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1
ELECTRIC GENERATOR
COURSE
IOSU CENDOYA - PRODUCT TECHNICAL MANAGER
16TH NOVEMBER 2010
G8XR - TAR500L4R
2
ELECTRIC GENERATOR
COURSE
9:15-11:00 Electrical design
Thermal design
Insulation
Manufacturing process
11:00-11:15 Break for coffee
11:15-13:00 Auxiliary elements
Preventive maintenance
Electrical tests
13:00-14:30 Lunch
14:30-17:00 Practice on the generator
2
3
INDAR
INDAR ELECTRIC S. L. designs
and manufactures rotative electric
machines since 1940
The company is located in
Beasain (Gipuzkoa)
Product
Engines
Synchronous
Asynchronous
Direct current
Generators
Synchronous
Asynchronous
Wind power (DFIM)
Direct current
Activity fields
Energy
Wind power
Hydroelectric
Cogeneration and thermal
Industry
Syderurgy and Metallurgy
Various industries
Naval
Propulsion
Various actuating systems
Generation
Submersible
Railway
Traction
Generation
Infrastructures
Pump
Desalination
4
ELECTRICAL DESIGN
ELECTRIC GENERATOR
COURSE
3
5
General Concepts
Power
Line Current
Line Voltage
Delta Star Connection
Connections in a three-phase system
Vf Vll 3 =
Ill Vll P 3 =
Vf Vll =
Ill Vll P 3 =
If Ill = If Ill 3 =
6
General Concepts
Magnetic field created by a wire covered
by current
X
Z
Y
I
H
4
7
General Concepts
Theorem of Ferraris:
A multiple phase winding of p pole pairs
and covered by multiple phase balanced
currents, whose frecuency is e produces p
fictitious pole pairs moving with e/p speed
along the winding without suffering any
modification
Rotating magnetic field
8
General Concepts
Synchronous
Permanent magnets
Wound rotor
Asynchronous
Squirrel Cage
Doubly fed (DFIM)
Rotor variable resistance
Wind Power Generators
5
9
Synchronous of magnets
Advantages
High performance
Low maintenance
Disadvantages
Full converter, more
expensive converter
Connection diagram
Asynchronous of cage
Advantages
The cheapest
Low maintenance
Disadvantages
Fixed speed
Constant reactive
consumption
Connection diagram
Asynchronous of wound rotor
Advantages
Variable speed
Moderate price converter
Disadvantages
Maintenance
Connection diagram
G
3~
PWM
Net
G
3~
Net
G
3~
PWM
Net
General Concepts
Wind Power Generators
10
DIMENSIONING OF THE
MACHINE
The volume of the machine is proportional to
the torque
D
2
*L T
T=P/ w

When fixing the power, if there are more poles,

the machine is slower as well as bigger
p
f
n
s
. 60
=
s
s
n
n n
s

=
6
11
GENERATED POWER CURVE
Partial load
Full load
Disconnection
Connection
Windspeedm/s
E
l
e
c
t
r
i
c
a
l
p
o
w
e
r
k
W
12
Losses in a generator
Mechanical
Power
Electrical
Power
Mechanical
Losses
Losses
in stator
copper
Iron losses
Losses
in rotor
copper
Additional
Losses
7
13
Losses in a generator
Mechanical losses
Bearings
Air movement
Steel losses
Hysteresis losses
Joule losses due to the Foucault currents
Stator copper losses
Rotor copper losses
Additional losses
Losses due to the current displacement
Losses in the parts
Various losses
14
DFIM: Doubly Fed Induction
Machine
Doubly Fed Induction Machine
Doubly Fed Asynchronous Generator
8
15
DFIM: Double Fed Induction
Machine
Stator is directly connected to main
Stator creates a magnetic field, which rotates with
the synchronous speed
Rotor is connected to a voltage inverter
variable with frequency
Magnetic field created by the rotor rotates with
respect to the rotor with variable speed
Both magnetic fields must rotate with the same
speed
16
DFIM: Double Fed Induction
Machine
Working with oversynchronous speed
Working with undersynchronous speed
e
synchronous
e
rotor
e
rotor field referred to rotor
e
synchronous
e
rotor
e
rotor field referred to rotor
9
17
Doubly-Fed Asynchronous Generator
Equivalent Circuit
Rotor parameters referred to stator
V2/s
/s /s
18
Power Distribution in a Wind Power
Generator
slippage P P P
P
P
stator
slippage
slippage
total rotor
slippage
total
stator
= =
=
+
+
1
1

When the slippage is negative (oversynchronous speed)

the rotor generates power
When the slippage is positive (undersynchronous speed)
the rotor consumes power
10
19
Doubly-fed Asynchronous Generator
Speed-Torque curve
Par en funcin del deslizamiento
-60000
-40000
-20000
0
20000
40000
60000
-1 -0,8 -0,6 -0,4 -0,2 0 0,2 0,4 0,6 0,8 1
Deslizamiento
P
a
r

[
N
m
]
T
o
r
q
u
e

(
N
m
)
Slippage
20
PROTECTION DEGREE
Design type IM B3: horizontal machine, floor mounted
with smooth shaft
Machine
Protection factor IP54: protected against dust and splashing
water
Ring body
Protection factor IP23: rainproof and protected against
penetration of solid bodies larger than 12 mm
Connection box
Protection factor IP55.
11
21
THERMAL DESIGN
ELECTRIC GENERATOR
COURSE
22
COOLING: LOSSES
Losses
Pcu = I
2
.R (Rotor & Stator)
Pfe = Hysteresis and Foucault (Rotor & Stator)
Pmec
Pcool = Electrofans & fans
Pfr = Bearings, brushes, aerodynamic resistance
Materials
Copper
Magnetic plate
Insulations
Bearings
Brushes
12
23
TYPES OF INSULATIONS
> $$$$ SPECIAL C
>> $$$ 180 H
>>> $$ 155 F
>>>> $ 135 B
MACHINE
SIZE
INSULATION
PRICE
MAX Temp. THERMIC
CLASS
24
CONDUCTION CONVECTION
- RADIATION
Conduction
Convection
Radiation
u A = . .
s
A
k Q
u o A = . .A Q
) .(
4
0
4
u u = e Q
13
25
DESIGN FACTORS
Ventilation type
Temperature of the cool focus
Insulation class
Height
Different operation points
Various
26
Ventilation
0
200
400
600
800
1000
1200
1400
0 0,5 1 1,5 2 2,5 3 3,5
m
3
/s
P
a
14
27
Heating of a machine
Curve
Heating stabilization
Types of performance: S1
Cool focus temperature
Measured thermal difference: it only
depends on the losses
28
Power and Speed Curve
0,00
200,00
400,00
600,00
800,00
1000,00
1200,00
1400,00
1600,00
1800,00
2000,00
80000 85000 90000 95000 100000 105000 110000 115000 120000
Serie1 Serie2 Serie3 Serie4 Serie5
15
29
Temperature Curve
Series 1 U Winding
Series 2 Outside air inlet temperature
(generator feeding)
Series 3 Outside air outlet temperature
Series 4 - Inside air inlet temperature
Series 5 Inside air outlet temperature
0,00
20,00
40,00
60,00
80,00
100,00
120,00
80000 85000 90000 95000 100000 105000 110000 115000 120000
Serie1 Serie2 Serie3 Serie4 Serie5
30
TYPES OF COOLING
Machine
Open
Closed
Ventilation
Electroventilated
Autoventilated
Type of Cooling
Ribbed housing
Heat exchanger
Water Jacket
Cooler
Air-air
Air-water
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31
SECTION OF G5XR-NCR450L4R
32
SECTION OF G8XR-TAR500L4R
17
33
PQTV CURVES
Connection DELTA
Frecuency 50 [Hz]
Speed 1680 [rpm]
Ambient temperature 50 [C]
Voltage 621 [V] Voltage 655 [V] Voltage 690 [V]
Max. Pow. 2040 [kW] Max. Pow. 2040 [kW] Max. Pow. 2040 [kW]
Pnet Qnet Cos Pnet Qnet Cos Pnet Qnet Cos
[kW] [kVAr] [-] [kW] [kVAr] [-] [kW] [kVAr] [-]
50 -670 0,07 50 -670 0,07
2040 -670 0,95 2040 -670 0,95
2040 0 1,00 2040 0 1,00 2040 0 1,00
2040 670 0,95 2040 670 0,95
50 670 0,07 50 670 0,07
Voltage 725 [V] Voltage 759 [V]
Max. Pow. 2040 [kW] Max. Pow. 2040 [kW]
Pnet Qnet Cos Pnet Qnet Cos
[kW] [kVAr] [-] [kW] [kVAr] [-]
50 -670 0,07 50 -670 0,07
2040 -670 0,95 2040 -670 0,95
2040 0 1,00 2040 0 1,00
2040 670 0,95 2040 670 0,95
50 670 0,07 50 670 0,07
0,95 UNDEREXCITED Q < 0
0,95 OVEREXCITED Q > 0
Graph P-Q
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
-800 -600 -400 -200 0 200 400 600 800
Qnet [kVAr]
Pnet
[kW]
621 [V] 655 [V] 690 [V]
725 [V] 759 [V]
34
MAXIMUM TEMPERATURES AND
INTENSITY LIMITS
165 Ttrip [C]
160 Talarm [C]
10 ---- 10 ---- ts
th
(min)
1775 ---- 1775 ---- Is
th
(T
AMB
= 50C)
1775 ---- 1775 ---- Is
th
(T
AMB
= 0C)
1950 ---- 1950 ---- Max_Is
th
10 ---- 10 ---- tr
th
(min)
760 ---- 760 ---- Ir
th
(T
AMB
= 50C)
760 ---- 760 ---- Ir
th
(T
AMB
= 0C)
835 ---- 835 ---- Max_Ir
th
1193 4190 787,045 2360 X
M
(mO/Equiv. Star)
43281 126288 35898 103737 R
M
(mO/Equiv. Star)
25,97 80,9 20,633 61,9 X
2
' (mO/Equiv. Star)
1,78 5,31 1,79 5,39 R
2
' (mO/Equiv. Star)
27,67 86,1 22,200 66,6 X
1
(mO/Equiv. Star)
1,64 4,93 1,64 4.93 R
1
(mO/Equiv. Star)
422 105 729 128 V
NET
+10%
341 95 533 115 V
NET
I
S|
(A/Line)
1833 1061 1824 1061 E
R|
(V/LL)
Delta Star Delta Star V
NET
= 690V
60 Hz 50 Hz T
WINDING
= 115 c
TAR500L4R
18
35
INSULATION
ELECTRIC GENERATOR
COURSE
36
INSULATION FUNCTION
It avoids passing the current between bodies
subjected to different voltage levels.
19
37
TYPES OF INSULATIONS
EARTH INSULATION
BETWEEN PHASES
BETWEEN TURNS
BETWEEN PLATES
BEARINGS
Shortcircuit
Hot points
Current passing
38
TYPES OF INSULATIONS
20
39
REQUESTS
MECHANICAL
THERMAL
ELECTRICAL
ENVIRONMENTAL
40
Partial Discharges
E=V/d (KV/mm)
Air-breaking voltage= 3 kV/mm
Breaking voltage of a generic insulation=300 kV/mm
Insulation lifetime = 20.000h according to the class
theory:
|
.
|

\
|
=
10
2 * 000 . 20 ) (
u u
u
class
lifetime
C C K
amb
150 50 100
max
= = = A u u u
000 . 20 * 8 2 * 000 . 20 2 * 000 . 20 ) 150 (
3 10
150 180
= = =
|
.
|

\
|
lifetime
years lifetime 20 ) 150 ( =
21
41
TYPES OF WINDINGS
TYPES OF WINDINGS
STAR-DELTA
TYPES OF CONNECTION BOXES
3 ACCESIBLE TERMINALS
6 ACCESIBLE TERMINALS
NUMBER OF PARALLELS
42
R R R
U
V W U1
U2
R
V1
V2
R
W1
W2
R
WINDING DIAGRAMS
R
R
R
U
W
V
22
43
ELECTRIAL TESTS
Insulation resistance
Dielectric strength
Wave comparator
Winding resistance
44
ELECTRIC GENERATOR
COURSE
JAVIER DOMINGUEZ SERVICE ASSISTANCE TECHNICIAN
16TH NOVEMBER 2010
G8XR - TAR500L4R
23
45
PT100
Measure the temperature
Place importance
Protection element
46
PT100
24
47
PT100
48
PT100
25
49
PT100
50
PT100
26
51
ENCODER
52
INDUCTIVE SENSOR
MEASURE THE SHAFT SPEED
REDUNDANT SISTEM
IT WORKS AGAINST WORKS A
DENTED WHEEL
27
53
ELECTROFANS
54
ELECTROFANS
28
55
HEATER RESISTANCE
56
GENERATOR COURSE
PREVENTIVE MAINTENANCE
29
57
Recommended Maintenance
Program
Re-grease bearings as indicated in
bearing plate.
Re-grease Bearings
Condition. Visual inspection Brush gear pressure
mechanism
Condition of cables, color,
insulation.
Visual inspection Brush connection
cables
Alignment. Operation of micro
switches.
Visual inspection Brush holders
Check contact surface for
uniformity and absence of severe
scratching. Check for uniform wear
on all the brushes.
Visual inspection Brushes
Condition and cleaning if
necessary.
Visual inspection Grid (external fan, ring
cowl)
Test insulation resistance. Test Stator and Rotor
insulation
Check rings for proper condition. Cleaning Ring unit
See Tightening Torques drawing. Check tightness Nuts and bolts
Operation. Check Roller Bearings
6 months
Observations Action Element
Maintenance
Interval
58
Condition, leakage. Visual Inspection
Seals (connection boxes,
cooler box, etc.)
Operation. Check Electric-fans
Wear, roundness. Test Slip rings
Change of brushes and
check brush gear pressure
mechanism.
Replacement Brushes
General condition, painting,
earth connection.
Check Machine
Condition, terminals, wiring
connection.
Check Connection box
Operation, alignment,
condition, tightening
torques.
Check Encoder
Operation. Check Heater Resistors
Resistance. Test
PT-100 elements (winding,
bearing, air ring)
Vibration, general condition,
insulation resistance, extra
noise.
Test Bearings
12 months
Observations Action Element
Maintenance
Interval
30
59
General Recommendation of the
Typical Spare Parts
2 pcs Bearing
1 pcs Re-greasing cartridges
9+1+1 pc Brush holders
18+2+1 pcs Brushes
2+1 pc Space heaters
4 pcs Seals (connection boxes,
cooler box, etc)
1 pc Encoder
3 pcs Electric fans
Amount Spare parts
60
If metallic tapping is heard, the bearing must be replaced.
Vibration factors:
Damaged bearings.
Alignment of the generator.
Loose the fixing points of the generator.
Vibrations transmitted from the coupling, gear box to
generator DE.
Take necessary actions to avoid this vibration sources.
Measure insulation resistance between shaft and frame.
Low insulation is a signal of future bearing failure, due to current
passage (eddy or parasite currents).
Bearings
31
61
Re-greasing of Bearings
Re-greasing is essential to ensure a good
working operation.
Use the grease type indicated in the bearing
nameplate.
A MIXTURE OF GREASES WITH DIFFERENT
PROPERTIES MUST NOT BE USED.
Check lubrication channel is open and full of
grease, dismount lubrication nozzle.
Re-grease as indicated on the bearing name
plate.
Lubrication nozzle in the D.E. and N.D.E. sides
to connect the grease pump.
62
32
63
Bolt Tightness
The bolts to be checked and their
corresponding tightening torque are listed in
the tightening torque drawing.
64
33
65
Cleaning of the Ring Unit
The sliding surfaces of the slip rings and
brushes should be kept smooth and clean.
Brush wear generates conductive coal dust
that generates conducting bridges over the
insulation surfaces.
Electric discharges may take place between
slip rings or to earth that can lead to failure.
The contact surface of slip rings forms a
patina, or skin, together with the brushes. It is
a benefit to brush operation.
66
Take the brushes out of their lodgings.
Use a small brush to collect the carbon dust
released by the brushes.
34
67
Use the vacuum cleaner to suck in all the
dust.
68
Spray the dielectric solvent (take the safety
measures indicated in the security sheet of the
product) all over the ring.
Allow all components of the ring unit to dry
completely (approx. 5 min.).
Use a clean cloth to remove any liquid or dirt
deposited in the ring unit.
35
69
Use the vacuum cleaner to suck in all the dust.
NOTE: Measure the insulation before and after
the cleaning.
70
Replacement of Brushes
The brushes wear due to the friction with the
slip ring.
6 months estimated lifetime between the two
marks.
NECESSARY CHANGE 19mm
RECOMMENDED CHANGE 24mm
36
71
Removal of brushes:
Undo the brush fixing screw.
Lift the brush-holder pressure mechanism.
Take the brush out of its housing of the brush-
holder.
Repeat this action for all the brushes.
72
Installation of brushes:
Insert a new brush.
Tighten the brush fixing screw.
Put the brush into the housing.
After mounting the two brushes into each brush-
holder, put a piece of sandpaper (No. 2) on the ring,
with the abrasive side up.
Apply the brush-holder pressure mechanism.
Move the sandpaper along the ring curve to ensure
correct bedding of the brush on the ring.
Repeat this process for all paired brushes of each
brush-holder.
37
73
Relation of Electrical Tests
Electric (ohmic) resistance.
Insulation resistance.
Surge test.
Withstand Voltage test.
74
Electrical Resistance
The winding ohmic resistance is measured
by a miliohmeter.
In case of short-circuit phase to phase, a
local material destruction is produced which
results on an open circuit.
38
75
Insulation Resistance
A DC voltage is applied.
Submit the insulation to a voltage difference.
Current leakages to earth or phase to phase
are measured.
Detects short circuits of high magnitude,
winding contamination, humidity,
76
Surge Test
Apply a pulse of voltage.
Introduce a voltage pulse through the beginning
of a winding and measure the reaction of the
winding to this pulse.
The frequency and amplitude of the induced
tension depends on the L and C of the winding.
Depends on the number of turns of a winding
and the type of iron core on which it is wound.
It compares the voltages produced by equal
windings.
39
77
Withstand Voltage Test
Applies a high voltage ((2 * UN) + 1000).
Detects initial failures (fabrication).
The IEC standards forces to carry out to
every machine in manufacturing process.
Partially destructive. For this it is not very
often tested on field.
DC-AC.
78
Types of Electrical Failure
OPEN CIRCUIT
CONTAMINATI
ON
PHASE TO
PHASE
EARTH
TYPE OF
FAILURE
ROTOR ROTOR STATOR STATOR
NO YES YES NO
YES NO YES YES
YES NO NO YES
YES YES YES NO
SURGE
TESTER
INSULATION
MEASURAMENT
OHMIC
RESISTANCE
40
79
Types of Electrical Failure
80
INGETEAM S.A.
Avda. Ciudad de la Innovacin, 13
E-31621 Sarriguren Navarra
Tel.: +34 948 28 80 00
Fax.: +34 948 28 80 01
Web: www.ingeteam.com
NIF: A-31-270853
THANK YOU FOR YOUR ATTENTION THANK YOU FOR YOUR ATTENTION