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1. SALIENT FEATURES OF 210 MW GENERATORS (TS

II/STAGEI)
1.1 GENERAL DESCRIPTION
The maximum continuous rating of the 210 MW generator erected in the
Thermal Station II is 247 MVA and is hydrogen cooled. The generation
voltage is 15KV with 5% variation on either side. The rated full load current is
9507A and the rated power factor is 0.85 lagging. The generator is cooled by
hydrogen and is maintained at a pressure of 3.12 Kg/Cm 2 at normal working
conditions. The maximum temperature of hydrogen at the extreme ends of
the generator (i.e.) the cold gas temperature allowed is 46 oC. The volume of
the gas inside the stator is 54.5M 3. The maximum allowable rise in stator and
rotor winding temperature rise is 74oC and 64oC respectively.

1.2 GENERATOR STATOR

Generator stator consists of the following components, the details of
which are given below.

1.3 HOUSING
The generator housing and enclosing ends are fabricated from steel
plate, which is rolled and welded to form the required shapes.

1.4 STATOR CORE

The stator core consists of a series of laminations pressed by a
hydraulic press during the stacking. Pressure is applied by a clamping
arrangement to ensure a tight core. The case is treated to protect it from rust

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formation. The core is permanently mounted in the outer housing. This
mounting is flexible.

1.5 FLEXIBLE MOUNTING

The magnetic attraction between the poles of rotor and the stator core
induces a double frequency vibration in the core. Transmission of this
vibration to the generator frame and foundation is largely avoided by a
flexible support between the inner and outer members of the housing. The
mounting is such that the little of the core vibration is transmitted to the
housing, but the core is rigidly restrained against load and short circuit
torques.

1.6 ARMATURE COILS

The copper strands which make up the armature coils are transposed
internally so that eddy currents are reduced. The coils are made in halves
and the ends are connected with an additional transposition to eliminate
eddy currents arising from end flud effects and to eliminate circulation of the
currents due to radial fluxes passing through the coils in the end zone.
The stator coils are insulated with Thermaclastic insulation. The
portions of the coils embedded in the slot are treated with a semi conducting
varnish and CORONOX is applied to the portion of the end turns to suppress
corona activity.

1.7 MAIN AND NEUTRAL LEADS

The main leads and the neutral leads are brought out through bushings
in the generator frame. These bushings provide both internal and external

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creep age distance required for the rated voltage. The lead connectors and
main lead bushings are cooled by gas inside the generator.

1.8 TEMPERATURE DETECTORS

Temperature Detectors are located in the generator armature winding
and in the gas passages. Those located in the gas passages measure the
temperature of the gas leaving the coolers. The leads from these detectors
are wired through the frame to the gas tight terminal board.

1.9 GENERATOR ROTOR

The rotor is forged from high strength steel. An axial hole is provided to
check the properties of the forging and to carry the loads from the field
winding to the exciter.

1.10 ROTOR WINDING

The windings are placed in radial slots in the rotor. Insulating cells are
first placed in the slots, and the coils are then assembled a half turn at a
time. Each full turn is composed of U shaped copper straps facing each
other so as to form a hollow conductor. Strips of glass laminate bonded to
the copper provide insulation between turns. Suitably positioned holes are
provided in the conductors and the insulation to provide for passage of the
cooling hydrogen. The entire rotor is placed in an even with special pressing
tools which periodically tightened. Following the last tightening operation,
the oven treatment is continued until all resins are curved. After the coils and
insulation are baked the pressing tools are removed and suitable wedges are
driven in the tops of the slot to secure the winding against centrifugal force.

1.11 RETAINING RINGS

The rotor end turns are supported by high strong steel retaining rings,
which are shrunk fit at the end of the rotor body. To facilitate assembly of the
retaining ring, it is heated and placed on the hot rotor. The shrink fit of the
retaining ring will decrease when the rotor is brought to speed. To prevent
axial motion of the retaining ring relative to the rotor body, a circumferential
locking ring is provided. The ring is split and the ends at the split are
provided with special extensions, which are used to contract or expand the
locking ring during assembly of the retaining on the rotor.

1.12 VENTILATION
Circulation of the hydrogen is obtained by a blower mounted on the
turbine end of the shaft just outside the retaining ring. The blower is located
immediately after the cooler so that the gas temperature rise due to the
blower losses will not be added to the total temperature rises of the electrical
component. Cold gas leaving the coolers is carried by means of duct work to
the opposite end of the generator where it introduced into the ventilating
paths of the stator leads. The cooling gas passes from one end of the
generator in the other through these ventilating paths the generator in the
other through these ventilating paths being discharged at the turbine end
where it passes from again through the blower and is re circulated through
the cooler.
A portion of the cold gas leaving the coolers is also diverted by means
of baffles and ventilating passages through the rotor. A portion of this gas

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enters the rotor at each end, flowing through the ventilating passages
provided in the rotor winding itself and is then discharged into the air gap at
the centre of the rotor where it is drawn back to the blower and re circulated
through the cooler on 2 pole rotors, the end turns have a ventilation circuit
separate from the straight portion of the winding. A special pattern of holes
is drilled radically in the end turns and cold gas from the coolers passes
directly into these holes at both ends of the rotor. This gap flows through
hollow passages in these end and is then discharged into the passages in the
straight portion of the rotor, and is then discharged into a special chamber
beneath the end turn winding near the centre of the pole from these it is
discharged into the air gap and then returns to the blower.

1.13 BEARINGS
The spherical support seats, as well as the stop dowel, are insulated
from the bearing seat and insulation is provided between the top half of the
bearing and the baring keeper.
In addition, insulation is provided on both ends of the generator to
prevent shaft currents from flowing through the bearings between the gland
seals and brackets and between the gland seal and the feed and drain lines
and between the bearing oil seals and the brackets.

1.14 HYDROGEN GAS COOLERS

The hydrogen is cooled by passing through coolers where the gas gives
up its heat to the cooling water in the finned tubes of the cooler. The nozzle
end is bolted solidly to the generator frame while a diaphragm, which
permits the cooler to move freely with temperature changes, supports the

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top end. The top end is covered with a gas tight steel cover which must be
removed to clean the cooler tubes. There is a bypass valve from the
generator housing to the above gas tight cover to equalize the gas pressure
on both sides of the diaphragm for normal operation.

1.15 GLAND SEALS

The oil is fed to the feed grooves through passages in the supporting
brackets. The gland ring is provided to restrict the flow of oil through the
seal. This ring can move radically with the shaft, but it is restrained from
rotating by a pin to the supporting structure. Oil leaving the gland seal rings
is caught in chambers on each side of the seal; from which it is drained back
to the gland seal oil system.

1.16 COLLECTOR RINGS

D.C. excitation is delivered to the generator field by a static exciter
through two collector rings. The collector rings are made of tool steel. The
wearing face is spirally grooved so as to interrupt the small arcing in the
contacts which carry currents between the collector rings and brushes, thus
preventing current concentration in small brush face areas, and to secure
more intimate contact between the ring and the brush by allowing the
entrapped air to more readily escape. The rings are provided with ventilating
passages, which give additional cooling surfaces and also force the air to
circulate in the immediate vicinity of the rings.
The collector rings are connected to the rotor winding by means of
radial leads, which are connected to axial leads in the bore of the shaft. The

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connection between the radial and axial leads is so constructed to provide a
good electrical connection. Gas tight seals are provided at the radial leads at
both ends of the axial leads. The borehole in the rotor shaft is sealed by
means of steel plugs. A tapped hole in the plug at the collector end of rotor is
provided so that a leakage test of the radial lead seals can be made.

1.17 BRUSH HOLDER

The collector ring brush holders are designed to permit changing
brushes with the use of tools. It is possible to change one brush at a time.
A special spring maintains a constant pressure on the brush for all the
length of the normal wear of the brush itself.

1.18 ASPECTS RELATED TO THE OPERATION OF THE

GENERATOR
1.18.1INITIAL OPERATION
1. Before the generator is rolled it should be ensure that the bearing
lubricating system and seal oil system are operating normally and that
the generator is filled with hydrogen at the required normal pressure.
2. Generator winding temperature are to be noted.
3. Gas coolers are to be commissioned. It should be ensured that required
quantity of water flow through all the coolers. The maximum water
temperature is 38C. Each section of the cooler should be adjusted to
have the same water flow to prevent damage to the tubes due to
excessive water velocity. For this the throttling valve on the outlets of
the individual section is to be adjusted. The pressure drop across each
section is the difference between the readings of the pressure gauges
of the inlet and outlet of a given section.
4. IT should be ensured that seal oil cooler is commissioned and adequate
and amount of water at normal temperature flows.

5. The shaft insulation is to be checked as follows. An insulated copper

wire may be earthed solidly at one end. The exciter shaft may be
touched with the other end. When the generator is running at full
speed with excitation and no load. While removing if a small spark is
observed that shows the insulation is proper. If no sparking is observed
the insulations are to be checked for any grounding.

1.18.2 NORMAL OPERATION

1. The generator should be operated in accordance with the capability
curve. The cold gas temperature should be maintained below 46C.
2. The hot spot temperature in various elements of construction, such as
stator and rotor temperature gradient limits the capacity of the
generator across the insulation of the windings. Any one of those
points may be the limiting factor depending on the load, power-factor
and the gas pressure. Generally hot spot temperature cannot be
measured directly. Temperature of the windings where the temperature
detectors are located can only be measured.

1.18.3 STATOR WINDING TEMPERATURE

In the stator winding coolant is passed through the interior of the
stator coil from one end to the other end. The heat flow is inwards from
stator copper to the coolant. The amount of heat flow outward from copper
through the coil insulation is small. At low loads the heat flow may reverse in
some portion of the coil. Since at the end where the coolant leaves is hot.
Temperature detectors are provided to measure the temperature of warm
coolant discharged from each stator coil.

1.18.4 STATOR DIFFERENTIAL EXPANSION

The capability of the stator winding is limited not only by total
temperature but also by the effects of cyclic differential expansion within the
stator winding and between the stator coils and the stator core. The
differential expansion is a function of the temperature rise of the winding.
The maximum load of the machine has to be limited to limit the differential
expansion.

1.18.5 STATOR CORE TEMPERATURE

During operation at leading power factors that is under excited
operation, the flud distribution in the generator is such that high losses occur
in the first few centimetres of iron at the ends of the stator core. So the
temperature of the core becomes the limiting factor in operation, rather than
the stator or rotor temperature. The cold gas temperature is determined by
the ability of the hydrogen cooler to absorb heat from hydrogen assuming a
constant supply of water of fixed temperature to the hydrogen cooler. The
difference between an average hydrogen temperature and the average
water temperature depends upon the amount of losses to be absorbed. Thus
when the load is increased without changing the gas pressure, the
temperature difference between the gas and water must increase, with the
result that the cold gas temperature goes up.
Generator capability curve is drawn so as to limit the hot spot
temperature in the stator and rotor windings and in the stator core and to
limit the temperature differential across the insulation of the windings. These

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capabilities are determined by calculation and shop test and are not directly
determined during commercial operation.
Operation in the range between zero power factor (over excited) and
rated power factor is limited by rotor winding temperature. This curve gives
the operation with the field amperes constant at rated value.
The region between the rated power factor (over excited) and unity
power factor is limited by stator winding temperature. Operation on this
portion of the curve corresponds to constant stator current. Field current will
vary with load and power factor but will always be less than the maximum
allowable value. During under excited operations at any power factor stator
core temperature alone will become the limiting factor.

1.18.6 SHAFT ALIGNMENT

The variation in elevation of the generator shaft is a function of the
temperature of its supporting members. The temperature of the bracket and
the frame, which support it, varies directly with the cold hydrogen
temperature. Consequently the generator shaft elevation varies directly with
the cold hydrogen temperature. The generator should be operated so as to
minimise the possibility of misalignment between the generator and turbine
shafts during load changes. During operation cold hydrogen temperature
should not exceed 2C more than rated value.

1.18.7 FRAME DISTORTION

Changes in the cold hydrogen temperature hydrogen gas pressure
cause distortion of the frame ends. This may result in increased hydrogen

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leakage and maintenance. The performance of the gaskets is also adversely
affected by high temperature. The generator should be operated so as to
limit frame and gasket distortion by maintaining constant cold gas
temperature and hydrogen gas pressure.

1.18.8 HYDROGEN COOLERS

The flow of water through the hydrogen coolers should be controlled by
outlet valves to prevent excessive pressure in the cooler. The water flow is
adjusted to maintain the cold gas temperature at or below the limiting value.
Hydrogen coolers are arranged so that they may be operated with one
section taken out of service. The maximum load, which may be safely carried
with one cooler section out of service and rated hydrogen pressure, is at
least 66 % of the rated load at rated power factor. Under these conditions,
the cold gas temperature may be allowed to go maximum of 48C.

1.18.9 UNBALANCED OPERATION

During unbalanced load, the stator demagnetising m.m.f. is not
constant in magnitude and does not maintain a fixed position with respect to
rotor poles. With the rotor running at normal speed and the stator m.m.f.
pulsating at normal frequency double frequency e.m.f.s are induced in the
rotor body and in the field winding. These e.m.fs produce currents, which
flow in the wedges, retaining rings, and rotor body. The path of these
damping currents is from the rotor body and wedges. Unbalanced poly phase
loads have the same tendency to produce high rotor temperature as singlephase loads, as they must be considered to be balanced faults produce

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similar localised heating effects. Appropriate relay protection should be
provided to clear such faults in time.
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