Index

1. Types of Generator
2. Main parts of Turbo generator & its functions
3. Operational aspects
4. Auxiliary Systems

4 April 2024 1
 LIBRARY OF DESIGNS
1000 MW

WATER COOLED STATOR

350 MW

HYDROGEN COOLED 660 MW

170 MW

AIR COOLED

DESIRED MW CAPACITIES

80 MW 1000 MW

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 GEN COOLING SYSTEM

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MAIN PARTS OF GENERATOR
1. Stator - Stator Frame (Fabrication & Machining)
2. Core Assembly - Stator Core, Core Suspension Arrangement
3.ENDSHIELD
4.Stator Winding Assembly - Stator Winding , Winding Assembly,
Connecting Bus bar
5. Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor,
Rotor Assembly
6. Completing Assembly - Bearing Assembly, Shaft Seal Assembly,
Oil Catchers, Insert Cover etc
7. Exciter
8. Auxiliary System

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 SPECIFICATIN OF THE GENERATOR
RATES PARAMETERS
(AT RATES H2 PRESSURE AND COOLING WATER TEMP.)
MAX. CONTINUOUS KVA RATING : 247000 KVA
MAX. CONTINUOUS KW RATING : 210000 K.W.
RATED TERMINAL VOLTAGE : 15750 V
RATED STATOR CURRENT : 9050 A
RATED POWER FACTOR : 0.85 Lag.
EXCITATION CURRENT AT MCR CONDITIONS : 2600 A
SLIP RING VOLTAGE AT MCR CONDITIONS : 310- V
RATED SPEED : 3000 RPM
RATED FREQUENCY : 50 Hz
EFFICIENCY AT MCR CONDITIONS : 98.49%
DIRECTION OF ROTATION WHEN VIEWED FROM
SLIP RING END : ANTI CLOCK WISE
PHASE CONNECTION : DOUBLE STAR
NO. OF TERMINALS BROUGHT OUT OF
STATOR :9
OVER ALL Stator DIA : 3960 MM
LENGTH OF STATOR : 4580 mm
LENGTH OF ROTOR : 9770 MM
WEIGHT OF STATOR : 175,00 KG. (Heaviest)
WEIGHT OF ROTOR
4 April 2024
: 42,200 KG. 5

TOTAL WT. OF GENERATOR : 239,00 KG.

 Main Parts of Turbogenerator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing

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 TURBO GENERATOR
CONSTRUCTION
• CONSTRUCTION OF GENERATOR IS ESSENTIALLY MANUFACTURE

• OF COMPONENT PARTS WHICH ARE ASSEMBLED PARTLY AT

• MANUFACTURER’S WORKS AND PARTLY AT SITE.

• IT IS USUAL TO CONSIDER THE MACHINE IN TWO MAJOR COMPONENTS:

FRAME

1. STATOR MAGNET CORE

WINDINGS

2. ROTOR

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 STATOR BODY

• FABRICATED GAS TIGHT STEEL STRUCTURE

SUITABLY RIBBED INTERNALLY.

• CAN WITH STAND EXPLOSION PRESSURE OF

HYDROGEN AIR MIXTURE WITHOUT ANY RESIDUAL
DEFORMATION.

• HYDROGEN GAS COOLERS HOUSED

LONGITUDINALLY INSIDE STATOR BODY.

• END SHIELDS FOR CLOSING CASING AND

SUPPORTING FAN SHIELDS AND SHAFT SEALS.
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 STATOR CORE
• IT PROVIDES PATH FOR MACHINE’S MAGNETIC FLUX AND
HAS SLOTS IN WHICH WINDINGS ARE ASSEMBLED.

• MADE UP OF SEGEMENTAL, VARNISH INSULATED PUNCHINGS

OF COLD ROLLED GRAIN ORIENTED SILICON STEEL

• IT CONSISITS OF SEVERAL PACKETS SEPARATED BY STEEL

SPACERS FOR RADICAL COOLING OF THE CORE BY
HYDROGEN.

• THICKNESS OF LAMINATIONS USED

0.013” – 0.014”
1-1/2 – 2-1/2” THICK PACKETS SEPARATED BY RADIAL
COOLING DUCTS TO PROVIDE PASSAGE FOR HYDROGEN.

* CORE BARS DESIGEND TO PROVIDE ELASTIC SUSPENSION

OF CORE IN THE STATOR
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 STATOR CORE STACKING

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4 April 2024 PMI Revision 00 11
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 STATOR CORE
SIDE
WRAPPER CORE BAR

CORE BAR TOP

CORE BAR
CORE
RING

BOTTOM
COREBAR

CORE
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 Main Parts of Turbogenerator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing

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4 April 2024 PMI Revision 00 15
4 April 2024 PMI Revision 00 16
 STATOR WINDING
• Three phase windings in two layers of individual bars
• Coil groups connected to Connecting Bus bar and finally to Terminal
Bushing
Involute shape at the end of bar helps withstands various forces
• Micalastic Insulation System (VPI process)

- Micalastic good conductor of heat

- Low flammability
- High resistance to moisture and chemical action
- Accommodates thermo-mechanical stresses
- Retains properties even after years of operation

VPI- Vacuum Pressure Impregnation

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STATOR WINDING AND INSULATION

• GENERATOR VOLTAGE IS INDUCED IN THE STATOR

WINDINGS AND EACH CONDUCTOR MUST BE CAPABLE OF
CARRYING RATED CURRENT WITHOUT GETTING
OVERHEATED.

• EACH COIL SIDE CONSISTS OF GLASS INSULATED SOLID

AND HOLLOW CONDUCTORS WITH WATER FLOWING
THROUGH THE LATTER.

• ADEQUATE PROTECTION PROVIDED TO AVOID CORONA AND

SURFACE DISCHARGE.

• COIL SIDES FIRMLY HELD IN SLOTS BY EPOXY GLASS GLOW

WEDGES WHICH ARE MECHANICALLY STRONG AND HAVE
HIGH DIELECTRIC PROPERTIES.
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 Generator

Stator Winding -
Lap type bar type of winding , and employsC
the direct water cooling. o
n
• The use of water cooling in the winding
permits high value of current densities in
the machine and thus reducing the size as
well as output per kg. of the materials.

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STATOR SLOT
SECTION

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 Generator Stator

• The three-phase stator winding is a

fractional-pitch two-layer type consisting of
individual bars. Each stator slot
accommodates two bars.
• The slot bottom bars and top bars are
displaced from each other by one winding
pitch and connected at their ends to form
coil groups.

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 Generator Stator

• Due to this reason the reliability of the

insulation between the elementary
conductor is of prime importance because
any faulty insulation can lead to
considerable localized heating and
insulation failure.

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 Generator Stator

• The lengths of the overhang and the angle

of overhang is optimized so as to give the
minimum length of overhang and minimum
losses.

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 Generator Stator

• Both the bars are held in the slot by

means of impact resistant plastic wedges.

• The wedging is ensured to be very tight so

that during the operation of the machine
the same should not get loosened.

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 Generator Stator

• The overhang part of the winding is tied by

means of glass cord and is kept in position
by means of insulating wedges.

• The complete system in the overhang

portion is designed to withstand the forces
encountered due to sudden short circuit.

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 STATOR SLOT

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 Generator Stator

• Consolidated stack of bar mica tape

Compounded with bitumen compound in
three stages coating with anti-corona
semi-conducting paint.
• To minimize corona discharges between
the insulation and the slot wall, a final coat
of semi-conducting varnish is applied to
the surfaces of all bars within the slot
range.
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 Generator Stator

• The semi-conducting paint at the outlet of

the slot is of different resistivity to have a
smooth gradient of the electro-static field
at the outlet from the slot.
• Off late Epoxy Mica Thermosetting
insulation system for stator bars is being
employed.

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 Generator Stator

• High-quality mica, selected epoxy resins

and a matching vacuum impregnation
process are the characteristic features of
the Micalastic insulation for large turbo
generators.

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 Generator Stator

• A consistent development has led to a

high-quality insulation system, the
reliability of which is ensured by
continuous quality control.
• Since 1960 this insulation has been
registered under the trade-mark
Micalastic by Siemens AG.
• RTDs are Provided to record temp
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 STATOR END WINDING

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 Stator END Winding Support

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 Stator End Winding Assembly

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4 April 2024 PMI Revision 00 37
 ABOUT HYDROGEN

• H2 is lightest gas with 0.09 gm / litre

while air’s 1.3 i.e. 14.4 times.
• Thermal capacity of H2 as gas is high.
• Thermal conductivity of H2 is 5 times
that of air. Its specific heat is 3.42 at 0°C,
as compared to 0.237 of air.
• 2 H2 + O2 mixture ignites on adiabatic
compression at 526°C, 3H2 + O2 at
544°C.
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 ABOUT HYDROGEN

• H2 and O2 combine slowly at 180°C or

in bright sunlight. Explosion occurs with
moist gases at 550 - 700°C.
• Ignition temp. of H2 in air is 538°C.
• Calorific value of H2 is 136 k Cal / gm.
• For filling in TGs, 99.9% v/v purity
gas is used. Traces of SO2 and NH3
shall not be detectable by analysis.
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 THDF: VENTILATION SCHEME

• Gas flow path 1 enters rotor on Turbine

end and cools rotor overhang and slots.
• Gas flow path 2 cools stator core.
• Gas flow 3 enters rotor on exciter end &
cools rotor overhang & slots, as well as
stator core end parts at both the ends.
• Hot gas from all paths returns through
air gap to compressor, and to coolers.
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 THDF: VENTILATION SCHEME - 2

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 4. DISTILLATE HEADER

• RING TYPE WATER HEADERS MADE OF COPPER

PROVIDED SEPARATELY FOR DISTILLATE INLET
AND OUTLET IN THE
STATOR ON TURBINE SIDE.

• HEADER SUPPORTED ON INSULATORS AND

ISOLATED FROM
STATOR BODY.

• INDIVIDUAL BARS PROVIDED WITH WATER

INLET/OUTLET
CONNECTIONS MADE OF TEFLON.

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 STATOR WINDING WATER

• Thermal capacity of water as liquid is

high. Pure water has high electrical
resistance / low conductivity.

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 Rotor
1. A high strength alloy steel single forging prepared by vacuum
cast steel
2. Slots for housing field windings
3. Strong coupling for withstanding short circuit forces

4. Supported on two journal Bearings

5. Provision of axial fan/compressor for forced ventilation
6. Retaining rings to contain rotor endwinding

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 ROTOR
ROTOR SHAFT AND BODY FORGED IN ONE PIECE FROM

CHROMIUM NICKET MOLYBDENIUM AND VANADIUM STEEL.

IT IS SUBJECTED TO A SERIES OF ULTRASONIC EXAMINATIONS

AND OTHER TESTS TO ENSURE ABSENCE OF INTERNAL

DEFECTS.

DYNAMICALLY BALANCED TO A HIGH DEGREE OF ACCURACY

AND SUBJECTED TO 20% OVERSPEEDING FOR TWO MINUTES

TO ENSURE MECHANICAL STRENGTH.

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 Generator Rotor

• The winding is manufactured in the form of

half coils which are insulated by means of
glass textolite formed along with each turn
of coils.

• Complete coil is brazed together.

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 Generator Rotor

• The coil is held against centrifugal forces

by means of wedges and by means of
non-magnetic retaining ring on the
overhang part of the winding.

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4 April 2024 49
 Generator Rotor

• The complete winding is tested for inter-

turn faults at various stages of its laying
and also subjected to HV tests at
important stages by means of a special
inter turn fault detector and also subjected
to high voltage tests at important stages.

• The finished and assembled rotor is

balanced and over speeded on the
balancing installation.
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4 April 2024 PMI Revision 00 51
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 FIELD WINDING
-
-MADE FROM HARD DRAWN SILVER BEARING
COPPER.

- ROTOR WINDINGS HELD IN POSITION

AGAINST CENTRIFUGAL
FORCES BY DURALIUM WEDGES IN SLOT
PORTION AND BY
NON-MAGNETIC STEEL RETAINING RINGS IN
OVERHAND PORTION.

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 - SLOT INSULATION IS IN THE FROM OF U-TROUGN MADE OF GLASS
CLOTH IMPREGNATED WITH EDOXY RESINS.

- INTER TURN INSULATION – LAYERS OF PERPEX GLASS CLOTH

GLUED TO
EACH CONDUCTOR AND CONSOLIDATED IN REGULATED
CONDITIONS OF
TEMPERATURE AND PRESSURE.

- END WINDINGS PACKED WITH BLOCKS OF GLASS LAMINATES TO

SEPARATE
AND SUPPORT THE COILS AND TO RESTRICT THEIR MOUEMENT DUE
TO
THERMAL AND ROTATIONAL FORCES.

B. SHAFT MOUNTED FANS

- TWO PROPELLOR TYPE FANS ARE SHAFT MOUNTED OF EITHER SIDE

OF
ROTOR BOOY FOR CIRCULATING COOLING GAS INSIDE
GENERATOR.
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 Generator Rotor

• Two axial fans are mounted on both sides

of the rotor for the purpose of providing
gas circulation inside the machine.
• Special ducts (fins) are provided in the
rotor body, through which the cooling gas
flows to the rotor end windings

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 THW 210/235: ROTOR SHAFT

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 Rotor Body with cross Pole Slot

Rotor
Wedge

Cross
Pole
Slot

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 Rotor End Winding

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 Rotor Fan Blades

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C. RETAINING RINGS

- END WINDINGS HELD IN POSITION AGAINST CENTRIFULAL FORCES

BY RETAINING RINGS MACHINED FROM HIGH STRENGTH, HEAT
TREATED, NON MAGNETIC ALLOY STEEL FORGINGS.

- SHRUNK FIT ON ROTOR BOYD AND LOCK NUT PROVIDED TO

PREVENT AXIAL MOVEMENT.

D. SLIP RINGS

- HELICALLY GROOVED ALLOY STEEL RINGS SHRUNK ON ROTOR

SHAFT AND INSULATED FROM IT.

- SLIP RINGS ARECONNECTED TO FIELD WINDING THROUGH SEMI-

FLEXIBLE COPPER LEADS.

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4 April 2024 63
G. BEARINGS

- PEDESTAL TYPE WITH SPHERICAL SEATING TO ALLOW SELF

ALIGNMENT.

- PEDESTAL MASSIVE STEEL CASTING. BEARING BUSH ALSO OF

CAST STEEL AND LINED WITH HIGM QUALITY WHITE METAL.

- TO PREVENT SHAFT CURRENTS, SLIP RING SIDE BEARING AND

CONNECTED PIPING INSULATED FROM EARTH.

H. SHAFT SEALS:

- USED TO PREVENT ESCAPE OF HYDROGEN FROM GENERATOR

CASING TO ATHMOSPHERE A LONG THE ROTOR SHAFT.

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4 April 2024 PMI Revision 00 65
E. BRUSH GEAR

- PROVIDED ON EXTENDED PART OF BEARING PEDESTAL ON

EXCITER SIDE.

- BRUSHES ARE SPRING LOADED TO MAINTAIN REQUIRED

CONTACT PRESSURE.

F. GAS COOLERS

- FOUR GAS COOLERS MOUNTED LONGITUDINALY INSIDE

GENERATOR
STATOR BODY SERVE THE PURPOSE OF COOLING HOT
HYDROGEN.

-COOLING TUBES MADE OF BRASS WITH COILER COPPER

AROUND
THEM
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 Rotor Slip Ring

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4 April 2024 68
 5. TERMINAL BUSHINGS

• WATER COOLED TERMINAL BUSHINGS HOUSED IN LOWER

PART
OF STATOR ON SLIP RING SIDE.

• TERMINAL BUSHINGS ARE HOUSED IN A CHAMBER OF NON-

MAGNETIC STEEL PLATES AND EFFECTING SEALING
PROVIDED
BETWEEN BUSHINGS AND STATOR BODY.

• THREE PHASE AND SIX NEUTRAL TERMINALS BROUGHT OUT.

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•
•

• 600 MW GENERATOR DETAILS

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 GENERATOR TECH DATA

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 GEN EXCITATION SYSTEM

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 SEAL OIL SYS SCHEMATIC

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 PRIMARY WATER SYS

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 SEAL OIL PARAMETERS

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 GAS SYSTEM PARAMETERS

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 GEN CAPABILITY CURVE

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• SOME IMPORTANT
• GENERATOR OPERATIONAL
• ASPECTS

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•
• THANK YOU
• ……..

4 April 2024 84