BRUSH TURBOGENERATORS

POWER WORLDWIDE

DAX 2-POLE TURBOGENERATORS

Equipment supplied to over 130 countries Over 120 years of electrical experience

Corby Power Station, UK, incorporating three BRUSH DAX turbogenerators.

Gas turbine driven DAX generator at Kipevu Power Station, Kenya.

Introduction
BRUSH DAX cylindrical rotor, air cooled generators are extensively used in public utility, cogeneration, CHP, industrial and offshore applications. These generators are designed to be driven by both steam turbines and gas turbines, with extensive operational experience of both applications. BRUSH has more experience of the use of gas turbines than any other generator manufacturer in the world and has also supplied machines to a large number of the major steam turbine companies. The continued success in both gas turbine and steam turbine power generation can be attributed to BRUSHs ability to meet the demanding interface requirements of the turbine manufacturers, coupled with competitive prices and keen deliveries.

50MW BRUSH DAX turbogenerator in Columbia.

Stator
The stator frame is a rigid structure, fabricated from mild steel plate and designed to withstand the mechanical stresses imposed during operation and under accidental short circuit conditions. Mounting pads are incorporated at appropriate points on the underside, with holes in each pad for foundation bolts. The core is built up from segmented laminations of low-loss, high permeability, high silicon content electrical steel. Radial ventilation ducts are formed at intervals along the core by H section steel spacers. The core is hydraulically pressed at predetermined stages during the building operation to ensure uniform compaction, the pressure being carefully monitored, and the finished core is clamped between heavy endplates. The stator winding is of the two layer diamond type, half coils being used for ease of handling during manufacture and winding. The insulation system is based on a resin rich mica glass tape which, when processed, results in a high performance insulation capable of continuous operation at temperatures up to 155C (Class F). The half coils are placed in the stator slots in two layers and wedged securely in position by polyester glass wedges prior to connection of the endwinding. The endwinding is securely braced to insulated support boards bolted to the core endplate. Spacer blocks are fitted between adjacent coil sides to produce a strong archbound, yet resilient, composite structure, capable of withstanding the forces that could arise in the event of an accidental short circuit. Finally, the completed stator is heated in an oven to fully cure the insulation.

Cunard Lines Queen Mary 2, the 17th cruise liner to use DAX generators for main power generation.

Connecting up the half coils to form the stator winding of a 100MW DAX turbogenerator.

Rotor
The rotor of a BRUSH DAX turbogenerator is manufactured from a one-piece forging of nickel chromium molybdenum alloy steel which is de-gassed and vacuum poured to obtain a uniform material which has excellent tensile properties. Axial slots, to carry the windings and for ventilation, are milled on the periphery of the body of the rotor. The rotor winding conductor material is high conductivity copper/silver alloy strip. The pre-formed coils are inserted into the slots, each turn being insulated from the next. The class F insulation system is moisture resistant, shockproof and capable of withstanding the high mechanical forces to which it will be subjected. After completion of the winding, the conductors are heated electrically and pressed to the correct depth using pressing rings. The conductors are held in place by aluminium alloy retaining wedges, which are connected together at each end by copper quarter-rings to form a fully interconnected damper winding. The rotor endwinding is braced with packing blocks between the conductors and is wrapped with insulation, after which the rotor endcaps are fitted. The endcaps, which retain the rotor endwinding, are maufactured from austenitic non-magnetic 18-18 manganese chromium steel. All completed rotors are tested in the Companys rotor overspeed test facility, which is equipped with comprehensive monitoring equipment.

A completed BDAX 98-330ER generator for GE LMS 100 gas turbine drive.

Bearings
The main bearings are normally fixed profile, white metal lined, hydrodynamic cylindrical or elliptical bearings. Other profiles, including tilting pad bearings, may be used for specific applications.
Typical rotor of a 55MW DAX generator.

The thrust bearings can be provided where necessary to suit particular turbine or site conditions.

Cooling
BRUSH DAX turbogenerators are cooled by air, either in open circuit or closed air circuit configuration. The generator internal system is similar in all cases. Cooling air is forced around the generator by means of two axial flow fans mounted on the rotor shaft. Cooling circuits are designed to cool the windings as uniformly as possible.
Steam turbine driven DAX generator with top mounted water cooled heat exchangers, Florida, USA.

Open ventilated generators are cooled by ambient air drawn into the machine through filters and exhausted through an outlet duct connected to the stator air outlet flange. Site considerations such as severe desert conditions, extremely salty atmospheres or unsuitably contaminated environments may necessitate the use of a closed air circuit machine, where the hot exhaust air is cooled by a secondary coolant before being returned to the inlet. The secondary coolant is usually water but, in some cases, may be air.

Excitation system
The majority of the BRUSH DAX range of turbogenerators are fitted with brushless excitation systems. The brushless exciter consists of a three phase, rotating armature, alternating current generator, with a shaft mounted fused rotating rectifier. The field winding is stationary. The brushless concept enables the exciter output to be connected to the generator field without the use of commutators, brushgear or sliprings. Double end drive generators use a brushless exciter that is capable of transmitting the full power from one of the turbines.
The exciter armature and rotating rectifier of a typical brushless exciter.

As an alternative, a static excitation system is available. In this system, power is taken from the generator output through suitable transformers and fed back to the main field via a controlled rectifier, brushgear and sliprings.

Features

The BRUSH DAX range of turbogenerators has the following features: Simple foundation design for economic and speedy civil work. Minimum number of individual power station components, offering substantial savings on expensive site time. All units are fully factory tested, reducing commissioning to proving interconnections and combined turbine/generator testing. Modular construction giving a fine balance between flexibility and standardisation of components for fast economic construction. Fully developed system readily adapted to any turbine design. Fully compliant with the provisions of the relevant international standard specifications, including IEC and IEEE.

Specifications

Voltage range: Speed: Excitation: Drive: Output range: Cooling:

Up to 20kV 3000 rev/min for 50Hz operation 3600 rev/min for 60Hz operation Brushless or static Single or double end 10 to 300MVA - also capable of synchronous compensator operation. Open circuit, filter ventilated Closed air circuit, water cooled Closed air circuit, air cooled

Experience
Industrial Units delivered Gas Turbines up to December 2007 General Electric Frame 5 General Electric Frame 6 General Electric Frame 7 General Electric Frame 9 Siemens Westinghouse W251 Siemens Westinghouse W501 Siemens Westinghouse W701 Mitsubishi MF 111 Alstom GT11 Siemens GT35 275 109 110 75 51 46 13 5 3 2

BRUSH DAX generators have been supplied for the following turbines/companies: Aero Derivative Units delivered Gas Turbines up to December 2007 General Electric LM 2500 General Electric LM 2500+ General Electric LM 5000 General Electric LM 6000 General Electric LMS 100 Pratt & Whitney FT4 Pratt & Whitney FT8 Rolls-Royce Avon Rolls-Royce Spey Rolls-Royce Olympus Rolls-Royce RB211 Rolls-Royce Trent 190 61 57 451 5 53 145 1 6 100 10 14 Steam Turbines Units delivered up to December 2007 1 1 1 6 4 1 1 20 5 63 6 1

Allen Power Dresser Rand EKOL Spol Elliott Company General Electric MAN Turbo Hitachi Mitsubishi Heavy Industries Shin Nippon Machinery Co Siemens Skoda Power Toshiba

Certificate No 21024

Certificate No 21025

Certificate No 936683

Certificate No 00282

Certificate No 00066

BRUSH ELECTRICAL MACHINES Ltd Falcon Works, Nottingham Road, Loughborough, Leics. LE11 1EX, England Tel: +44 (0)1509 611511 Fax: +44 (0)1509 610440 E-mail: salesuk@brush.eu Web: www.brush.eu
SM0000247H

BRUSH HMA b.v. PO Box 3007, 2980 DA Ridderkerk The Netherlands Tel: +31 180 445500 Fax: +31 180 445566 Email: salesnl@brush.eu Web: www.brush.eu

BRUSH SEM s.r.o. Edvarda Benese 39, 301 00 Plze Czech Republic Tel: +420 37 8210111 Fax: +420 37 8210214 Email: salescz@brush.eu Web: www.brush.eu

BRUSH TURBOGENERATORS Inc. 15110 Northwest Freeway, Suite 150, Houston, Texas 77040, USA Tel: +1 (281) 580 1314 Fax: +1 (281) 580 5801 Email: salesus@brush.eu Web: www.brush.eu
11/2008