Basic Electrical

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 VOLTAGE V - voltage

CURRENT - I Ampere

ACTIVE POWER W -watts

REACTIVE POWER - VAR - var

APPERENT POWER VA - va

RESISTOR R - ohms

INDUCTOR L - henry

CAPACITOR C - farad

POWER FACTOR cos

FREQUENCY f - hertz

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 f = NP/ 120 where
N = rotor speed in r.p.m.
P = number of rotor poles
f = frequency of e.m.f. in Hz

The world today is divided between countries generating their power at 50

Hz (e.g. Europe, Africa, Australia, Asia, and South America)

and others (e.g., the United States/ North America, parts of Japan & Asia)
at 60 Hz.,

Additional frequencies (e.g., 25 Hz) can still be found in some locations,

but they constitute the rare exception.

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Electrical-mechanical equivalence.

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Electrical-mechanical equivalence.

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TURBOGENERATOR
Date 23/07/2009
 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

The basic function of the generator is to convert mechanical

power, delivered from the shaft of the turbine, into electrical

power.

A generator is actually a rotating mechanical energy converter

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 INTRODUCTION

In 1831-1832 Michael Faraday (17911867), 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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Faradays Law of Electromagnetic Induction

This basic law, defined by genius of the great English chemist and

physicist Michael Faraday, presents itself in two different forms:

1. A moving conductor cutting the lines of force (flux) of a constant

magnetic field has a voltage induced in it.

2. A changing magnetic flux inside a loop made from a conductor

material will induce a voltage in the loop.

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 INTRODUCTION

The hydroelectric generator from Lauffen, Germany . The commercial birth

of the alternator (synchronous generator) can be dated back to August
24, 1891
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 INTRODUCTION
Principle of operation of Generator

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 E M F Equation of Generator
E rms/Phase = 4.44 Kp Kd f T

where

T = turns (T) per phase

Pitch Factor Kp = emf induced in short pitch coil

emf induced in Full pitch coil

Distribution Factor Kd = emf with distributed winding

emf with concentric winding

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 GENERATOR COMPONENTS
The generator must be able to cope with large and fast load changes,
which show up inside the machine as changes in mechanical forces and
temperatures. The design must therefore incorporate

Electrical current-carrying materials (i.e., copper),

Magnetic flux-carrying materials (i.e., highly permeable steels),
Insulating materials (i.e., organic or inorganic),

Structural members (i.e., steel ), and

Cooling media (i.e., gases and liquids),

All working together under the operating conditions of a turbogenerator.

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 TYPES OF FORCES EXPERIENCED BY STATOR

STATOR - SIGNIFICANT DYNAMIC FORCES IN TERMS OF

VIBRATION
TORSIONAL LOADS
ELECTROMAGNETIC LOADING,
THERMAL LOADING
HIGH-VOLTAGE LOADING.

MOST CRITICAL COMPONENT OF STATOR IS STATOR WINDING

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 TYPES OF FORCES EXPERIENCED BY ROTOR

ROTOR - THE HIGH SPEED ROTATING MEMBER

SEVERE DYNAMIC MECHANICAL LOADING

TORSIONAL LOADS
ELECTROMAGNETIC LOADING,
THERMAL LOADING
HIGH-VOLTAGE LOADING.

THE MOST CRITICAL COMPONENT IN THE GENERATOR ARE THE

RETAINING RINGS, MOUNTED ON THE ROTOR. DESIGNED FOR
HIGH-STRESS OPERATION

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DEVELOPMENT OF TG

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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 1891
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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 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
Cont. permi. unbalanced load : 8%
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 20C
U-X : 0.0008994 ohms
V-Y : 0.0009091 ohms
W-z : 0.0009081 ohms
Generator rotor winding
resistance at 20C F1-F2 : 0.09421 ohms

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 DTPS GENERATOR DETAILS
Short-circuit ratio (SCR) is defined as the ratio of the field current required
to produce rated terminal voltage on the open circuit condition, over the
field current required to produce rated stator current on sustained three-
phase short circuit, with the machine operating at rated speed.
During operation, to maintain constant voltage for a given change in load,
the change in excitation varies inversely as the SCR. This means that a
generator with a lower SCR requires a greater change in excitation, than
a machine having a higher SCR, for the same load change.
The inherent stability of a generator in a power system is partly
determined by its short-circuit ratio
Short circuit ratio of DTPS generators : 0.52

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 DTPS GENERATOR DETAILS
There are two components of negative sequence to consider.

The first is the continuous I2 component, which refers to the amount of

phase unbalance the generator can tolerate for an infinite operating
period

For large steam turbine generators, a typical continuous I2 value of 8

would be normal. This means that the generator could carry a continuous
phase unbalance in the stator winding of 8% or 0.08 pu of the rated
stator current, without damaging any of the generator components,
specifically the rotor.

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 DTPS GENERATOR DETAILS

The second is the transient component called I22 t , which refers to the
degree of short-term phase unbalance that the generator can withstand.
A typical transient value for I22 t would be 10.
This means that the generator could withstand 100% or 1 pu phase
unbalance for 10 seconds
Negative sequence current capability I22 t ,t-Time in Sec. : 10 for DTPS
generators

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Negative-sequence inverse time relationship.

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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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Rating of TURBOGENERATOR

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 GENERATOR MAIN COMPONENTS

STATOR Armature

INSULATION

ROTOR - Field

BUSHING

EXCITATION SYSTEM

H2 COOLERS

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Advantages of stationary Armature & rotating Field
It is easier to insulate stationary winding for high voltages for which the
alternators are usually designed. It is because they are not subjected to
centrifugal forces and also extra space is available due to the stationary
arrangement of the armature.
The stationary 3-phase armature can be directly connected to load without
going through large, unreliable slip rings and brushes..
Due to simple and robust construction of the rotor, higher speed of rotating
d.c. field is possible. This increases the output obtainable from a machine
of given dimensions.
Note: All alternators above 5 kVA employ a stationary armature

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 STATOR

STATOR FRAME

STATOR CORE

STATOR WINDING

STATOR INSULATION

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 STATOR FRAME
THE BASIC PURPOSE OF THE STATOR FRAME IS

TO PROVIDE SUPPORT FOR THE STATOR CORE

TO ACT AS A PRESSURE VESSEL FOR THE HYDROGEN COOLING

GAS IN HYDROGEN-COOLED GENERATOR
The type of steel used in the frame is generally highly weldable material with
good strength and low-temperature ductility (i.e., mild steel) to contain the
internal hydrogen gas pressure.

SEGREGATED INTERNALLY TO CREATE A VENTILATION CIRCUIT

WITHIN THE GENERATOR

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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 FRAME
Wrapper Plate

H2Cooler
Stator winding
Rotor
Rotor winding

Terminal
Bushing

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STATOR FRAME

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 Stator Core
The principle function of the stator core is to carry electromagnetic
flux.
The core must handle magnetic field flux densities in the stator
teeth and in the core-back or yoke area.
The stator core is made up of thin sheets of electrical grade, 3% to 4%
silicon ,CRNO or CRGO, and 0.355 mm or 0.483 mm thick steel
Radial Ducts 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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Stator Core - Laminations

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 Stator Core - Laminations
There are numerous terms for these sheets; i.e. coreplate, punchings or
laminates.
They are segmented, meaning that generally from 10 to 24 laminates
are laid side by side to form a full 360 degree ring layer.
Each of these layers is staggered relative to the locations of adjacent
layers above and below, by the butted radial edges of the adjacent
laminates in each ring layer.
Staggering advantages
1) has significant effect in increasing the mechanical integrity of the stator
core as an assembled unit
2) beneficial effect in reducing shaft voltages on the rotor due to magnetic
circuit dissymmetry.

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 Stator Core - Laminations

Each lamination is insulated on both sides with an organic or inorganic

compound of very thin dimension.

The purpose of the interlaminar insulation is to confine any induced eddy

currents

To reduce the eddy-current effect due to axial flux impingement in the

core-ends and its subsequent effect of increase in core-end heating, the

core teeth are slit, in end core section

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 Stator end Cores

SLIT CORE
TEETH

Eddy-current activity in the core-ends is increased due to stray and

end leakage flux, from axial impingement on the core teeth in the end-region
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SATOR CORE PACKET

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 MOUNTING OF CORE IN STATOR FRAME

To keep the laminated ring segments in line with each successive layer,
they are fitted onto keybars in a stator frame structure

A large full ring pressing plate at each end of the stator

Additional use of through-bolts installed through holes in the core yoke

area that extend the full axial length of the stator core and through the
pressing plate.

In the area of the core teeth substantially strong fingers are installed on
top of the core teeth at the ends

High-pressure loading of up to 250 tons per inch,

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 MOUNTING OF CORE IN STATOR FRAME
Stator Core
Support bar
Pressure Plate
Insulated
Through Bolt
Clamping Finger

Stator Core

Locking Key of
Stator Core Support bar

high-pressure loading of up to 250 tons per inch

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STATOR CORE SUPPORT BAR

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STATOR CORE SUPPORT BAR & RIB

Circumfer.
Rib

Core Support Bar

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STATOR CORE Ventilation spacers

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STATOR WINDING

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 STATOR WINDING
Three phase windings in two layers of individual bars
Stator winding is divided in three phases
Star connected to allow neutral grounding
Top and bottom bar displaced by one winding pitch and connected to
coil groups
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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 STATOR WINDING
Armature windings are generally distributed windings
Advantages
1) distributed winding generates a voltage wave that is nearly a sine
curve.i.e. reduced harmonic content
2) Copper is evenly distributed on the armature surface. Therefore,
heating is more uniform and this type of winding is more easily cooled

A.C. armature windings may use full-pitch coils or fractional-pitch coils

A coil with a span of 180 electrical is called a full-pitch coil.
A coil with a span of less than 180 electrical is called a fractional-pitch
coil
Advantages
1) less copper is required per coil
2) the waveform of the generated voltage is improved

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 STATOR WINDING
Distributed, Fractional Pitch , double Layer, Star Connected LAP
winding
R Y B

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Connection Diagram of Stator Winding

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STATOR SLOT

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 STATOR SLOT ripple spring
To ensure good contact between the stator bar and the core, in the slots,

a side packing filler is also generally inserted along side both top and

bottom stator bars

The side filler is impregnated with semi conducting material to assist with

the electrical contact to the stator core.

The base material is usually made up of strong resin-filled glass weave

material

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 STATOR SLOT ripple spring

Side packing ripple spring with semi conducting impregnation.

.

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 STATOR SLOT - wedge
Due to the current flowing in the stator bars, there is a reaction force in
each slot which varies according to the level of current and direction of
flow at any
Instant
creates forces between bars that are both repulsive and attractive
at any give time in the alternating cycle. due to the cross-slot flux
produced by the normal load current.
The stator bars tend to vibrate in the slota phenomenon called
bar bouncing.
Wedges are used in the slot to minimize the relative motion, and avoid
fretting damage against themselves and the stator core and bar packing
systems

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 STATOR SLOT wedge

SINGLE-PIECE FLAT STATOR SLOT WEDGE

.
.
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 CONDUCTOR BAR CONSTRUCTION
To reduce the effect of the eddy currents within each individual stator bar,
the
conductors are made up of numerous copper strands
Due to the difference in the magnetic field from the top to bottom of the
slot, additional circulating current could flow from top to bottom strands in
a single bar
To reduce the effect of the circulating currents, the strands are Roebel
Transposed in each bar
Roebel transposition of the copper strands refers to the re-positioning of
each strand in the stator bar stack such that, it occupies each position in
the stack at least once over the full length of the stator bar.

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CONDUCTOR BAR CONSTRUCTION

ROEBEL TRANSPOSITION: 3D VIEW.

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WINDING in Core

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WINDING OVERHANG PORTION

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 STATOR END 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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 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 porcelain cylinder

Differential pressure of gases or forced water for cooling

Construction which is bolted to stator bottom

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TERMINAL BUSHING

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STATOR TERMINAL CONNECTIONS

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 Stator Core Cooler
Insert
Wdg Cover
Overhang
Rotor fan
Oil Catcher

Bearing

Shaft Seal

Stator Rotor Terminal Bushing

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 WINDING INSULATION
The reason for using insulating materials is to separate electrically the
conducting parts of equipment from each other and from earthed
components.

Thermal class Operating temperature (C)

Y 90
A 105
E 120
B 130
F 155
H 180
200 200
220 220
250 250

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 WINDING INSULATION
MICALASTIC Insulation- High Quality Mica, Selected Epoxy Resin & matching
vacuum impregnation process. Extremely dependable insulation system for High
voltage(upto 30 kv) turbo generators
Why MICALASTIC Insulation ?
It has long electrical life
It is a good conductor of heat as it has high mica content & void free synthetic
resin
It is highly resistant to effect of high temp. & temp. changes
Its elasticity enables it to accommodate thermo-mechanical stress
It does not burn, it provides protection against moisture
Highly resistant to chemical action
Retains its outstanding properties even after years of operation

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WINDING INSULATION

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CONDUCTOR BAR INSULATION
6

5
4

1
3

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 STATOR OVERVIEW

Core supporting KEY bar

Circumferential ribs

Core
End Terminals

Winding
Overhang

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ROTOR

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 ROTOR
THE ROTOR CARRIES FIELD WINDINGS.
SILVER BEARING COPPER IS USED FOR THE WINDINGS WITH
MICA AS A INSULATION BETWEEN CONDUCTORS.
MICANITE ,A STRONG INSULATOR IS USED FOR LINING THE SLOT.
DURALUMIN WEDGES ARE USED FOR PREVENTING THE LIFT OF
WINDING OUT OF THE SLOTS DUE TO CENTRIFUGAL FORCES.
THE ROTOR END WINDING OUTSIDE THE SLOTS ARE COVERED
BY NON-MAGNETIC STEEL RETAINING RINGS.
RETAINING RING IS USED TO TAKE UP THE CENTRIFUGAL FORCE
OF ROTOR END WINDINGS, IT IS SHRUNK FITTED AT ONE END

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 Salient pole rotor
The individual rotor poles protrude from the center of the rotor,
characterized by;
concentrated windings,
non-uniform air gap,
larger rotor diameters,
used in applications requiring low machine speed and a large number of
machine poles (example hydroelectric generation).

The salient pole rotor does not provide the mechanical strength
necessary for these high-speed applications. Also, the salient pole rotor
presents too much wind resistance when rotating at high speeds

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Salient pole rotor

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 Cylindrical rotor -
The individual rotor poles are produced using a slotted cylindrical rotor,
characterized by:
Winding distributed symmetrically, concentrically in corresponding
positions on opposite sides of a pole,
nearly-uniform air gap,
smaller rotor diameters,
used in applications requiring high machine speed and a small number of
machine poles, typically 2 or 4 poles (example - steam or gas turbine
generators).
The cylindrical rotor is typically a solid piece of steel (made from a single
forging) for reasons of strength given the high rotational speeds to which
the rotor is subjected
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ROTOR -Winding

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 ROTOR SLOT

Rotor Wedge

Top Slot Liner

Conductor

Inter turn Insulation

Slot Liner

Sub Slot

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 ROTOR

ROTOR forging 2 pole

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 ROTOR POLE

ROTOR forging 4 pole

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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 wedges
The wedges that hold the rotor winding in the slots are always highly
stressed

The wedges must hold the copper winding and its insulation systems in
place at high rotational speeds

Allow cooling gas to pass through them.

The wedges do not usually sit tight in the slots. They have a loose fit,
relatively speaking, to allow the copper winding underneath to expand
axially during operation.

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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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 Retaining Rings

Required to hold the end-winding copper of the rotor winding against

centrifugal loading during operation..

Retaining-rings are generally the most highly stressed component in the

generator.

Nonmagnetic materials have been the main choice for retaining-rings

because of their electromagnetic high reluctance.

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ROTOR Retaining Ring

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ROTOR Retaining Ring

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ROTOR END WINDING

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COOLING OF ROTOR WINDING

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CONNECTION OF EE COUPLING

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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 General Arrangement

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GENERATOR COOLING SYSTEM.

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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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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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 Synchronizing Procedure
The process of paralleling a synchronous machine onto infinite busbars is
known as synchronizing.
Before a synchronous generator can be synchronized onto live busbars,
the following conditions must be satisfied:
the voltage of the generator must be equal to that of the busbars;
the frequency of the generator must be equal to that of the busbars;
the phase sequence of the generator must be the same as that of the
busbars; and
at the instant of synchronizing, the voltage phasors of the generator and
the busbars must coincide.

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 EXCITATION SYSTEM

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 20C U-O / V-O / W-O : .0043
ohms

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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 20 c)
Rotor winding resistance
at 20C U-V / U-W / V-W : .00064 ohm
Fuse Rating : 750 V / 400 amps
Fuse resistance : 350 ohms
No of Diodes/rectifi. Wheel : 30

No of fuses blown per bridge arm 2 fuses switch off field

forcing
3 fuses shut down

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BRUSHLESS EXCITER
FEATURES:

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 EXCITER
PMG Main Exc. Rectifier Gen. Gen.
Rotor Rotor Assembly 3 phase o/p Rotor stator

Main Exc.
PMG Stator
Stator
CT

AVR
PT
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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 Stator

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Main Exciter Stator

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 Exciter Rotor Assembly

Rotating Diode
Wheels
Main Exciter
Rotor

PMG Poles Cooling Fan

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Generator & Exciter
3200 Amps 420 Volts

MAIN
PMG
EXCITER
GENERATOR

3,
105 Amps
DIODE WHEELS
220 Volts,
400 Hz 26 Amps
60 Volts CT
AVR 3 , 10286 Amps
16500 Volts
PT

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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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COOLING OF EXCITER

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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 - 02
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 - 03

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
Month DD YYYY
 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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Capability limiters
synchronous generator capability limiters are as follows
1.MVA or armature current limit of generator: this depends on the cooling
system of generator so that temperature rise in generator is limited to safe
value. depending on cooling system effectiveness and temperature limit for
the insulation used in generator, MVA limit is decided.
2.MW limit: this is determined by the power output capacity of prime mover to
which generator is connected.
3.rotor angle limit: this is related to stability of generator which is
synchronised to the grid. ideally this could be 90 degree, but in practice this is
limited to70 degree so as to have better stability margin in transient and
dynamic condition. the generator falls out of synchronism in transient
condition if rotor angle is close to 90 degree.
4. rotor current limit: the field winding placed on rotor has got limited current
carrying capacity, beyond which it may burn .so this limit is used.
all these limiters make capability curve of g generator within which the
generators operates safely

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 STATOR WINDING

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