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.
50MW BRUSH DAX turbogenerator in
Columbia.
Cunard Line’s 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.
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 BRUSH’s ability to meet the demanding interface requirements of the
turbine manufacturers, coupled with competitive prices and keen deliveries.
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 155°C (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.

A completed BDAX 98-330ER generator
for GE LMS 100 gas turbine drive.
Typical rotor of a 55MW DAX generator.
Steam turbine driven DAX generator with
top mounted water cooled heat
exchangers, Florida, USA.
The exciter armature and rotating rectifier
of a typical brushless exciter.
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 Company’s rotor overspeed test facility, which
is equipped with comprehensive monitoring equipment.
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.
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.
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.
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 ANSI.

Specifications Voltage range: Up to 20kV

Speed: 3000 rev/min for 50Hz operation
3600 rev/min for 60Hz operation
Excitation: BRUSHless or static
Drive: Single or double end
Output range: 10 to 300MVA - also capable of synchronous compensator
operation.
Cooling: Open circuit, filter ventilated
Closed air circuit, water cooled
Closed air circuit, air cooled

Experience BRUSH DAX generators have been supplied for the following turbines/companies:

Industrial Units delivered Aero Derivative Units delivered Steam Units delivered
Gas Turbines up to Dec 2005 Gas Turbines up to Dec 2005 Turbines up to Dec 2005

General Electric Frame 5 275 General Electric LM 2500 171 Allen Power 1
General Electric Frame 6 101 General Electric LM 2500+ 46 Dresser Rand 1
General Electric Frame 7 110 General Electric LM 5000 57 Elliott Company 6
General Electric Frame 9 37 General Electric LM 6000 388 General Electric 3
Siemens Westinghouse W251 51 General Electric LMS 100 3 Hitachi 1
Siemens Westinghouse W501 46 Pratt & Whitney FT4 53 Mitsubishi Heavy Industries 17
Siemens Westinghouse W701 13 Pratt & Whitney FT8 98 Shin Nippon Machinery Co 3
Mitsubishi MF 111 5 Rolls-Royce Avon 1 Siemens 60
Alstom GT11 3 Rolls-Royce Spey 6 Skoda Power 1
Siemens GT35 2 Rolls-Royce Olympus 100 Toshiba 1
Rolls-Royce RB211 10
Rolls-Royce Trent 7

BRUSH ELECTRICAL MACHINES Ltd BRUSH HMA b.v. BRUSH SEM s.r.o. BRUSH TURBOGENERATORS Inc.
PO Box 18, Loughborough, PO Box 3007, 2980 DA Ridderkerk Edvarda Benese 39, 301 00 Plzen Houston,
Leics. LE11 1HJ, England The Netherlands Czech Republic Texas, USA
Tel: +44 (0)1509 611511 Tel: +31 180 445500 Tel: +420 37 8210111 Tel: +1 (281) 580 1314
Fax: +44 (0)1509 610440 Fax: +31 180 445866 Fax: +420 37 8210214 Fax: +1 (281) 580 5801
E-mail: sales@bem.fki-et.com Email: sales@hma.fki-et.com Email: sales@sem.fki-et.com admin@houston.rm.fki-et.com
Web: www.fki-et.com/bem Web: www.fki-et.com/hma Web: www.fki-et.com/sem Web: www.fki-et.com

SM0000247E 10/2006