INTRODUCTION TO DESIGN OF LARGE SIZE TURBOGENERATORS HISTORY OF DEVELOPMENT - Globally First single phase generator of 75 KW First 3 phase generator,

salient pole First turbo type 3 phase 25 MW generator UK made 50 Hz as standard frequency for Europe First Hydrogen cooled 3 phase 30 MW generator First Hydrogen cooled TG with direct cooling of rotor First generator with water cooled stator winding First generator with water cooling for stator and rotor wdg HISTORY OF DEVELOPMENT IN BHEL Three Plants set up : In 1950s: In 1960s: In 1960s: At Bhopal with British collaboration 30 MW & 120 MW Hydrogen Cooled At Haridwar with Russian Collaboration 100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled At Hyderabad with CZECH Collaboration 60 MW Air Cooled & 110 MW Hydrogen Cooled 1888 1900 1912 1925 1937 1949 1956 1959

POWER OUTPUT OF TURBOGENERATOR P D2 . L . B . A . n P Power in MVA D Bore Diameter of Core in meters L Length of Active Rotor Body in meters B Air Gap Flux Density in Tesla A Stator Ampere-Turn Loading in Amp./meter n Speed in rpm GENERATOR MODULES Air Cooled Turbogenerator : Hydrogen Cooled Turbogenerator : Hydrogen/Water Cooled TG : MODULE NOMENCLATURE (EXAMPLE) TARI 108/46 THRI 108/44 THDF 115/59 MW CAPACITY RANGE OF TURBOGENERATOR Air Cooled Turbogenerator : Hydrogen Cooled Turbogenerator : Hydrogen and Water Cooled Turbogenerator : 80MW 240MW 100MW 350MW 450MW 1000MW
Page 1 of 7

TARI THRI THDF

INTRODUCTION TO DESIGN OF LARGE SIZE TURBOGENERATORS TARI GENERATORS - DESIGN FEATURES Direct cooling of stator core and rotor winding Indirect cooling of stator winding Horizontally split casing design for stator Vertically side mounted coolers in a separate housing VPI insulation system Separately assembled stator core and winding for reducing the manufacturing cycle Static/ brushless excitation system THRI GENERATORS - DESIGN FEATURES Direct hydrogen cooling of stator core and rotor winding Indirect cooling of stator winding Explosion proof single piece stator frame End shield mounted bearings VPI insulation system Top ripple springs in stator slots to contain bar bouncing forces Cold gas temperature control valve to maintain cold gas temperature constant Ring type shaft seals Static/brushless excitation system THDF GENERATORS - DESIGN FEATURES Direct water cooling of stator winding and direct axial hydrogen cooling of rotor winding Optimally designed leaf spring support for core end shield mounted bearings VPI insulation system Massive support ring for stator winding overhang to absorb short circuit forces Side and top ripple springs in stator slots to contain bar bouncing forces 5 stage axial compressor and vertical hydrogen coolers on turbine end Cold gas and primary water temperature control valves to maintain average inlet cooling medium temperatures constant Double flow ring type shaft seals Brushless excitation system MAIN PARTS OF TURBOGENERATOR Stator - Stator Frame (Fabrication & Machining) Core Assembly - Stator Core, Core Suspension Arrangement End Shields Stator Winding Assembly - Stator Winding , Winding Assembly, Connecting Bus bar Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor, Rotor Assembly Completing Assembly - Bearing Assembly, Shaft Seal Assembly, Oil Catchers, Insert Cover etc Exciter Auxiliary System

Page 2 of 7

INTRODUCTION TO DESIGN OF LARGE SIZE TURBOGENERATORS STATOR FRAME Rigid fabricated cylindrical frame Withstands weight of core & wdg, forces & torques during operation Natural frequency away from exciting frequencies (away from 50/100 HZ) Provision for H2/CO2 filling Provision for temp measurements Foot plates for supporting on foundation Provision for H2 coolers STATOR CORE Made up of punched segments of thin sheets of ETS Core punchings / stampings coated by insulating varnish Vent segments at designed intervals for flow of cooling gas Compressed with tension bolts, pressure plate and clamping fingers Stepped arrangement at the end for reduction in eddy current losses END SHIELDS Closes both ends of Stator Frame Fabricated rigid box type structure in two parts Supports and houses bearings Houses H2 Coolers (for water cooled design) Provision for mounting Shaft seal body, Oil catchers, etc Provision for supply of Bearing Oil, Seal oil, Thrust oil and its drain STATOR WINDING Three phase windings in two layers of individual bars Top and bottom bar displaced by one winding pitch and connected to coil groups Coil groups connected to Connecting Bus bar and finally to Term Bushing Involute shape at the end of bar helps withstands various forces VPI (Vacuum Pressure Impregnation) Insulation System Good conductor of heat Low inflammability High resistance to moisture and chemical action Accommodates thermo-mechanical stresses Retains properties even after years of operation STATOR WINDING INSULATIUON Type of Insulation Systems

BITUMEN MICA SYSTEM (Thermoplastic Insulation) EPOXY MICA SYSTEM (Thermosetting Insulation) o Resin Rich Insulation o Resin Poor Insulation
Page 3 of 7

INTRODUCTION TO DESIGN OF LARGE SIZE TURBOGENERATORS Resin Poor Insulation System In this System, Mica Tapes with 8-10% Resin Content are used for taping Stator Bars which are subsequently treated as per Vacuum Pressure Impregnated (VPI) Process in Resin Tank, during which Resin Permeates through the Insulation from Outside. Used for all Generators manufactured based on Siemens Technology.

Long electrical life (beyond 30 years) Retains properties over years of operation Good conductor of heat Highly resistant to high temperatures & temperature changes Moisture resistant No fungus growth Highly resistant to chemical-corrosive gases, vapors, oil, weak acids or alkalis Shows only an insignificant increase in the gradient of dielectric dissipation factor with increasing temperature

VPI Process can be adopted for : Impregnating individual Bars for further assembly (Bar Type) or Assembly of Winding Bars in Green Stage and impregnating Wound Core (Total Impregnated Type). Epoxy Resin fills all Gaps/Voids by Capillary Action without blocking ventilation Space due to its low Viscosity. Total Impregnation Insulation System

State of the art technology: o Stator winding bars are taped with class-F resin poor mica glass tape o The bars are assembled in core with green stage insulation o Complete core alongwith winding (called cage core) is then impregnated and cured through VPI (Vacuum Pressure Impregnation) process o Epoxy resin fills all gaps and voids not only inside bar insulation but also between winding and core as well as in overhang portion Advantages: o State of art insulation technology o Void free high voltage insulation system o Elimination of air gap between core & winding results in Higher mechanical bond Reduced corona and partial discharges High dielectric strength & low dissipation factor Thus increased electrical life o Better heat transfer from bars to core o All core packets are glued and cured. No more core looseness. Thus no stator earth faults attributed to core Advantages to customer: o Longer service life o Lesser maintenance
Page 4 of 7

INTRODUCTION TO DESIGN OF LARGE SIZE TURBOGENERATORS

o o o o o o o

First inspection after 10,000 hrs. (Check only IR value. Rotor withdrawal not required.) Major inspection after 40,000 hrs to 60,000 hrs Glue injection in overhang not required during overhaul No need to check slot wedge system Checking of end winding support system not required No more core looseness. No faults attributed to core Spare bars, spare wedges etc not required leading to reduced inventory of spares

TERMINAL BUSHING Tubular construction for gas / water cooling High conductivity copper for taking out electrical power Connection flanges are silver plated to minimise contact resistance Insulated with a epoxy resin cylinder or porcelain cylinder Differential pressure of gases or forced water for cooling Bolted on to stator bottom directly or housed in a box type construction which is bolted to stator bottom ROTOR A high strength alloy steel single forging prepared by vacuum cast steel Slots for housing field windings Strong coupling for withstanding short circuit forces Bending critical speed away 5% of operating speed Supported on two journal Bearings Provision of axial fan/compressor for forced ventilation Provision of damper wedges for increasing negative sequence capability of rotor BEARING ASSEMBLY Sleeve Bearing Supports Rotor weight Reduces shaft vibrations Minimises frictional losses Located in End Shields or outside stator depending upon type of machine Self aligning outer part Insulated from Stator or End Shield to prevent flow of shaft current Inner surface is made of babbit material (Tin alloy) SHAFT SEAL ASSEMBLY Prevents escape of H2 through junction of rotor and stationary part Maintains continuous oil film between Seal Ring and rotor journal Clearance should be sufficient to maintain oil film without unnecessary large oil flow and with minimum frictional losses Ring relief oil for balancing the gas pressure on seal ring Inner surface of Babbit material

Page 5 of 7

INTRODUCTION TO DESIGN OF LARGE SIZE TURBOGENERATORS EXCITATION SYSTEM Static Excitation

Rotor Field Winding is connected to Slipring mounted on rotor Excitation is provided by current transfer by contact through Carbon Brushes, Slipring and field lead

Brushless Excitation System / Brushless Exciter

Eliminates Slip Rings, Brushgear and Field Breaker Eliminates all problems associated with transfer of current via sliding contacts Simple, Reliable and ideally suited for large sets Minimum operating and maintenance cost Self generating excitation unaffected by system fault/disturbances because of shaft mounted pilot exciter Assembled as Single Unit with all assemblies mounted on Base Plate with Two Side Mounted Air Coolers and is enclosed by External Hood. Increasingly popular system the world over High response excitation with fast acting AVR Multi contact electrical connections between exciter and generator field Stroboscope for fuse failure detection Provision of Quadrature Axis Coils in Main Exciter Stator for Generator Field Current Indication Rotor Earth fault monitoring system RC circuit to avoid over voltages Dehumidifier for use during shut down

AUXILIARY SYSTEM Primary Water System : Dissipation of losses in Stator winding, bushings, bus bar Seal Oil System Prevents H2 losses at the shaft entry into stator Gas Flow System Facilitates H2 filling & maintains gas pressure in stator GENERATING TESTING Routine Tests

Mechanical Heat Run Short Circuit (SC) Heat Run : 100% Current Open Circuit (OC) Heat Run OCC & SCC Characterstics Temperature Rise, Losses & Efficiency Calc Bearing Vibrations & Hydrogen Leakage Direct Axis Synchronous Reactance HV, Tan-Delta, Delta-Tan-Delta Measurements

Page 6 of 7

INTRODUCTION TO DESIGN OF LARGE SIZE TURBOGENERATORS Special (Type) Tests

Sudden Circuit Test (at 50% Voltage) SC Run with One Cooler Out Retardation Test Zero & Neg. Sequence Reactance Telephonic Harmonic Factor (THF) Voltage waveform Deviation Factor Shaft Voltage

Additional Tests

Natural Frequency Measurement Test on Stator Winding Overhang Stator Winding Overhang Vibration Measurements PD Measurement on individual phase Pressure Distribution Test

TRANSPORTATION RAIL Transportation : Maximum rail transportable width is 4100 mm 24 Axle Special wagon for 500MW TG Transportation : ROAD Transportation: When the generator stator width is more than 4100 mm, the Generator is to be transported by Road. AT Present : 500 MW TG : Being transported by Rail. THRI/TARI TG : Being transported by Road.

Page 7 of 7