increased or
decreased.
Cause: Dissimilar governor speed regulation.
Unbalanced ammeter reading as load increases, kW meter balanced.
Cause: Droop circuit settings not identical or one droop kit
reversed.
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Alternator Maintenance
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Alternator Maintenance

Introduction

Generators are the most important as well as the most expensive

piece of equipment in a power system and they are also subject
to more possible types of troubles than any other equipment if
not maintained and protected in a proper way.

The choice of equipment protection ,which is governed by the

method of earthing,type of prime mover,importance of machine
etc.,must be carefully considered.

Before carrying out any maintenance work the generator should

be stopped and isolated electrically from all external loads or
supplies.
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Alternator Maintenance

Mechanical checks
It should be checked that machine is received without any damage
and is erected correctly .
Bearing must be lubricated.
The rotor should be checked for free running by hand cranking.
In case of single bearing machine,it should be ensured that split
locking plate is removed before starting the generator.
The direction of rotation must be correct.
All the fuse link must be provided.
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Alternator Maintenance

Ventilation

It should be checked that all ventilation grids,gland plates and

covers are firmly and correctly fitted in position and the
generator inlet and outlet and ventilation ducts are not
obstructed in any way.
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Alternator Maintenance

Electrical checks
Insulation check
If the machine is stored for long or suspected to be damped, the
Insulation resistance of the winding should be checked and the
machine dried out.

While checking insulation resistance of winding it must be ensured

that all connection to these windings including generator control
unit and rotating rectifier assembly are removed.

The insulation resistance of all the winding should be checked

using a 500V megger before the generator is put in operation.
The insulation resistance between any winding and earth should
not be less than one mega ohm.
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Alternator Maintenance

If the insulation resistance is less than one megaohm,the

generator should be cleaned and dried out until the insulation
resistance is at least equal to minimum value.

A method of drying out is to circulate hot air through the

machine. It may be done by by placing heaters inside or near the
machine.
Care should be taken that no part of the winding exceeds
90 deg. C total temperature by thermometer.
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Alternator Maintenance

Connection checks

Most of the problems that arise during operation are due to

wrong , loose or snapped connections from switchgear to the
machine. Hence it is important to check these connections
thoroughly.

The connections between AVR and the generator terminals

should be checked as per one of the three connection diagrams,
depending upon the type of AVR input.Check for transients
damage or loose connections.
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Alternator Maintenance

Running checks and commissioning

Check for transit damage or loose connections
Disconnect exciter field leads, using 500V megger,check the
exciter field ground insulation(at least 1Mohm).
Reconnect with correct polarity (see connections in drawing
provided).
Caution
Do not megger or flash test the generator winding unless all leads
to the AVR have been disconnected.
Run up the generator on no load to rated speed.The output voltage
should build up in a few seconds and stabilize at the rated voltage,
which can be trimmed to exact value required .Check that Vtrim
covers the requires range.
Do Not Start The Generator With Load On.
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Alternator Maintenance

The generator may now be loaded and regulation checked.

To check underspeed protection ,reduce the speed to 90% of rated

speed, and observe that a small red light appears on the
emergency shutdown the engine.

Observe that output voltage of the generator falls in proportion

to the falling engine speed.
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Alternator Maintenance

Residual voltage checks

The minimum residual voltage at the generator terminals required

for positive build up is about 8V ac with the generator running at
rated speed.

If the machine does not build up due to low or loss of residual

magnetism, the following procedure is adopted with the generator
stationary.

The exciter field leads F1,F2 are disconnected from AVR and
connected to 12Vbattery with its positive lead connected to F1
and negative to F2 for few seconds. F1, F2 are then disconnected
from battery and reconnected to AVR as before.
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Alternator Maintenance
Sensing input AVR
Power input Connect to 60W bulb

U V W N
R Y B N +ve From 12 V
-ve Battery

MAIN STATOR EXCITER

STATOR

EXCITER
MAIN ROTOR ROTOR

ROTATING
CLOCKWISE RECTIFIER
ROTATION ASSEMBLY EXCITER
MAIN STATOR
FROM DRIVE STATOR
END
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Alternator Maintenance

Rated voltage and Phase balance checks

The generator is started and run at its rated speed
The generator should be excited on no load till the rated voltage
is developed between line to line.
The voltage balance on three lines of the generator should be
checked.

Direction of phase rotation and phase sequence

Standard phase sequence is UVW for clockwise rotation at the
driven end.
However the operators must ensure that direction of rotation and
phase sequence are the same as stated in the name plate of the
machine.
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Alternator Maintenance

Harmonic circulating current and neutral connection

When two or more generators operating in parallel and having
their star point connected together.
Chances are that they may have slightly different line to
neutral voltage waveform.
The harmonics voltages which do not balance-out will result
in the circulation of harmonic currents.
The sum of current in 3-phases will flow through the neutral
causing additional heating of the generator .
Such circulation of current can be avoided by connecting the
star point of one generator to to the neutral line only.
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Alternator Maintenance

Caution

Rotor should be freed before running the single bearing

generator.

The space heaters must be switched off before running the

generator.

The generator should be isolated and its prime mover should be

shut down immediately when the operator observes any abnormal
operation.

Connection diagram,dimension drawing,all instruction should be

followed as per manufacturer guidelines.
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Alternator Maintenance

Maintenance
Depending on the individual site conditions,frequent ,
maintenance should be practiced.
Before carrying out any maintenance work the generator should
be stopped and isolated electrically from all external loads or
supplies.
General cleaning
Both interior and exterior of the machine (particularly the
windings, bearing,ventilation openings,exciter etc,) should be
kept free from any oil or dust by blowing out frequently with clean
dry air at a pressure not exceeding 3.5kg/cm2.
If the blowing is ineffective to remove oil or dust,the parts should
be carefully cleaned with a rag lightly damped in white sprit.
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Alternator Maintenance

Connections Maintenance
All the external and internal connections(including rotating
rectifier assembly and AVR) must be checked for tightness at
joints and continuity.

Fuse link should make a good fit in holders.

All the hardware,including those of terminals,should be tightened

if required
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Alternator Maintenance

Loss of residual

If the generator residual is completely lost because of long

storage or demagnetizing due to any maloperation,it will be
necessary to disconnect the exciter field terminals at the AVR
and connect a 12V battery directly across the field (with correct
polarity) for few seconds, to re-established the residual.
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Alternator Maintenance

Rotating rectifier assembly

The health condition of the diodes can be checked when required
as follows
The pigtail terminal of each diode is disconnected.
Using an ohmmeter with at least 1.5 Volts source, the resistance
of diode between stud and pigtail in both direction is measured.
Diodes in good condition will show a low resistance in the
forward direction and very high resistance (upto 1mohm) in
reverse direction.
A high resistance in both directions or a low resistance in both
direction indicates a faulty diode which should be replaced.
Failure of surge suppressorcan be detected by smell and
appearance.
Failure of fuses can be detected by checking its continuity using
millimeter.
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Alternators
DIODE CHECKING WITH MULTI-METER

- ve + ve

Cathode
Forward Bias Reverse Bias

Multi-meter reading Multi-meter reading

less than 100 more than 10,000
Ohms Ohms

Anode

+ ve - ve
FAULTY DIODE WILL SHOW SHORT IN BOTH DIRECTIONS
OR OPEN IN BOTH DIRECTIONS
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Alternator Maintenance

Bearings
The roller bearing or ball bearing will run for a long periods.
The bearing s are to be relubricated with correct quantity of
grease in the interval stated on the name plate of generator, in
order to replenish any grease lost during running.
If the grease is caked before commissioning ,it has to be
completely replaced.
Grease of different makes and grades should not be mixed.
When the machine has to be stationary for long period,the rotor
should be turned periodically to avoid setting of grease at the
bottom of housing.
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Alternator Maintenance

Dos

Maintain log book.

Monitor the parameter.
Check the performance.
Check IR when set is kept idle for long .
Check mechanical and electrical joints periodically.
Check and calibrate protective relays.
Check earth connections.
Switch on space heaters ,when fitted,while set is idle.
Use correct size / rating of cables.
Check alignment periodically.
Use genuine spares.
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Alternator Maintenance

Don't s

Do not meggar with AVR in circuit.

Avoid moisture entry in to the machine.
Do not load at low lagging P.F.
Do not run at low speed on load.
Do not overload.
Do not open the machine when running and live.
Do not mix different grade and make of grease.
Do not disturb bearing unnecessarily.
Avoid unbalance load.
Do not field flash with AVR in circuit.
Do not block / restrict ventilation.
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Alternator Maintenance

Maintenance of AC generator Daily checks

Vibration.
Noise.
Temperature of respective parts.
Lubricating condition.
Oil leakage.
Condition of ventilation.
Battery condition.
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Alternator Maintenance

Mechanical maintenance

General cleanliness.
Bearing - Sleeve Bearing.
Cooler.
Alignment.
Tightness of joints.
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Alternator Maintenance

Electrical maintenance

Rotating rectictifier assembly.

Generator control unit.
Space Heater.
Residual magnetism.
Insulation resistance.
Protective relays.
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S.P.S.C Check List

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S.P.S.C Check List

SR NO ACTIVITY SIGNIFICANCE
1 CHECK CLEANLINESS, CLEAN WITH DRY AIR DUST ON WINDINGS PROMOTES ABSORPTION OF
BLOWER. MOISTURE LEADING TO LOW INSULATION
RESISTANCE.
2 CHECK FOR OBVIOUS LOOSE CONNECTIONS AT LEADS TO VOLTAGE DROP AND OVERHEATING AT THE
ALTERNATOR OUTPUT TERMINALS CONNECTION, IF NEGLECTED LEADS TO
BURNING/BREAKING OF ALTERNATOR STATOR COIL
AT THE LUG
3 CHECK VOLTAGE BETWEEN "RY", "YB" AND "BR" TO CONFIRM BALANCED VOLTAGES. UNBALANCED
BY MULTIMETER, AT NO LOAD VOLTAGES INDICATE LOOSE NEUTRAL CONNECTION /
STATOR WINDING PROBLEM
4 CHECK NO LOAD EXCITATION VOLTAGE ( DC ANY PROBLEM IN ALTERNATOR WILL INCREASE THE
VOLTAGE OUTPUT OF AVR) EXCITATION VOLTAGE, AVR SENSING INPUT & DIODES
AT RRA TO BE CHECKED. IT IS ADVISABLE TO MARK
THE NO LOAD EXCITATION VOLTAGE ON THE
ALTERNATOR AT THE TIME OF COMMISSIONING, FOR
FUTURE REFERENCE.
5 CHECK UFRO SETTING BY NOTING THE INCORRECT SETTING MAY CAUSE VOLTAGE DROP ON
FREQUENCY AT WHICH THE UFRO LED GOES OFF LOAD IF THE KNEE POINT IS TOWARDS 50HZ AND
OVEREXCITATION AT LOWER FREQUENCIES IF IT HAS
SHIFTED TO LOWER FREQUENCY.
6 CHECK THE DG ON LOAD TO CONFIRM PROPER PERFORMANCE ON LOAD
7 CHECK AMMETER READING IN R, Y & B POSITIONS TO CONFIRM BALANCED LOAD ON ALL PHASES
OF AMMETER SELECTOR SWITCH
8 CHECK LOAD CURRENT IN ALL THREE PHASES BY TO CONFIRM ACCURACY OF AMMETER, TO CONFIRM
TONG TESTER/CLAMP METER CURRENT IS WITHIN NORMAL LIMITS FOR THE
ALTERNATOR
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S.P.S.C Check List

SR NO ACTIVITY SIGNIFICANCE
9 CHECK CT CURRENTS BY TONG TESTER TO CONFIRM CT RATIO MATCHES WITH ACTUAL RATIO
OF PHASE CURRENT TO CT OUTPUT CURRENT.
WRONG CT RATIO WOUL RESULT IN WRONG READING
ON METERS AND MAY LEAD TO OVERLOADING OF
GENERATOR.
10 CONFIRM FREQUENCY AT MAXIMUM AVAILABLE OPERATION AT HIGHER FREQUENCY AT WILL CAUSE
LOAD (STEADY STATE) IS NOT ABOVE 50 HZ HIGHER FUEL CONSUMPTION.
11 CONFIRM FREQUENCY (DURING STEADY STATE OF OPERATION AT LOWER FREQUENCY AT WILL CAUSE
LOAD) IS NOT BELOW 50HZ HIGHER EXCITATION OF ALTERNATOR.
12 CONFIRM NORMAL TEMPERATURE OF EACH LOOSE CONNECTION AT TERMINALS / BETWEEN
CABLE ALTERNATOR OUTPUT CABLES BOTH CABLE AND LUG CAN BE DETECTED BY Mv DROP
NEAR ALTERNATOR AND NEAR THE BREAKER AND METHOD. THE LOOSE CONNECTIONS LEAD TO
CHECK mV DROP AT THE CONNECTIONS. VOLTAGE DROP AND OVERHEATING AT THE
TERMINALS.
13 CALCULATE KVA USING THE FORMULA KVA = IF THE VOLTAGE SETTING IS HIGH (SAY 440 V), THE
SQRT 3 x V x I SET WILL BE OVERLOADED EVEN BELOW RATED
CURRENT
14 IF KW METER IS AVAILABLE, CALCULATE POWER IF POWER FACTOR IS CLOSE TO UNITY THE
FACTOR ALLOWABLE CURRENT IS LESS THAN THE RATED
CURRENT AS AT UNITY PF KVA = KW. ALSO IF THE PF
IS LESS THAN 0.8 THE ALTERNATOR WILL BE
OVERLOADED AT RATED KW.
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S.P.S.C Check List
16 PROBLEM OF BOTH SPEED AND VOLTAGE
HUNTING TOGATHER CAN BE SOLVED ONLY BY
METHOD OF ELIMINATION OF DOUBT.ELIMINATE
DOUBT ON AVR BY REPLACING THE SAME WITH A
SERVICE AVR ONLY AFTER ENSURING THERE WAS
NO LOOSE CONNECTION IN THE ORIGINAL AVR
INPUT/OUTPUT CONN
17 IN HIGH HUMIDITY ENVIRONMENT, ADVICE THE
CUSTOMER, IN WRITING, TO INSTALL SPACE
HEATER.
18 IN CASE REWINDING OF COMPONENT IS
REQUIRED, ADVISE THE CUSTOMER IN WRITING,
TO SEND THE ALTERNATOR / COMPONENT TO
AUTHORIZED REWINDERS ONLY.
IN CASE OF SUCH LOOSE CONNECTION/S, THE SAME
WILL GET CORRECTED WHILE REPLACING THE AVR
AND PROBLEM WILL BE SOLVED. THIS MAY RESULT IN
UNNECESSARY REPLACEMENT OF AVR.
CHANCES OF MOISTURE ABSORPTION ARE HIGH IN
HUMID ENVIRONMENT. THE PROCESS TAKES PLACE
WHEN THE TEMPERATURE WITHIN THE ALTERNATOR
FALLS BELOW THE ROOM TEMPERATURE. HENCE IT IS
NECESSARY TO KEEP THE WINDINGS AT HIGHER THAN
ROOM TEMPERATURE. THE WINDINGS GET
TO ENSURE THE QUALITY OF REWINDING AND TO
PREVENT ISSUES IN CASE OF A FAILURE AFTER
REPAIRS.
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Thank You