Académique Documents
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Alternator Training
Date : 28.02.07
Place : C.E.S.C.
P.D.P.L
Alternators
P.D.P.L
Alternators
PRINCIPLE OF OPERATION OF SELF EXCITED, SELF REGULATED MACHINES
OUTPUT
Reference
Sensing
AVR Output of AVR
Power
EXCITER
MAIN ROTOR ROTOR
ROTATING
CLOCKWISE RECTIFIER
ROTATION ASSEMBLY EXCITER
MAIN STATOR
FROM DRIVE STATOR
END
P.D.P.L
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.
P.D.P.L
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.
P.D.P.L
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.
P.D.P.L
Alternators
ROTATING RECTIFIER ASSEMBLY
Aluminium Plate + ve
Forward
Diodes
+ ve
To Main Rotor
Exciter - ve
Rotor
Reverse Surge
Diodes Suppressor
Aluminium Plate - ve
P.D.P.L
Alternators
Rating
Output KVA
Power factor
Frequency
Alternators
Type of load
Linear load.
Non linear load.
P.D.P.L
Alternators
Types of load
Linear load
Alternators
Alternators
Alternators
Motor loads
Auto transformer
65 % tapping 4 x full load current.
80 % tapping 4.8 x full load current.
P.D.P.L
Alternators
Alternators
Derating on Alternators
Alternators
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
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
To
Busbars Load
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Alternators
Parallel Operation
V A Hz
kW
p.f.
12 O'CLOCK POSITION
S F
SYNCHROSCOPE LAMPS
SYNCHRONIZING PANEL
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Alternators
Load Sharing
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.
P.D.P.L
Alternator Maintenance
P.D.P.L
Alternator Maintenance
Introduction
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
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.
Alternator Maintenance
Alternator Maintenance
Connection checks
Alternator Maintenance
Alternator Maintenance
Alternator Maintenance
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.
P.D.P.L
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
EXCITER
MAIN ROTOR ROTOR
ROTATING
CLOCKWISE RECTIFIER
ROTATION ASSEMBLY EXCITER
MAIN STATOR
FROM DRIVE STATOR
END
P.D.P.L
Alternator Maintenance
Alternator Maintenance
Alternator Maintenance
Caution
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.
P.D.P.L
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.
Alternator Maintenance
Loss of residual
Alternator Maintenance
Alternators
DIODE CHECKING WITH MULTI-METER
- ve + ve
Cathode
Forward Bias Reverse Bias
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
Alternator Maintenance
Don't s
Alternator Maintenance
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
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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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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16 PROBLEM OF BOTH SPEED AND VOLTAGE IN CASE OF SUCH LOOSE CONNECTION/S, THE SAME
HUNTING TOGATHER CAN BE SOLVED ONLY BY WILL GET CORRECTED WHILE REPLACING THE AVR
METHOD OF ELIMINATION OF DOUBT.ELIMINATE AND PROBLEM WILL BE SOLVED. THIS MAY RESULT IN
DOUBT ON AVR BY REPLACING THE SAME WITH A UNNECESSARY REPLACEMENT OF AVR.
SERVICE AVR ONLY AFTER ENSURING THERE WAS
NO LOOSE CONNECTION IN THE ORIGINAL AVR
INPUT/OUTPUT CONN
17 IN HIGH HUMIDITY ENVIRONMENT, ADVICE THE CHANCES OF MOISTURE ABSORPTION ARE HIGH IN
CUSTOMER, IN WRITING, TO INSTALL SPACE HUMID ENVIRONMENT. THE PROCESS TAKES PLACE
HEATER. 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
18 IN CASE REWINDING OF COMPONENT IS TO ENSURE THE QUALITY OF REWINDING AND TO
REQUIRED, ADVISE THE CUSTOMER IN WRITING, PREVENT ISSUES IN CASE OF A FAILURE AFTER
TO SEND THE ALTERNATOR / COMPONENT TO REPAIRS.
AUTHORIZED REWINDERS ONLY.
P.D.P.L
Thank You