Bahir Dar University

Institute of Technology

Faculty of Electrical and Computer Engineering

Electrical Machines II (EME 3182)

UNIT FOUR
Design of Synchronous Machine

By: Atnafu Alemu

[email protected]
June 28, 2024 1
 Outlines

 Specific loading,
 output equation,
 main dimensions
 Types of winding, number of turns,
 Number of slots and slot design
 Field design
 Cooling of alternators

June 28, 2024 2

 Introduction
 Synchronous generators or alternators are synchronous machines used to
convert mechanical power to AC electric power.
Synchronous Generators Construction
 In a SG, a DC current is applied to the rotor winding, which produces a
rotor magnetic field.

 The rotor of the generator is then turned by a prime mover, producing a

rotating magnetic field within the machine.

 This rotating magnetic field induces a three-phase set of voltages within the
stator windings of the generator.
Cont’d…

 For SG, the field windings are on the rotor, so the terms "rotor
windings" and " field windings" are used interchangeably.

 Similarly, the terms "stator windings" and "armature windings" are

used interchangeably.

 The rotor of a SG. is essentially a large electromagnet.

 The magnetic poles on the rotor can be of either salient or non-

salient construction.

 Salient pole is a magnetic pole that sticks out from the surface of the
rotor.

 Non-salient pole is a magnetic pole constructed flush with the

surface of the rotor.
 Non - salient two-pole rotor

 Non-salient-pole rotors are

normally used for two- and four-
pole rotors,
 Salient-pole rotors are normally
used for rotors with four or more
poles.
Salient six-pole rotor for a SM.
a) Salient-pole type b) Cylindrical-rotor /Non-salient Pole Type
 Cont…

 A DC current must be supplied to the field circuit on the rotor.

 Since the rotor is rotating, a special arrangement is required to get

the DC power to its field windings.

There are two common approaches to supplying this dc power:

i. Supply the dc power from an external dc source to the rotor by

means of slip rings and brushes.

ii. Supply the dc power from a special dc power source mounted

directly on the shaft of the SG

Cont…

 Under steady state conditions, its speed depends on the frequency of

armature currents and the number of field poles.
120𝑓
𝑁 = 𝑁𝑠 =
𝑃

 In synchronous machines, the armature winding either exports ac

power (synchronous generator) or imports ac power (synchronous
motor) where as the field winding is always energized from dc
source.
 Types of Synchronous Generators
1. Hydro generators:
The generators which are driven by hydraulic turbines are
called hydro generator. These are run at lower speeds less than
1000 rpm.
2. Turbo generators:
These are the generators driven by steam turbines. These
generators are run at very high speed of 1500rpm or above.
3. Engine driven Generators:
These are driven by IC engines. These are run at a speed less
than 1500 rpm. Hence the prime movers for the synchronous
generators are Hydraulic turbines, Steam turbines or IC
engines
 Hydraulic Turbines: Pelton wheel Turbines: Water
head 400 m and above
 Francis turbines: Water heads up to 380 m
 Keplan Turbines: Water heads up to 50 m
 Steam turbines: The synchronous generators run by
steam turbines are called turbo generators or turbo
alternators.
Steam turbines are to be run at very high speed to get
higher efficiency and hence these types of generators are
run at higher speeds.
 Diesel Engines: IC engines are used as prime movers
for very small rated generators.
4.1 Specific loading
 4.2 main dimensions
 The main dimensions of salient pole machines are D and L.
 The choice of D and L depends on the type of pole and the
permissible peripheral speed.
 Two types of poles used are (i) Rectangular poles
(ii) Round poles.
Run-away speed is the speed in which the prime mover would
have , if it is suddenly unloaded when working at it rated load.

Peripheral Speed
4.3 Number of turns,
4.4 Design of damper winding
 Design of turbo generators
 The values of specific loading for conventionally cooled
generators.

 The values of specific loading for large water cooled cooled

generators.

The maximum peripheral speed is 175m/s

 4.5 Cooling of alternators
• During operation various losses occur in Stator and Rotor
• Losses are causes to increase temperature, this will
affect the alternator efficacy.
• So, the temperature rise of generator is controlled by means
of cooling.
• Main losses in Generator are:
 Core or Iron loss,
 Windage loss,
 Bearing & seal loss.
 Methods of cooling
• Air -up to 100MW -Direct Air
-Enclosed Air
 Hydrogen above 100MW
 Water + Hydrogen higher MW(210,500 etc..)
 In higher capacity generators we use water and
hydrogen as coolant.
 Hydrogen for rotor and stator windings.
 Water for stator core
In recent years power engineers use hydrogen as main
coolant, because of
 Its Specific heat,
 Density,
 Thermal conductivity
 Advantages of hydrogen gas as a coolant:
• High heat transfer coefficient, ensuring efficient
cooling.
• Rapid absorption and rejection of heat as it flows
through the generator windings.
• Lower density than air, requiring less energy for
circulation through generator components.
• Minimizes windage, reducing braking effects on the
alternator’s rotating parts.
 Enclosed Air Cooling

Water Cooling

Deionized water is supplied by a closed-loop auxiliary system

Water + Hydrogen cooled alternator
 Examples
Examples 1
Design the stator frame of a 500 kVA, 6.6 kV, 50 Hz, 3
phase, 12 pole, star connected salient pole alternator, with
Specific magnetic and electric loadings may be assumed as
0.56 Tesla and 26000 Ac/m respectively.
Peripheral speed must be less than 40 m/s and
slot loading must be less than 1200.
Find:
(i) Internal diameter and gross length of the frame
(ii) Number of stator conductors
(iii) Number of stator slots and conductors per slot
solution
(i) Diameter and gross length of stator:
Assuming the winding to be full pitched Kw = 0.955
Output coefficient
Co = 11 x Bav q Kw x 10-3
= 11 x 0.56 x 26000 x 0.955 x 10-3 = 153
Speed in rps ns = 2f/p = 2 x 50/12 x = 8.33 rps
Output Q = C0 D2Lns
D2L = Q / C0 ns = 500/( 153 x 8.33) = 0.392 m3
Using round poles for the salient pole alternator and assuming
ratio of pole arc to pole pitch as 0.65 and pole arc equal to core
length. Pole arc/ pole pitch = core length/ pole pitch = 0.65
L = πD/p = πD/12 L = 0.17D
Substituting this relation in D2L product and solving for D and L
D = 1.32 m and L = 0.225 m.
• Peripheral speed = πDns m/s = π x 1.32 x 8.33
= 34.6 m/s (with in limitations)
(ii) Number of stator conductors
Eph = 6600/√3 = 3810 volts
Air gap flux per pole = Bav x πDL/p
= 0.56 x π x 1.32 x 0.225/12
= 0.0436 wb
We have Eph = 4.44f Φ Tph Kw
Hence Tph = 3810/ ( 4.44 x 50 x 0.955 x 0.0436)
= 412
Total number of stator conductors/phase
Zph = 412 x 2 =824 conductors
Total number of conductors = 412 x 6 = 2472
(iii) Number of stator slots and conductors per slot
Considering the guide lines for selection of number of slots
Selecting the number of slots/pole/phase = 3
Total number of slots = 3 x 12 x 3 =108
Slot pitch = πD/S = π x 132/ 108
= 2.84 cm (quite satisfactory)
Number of conductors per slot = 2472/108 ≈ 24
Hence total number of conductors = 24 x 108 = 2592
Turns per phase = 2592/6 = 432
Slot loading:
Full load current = 500 x 103 / (√3 x 6600) = 43.7 amps
Slot loading = current per conductor x number of conductors/ slot
= 43.7 x 24
= 1048.8 (satisfactory)
Example 2
A 3 phase 1800 kVA, 3.3 kV, 50 Hz, 250 rpm, star
connected salient pole alternator has the following
design data.
Stator bore diameter = 230 cm
Gross length of stator bore = 38 cm
Number of stator slots = 216
Number of conductors per slot = 4
Cross-Sectional area of stator conductor = 86 mm2
Using the above data, calculate:
(i) Flux per pole
(ii) Flux density in the air gap
(iii) Current density
 solution
(i) Flux per pole
Eph = 3300/√3 = 1905 volts
Number of slots per phase 216/3 = 72
Number of conductors per slot = 4
Total number of conductors per phase = 72 x 4 = 288
Number of turns per phase Tph = 288/2 =144
We have from emf equation Eph = 4.44f Φ Tph Kw
Assuming Kw =0.955
Flux per pole Φ = Eph/ (4.44f Tph Kw)
= 1905/( 4.44 x 50 x 144 x 0.955)
= 0.0624 wb
(ii) Flux density in the air gap
Air gap flux per pole = Bav x πDL/p
D = 230 cm, L = 38 cm, Ns = 250 rpm and P = 24
Bav = Φ / πDL/p
= 0.0624 x 24 / (π x 2.3 x 0.38)
= 0.55 Tesla
(iii) Current density
X-sectional area of the conductor = 86 mm2
Full load current of the machine (IF)
IF = 1800 x 103 / (√3x 3300) = 314.9 amps
Hence Current density = 314.9/86
= 3.7 amp/mm2
 Q?

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