TURBOGENERATOR

Date – 11/10/2008
 INDEX

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

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INTRODUCTION

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 INTRODUCTION

In 1831-1832 Michael Faraday discovered the operating principle of

electromagnetic generators.

The principle, later called Faraday's law, is that a potential difference

is generated between the ends of an electrical conductor that moves
perpendicular to a magnetic field.

He also built the first electromagnetic generator, called the 'Faraday

disc'

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 INTRODUCTION
Principle of operation of Generator

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DEVELOPMENT OF TG

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 Development of TG
Global development

 First single phase generator of 75 KW 1888

 First 3 phase generator, salient pole 1900
 First turbo type 3 phase 25 MW generator 1912
 CEA, UK made 50 HZ as frequency for Europe 1925
 First Hydrogen cooled 3 phase 30 MW generator 1937
 First Hydrogen cooled TG with direct cooling of rotor 1949
 First generator with water cooled stator winding 1956
 First generator with water cooling for stator and rotor wdg 1959

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 DEVELOPMENT IN INDIA

IN 1950s:
At Bhopal with British collaboration
30 MW & 120 MW Hydrogen Cooled

IN 1960s:
At Haridwar with Russian Collaboration
100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled

IN 1960s:
At Hyderabad with CZECH Collaboration
60 MW Air Cooled & 110 MW Hydrogen Cooled

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 TYPES OF TURBOGENERATOR
Generator Modules :-
 Air Cooled Turbogenerator - TARI
 Hydrogen Cooled Turbogenerator - THRI
 Hydrogen/Water Cooled TG - THDF and THW

Module Nomenclature -
 THRI 108/44
 THDF 115/59

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LIBRARY OF TURBOGENERATOR

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 DTPS GENERATOR DETAILS
 Make : BHEL
 Type : THRI 108/44
 Code : IS : 5422, IEC - 4
 Stator winding cooling : Indirectly hydrogen cooled
 Rotor Winding cooling : Directly hydrogen cooled
 MW rating : 250
 MVA rating : 294.1
 Rated terminal voltage : 16.5 KV
 Rated Stator current : 10286 amps
 Rated power factor : 0.85 Lag
 Rated speed / frequency : 3000 rpm / 50 Hz

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 DTPS GENERATOR DETAILS
 Negative sequence current capability (I}t), t-Time in Sec. : 10

 Efficiency at MCR condition : 98.93 %

 Short circuit ratio : 0.52
 Phase connection : Double Star
 No. of terminal brought out : 06
 Generator Stator winding
resistance in phase at 20ºC
U-X : 0.0008994 ohms
V-Y : 0.0009091 ohms
W-z : 0.0009081 ohms
 Generator rotor winding
resistance at 20ºC F1-F2 : 0.09421 ohms

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 GENERATOR MAIN PARTS

 STATOR

 ROTOR

 BUSHING

 EXCITATION SYSTEM

 H2 COOLERS

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 GENERATOR CROSS SECTION
Stator Core Cooler
Insert
Wdg Cover
Overhang
Rotor fan
Oil Catcher

Bearing

Shaft Seal

Stator Terminal Bushing

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 GENERATOR FRONT VIEW
Stator Frame
H2 Cooler Coolers

Foundation

Bushing

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 STATOR
 STATOR FRAME

 STATOR CORE

 STATOR WINDING

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 STATOR FRAME
 Totally enclosed fabricated gas tight cylindrical

structure. Withstands weight of core & winding,

forces & torques during operation natural freq. Away

From exciting frequencies

 provision for H2/CO2 filling

 Provision for temp measurements

 Foot plates for supporting on foundation

 Provision for H2 coolers

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 Stator Core
 Made up of punched segments of
thin sheets of CRGO,loss less steel
 Punchings coated by insulating
varnish
 Vent segments at designed

intervals for flow of cooling gas

 Compressed with tension bolts,

pressure plate and clamping

fingers
 Stepped arrangement at the end

for reduction in eddy current

losses

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MOUNTING OF CORE IN STATOR FRAME

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SATOR CORE PACKET

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STATOR CORE SUPPORT BAR

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STATOR SLOT

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STATOR WINDING

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 STATOR WINDING
 Three phase windings in two layers of individual bars
 Top and bottom bar displaced by one winding pitch and connected to
coil groups
 Coil groups connected to Connecting Bus bar and finally to Term Bushing
 Involute shape at the end of bar helps withstands various forces
 Micalastic Insulation System (VPI process)

- Micalastic good conductor of heat

- Low flammability
- High resistance to moisture and chemical action
- Accommodates thermo-mechanical stresses
- Retains properties even after years of operation
VPI- Vacuum Pressure Impregnation
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Connection Diagram of Stator Winding

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CONDUCTOR BAR CONSTRUCTION

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WINDING OVERHANG PORTION

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 STATOR WINDING ASSEMBLY

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

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 ROTOR

 High strength alloy steel single forging prepared by vacuum cast steel

 Slots for housing field windings

 Strong coupling for withstanding short circuit forces

 Supported on two journal Bearings

 Provision of axial fan/compressor for forced ventilation

 Provision of damper wedges for increasing negative sequence

capability of rotor

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 ROTOR POLE

Rotor
Wedge

Cross
Pole
Slot

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 ROTOR SLOT

Rotor Wedge

Top Slot Liner

Conductor

Inter turn Insulation

Slot Liner

Sub Slot

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ARRANGEMENT OF DAMPER WEDGES

1. ROTOR BODY 5. RETAINING RING

2. DAMPER BAR 6. SILVER PLATED SHRINK SEAT
3. SILVER PLATED ROTOR END WEDGE 7. TRANSVERSE SLOTS
4. ROTOR WINDING 8. ROTOR WEDGE
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COOLING OF ROTOR WINDING

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ROTOR END WINDING

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CONNECTION OF EE COUPLING

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ROTOR FAN

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

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ROTOR END WINDING

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 GENERATOR COOLING SYSTEM.
 The generator losses are dissipated as heat through stator and rotor bodies. This
heat should be taken out for safe operation of the generator.

 The primary cooling medium is hydrogen, which in turn is passed through a water
cooled heat exchanger.( 4 nos.)

 Hydrogen gas density is only 1/14 that of air. Hence windage losses are reduced.

 Thermal conductivity 7 times that of air. Hence casing size reduced.

 Only disadvantage is hydrogen and air mixture is explosive mixture.

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COOLING CIRCUIT IN TG

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 HYDROGEN COOLER
 Hydrogen coolers are provided to cool the hot gas & to maintain cold

gas temp. After cooler to @ 40 deg.Cel.The cooling water flows through

the tubes & hydrogen gas is passed over the tubes with the help of

shaft mounted fans.

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

tubes.

 Four hydrogen coolers.

 On load cooler isolation facility ( part load )

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COOLER ISOLATION FACILITY ( PART LOAD )

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 TERMINAL BUSHING
 Tubular construction for gas / water cooling

 High conductivity copper for taking out electrical power

 Connection flanges are silver plated to minimise contact resistances

 Insulated with a epoxy resin cylinder or porcelain cylinder

 Differential pressure of gases or forced water for cooling

 Bolted on to stator bottom directly or housed in a box type

 Construction which is bolted to stator bottom

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TERMINAL BUSHING

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COOLING OF TERMINAL BUSHING

1. HYDROGEN SIDE FLANGE

2. TUBULAR COPPER COND.

3. INSULATING CYLINDER

4. MOUNTING FLANGE

5. RUBBER GASKET

6. AIR SIDE TERMINAL BOLT

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 END SHIELD

 Closes both ends of Stator Frame

 Fabricated rigid box type structure in

two parts

 Supports and houses bearings

 Provision for mounting Shaft seal body,

Oil catchers, etc

 Provision for supply of Bearing Oil,

Seal oil, Thrust oil and its drain

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 EXCITATION SYSTEM
 Make : BHEL
 Type : Brushless Excitation system
with Rotating Diodes
Main Exciter
 Type : ELR70 /62-30/ 6-10
 Active Power : 1350 Kw
 Rated current : 3200 amps
 Rated voltage : 420 Volt
 Frequency : 50 Hz
 Stator winding resistance F1-F2 : 2.3 ohms (at 20º c)
 Rotor winding resistance
at 20ºC U-V / U-W / V-W : .00064 ohm
 Fuse Rating : 750 V / 400 amps
 Fuse resistance : 50 µ ohms
 No of Diodes/rectifi. Wheel : 30

Pilot Exciter
 Type : ELP50 /29-30/ 16
 Apparent power : 35 KVA
 .Rated current : 105 amps
 Rated voltage : 220V± 22V
 Frequency : 400 Hz
 Speed : 50 cycles /sec
 Stator winding resistance at 20ºC U-O / V-O / W-O : .0043 ohms

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BRUSHLESS EXCITER
FEATURE:
High response excitation with fast
acting AVR

Multi contact electrical connections

between exciter and
 generator field

Stroboscope for fuse failure

detection

Rotor Earth fault monitoring system

RC circuit to avoid over voltages

Dehumidifier for use during shut

down
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 BRUSHLESS EXCITATION SYSTEM

ADVANTAGES

 Eliminates Slip Rings, Brushgear

 Eliminates all problems associated with transfer of current via sliding contacts

 Simple, Reliable and ideally suited for large sets

 Minimum operating and maintenance cost

 Self generating excitation unaffected by system fault/disturbances because of

shaft mounted pilot exciter

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Rectifier Wheel

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PMG ROTOR & FAN

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

 The controlled rectified D.C.Output from AVR fed to the main exciter
field.

 The induced three phase A.C.Voltage is rectified in the rotating bridge &
fed to the generator rotor winding through the D.C. Leads in the shaft.

 Pilot exciter, main exciter & rotating diodes all are mounted on a single
shaft. The rotor is supported on a journal bearing positioned between
main & pilot exciter. Lubrication of the bearing is from turbine oil
system.

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 COOLING OF EXCITER

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

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

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 CASE STUDY - 01
 UNIT # 2

 Occurrence Date- 07/07/2002

 Taken in operation on- 27/08/2002

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CRACK ON SUPPORT BAR

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REPAIRED SUPPORT BAR

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 CASE STUDY - 01
 UNIT # 2

 Occurrence Date- 29/07/2000

 Protection operated -Generator Diff. Protection

 Taken in operation on- 27/08/2000

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Case History

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 CASE STUDY - 02
 UNIT # 2

 Occurrence Date- 25/08/2005 ,07.11 Hrs.

 Protection operated -95 % Stator E/F, Stator interturn

 Taken in operation on- 26/09/2005 , 02.05 Hrs

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Thank you
11/10/2008
 TESTS DURING O/H
TESTS ON STATOR
 VISUAL INSPECTION
 STATOR WINDING RESISTANCE
 IR/PI TEST @ 2.5 kV ON STATOR
 TAN DELTA & CAPACITANCE MEASUREMENTS
 NFT,DYNAMIC MECHANICAL RESPONSE OF END-WINDINGS
 WEDGE TIGHTNESS MAP
 DIGITAL ELCID TEST

TESTS ON ROTOR
 VISUAL INSPECTIONS
 AC IMPEDANCE TEST
 WINDING RESISTANCE
 RECURRENT SURGE OSCILLOGRAPH
 DIODE CHECKS

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 STATOR CORE

 DIGITAL ELCID TEST

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

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ROTOR

 RECURRENT SURGE OSCILLOGRAPH

A fast step voltage impulse (12 V) is repeatedly applied using a
Recurrent Surge Oscillograph (R.S.O.) to the rotor winding at one of the
leads and the terminal voltage waveform, consisting of reflections from
rotor windings, is examined at the other lead. The process is repeated
after interchanging the leads and the two waveforms are superimposed to
check for rotor winding abnormalities like shorted turns, earth faults,
interturn faults or rotor high resistance areas. The method is largely suited for 2
pole machines.
Benefits:
Effective detection of rotor winding interturn shorts or high resistance joints.

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

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

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