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Stator Construction
WEG Group
Generator stator frame construction isolates normal core generated
double frequency vibration from the foundation and distributes
airflow to provide uniform temperatures in the core.
End Stacks
End Stacks
The end sections of the stator core are
The end sections of the stator core are
stepped back from the air gap to minimize
stepped back from the air gap to minimize
fringing flux and to reduce end iron
fringing flux and to reduce end iron
heating when the machine is operated
heating when the machine is operated
outside of the normal power factor range.
outside of the normal power factor range.
Installation of stator core clamping plates on lamination stack.
© Electric Machinery 2011. Publication NA.10004.gb.11-09.01. Electric Machinery, the Electric Machinery logo and any version thereof are trademarks and service marks of Electric Machinery.
The other names mentioned, registered or not, are the property of their respective companies.
2-Pole Turbine Generators
Rotor Construction
WEG Group
The rotor is designed to withstand cyclic duty and rapid loading.
Radial ventilation provides even cooling. Low vibration levels are
achieved by dynamic balancing and machine design.
Field Coils
s coils are made of silver-bearing
s Rotor
strap copper for greater creep
resistance. The coil is accurately formed
to precisely fit in the rotor slot with
minimum distortion. Ventilating slots
are punched in the straight portion of
the coils to allow for radial discharge
s of cooling air.
Rotor Forging and Machining Rotor Slots s Each field coil is suspended over a pole
and inserted, turn-by-turn, into the slots.
The rotor forging is a special alloy steel Slots for field windings are step milled over s
Individual turns are insulated with
containing nickel, chromium, molybdenum, the entire length of the rotor body. They
Nomex which is coated with a B-state
and vanadium. It has the physical are milled in a pattern to give the 2-pole
resin. The coils are pressed to a specified
properties required to withstand the configuration and also to provide liberal
size, then heated to cure the resin and
stresses encountered over a wide range area for field copper. Step milling
bond the turns. Aluminum alloy slot
of temperature and load conditions. The minimizes stress level at the roots of the
wedges are inserted to hold the winding
forging material is produced from an teeth, one of the most critical parts of the
firmly in place.
electric furnace vacuum degassed ingot. rotor. Grooves for slot wedges are
All forgings are heat treated after the accurately machined into the slot walls.
forging operation and stress relieved after Slots for rotor ventilation are positioned s s A teflon coated strip is placed on top of
rough machining. To control quality, a directly under the rotor coil slots and are the coils to help in providing a controlled
chemical analysis is made of each heat reduced width extensions of the regular slip plane for coil expansion and
cycle, and radial test samples are taken milled coil slots. s
contraction that occurs during start/stop
from the rotor body to indicate the physical and loading cycles.
properties. Longitudinal tensile and impact
test specimens are taken from the extra
material at the end of the forging. The
holes from which the radial samples were
taken are tapped and plugged with steel,
and are positioned to be at the centers of
the poles. The forging manufacturer
performs an impact test to determine the
low temperature ductility of the steel. In
addition, ultrasonic tests and magnetic
particle tests are made to assure that the
forging is sound.
Machining radial slots in rotor forging. Rotor slots for field winding.
Rotor retaining rings. Rotor winding process. Rotor end turn area.
© Electric Machinery 2011. Publication NA.10005.gb.11-09.01. Electric Machinery, the Electric Machinery logo and any version thereof are trademarks and service marks of Electric Machinery.
The other names mentioned, registered or not, are the property of their respective companies.
2-Pole Turbine Generators
Bearings and Seals
WEG Group
Bearing housings are bracket (and shield) mounted and provide
easy access. Pressurized seals prevent ingress of dirt. Pressurized
oil seals prevent the lose of oil or oil vapor.
Lubrication
The amount of oil entering the bearing
is metered so that just the right quantity
comes in contact with the journal. The
oil flows over the bearing surface in a
fan-shaped pattern. Oil flows outward
toward each end of the bearing where it is
collected in drain grooves and discharged
into the bearing housing. If any oil passes
the shaft seals which are located outside
the drain groove, it is thrown into a
secondary drainage area by a shaft slinger.
Metal labyrinth seals pressurized by rotor
fans prevent leakage of oil and vapor from
the housing.
Bearing Sealing
The bearing housings are part of the
bearing bracket structure and are
completely external to internal air passages
of the machine. Each bearing housing has
three labyrinth type seals that are
pressurized with high pressure air from the
shaft mounted blower. Along with slingers
machined in the shaft, an oil seal is
provided at the end of each journal to
prevent oil from escaping along the shaft.
The inner chambers of the oil seals are
vented to the atmosphere. An air seal is
provided at the entrance to the machine
to prevent foreign material or oil from
entering the machine.
Bearing House Seal Diagram.
Bearing Sleeves
Precision machined split type bearings are The bearings incorporate a generous load
designed with a spherical seat for supporting area in the lower sleeve.
alignment. After removing surface silicon Carefully designed clearances insure proper
and graphite, the ductile iron bearing lubrication and cooling. Adequate drains
shells are electrolytically etched by the are provided for end leakage. The bore is
Kolene process. The shells are then tinned elliptical to prevent oil whip. A bearing
and babbitted by centrifugal casting which temperature detector is inserted in the
insures a strong metallurgical bond lower half of each bearing in the load
between the ductile iron and the babbitt. carrying area. These detectors monitor
Only tin based babbit with high resistance bearing temperatures and may be used to
to corrosion is used. actuate alarms or shut-down circuitry.
WEG Group
Electric Machinery
800 Central Avenue NE
Minneapolis, Minnesota 55413
United States
Tel: +1 612 378 8000
Fax: +1 612 378 8051
www.electricmachinery.com
© Electric Machinery 2011. Publication NA.10006.gb.11-09.01. Electric Machinery, the Electric Machinery logo and any version thereof are trademarks and service marks of Electric Machinery.
The other names mentioned, registered or not, are the property of their respective companies.
2-Pole Turbine Generators
Stator Winding Construction
WEG Group
Class F stator insulation and Vacuum Pressure Impregnation (VPI)
is provided.
the stator winding process.
Strand Insulation
The strand insulation consists of polyester/
glass fibers.
Transpositions
individual turn in the end turn area.
Half coil strands are assembled using a
Roebel transposition.
Bonding
To prevent wire movement and provide a
uniform solid base for ground insulation,
the coil strands are bonded together under
heat and pressure with a thermosetting
adhesive.
Stator winding in progress.
Duraguard VPI Insulation Coil Forming
Duraguard VPI Insulation
System The coils are precisely formed using steel
System
The Duraguard insulation system is a forming cradles.
MICA Tape Ground vacuum pressure impregnated epoxy-mica
The Duraguard
insulation system thatinsulation system is a
offers the following Coil Insulation
Wall Insulation
vacuum
benefits: pressure impregnated epoxy-mica
insulation
system that offers the following turn insulation of multi turn coils is applied
DDGL Magnet Wire to each turn using mica glass tape.
benefits:
The main ground insulation is mica glass
Bonding Material s Full Class F (155°C) Thermal Capability
materials are applied to the outside of
s Outstanding Dielectric Properties
Resistance the coils.
The other names mentioned, registered or not, are the property of their respective companies.
2-Pole Turbine Generators
Ventilation and Enclosures
WEG Group
The cooling circuit provides uniform ventilation and effective
cooling throughout the machine.
Stator Ventilation
Stator winding end turns are cooled by air
discharging radially for the rotor fans, and
passing through the spaces between the
end turns. The stator core is uniformly
cooled by air that flows from several
inter-connected center chambers that
receive air directly from the fans. From
these center chambers the air first flows
radially down to the air gap via one group
of stator core ducts. These ducts are
equipped with directional spacers to direct
the air flow in the direction the rotor is
moving. The air in this pressurized portion
of the air gap also flows axially in both
directions to other groups of ducts
equipped with directional spacers designed
to scoop air from the air gap and direct it
radially through the stator core ducts. The
stepped ends of the stator core facilitate
easy entry of air for gap cooling that
portion of the stator core.
Rotor Ventilation
Air flow in generator with TEWAC enclosure and water air heat exchangers. Rotor ventilation slots are positioned
directly under the rotor coils. Holes are
pierced at regular intervals along the
length of the rotor conductors. Holes in the
Machine Ventilation copper are matched with the holes in the
Air is brought to the fan inlet at (A). The aluminum wedge to allow radial discharge
air passes through the fan (B), with some of warm air from the ventilation slot.
passing over the stator coil end turns (C),
During operation cool air is introduced
then through the air gap and stator under the retaining ring at each end of the
ventilating ducts (D) into the annular space rotor. Part of this air passes through the
(E) behind the core. The air that passes space between the rotor coil end turns and
through the stator coil end turns flows is discharged through ventilation holes in
the retaining rings. The remaining part of
through tubes (F) to the annular portion (G) the air enters the rotor ventilation slot.
surrounding the central part of the core. This
air then passes to the air gap through the Some of the air is radially discharged near
core ventilating ducts (I) and is discharged the end of the rotor. However, because the
slot below the conductors is much larger
through a duct on top of the frame. than the exit holes, it carries much more
air than can discharge at one point. As a
result, some of the air is discharged over
the entire length of the rotor.
Enclosures
TEWAC (Totally Enclosed Water Air
Cooled) generators are typically applied in
dirty conditions or on machines in base
load service. They are provided with a top
mounted air enclosure containing two
water to air heat exchangers (J), each
rated for 66% (100% optional) of rated
generator capacity with one cooler out of
service. The hot air discharging from the
duct at the top of the frame is cooled as
it passes through the coolers and then
returns at (A) for recirculation.
WEG Group
Electric Machinery
800 Central Avenue NE
Minneapolis, Minnesota 55413
United States
Tel: +1 612 378 8000
Fax: +1 612 378 8051
www.electricmachinery.com
© Electric Machinery 2011. Publication NA.10008.gb.11-09.01. Electric Machinery, the Electric Machinery logo and any version thereof are trademarks and service marks of Electric Machinery.
The other names mentioned, registered or not, are the property of their respective companies.
2-Pole Turbine Generators
Factory Testing
WEG Group
A comprehensive factory testing schedule is carried out on all
generators to ensure further enhanced reliability. Full load current
and voltage testing is included.
Electric Machinery
800 Central Avenue NE
Minneapolis, Minnesota 55413
United States
Tel: +1 612 378 8000
Fax: +1 612 378 8051
www.electricmachinery.com
© Electric Machinery 2011. Publication NA.10010.gb.11-09.01. Electric Machinery, the Electric Machinery logo and any version thereof are trademarks and service marks of Electric Machinery.
The other names mentioned, registered or not, are the property of their respective companies.