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POWER GENERATION.
POWER TRANSMISION
STEPUP
POWER DISTRIBUTION
STEP DOWN
COUSTOMERS USE
STATOR ROTOR
EXCITER
TESTING PROCESS
INTRODUCTION
It is a well-known fact that all power plants are located in such a place where
there are lots of resources. For example THERMAL POWER PLANTS near coal
We need coal to produce steam, Steam helps to rotate the turbine, turbine will
be rotating the shaft of the rotator and in turn exciter is also been rotated to
STATOR
Stator Frame,
Stator Core,
Stator Winding,
Generator Coolers,
Stator End Covers.
ROTOR
Rotor shaft,
Rotor winding,
Rotor Retaining Ring,
Field Connections.
EXCITER
Design features,
Rectifier wheels,
Field Connections.
BEARINGS
SKID
TESTING PROCESS
BREAKERS
NOTES ON GENERATOR
INTRODUCTION
Types of Generators
GENERATOR BEARINGS
The generator rotor is supported at two journal bearings. The bearings
consist of a bearing pedestal and bearing shell is split into two halves to facilitate
assembly. The bearing pedestals are iron castings and the bearing shells are
steel castings. The bearing pedestal is provided with a spherical seating surface
and the bearing shell rests in it with its outer spherical surface. The inner surface
of bearing shell is provided with spiral grooves and cast with Babbitt metal.
Bearing Temperatures:
The temperature of each bearing is monitored by one double-element
RTD. The RTD is screwed in position on side of the lower bearing sleeve from
outside with the detector extending to the Babbitt liner.
STATOR
INTRODUCTION:
Stator frame is of welded construction, supports the core and the windings. It
consists of air duct pipes and radial ribs, which provide rigidity to the frame.
Footings are provided to support the stator on the skid. The
stator frame should be rigid due to the various forces and
torques during operation. The welded stator frame consists of
two end plates, axial and radial ribs. The arrangement and
dimensioning of the ribs are determined by the cooling air
passages, the required mechanical strength and stiffness. The
end covers are aluminium alloy castings. The stator frame is
fixed to the skid with the help of hexagonal bolts. The skid is
interim fixed to the concrete foundation through foundation
bolts.
Stator core:
The core packed into the stacking frame is pressed firmly together
between the end plates of the machine frame and fixed in this position by welding
the axial ribs of the core and the end plates of the frame. End fingers on the
inside diameter of the end plates transmit the pressure to the teeth of the core.
The compressive force produced prevents the laminations and teeth from
vibrating. An eye is welded to each end plate for attaching suitable lifting gear
with adequate lifting capacity for transporting the complete machine. All the
forces that occur during normal operation or on short circuits are transmitted from
the stator yoke to the base frame via the seating plates and into the foundation.
Location of Bars:
A semi-conducting wrapper of graphite paper in the slot
protects the bar. The stator winding is protected against the
effects of current forces in the slot section. To ensure tight
seating of the bar at the slot bottom, a slot bottom-equalizing
strip of press path is inserted. A top ripple spring is arranged
between two compression strips to exert a continuous pressure
on the bars. The bars are shaped so that, cone shaped end
windings are obtained. In order to reduce the stray losses a
small cone taper of (13-20 ) is used. On the wide sides of the
bars spacers of insulating material are inserted at regular
intervals.
Bearings :
The rotor runs in two floating type guide bearings, designed as pedestal
bearings, with forced oil or oil-ring lubrication. The driven end bearing is secured
to the base frame and insulated from the latter. As the connections are designed
to prevent short-circuiting of the insulation.
Enclosure :
The enclosure consists of the inner and outer components. The inner
components comprises of the winding covers, which form an angular enclosure
of the overhang of the stator winding and are also used as air ventilator rings.
The outer enclosure consists of top and bottom parts and is designed as required
for the particular degree of protection, as indicated in the dimension drawing or in
“Technical data”. The ventilating circuit is of the double - ended symmetrical
arrangement.
STATOR CORE:
Stator core is stacked from insulated electrical sheet laminations and suspended
in the stator frame from insulated dovetailed guide bars. Axial compression is
obtained from clamping fingers, clamping plates and non-magnetic clamping
bolts which are insulated from the core. In order to minimize the hysterics and
eddy current losses of the rotating magnetic flux which interacts with the core.
The entire core is built up of laminations, each layer of which is made from a
number of individual segments. The segments are punched from silicon steel. In
the outer circumference the segments are stacked in insulated trapezoidal guide
bars, which hold them in position. The guide bar is not insulated to provide for
grounding the core. The laminations are hydraulically compressed and heated
during the stacking procedure. The complete stack is kept under pressure and
fixed in the frame by means of cell
STATOR
Stator frame is of welded construction, supports the core and the windings. It
consists of air duct pipes and radial ribs, which provide rigidity to the frame.
STATOR
Stator frame is of welded construction, supports the core and the windings .It
consists of air duct pipes and radial ribs, which provide rigidity to the frame.
Footings are provided to support the stator on the skid. The stator frame should
be rigid due to the various forces and torque’s during operation. The welded
stator frame consists of two end plates, axial and radial ribs. The arrangement
and dimensioning of the ribs are determined by the cooling air passages, the
required mechanical strength and stiffness. The end covers are aluminium alloy
castings. The stator frame is fixed to the skid with the help of hexagonal bolts.
The skid is interim fixed to the concrete foundation through foundation bolts.
Electrical Connection of Bars and Phase Connections:
Brazing makes Electrical Connection of Bars: Electrical connection
between the top and bottom bars, one top bar being brazed to associated bottom
bar. The coil connections are wrapped with tapes. The thickness of the wrapper
depends on the machine voltage. After taping, an insulating varnish is applied.
Phase Connectors: The phase connectors consist of flat copper sections, the
cross-section of which results in a low specific current loading. The connections
to the stator winding are of riveted and soldered type. The phase connectors are
wrapped with resin-rich mica tape, which contain synthetic resin having very
good penetration properties. The phase connections are then cured at a certain
temperature, with the shrinking tapes contracting so that a void free insulation is
obtained.
Output Leads:
The beginning and ends of the three phase windings are solidly bolted to
the output leads with flexible. The output leads consist of flat copper sections
with mica insulation. To prevent eddy-current losses and inadmissible
temperature rises; the output leads are brought out through insulating plates.
ROTOR
Introduction:
ROTOR WINDING
Construction:
The field winding consists of several series connected coils inserted into
the longitudinal slots of the rotor body. The coils are wound so those two poles
are obtained. The solid conductors have a rectangular cross-section and are
provided with axial slots for radial discharge of the cooling gas. The individual
conductors are bent to obtain half turns. After insertion into the rotor slots, these
turns are combined to form full turns of series connected turns of one slot
constituting one coil. The individual coils of the rotor winding are electrically
series connected so that one north and one south magnetic pole are obtained.
Insulation:
The insulation between the individual turns is made of layers of glass fiber
laminate. The coils are insulated from the rotor body with L shaped strips of glass
fiber laminate with Nomex interlinear. The strips are provided with axial slot of the
same cross- section and spacing as used on the rotor windings.
ROTOR SHAFT:
The rotor shaft is forged from a vacuum cast steel ingot. The high
mechanical stresses resulting from the centrifugal forces and short circuit
torque’s call for high quality heat-treated steel. The rotor consists of an
electrically active portion and two shaft ends. Approximately 60% of the rotor
body circumference has longitudinal slots, which hold the field winding. Slot pitch
is selected so that 180 displace the two solid poles. The rotor wedges act as
damper winding within the range of the winding slots. The rotor teeth at the ends
are provided with axial and radial holes, enabling the cooling gas to be
discharged into the air gap after, intensive cooling of the end windings.
Direct Cooling: Usually use in the rotor to eliminate hotspots and differential
temperatures between adjacent components, which would result in mechanical
stress particularly in the copper conductors.
1. It is directed into rotor end winding space. Part of it also flows over the
individual coils for cooling in the rotor end winding and then leaves the end
windings via the bores in the rotor teeth. Other part flows from the rotor
end winding space into slot bottom ducts. From this it will discharge into
the air gap via radial ventilating ducts.
2. Air is directed over stator end windings to the air ducts into the space
between the generator housing and the stator core. Then air flows into the
ventilating slot of the stator core, where it absorbs heat from the stator
core and stator windings.
3. It is circulated into the air gap via the rotor-retaining ring. The air then
mixes with the hot air flowing via ventilating ducts in the stator core into
the outer hot air compartment in the stator frame for being returned to the
cooler.
The three flow paths in the air gap and hot air is returned to the cooler
via hot air ducts for re-cooling and drawn again by the fans.
ROTOR WINDING
Construction:
The field winding consists of several series connected coils inserted into
the longitudinal slots of the rotor body. The coils are wound so those two poles
are obtained. The solid conductors have a rectangular cross-section and are
provided with axial slots for radial discharge of the cooling gas. The individual
conductors are bent to obtain half turns. After insertion into the rotor slots, these
turns are combined to form full turns of series connected turns of one slot
constituting one coil. The individual coils of the rotor winding are electrically
series connected so that one north and one south magnetic pole are obtained.
Insulation:
The insulation between the individual turns is made of layers of glass fiber
laminate. The coils are insulated from the rotor body with L shaped strips of glass
fiber laminate with Nomex interlinear. The strips are provided with axial slot of the
same cross- section and spacing as used on the rotor windings.
The turbo-generator under test is assembled separately with out coolers and
enclosures (if any), on a test foundation frame using it's own bearings and
coupled to a calibrated D.C. drive motor with gearbox of suitable capacity (1900
kw /1300/290 kw). The generators, which have brush less excitation system, are
tested with additional test pit slip rind shaft. The power to the drive motor and the
field of the generator are drawn independently from the Thyristor connectors /
Ward - Leonard sets situated in electrical machine rooms and controlled from test
gallery.
The machine is rolled and run at rated speed after ensuring the bearing oil, and
kept at rated speed for stabilization of bearing temperatures. The vibrations are
measured at rated speed on both the bearings housings (pedestals) in
Horizontal, vertical and Axial directions with the help of vibrating meters which is
internally connected to the monitor and the vibrations are noted in the form of
graphs. The temperature of stator is monitored by RTDs / Thermocouples
embedded in winding, core and tooth.
The excitation is reduced and cut off. The speed is reduced and the machine is
cooled at lower speed. The temperatures are checked from RTDs. The machine
is stopped when it is sufficiently cooled down.
output
% Efficiency of TG = . 100
output +total losses
The excitation is reduced and cut off. The speed is reduced and the machine is
cooled at lower speed. The temperatures are checked from m/c RTDs. The m/c
is stopped when it is sufficiently cooled down.
Equipment
50 Hz (Power frequency) A.C source.
A.C.Voltmeter.
A.C.Ammeter
Multimeter for continuity checks.
Current trasformer (50 / 5A OR 100 / 5A)
Connecting leads.
Evaluation of Impedance:
V
Z =
I
Where Z : Impedance in ohm
V : Voltage in Volts.
I : Current in Amps.
Equipment:
Motorized Megger (1000 V/ 2500 V)
Earthing Rod & earthing cable.
Insulation resistance of the rotor windings are measured before and after high
voltage test using Megger of 1000 V for rotor windings. The values are taken at
15 sec. And at 60 sec. A absorption coefficient of insulation is found out as ,
IR at 60 "
Absorption coefficient =
IR at 15 "
The m/c is prepared for High voltage test. When high voltage test is done on one
phase, all other phases and rotor winding, instrumentation cables are earthed.
Equipment's:
Digital micro ohmmeter and it's measuring leads.
Thermometer.
DC resistances of rotor windings are measured separately using micro
ohmmeter.
where,
R20 = Resistance at 200 C in m
0
T = average temperature of the rotor winding in C
Rt = measured resistance of winding in m
Design Features :
The exciter consists of
Rectifier wheels
Three-phase main exciter
Three-phase pilot exciter
A common shaft carries the rectifier wheels, the rotor of the main exciter
and the permanent-magnet rotor of the pilot exciter. The generator and exciter
rotors are thus supported on a total of three bearings. Mechanical coupling of the
two shaft assemblies’ results in coupling of the dc leads in the central shaft bore
through the Multi contact electrical contact system.
Rectifier Wheels:
The main components of the rectifier wheels are the silicon diodes, which
are arranged in the rectifier wheels in a three-phase bridge circuit. A plate spring
assembly produces the contact pressure for the silicon wafer of the diodes. One
diode each is mounted in each light metal heat sink and then connected in
parallel. Associated with each diode is a fuse, which serves to switch off the
diode from the circuit if it fails. Each arm of the diode bridge is provided with one
R.C.block. The three-phase connection between armature and diodes is obtained
via copper conductors arranged on the shaft circumference between the rectifier
wheels and the main exciter. One conductor is provided for each arm of Diode
Bridge. The conductors originate at a bus ring system of the main exciter.
Three-phase Pilot Exciter:
The three-phase pilot exciter has a frame, which accommodates the
laminated core with the three-phase winding. The rotor consists of a hub with
mounted poles. Each pole consists of separate permanent magnets, which are
housed, in a non-magnetic metallic enclosure.
The machine is prepared for open circuit characteristic and a 500 resistance
is connected across the slip rings. This is to allow a minimum current to pass
through the diodes for voltage measurement. The machine is run at rated speed
and field is excited gradually in suitable steps upto rated output voltage.
At each step following parameters are noted:
Va : out put voltage of exciter.
If : field current of the exciter.
Vq1,Vq2 : quadrature axis coil voltages, and
Vd : Drive motor voltage.
Id : drive motor current. and bearing vibrations.
Rt . (235 +20)
R20 = ------------------
( 235+t)
Before performing these tests, all the diodes are shorted by the copper wire. This
is to protect the diodes during meggering and HV tests on armature winding.
Rotor and stator bodies are properly earthed. IR values of the windings are
measured with 500 or 1000 volts megger and values at 15" and 69" are noted
before and after High voltage tests.
HV test is done on individual windings using high voltage test kit by regulating
primary voltage to transformer. Slowly HV is reached and maintained for one
minute and reduced to zero. The object is then discharged by earth rod and IR
values are taken. When test is done on one winding, the other windings are
earthed.
S t a t o r c o r e F l u x T e st : I m m e d i a t e l y a f t e r t h e c o r e i s b u i l t
up and before it is wound, a test is made to detect the
presence of local “hot spot”. Whenever there are shorts
between adjacent core lamination s, due to break of inter
laminar insulation or burrs on the edges, high eddy currents
flow giving rise to temperature rise in that zone. Several turns
of cable are wound through the machine bore and out side
frame. The winding is fed from a single-phase variable voltage
50 cycles supply. The object is to set up in the core, the full
working flux corresponding to rated voltage of the machine.
Bad local heating is caused by shorted and burred core
laminations and may be detected after a short time by running
the hand over the surface of the core. A set of reading on
core thermocouples is also taken as well as external contact
thermometers are used to take temperature at other points of
yoke and core. The remedy for such defects is to introduce
further insulation between laminations and in all, but the worst
cases; this may be done with out dismantling the core.
Wattmeter connected to the input indicates the iron loss and
by keeping comprehensive records for every size and type of
machine, the readings obtained may be used to estimate the
stator core loss in service. By intelligent analysis of the
results a bad core with perhaps an excessive iron loss may be
detected and remedied before it is wound.
1.0.0 Scope: This test procedure covers procedures for Routine Tests on
Turbo generators.
2.0.0 Tests conducted:
1. Mechanical run and measurement of vibrations at rated speed.
2. Measurement of mechanical losses, short circuit characteristic and
losses.
3. Measurement of mechanical losses, open circuit characteristic and
losses.
4. Measurement of shaft voltage.
5. Checking of phase sequence.
6. Measurement of Rotor Impedance (rotor inside stator).
7. Measurement of insulation resistance of stator & rotor windings before
and after high voltage test (m/c at rest).
8. High Voltage test on stator and rotor windings (m/c at rest).
9. Measurement of Polarization Index of stator winding.
10. Measurement of d.c. Resistance of stator & rotor windings in cold
condition.
11. Measurement of d.c. Resistance and insulation resistance of RTDs.
TYPE TESTS ON TURBOGENERATORS
1.0.0 Scope: This test procedure covers procedures for Type Tests on
Turbo generators.
thermometer.
FORMULA WRITE
T es t be t w ee n p a ra l l e l s t rap s : T h i s i s a t e s t o f s t r a p
insulation provided for eddy E. M. F., a low voltage of the
order of 350 volts for 3seconds is applied.
SC losses
Iron losses at 110%
En
Iron losses at 110%
In
Rotor losses
Zn =Vn / (1.732 X In )
Z =V /(1.732 X I)
R =P/(3 X I2 )
Xa =(Z2 X R2 )(1/2)
%Xa =(Xa /Zn )X100
%Xp =0.63(%Xa)
Cx = C4 X R4 (R3+100)
N X (R3 + S)
Ia Ib %In Ir Vd Id Losses
RUN UP OF GENERATOR:
Start up of generator:
Prior to running the generator oil system should be placed into operation.
The oil flow to the bearings should be checked to ensure an adequate flow. In
addition, drains should be inspected for proper operation.
Run up:
During run up to rated speed, the bearing oil inlet temperature should be
in accordance with the turbine manual. During run up the critical speed ranges
should be passed through quickly and at a uniform rate. Smooth running
depends on several factors. Even minor temperature difference of 1 to 2 dig C
between opposite sides of the rotor may result in rotor distortion, which could
lead to inadmissible vibrations due to unbalance.
Varsity:
To protect the rectifier bridge against over voltages occurring during starting or
during fault conditions, a non-linear resistor is provided. This protective resistor
consists of 6 varistor discs parallel connected between the positive and negative
bus rings.
The varistor discs are clamped between the bush rings by means of insulated
screws. Electrical contact between the varistor discs and the bus rings is ensured
by discs of annealed copper inserted between them.
End shields:
The end of the brushless exciter are closed by endshields. Depending on the
degree of protection of the machine, these endshields have either ventilating
slots or welded-on connection pieces for ventilating ducts.
The endshields on one end is of split construction and has a split sealing ring
screwed to its inner diameter and embracing the sleeve of the rotor hub with little
clearance. The end shield on the other end of the exciter is unplugging.
Ventilation:
The brushless exciter used closed circuit cooling, the air inlet
being on one end and the outlet on other end. The rotor spider
is provided with openings, permitting the passage of cooling air
past the rectifier heat sinks and also over the bus rings
together with the varistors and the carrier storage-effect circuit.
Maintenance:
The brushless exciter requires only a minimum of maintenance. The machine is
inspected for dust deposits at suitable intervals and are removed when
necessary, usually it is found in the region of heat sinks. A suitable method of
blowing with compressed air is used for this purpose.
TEMPERATURE DETECTORS
R = Ro(1 + a.T)
Ro= reference resistance at 0C
a = temperature coefficient
T = temperature in C
The temperature coefficient (a) is 3850/deg C, this being the mean value
for the range 0 - 100C.
Rod Type Thermostats :
Rod-type thermostats are used for detecting temperature
limits. These instruments utilize the different coefficients of
thermal expansion of two dissimilar metals. When exposed to a
temperature rise a rod arranged inside a tube and fitted to one
end of it features a linear expansion different from that of the
surrounding tube. As a result of this a movement is initiated in
a switching head at the other end of the detector tube, which in
turn actuates a change over contact. This changeover contact
operates on rising and falling temperature when the set value is
reached. The contacts are connected to the detector tube. The
rod type thermostats are employed for temperature detection in
pressurized surroundings.
VIBRATION PICKUP
Bearing Housing Vibration Measurement:
The vibration pickup for measurement of the absolute bearing vibration
converts mechanical vibrations into an electrical signal in a seismic type
transducer operating on the permanent magnet plunger coil principle. The
permanent magnet and magnetic flux return path elements are solidly connected
to the sensor casing. The plunger coil is suspended in the sensor casing by
means of a spring.
The maximum velocity of the absolute vibration is measured by means of
the transducer, which is attached to the bearing housing. Vibration in the bearing
housing produce a relative movement between the permanent magnet and the
plunger coil, which induces a voltage in the coil portion to the vibration velocity.
The output signal of the transducers is integrated amplified and then
displayed and recorded as peak-to-peak maximum velocity vibration values.