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TYPES OF HYDRO-TURBINES :
A) Reaction Turbines
1.Francis
2. Kaplan
3. Propeller
4. Bulb
B) Impulse Turbines1. Pelton
Head Range
2m
to
70 m Kaplan
30m to
450 m Francis
300m to
1700 m Pelton
VALVES:
There are two types of valves:
1.Spherical valve: It is used where the head is high, i.e. to sustain high pressure.
(For Heads above 200m)
1.
2.Butterfly valve: It is used where the inlet pressure of water is comparatively
lower.
(For Heads above 200m)
HEAD CALCULATION
• Avg. Gross Head = MDDL + 2/3(FRL - MDDL) -TWL(4 UnitsRunning)
= 203 + 2/3(208 - 203) -184.24
= 22.09 m.
• Rated/Net Head = Avg. Gross Head - Head Loss
= 22.09 - 0.75
= 21.34 m.
• Max. Gross Head = FRL - min TWL= 208.00 - 181.78= 26.22 m
• Max. Net Head
= Max. Gross Head-Head Loss
= 26.22-0.75
= 25.47 m
• Min. Gross Head = MDDL - TWL(4 Units Running)
= 203.00 - 184.24
= 18.76m
• Min. Net Head
= Min. Gross Head - Head Loss
=18.76 - 0.75
=18.01 m.
SELECTION OF MACHINE SPEED
• Fromeconomical point of view, the turbine and generator should have the highest
practicable speed to develop given hydropower for given design head.However,
final speed may be selected considering the following parameters:
• Variation of head,
• Silt content,
• Cavitation,
• Vibrations,
• Drop in peak efficiency etc.
• From the available formulae, the specific speed for a specific head is calculated.
Then for even number of poles of generator, rated speed is obtained. On the basis
of this rated speed, corrected specific speed is calculated.
CALCULATION OF SPEED:
• Specific speed w.r.t. Head
– Kaplan Turbine, Ns = 2570 * H-0.5
….HARZA
= 2334 * H-0.5
….USBR
– Francis Turbine, Ns = 3470 * H-0.625
….HARZA
• Rated Speed
–N = Ns * H5/4 * P-1/2
• Synchronous speed (N=120f/p) nearest to Rated speed obtained from above
formulae is selected.
•Corrected Specific speed, Ns = N * P1/2/H5/4
HYDRO GENERATORS
Hydro Generators are low speed salient pole type machines.
Rotor is characterized by large diameter and short axial length.
Capacity of such generator varies from 500 KW to 500 MW.
Power factor are usually 0.90 to 0.95 lagging.
Available head is a limitation in the choice of speed of hydro generator.
Standard generation voltage in our country is 3.3KV, 6.6KV, 11 KV ,13.8 KV, &
16KV at 50 Hz.
Short Circuit Ratio varies from 1 to 1.4.
CLASSIFICATIONS
Classification of Hydro Generators can be done with respectto the position of rotor
( i) Horizontal
(ii) Vertical (two types)
a) Suspension Type
b) Umbrella Type
GENERATOR BARREL
Di (Air gap diameter, select from fig. 8 on page no. 25 of BHEL curve)
Da (outer core diameter)
Df (Stator frame diameter)
Db ( Inner diameter of generator barrel)
UMBRELLA TYPE GENERATOR
COMBINED LOWER THRUST & GUIDE BEARING
SELECTION OF NO. OF POLES
Nsyn (Sync. Speed) = 120 F
P
Synchronous Speed Of The Generator Depends Upon The Specific Speed Of The
Turbine
Nsyn = Ns X Hn1.25 / Pt0.5
EXCITATION SYSTEM – COMPONENTS
EXCITATION SYSTEM – COMPONENTS
1.EXCITATION TRANSFORMER (DRY TYPE )
2. RECTIFIER SYSTEM
3.AUTOMATIC VOLTAGE REGULATOR
4.FIELD FLASHING UNITS
5.FIELD CIRCUIT BREAKER
6. DISCHARGE RESISTOR
AIR COOLING SYSTEM
Generator is provided with a closed, recirculating air cooling system
The cooling pressure is created by fanning action of rotor spider
The air circulates through radial ducts provided in the rotor rim which allows a
cooling air flow to be distributed radially and uniformly all along the machine axis
The air circulation path is
spider-> rim -> inter-pole areas-> stator winding-> stator core radial duct-> air
coolers-> lower and upper floors-> lower and upper air baffles-> spider
BRAKING AND JACKING SYSTEM
The hydro generators are provided with mechanical friction braking system which
helps to stop the generator’s rotation after unit is stopped / tripped off-line
The brakes are normally applied when the unit speed is slowed down to less than
25% of the rated speed to avoid wearing of thrust bearing pads
Brake shoes situated on the lower bracket are pressed against the brake tracks on
the rotor to bring the machine to the rest
Brake shoes are also used as jacks for lifting of the rotor for which the oil under
pressure (about 100 kg/cm2) is fed from high pressure pump unit.After jacking the
rotor can be maintained in lifted position by turning the locking nut and releasing oil
pressure.
In modern hydro electric generators specially Pelton wheels, electrical dynamicbraking is used
in addition to mechanical braking system which will reduce wear onthe mechanical brakes
The dynamic braking is initiated at around 50% of rated speed and maintaineduntil mechanical
friction brakes are applied which are normally applied at 10 -15% inconjunction with dynamic
braking
Fig 22. T.G. Set Section
DESIGN STUDY
OUTPUT COEFFICIENT
(derived from output equation of AC machines) (Pg-456,AK Sawhney)
Output Equation:Q = C0 * D2 * L * Ns
Where, output coefficient, C0 = 11 * Bav * ac * Kw * 10^(-3)
Q = kVA rating of machine
Bav = specific magnetic loading
ac = specific electrical loading
Kw = winding factor
From these equations we can infer that the volume of active parts is inversely
proportional to the value of output coefficient C0. Thus an increase in value of
Results in reduction in size and cost of machine and so looking from the economics
point of view the value of output coefficientshould be as high as possible.
Now we see that output coefficient is proportional to specific magnetic and
electricloading.Therefore the size and cost of the machine decreases if we use increasedvalues
of specific magnetic and electric loading. Hence economically these valuesshould be as high as
possible. their limit is decided by analyzing the effect ofincreased loadings on performance
characteristics of machine. Too high values mayhave adverse effects on temperature
rise,efficiency,power factor(in case of inductionmotors) and commutation conditions (in case of dc
machines).Therefore optimumvalues are selected.
We can calculate the output coefficient from a graph (Large AC Machines, JH Walker, Figure
1-1 page 4.) if we know the number of poles of the machine. The graph is obtained by
analyzing the published data of 40 generators in manufacture in USA, Canada, UK,
Japan a Europe
MACHINE PARAMETERS
Bore Diameter : It is the inner diameter of the stator core.
Flywheel Effect:
(or Mechanical Inertia is defined in terms of the start up time
of the unit)
(Standard Handbook of Powerplant Engineering
by Thomas C. Elliott, Kao Chen, Robert Swanekamp)
Tm = (WR2 * n2) / [(1.6 * 10^6)P]
Where n = rotational speed of unit in rounds/min
P = full gate turbine capacity in H.P.
WR2 = Product of revolving parts of unit and square of radius of gyration
(turbine runner, shaft and generator rotor), lb-ft2
For preliminary design studies in which the unit WR2 is not known, its value may
be
estimated from the following U.S. Bureau of Reclamation formulas:
Turbine WR2 = 23,800 [P / n^(3/2)]^(5/4)
Generator WR2 = 356,000 [kVA / n^(3/2)]^(5/4)
The heavy pole pieces produce a flywheel effect on a slow speed rotor. This helps to
keep the angular speed constant and reduce variations in voltage and frequency of
the generator output.
In our design we have used the formula:
Flywheel effect (GD2) is computed as follows:
Generator WR2= 15000 x (KVA/ N3/2)5/4
Where KVA = Unit rating in KVA
N= Unit speed in RPM
Page no. 1.51. Power Engineer’s Handbook by TNEB Engineer’s
Association, Chennai
GD2 = 4 x WR2
Number of poles :
Can be calculated as P=120f/N
Number of poles :
Can be calculated as P=120f/N
Where f =frequency of output
N=speed of the rotor
Air gap Diameter calculation (same as bore diameter)
a.Di Obtained from BHEL graph (Air Gap diameter)
b.Di= (60 * Vr) / (pi * N)
pi=22/7
Where Vr = Max. Peripheral velocity.
It can be obtained from Fig. 1-2 Page 5, Large AC Machines by J.H.
Walker
The bigger of the above two diameters is selected.
Stator Core and frame length calculation:
Stator core length is the gross length of the stator. It can be calculated using
the formula for output coefficient.The output coefficient can be obtained from
graph and air gap diameter calculated above. Once these two are known
stator length can be calculated using the formula:
Stator core length,Lt = W/ (Ko* Di2 * N)
Where W = Rated KVA of machine
Ko = Output coefficient obtained from curve
(Fig 1-1, Page 4, LargeAC Machines by J.H. Walker.)
N= Rated RPM of the machine
And Y =Pdsecθ3/2
or glass rovings.
The two vertical stacks used are also insulated from each other.
Further the eddy current loss in the top coil side is more than that in the lower
one so there is a difference in the rise of temp of the two.
This temp rise difference is reduced by increasing the no of strands in the top coil
sidethere by reducing the thickness of the strands in the top coil side.
To reduce the circulating current losses it is essential to use some form of
transposition of conductor laminations in the slots.
In the transposition each conductor lamination is arranged to move continuouslythrough all
positions in depth of coil side so that the leakage reactanceof all theconductor laminations is
equalized so that no circulating current flows. Roebeltransposition is widely used for this purpose
Bitumen mica folium applied to the slot portion of the bar while mica tape onthe overhang portion
was most commonly used insulating materials earlier.The mica tape 0.13 mm thick and 20 mm
wide is wrapped by hand up to 20half layers. So this process is both time consuming and
expensive.
2.Epoxy Novalak mica paper insulation system:
The rows of conductor stacks are bound with epoxy based resins. This is
done by usingtwo highly loaded epoxy glass separators. The stack is then
pressed at 160 degree Celsius to form a rigid mass. This type of construction
does not require the filling of external voids.
The over hang insulation is in the form of a no of layers offlexible isopthalatevarnished polyester
backed mica flake tapes. The insulation of the slot portionconsists of a no of half lap layers of
epoxy novalak bonded glass backed micapaper tape.
This system permits the machine to be operated at a higher temp rise due to
its greater thermal conductivity.
Multi turn coil:In this type of coils an additional insulation between between
individual turns has to be provided. The interturn insulation mustbe designed to
withstand surges of magnitude 1.5 times of the line voltages.
The inter turn insulation used is mica tape half overlap and asbestos. The thickness
of the mica tape is 0.13 mm and that of asbestos 0.38 mm.
Multi turn coils epoxy novalak mica paper system : The epoxy novalak mica paperinsulation used
is different for the slot portion of the conductor and the over hang.Novalak mica paper tapes are
used for the slot portion while isopthalate varnishedmica flake tapes are used for the over hang.
(source: Pg-744, A.K.
Sawhney)
WINDINGS
TWO TYPES:
1.Concentrated windings:these the mainly used in design of field windings
for salient pole machine
2.Distributed windings: are used in stator and rotor of all the ac machines
ARMATURE WINDINGS:
1. Closed windings: are used for dc machines and ac commutator
machines .
2.Open windings : are used only for ac machines like synchronous
machines and induction machines.
Related Terms:
1. Pole pitch
:
peripheral distance between adjacent
poles.
2. Coil span
:
peripheral distance between two coil sides.
3.Full pitch coil
:
coil span = pole pitch
4. Chorded coil
:
coil span < pole pitch
CLOSED WINDINGS :
Two types:
1. Lap windings
: a=P
2.Wave windings:a = 2
Where,a = no of parallel paths
P = no of poles
Lap Windings :
yb= 2C / P +/-K
yw= yb– yf= 2
yc= 1
Where,C = no of coils
P=no of poles
yc= commutator pitch
yb= back pitch
yw= winding pitch
K=Fraction or integer such thatyb is an odd integer.
Wave windings :
yc=(C + 1) / (P/2)
yw= 2 yc
y w= y b + y f
Where,C = no of coils
P=no of poles
yc = commutator pitch
yb = back pitch
yw= winding pitch
Note: Above relations are given only for progressive windings
as
retrogressive windings are rarely being used.