Turbo generator

and Auxiliaries
 Index
1. Historical developments
2. Types of Generator
3. Main parts of Turbo generator & its functions
4. Operational aspects
5. Auxiliary Systems
 Development of TG
Global development

First single phase generator of 75 KW 1888

First 3 phase generator 1900
First turbo type 3 phase 25 MW generator 1912
CEA, UK made 50 HZ as standard frequency for Europe 1925
First Hydrogen cooled 3 phase 30 MW generator 1937
First Hydrogen cooled TG with direct cooling of rotor 1949
First generator with water cooled stator winding 1956
First generator with water cooling for stator and rotor wdg1959
 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
Generator cooling System
 Main Parts of Turbo generator
1. Stator - Stator Frame (Fabrication & Machining)
2. Core Assembly - Stator Core, Core Suspension Arrangement
3. End Shield
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
 Main Parts of Turbogenerator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing
 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 : 42,200 KG.
 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
1. 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.
2. STATORE 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
 STATOR CORE
• Core is made of segmental laminations
0.5mm thick, insulated by Class B or F
varnish permitting maximum or hot spot
temp. of 135°C or 155°C continuous.
• Lamination thickness is uniform within
a specified tolerance range. Core is
pressed at a press.of 12 -18 Kg/cm² in
assembly. Tightness checked in stages.
STATOR CORE STACKING - TARI
TG
 STATOR
SIDE
WRAPPER CORE BAR

CORE BAR TOP

CORE BAR
CORE
RING

BOTTOM
COREBAR

CORE
 Main Parts of Turbogenerator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing
 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

3. 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.
STATOR SLOT - TARI/THRI
STATOR END WINDING - TARI TG
Stator END Winding Support
Stator End Winding Assembly
 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.
 ABOUT HYDROGEN - 2

• 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.
 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.
THDF: VENTILATION SCHEME - 2
 110 MW TG 985-32
VENTILATION DIAGRAM
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.
 STATOR WINDING WATER

• Thermal capacity of water as liquid is

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

 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. Bending critical speed away ±5% of operating speed
5. Supported on two journal Bearings
6. Provision of axial fan/compressor for forced ventilation
7. Provision of damper wedges for increasing negative sequence
capability of rotor
4. 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.

- GAS PICK UP SYSTEM EMPLOYED FOR DIRECT COOLING OF

ROTOR WINDING
- 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 SEPARAT

AND SUPPORT THE COILS AND TO RESTRICT THEIR MOUEMENT DUE TO
THELMAL 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.
THW 210/235: ROTOR SHAFT
 Rotor Body with cross Pole Slot

Rotor
Wedge

Cross
Pole
Slot
Rotor Fan Blades
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.
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.
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 TO INCREASE SURFACE AREA OF COOLING.
Rotor Slip Ring
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.

 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 Babbitt material
Auxiliary System

1. Primary Water System

2. Seal Oil System
3. Gas Flow System
 Seal Oil System
Prevents H2 losses at the shaft entry into stator
 Gas System
Facilitates H2 filling & maintains gas pressure in stator 1. H2 BOTTLE
2. H2 PRESS REDUCER
3. N2 BOTTLE.
4. N2 PRESS REDUCER
5. PW TANK
6. PRESS CONTROLLER
7. UPR. GEN GAS HEADER
8. LWR.GEN GAS HEADER
9. GAS DRIER HEATER
10. GAS DRIER FAN
11. GAS DRIER CHAMBER
12. CO2/H2 PURITY TRANS.
13. DEHYDR. FILTER
14. PRESS REDUCER
15. COMPRD. AIR HOSE
16. COMPRD. AIR FILTER
17. CO2 FLASH EVAPORTR
18. CO2 BOTTLE
 New dev - Total Impregnated generator
• A VOID FREE HIGH VOLTAGE INSULATION ALON G THE ENTIRE LENGTH OF THE BAR
• A MECHANICALY FIRM BOUND BETWEEN ALL WINDING
• COMPONENTS AND THE INNER FRAME AND CORE
• BETTER SUITABILITY AGAINST THERMAL STRESSES DURING OPERATION
• BETTER HEAT TRANSFER

• LESS INSULATION THICKNESS - SPACE OPTIMIZED

• MACHINE LIFE IMPROVES
• INCREASE IN GENERATOR EFFICIENCY
• INCREASE IN SHORT CIRCUIT RATIO
• INCREASE IN LINE CHARGING CAPABILITY
• REDUCTION IN SPARES INVENTORY - STATOR BARS AND STATOR SLOT WEDGES ARE
NO MORE REQUIRED AS SPARES
•REDUCTION IN OVERHAULING REQUIREMENTS :
•STATOR WEDGE TIGHTNESS CHECKING NOT REQUIRED
•LOOSENING OF CORE AND FASTNERS REDUCED
•GLUE INJECTION NOT REQUIRED
•ROTOR WITHDRAWL DURING INITIAL INSPECTION NOT REQUIRED
 Generating testing

1. Mechanical test
2. Open Circuit characteristics
3. Short circuit characteristics
4. Sudden short circuit test
5. Voltage wave form
6. Tan  test
7. Vibration Measurement
WOUND STATOR CORE BEING LOADED FOR TOTAL
IMPREGNATION
CURING OF TOTALLY IMPREGNATED
WOUND CORE
INSERTION OF IMPREGNATED WOUND
CORE IN STATOR
Generator Stability Curve
Generator Rotor Purge Test
Generator Rotor Winding Cooling
THANK YOU

END