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(updated) BLOCK02ELECTRICALMACHINEBLOCK:
Seminar
Block02isdesignedtomanufactureturbogeneraterandmediumsizeACelectricalmachines.
Reports
02Electricalmachinesblockconsistsofthefollowingworkcentres
(updated
Placement 1.3211PressShopManufacturingoflaminationandcoreassembly.
2.3212LightMachineShop:
Papers
(updated) Allhardwareitemsareprocessedinthisshop.
3.3213HeavyMachineShop:
Forums
Computer a.RotorSloting
Science/IT b.FinishMachining
Electronics c.Drilling
Electrical 4.3214CopperShop:
Manufacturingofrotorcoils.

Mechanical 5.3215CoilShop:
Chemical Manufacturingofexcitercoilsandcorecoils.
6.3216StatorWindingShop:
Civil
Manufacturedwindingofstatorslayeddowninstaterhere.
CAT/
7.3217AssembelyShop:
MBA
GMAT/ TotalassemblyofTurbogenerator
8.3218RotorWindingShop:
Foreign
Rotorassemblyisdonehere.
MBA
LatestJobs 9.3219InsulationShop:
Engineering Manufacturingofinsulationitems.
10.CDC:CentreDispatchCell.
Jobs/
Technical
Forhandlingandtransportingthevariouscomponentsoverheadcranefacilitiesare
Jobs
Managementavailable,dependingupontheproductmanufacturedhere.Therearealsoanumberofselfpropelled
electricallydriventransfertrolleysforintermovementofcomponents/assemblies.
Jobs
Sitemap

AboutUs
Termsofuse
ELECTRICALMACHINES:

ThedepartmentsinvolvedinmanufactueoftheElectricalMachinesare:
*ElectricalMachinesEngineering.

ElectricBlockMachine

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*TechnologyDepartment.
*PlanningSection
*ProductionDepartment
*CommercialSection
*PurchaseSection
ProductiondepartmentistheBlock02whichIamdescribinghere.

PHYSICALASPECTSTOELECTROMECHANICALENERGYCONVERSION:
Ingeneralterms,anelectromechanicalenergyconversiondeviceisalinkbetweenanelectrical
andmechanicalsystem.Byapproximatelycouplingthetwosystems,itmakespossibleconversionof
energyfromelectricaltomechanicalformorfrommechanicaltoelectricalform.Inadeviceacting
asagenerator,themechanicalsystemdeliversenergythroughthedevicetotheelectricalsystemin
adeviceactingasmotortheelectricalsystemdeliversenergythroughthedevicetothemechanical
system.The process is essentialy reversible,although part of energy is irreversibly converted to
heatanymotorcanbemadetorunasagenerator,andanycanbemadetorunasageneratorandany
generatorcanbemadetodelivermechanicalpowerasamotor.
Thecouplingbetweentheelectricalandmechanicalsystemsismagneticfieldsareingeneral
present,and energy stored in these fields is inevitably associated with the energy conversion.The
energyinthecouplingfieldofthedevicemaychangeduringtheenergyconversionprocess.Infactit
maybesaidthatthetendencyfortheenergyinthecouplingfieldtoreleaseitselfandtodoworkis
thereasonforthecouplingbetweentheelectricalandmechanicalsystems.
Electromechanicalenergyconversionaccordinglydependsontheexistenceofthenatureinthe
phenomenainterrelatingmechanicalandelectricalfieldsontheonehandandmechanicalforceand
motionontheother.Theprinciplephenomenautilizedpracticallyarethefollowing:
1.Amechanicalforceisexertedonthecurrentcarryingconductorinamagneticfield,andbetween
current carrying circuit by means of their magnetic fields.The energy conversion process is
reversiblebecauseavoltageisinduceinacircuitundergoingmotioninamagneticfield.
2.Amechanicalforceisexertedonaferromagneticmaterialtendingtoalignitwithorbringitinto
thepositionofthedensestpartofthemagneticfield.Whenacurrentcarryingcoilcreatesamagnetic
field,theenergyconversionprocessisreversiblebecausemotionofthematerialwillcauseachange
inthefluxlinkingthecoil,andthechangeinthefluxlinkageswillinduceavoltageinthecoil.
3.Amechanicalforceisexertedontheplatesofachargedcapacitorandonthedielectricmaterial
in an electric fieldconversely relative motion of the plates and dielectric results in a change of
eitherthechargeorthevoltagebetweentheplatesorboth.
4.Certaincrystalsareslightlydeformedwhenvoltagegradientsareappliedinparticulardirections
,andconversely,whentheyaredeformed,anelectricchargeappears.Thisphenomenonisknownas
the piezoelectric effect.Although the deformation of the crystal when voltage is applied is
small,theassociatedmechanicalforcemaybeverylarge.
5.Mostferromagneticmaterialshowsaverysmalldeformationundertheinfluenceofamagnetic
field and,conversly ,the magnetic properties are affected when the materials are strained
mechanically.Thisphenomenoniscalledmagnetostriction.Asinthepiezoelectriceffect,thefull
elasticforceofthematerialisavailableeventhoughthechangesindimensionsaresmall
ROTATINGMACHINES:BASISOF
OPERATION:
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Indiscussingandanalyzingtheoperationofphysicaldevices,morethanoneviewpointcanbe
adopted.Thesimplestviewpointleadstoquick,earthyunderstandingofcertainspecific
features,butitisfrequentlyarestrictedone,whichdoesnotfullyrevealthegeneralproperties
commontomanysimilardevices.Mostsophisticatedandgeneralizedusuallyevolvedonlyafter
someexperiencewithsimilarapproaches,highlightthegeneralcommonpropertiesandlead
ultimatelybothtogreaterinsightandtovaluablecriterialforoptimumoperation.Allelectric
machinesoperateonthesamebasicprinciplesandonlyafewfundamentallawsgovernthe
behaviourofthesemachines.Athroughunderstandingofthesefundamentallawsisessentialforthe
studyofelectricalmachines.Theselawsarelistedbelow:

THEFUNDAMENTALLAWS:

1.FARADAY'SLAWOFINDUCTION
2.KIRCHOFF'SLAWOFELECTRICCIRCUIT
3.CIRCUITALLAWOFTHEELECTRICFIELD(AMPERE'SLAW)
4.LAWOFFORCEONTHECONDUCTORINAMAGNETICFIELD(BIOTSAVART'S
LAW)
1.FARADAY'SLAWOFINDUCTION:
Ifamagneticfluxlinkingaclosedconductingcircuitischanginganelectromotiveforceis
inducedinthecircuit.
Ifrepresentsthefluxlinkingthecircuitanddthechangeinfluxduringthetimedt,then
themagnitudeoftheinducedemfisproportionaltotherateofchangeofflux,d/dt
e=nd/dt
ThedirectionoftheinducedemfisdeterminedbyLenz'slaw,whichstatesthattheinduced
emfopposesthechangeinflux.
2.KIRCHOFF'SLAWOFELECTRICCIRCUIT:
A.KIRCHOFF'SMESHLAW:
Aroundanyclosedloop(ormesh)inanetwork,thealgebraicsumofallemf'sandpotential
dropsisequaltozero.
B.KIRCHOFF'SCURRENTLAW:
Atanynode(orjunction),thetotalcurrententeringthenodeisequaltothetotalcurrentleaving
thenode.Alternativelythealgebraicsumofallthecurrentsatanode(orjunction)iszero.
3.CIRCUITALLAWOFTHEELECTRICFIELD(AMPERE'SLAW):
Thelineintegralofthemagneticfieldstrengthalongaclosedpathisequaltothesumofthe
ampereturnswithwhichthispathislinked

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TURBOGENERATORS
INTRODUCTIONTOTURBOGENERATORS:
Thegrowinguseofelectricalintheworldleadstonewproblemsconcerningthegenerationof
electricalenergy.Themostfrequentlyusedmachines,forthegenerationofelectricalpowerarethe
synchronousmachines.
Faraday'slawofelectromagneticinductionstatesthattheinduced
voltageisproportionaltotherateofchangeofthelinkageofthemagneticlinesofforce.Inthecase
ofelectricalrotatingmachinerythepartofthemachine,inwhichthevoltageisinducediscalledthe
armature.Thecomponent part of the electrical machine which carries the excited or field winding
fortheproductionoftherequiredmagneticlinesofforceiscalledthefieldsystem.Ifthefieldisso
providedthattheofforceafteraparticulardistancechangetheirdirection,thefieldsystemissaidto
posses alternating poles.Alternating poles mean that the poles are alternatively north and south
poles.Thechangeoffluxiscausedwhenthearmaturemovesinafluxsetbyalternatingpoles.Itis
naturallyjustthesamewhetherthepolesmovesandthearmaturewindingremainsstationaryorthe
polesremainsstationaryandthearmaturemoves.Almostallalternatingcurrentgeneratorsarenowa
daysdesignedwithrotatingfieldsystem.Thisarrangementisthenaturalorderofthingsforafew
verygoodreasons:

1.Thehighvoltage,highcurrentandthereforehighpowerhandlingelementisthearmatureonany
ACorDCrotatingelectricalmachine.Armaturecoilsarethereforelargerthanfieldcoils.

2. Since no alternate switching of coil polarities is needed on an AC machine, no commutator

functionisneeded.Thus,thehighpowerwindingsmaybemadestationaryfordirectconnection.The
universalmotorisanexceptiontothiscondition.

3.Thefieldstructureandcoilsarenotordinarilyrequiredtohandlemorethanafractionofthetotal
power.Thus,theirrotatingelectricalconnectionmaybemadesmaller.Sincenopolarityswitchingis
required,collectorareusuallyused.

4.Thearmatureand fieldcoils are both placed in slots in the punched magnetic structure,but the
stationaryarmaturecanbeconvenientlymadetowithdeepertohandletherequiredlargercoils.

5.ItiseasiertocoolthestatorthantherotorwhichisanadvantageofthenormalACconstruction.

6. The main reason for designing the alternating generator with rotating field system is that AC
generatorsaredesignedforhighvoltages(433kV),whicharedifficulttobetappedfromsliprings
incaseofrotatingarmaturetype.Forsmallervoltagestherotatingarmaturetypemaybecheaperbut
inordertoachieveuniformityallACgeneratorsaredesignedwithrotatingfields.
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7.Itiseconomicaltohavearmaturewindingonthestatorandfieldwindingontherotor.Inorderto
illustrate this,consider a 3phase ,starconnected,200MVA,11kV,synchronous machine.Its line
currentis10,500A.Ifthearmaturewindingisplacedontherotor,threeslipringseachcapableof
handling10,500 A would be required.Further each slip ring must be properly insulated from the
shaft for a voltage of 11/1.732,i.e.6.35 kV.The starpoint of the 3 phase winding must also be
brought out through fourth slipring,in order to connect it to a grounded metal plate through a
resistance.
Assumenowthatlowpowerrequiredforthefieldwindingis1MWat500volts.Thentheexcitng
or field current is 1000/0.5=2000A.Only two slip rings,each capable of handling 2000A,are
required.Alsoeachslipringshouldbeinsulatedfromtheshaftforavoltageof500voltsonly.This
showsthatitischeapertohavefieldwindingontherotorratherthanthearmaturewinding.Thusthe
construction of synchronous machine with armature winding on the rotor is much more
economical.In addition,a synchronous machine with armature winding on the stator and field
windingontherotorhasreducedslipringlossesandisthereforemoreefficient.
8.Stationaryarmaturewindingscanbeinsulatedsatisfactorilyforhighervoltages,allowingthe
constructionofhighvoltage,say33kV,synchronousmachines.
9.Lowpowerfieldwindingontherotorgivesalighterrotorandtherefore,lowcentrifugalforces.In
viewofthis,higherrotorspeedsarepermissible,thusincreasingthesynchronousmachineoutputfor
givendimensions.
Thetypeofconstructionusedforasynchronousgeneratordependsuponthetypeofprime
mover.Threedifferenttypesofprimemoversverycommonlyusedthesedays.Theseare:
1.STEAMTURBINES
2.HYDRAULICTURBINES
3.DIESELTURBINES
1.STEAMTURBINES:Steamturbineshaveefficiencyatlargespeedsandhencesynchronous
machinesdrivenbysteamturbinesarehighspeed.
Weknowthat

NS=120f/P

For a standard frequency 50 cycles/second and with the minimum possible number of poles
to,the maximum operational speed of a synchronous machine by turbine alternators is 3000
revolution/minute.InAmerica,however,themaximumoperationalspeecdofsuchgeneratorsis3600
revolution/minute,asthefrequencyis60cycles/second.Suchhighspeedscallforhorizontalshaftof
the machine and have to be designed with rather lower values of the diameter of the rotor.The
peripheralspeedofmachineisgivenby:

v =DN/60

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whereDisthediameteroftherotorinmetersandNisthespeedoftherotorinrevolutionsper
minute.Sincetheperipheralspeedincreasesproportionallywiththediameterandwiththeincrease
inperipheralspeedthemuchforcesactingontherotorincrease,thediametersarekeptlowandthe
rotorshavecylindricalshapes.
2.HYDRAULICTURBINES:
Hydraulicturbineshavedifferentforms.Thetypeofhydraulicturbineusedasaprime
moverforthegenerator,dependsuponthewaterheadavailable.Ifthewaterheadavailableishigh,
apeltonwheelisusedasahydraulicturbine.Insuchacasethehydraulicturbinehasahighspeed
and both the turbine and generator may either be vertical or horizontal, the horizontal type being
morefrequent.Peltonwheelsareusedforwaterheads400mandabove.Uptoawaterheadof380
m Francis turbines are used and in water heads upto 50 m Kaplan turbines , the turbine and the
generatorareoftheverticaltype.Sincethewaterheadisnothigh,thespeedofsuchaprimemover
varies from 50 rpm . The type of synchronous machine used with the hydraulic turbines are the

salient polesynchronousmachine,i.e.synchronousmachineswithprojectedpoles.
3.DIESELENGINES:
Diesel engines, as prime movers are thesedays usedin lowrating
synchronousmachines.Theyareuniversallymanufacturedashorizontaltypeandthereforeboththe
primemoverandthegeneratorareofhorizontalconstruction.Becauseoftheslowspeeds of the
diesel engines, the synchronous generator used this type of prime movers are salient pole
synchronousmachineswhendrivenbyadieselengine.Synchronousmachinesareverysensitiveto
thetorquevariationsorswingsofthedieselengines.
Thereportdescribestheoperationandandmaintenanceaspectsofaturbo
generatorsanditsauxilasiesalongwiththeirconstructionalfeatures.Themachinebeingdeveloped

ontheprovenlineskodal design under collaboration with Czechoslovakia,the operation and the

maintenance procedures are developed based on the manufactures and his collaborators

experienced inthefieldoTurboMachines

SYNOPSISOFTHEFUNCTIONOFTURBOGENERATORS:
1.Thegeneratorrotorisdrivenbyaprimemoverandondriversidegas/diesel/steam/hydro
,dependingontheequipmenttowhichitismeantfor.
2.Thenondrivesideoftherotorisequippedwitharotatingsidearmature,whichproducesAC
voltage.ThisisrectifiedtoDCbyusingaDCcommutator/rotatingdiodewheeldependinguponthe
typeofexciter.
3.Therearendofaboveexciterarmatureismountedwithapermanentmagnetgeneratorrotor.
4.Astheaboverotatingsystemisputintooperation,thePMCstatorproducesACvoltage.
5.ThisvoltageisrectifiedbythyristorcircuittoDC.
6.Thissupplyisgiventoexciterfield.thefieldisalsocontrolledbytakingfeedbackfrommain
generatorterminalvoltage,tocontrolexternalfieldvariationsrequiredbyautomaticvoltage
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regulator.
TherectfiedDCsupplyoutofexciterissuppliedtoturbogeneratorrotorwindingeither
throughbrushesorcentralleadwhichwillbedirectlyconnectedtotorbogeneratorrotor
winding.Thisdependsontypeoftheexciterviz.,DCcommutatormachineorbrushlessexciter.
7.ThemainACvoltageofgeneratorisfinallyavailableatturbogeneratorstatorasindicatedin
thefigure.
Necessaryprotectionequipmentisalsohoweverwhichisnotcoveredinthisscope

LARGESIZETURBOGENERATORS(LSTG):
Thesetypeofgeneratorsarethosewhichhassteamturbinesastheirprimemoverandcurrentis
suppliedbyexcitersystem.Theirmaintypesare:

1.THRI
2.TARI
3.THDI
4.THDD
5.THDF
6.THFF

Herebasictermsare

T=Turbogenerator
A=Aircooled
H=Hydrogencooled

R=Directradialcoolingwithgas
D=Directaxialcoolingwithgas
F=Directaxialcoolingwithwater
I=Indirectcooling

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MAINPARTSOFLSTG:

ThemainpartsofTurbogeneratorare:
STATOR:

Itincludesstatorframe,statorcore,statorwinding,generatorcoolers,statorsend
covers,temperaturemeasuringdevice.
ROTOR:

Itincludesrotorwinding,rotorshaft,fieldconnections,rotorretainingrings,fansand
bearings.
COOLINGSYSTEM:

Itincludesthecoolingcircuitsrequiredfortheeffectivecoolingofthegenerator.Thereare
mainly4typesofcoolingsystemdependingupontheratingofthegenerator

*Aircoolingsystem(60MW)
*Hydrogencooling(100MW)
*Watercooling(500MW)
*Waterandhydrogencooling(1000MW)

EXCITERS:
Smallgeneratorswhicharecoupledtomaingenerators.Thepurposeofthisistoprovidethe
necessaryexcitationcurrents.

STATOR

CONSTRUCTIONALFEATUREOFSTATORBODY:
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1.STATORFRAME:
Thestatorframeconsistsofacastingofweldedplateconstructionreinforcedinternallyinthe
radial and axial direction by web plates making the entire frame perfectly rigid to minimize core
vibrationsandsuitablydesignedtoensureefficientcooling.Wedgeshapedsteelguidebarswelded
totheframedirectlysupportthestatorcore.
Endcovers,whicharemadeofAluminiumalloy,areboltedtotheendsoftheframe.In
theendcovers,arelocatedsuctionductswithspeciallydesignedguidevanes,toensureuniformity
in fanning suction all around. Ingress of oil vapours into the machine is minimized, by sealing
aroundtherotorandatthedividingplanesoftheendcovers.

2.PIPECONNECTION:

To attain a good aesthetic look the water connection to gas coolers is done by routing
stainlesssteelpipesinsidethestatorbodywhichemanatefrombottomandemergeoutofwall.
FromsidewallstheseareconnectedtogascoolersbymeansofUtubesoutsidethestator
body.Forfillingthegeneratorwithhydrogen,aperforatedmanifoldisprovidedatthetopinsidethe
stator body.Before filling hydrogen,carbondioxide is filled as hydrogen react to air result in
explosive mixture.Thus carbondioxide displace displace air and later it is replaced by
hydrogen.SameprocedureisadoptedwhenitisrequiredtoshutT.G.

3.TERMINALBOX:

Thebearingandendsofthreephasesofstatorwindingarebroughtouttotheslipringendof
thestatorbodythroughterminalbushinginaterminalbox.Theterminalboxisweldedconstruction
of(nonmagnetic)austenlticsteelplates.Thismaterialeliminateschancesofstraylossesduetoeddy
current,whichmayresultintoexcessiveheating.

CONSTRUCTIONALFEATUREOF
STATORCORE:

CORE:
Themainfeaturesofcoreare:
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*Toprovidethemechanicalsupport(holdingthewindings).

*Tocarryeffeectivelytheelectromagneticfluxgeneratedbythe
rotorwinding.
*Toensuretheperfectlinkagebetweencoreandrotor.

Inordertominimizethehysteresisandeddycurrentlossesoftherotatingmagneticflux,which
interactswiththecore,theentirestatorcoreismadeupofsegmental,annealedinsulatedpunchingof
hotrolledhighqualitysiliconsteel.Thesepunchingsareassembledinaninterleavedmanneronthe
machineguidebarsandseparateintopacketsofapproximately50mmthickbetweenwhicharethe
ventilation ducts.Between two packets one layer of ventilation is provided.Steel spacer are spot
weldedonstampings.
The spacers from ventilating ducts where the cold hydrogen from gas coolers enter the core
radiallyinwardstherebytakingawaytheheatgeneratedduetoeddycurrentlosses.
Thepunchingsasshowninthefigurearestampedfromthinsheetsof0.5mmthickandcontain
openendslotsforthestatorbarswithdovetailslotsforwedgestoholdthestatorbarsinplace.Other
dovetailslotsatthebackofthepunchingareforassemblyandlockingofthesegmentsontheguide
bars.Theassembledpunchingsareclampedintoastiffcylindricalcorebypressureappliedthrough
steelandclampingplate.Pressureisappliedtotheteethbynonmagneticpressuringfingers,which
areboltedtotheendclampingplates.Inordertoreduceendheatingfromendleakagefluxandits
associatedelectricallossesthatareoccuringattheendsofthestatorcore,thepacketsofpunchings
are stepped back to increase the gap between the punchings and rotor.Theinsulationisathermo
settingvarnish,whichmaintainsitsinsulatingvalueattemperaturesabovethenormaltemperature
range.

OPERATIONS:

A.TheColdRolledNonGrainOriented(C.R.N.G.O)steelsheetsintherequiredshapes
accordingtothesizeofthelaminationsandthenfedintotheshearingpressforpunchingand
dovetailshapedstatorlaminationssegments.

B.BLANKINGANDNOTCHING:
Theholesandslotsaremadeonsegments.Nearly500tonnescrankpressisusedforthis
purpose.

C.DEBURRINGOPERATIONS:

Inthisoperationtheburnsinthesheetduetopunchingaredeburred.Therearechancesofshort
circuitwithinthelaminationsiftheburnsarenotremoved.Thepermissiblelimitisabout5
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micrometers.Fordeburringpunchedsheetsarepassedunderrollers(withrequiredclearance)to
removethesharpburnsoredges.

D.VARNISH:

Thelaminationsarenowvarnishedtoprovideinsulation.
E.

Alkylphenolicvarnishisusedtoprovidetheinsulationbetweenthelaminationsthenitis
passedthroughfurnacesothatitmaygetconsolated.

CONSTUCTIONALFEATUREOFSTATORWINDINGS:
The double layer stator windingis of the involute type and is manufactured from electrolyic
copper.It is located in open slots.The coils are pre formed from copper strips as half coils.The
windingiscomposedofinsulatedhalfcoilbarsassembledinthestatorslotsintwolayersandare
brazedtogetherateachendtoformcoils.Theyareinturnsuitablygroupedintoproperphases,using
bus type connector rings supported on end brackets.The stator bars are composed of insulated
copperstrandstransposed by rouble method so that the eddy current losses are reduced and to
ensure proper distribution of flux.A futher partial transposition is carried out in the end
windings.These arrangement s avoid circulating current losses which would otherwise be present
underloadconditionsduetodistributionofmagneticfluxintheslot.
The bars are insulated with mica based insulation.This insulation has excellent electrical
properties,and does not require impregnation.Its moisture observation is extremely low.And outer
coveringofasbestostapeisappliedtoprotecttheabrasionintheslot.Inordertominimizetheeffect
ofCoronaslightlyconductivecoating(containinggraphite)isthenappliedtothebarintheslot
portion and semi conductive coating is applied to a certain length on the overhang portion of
bars.Anadvantageoftheinvolutecoilwindingisthatendwindingisatanangletothestatorcore
endthusminimizingthestraylossesinthestatorcoresupporters.

ENDWINDING:
Theendwindingi.e.theoverhangportionhasbeingthroughlyreinforceagainsttheshortcircuit
forceswithepoxyglasslaminatedspacersandbyfurtherbindingontothefastenerblockswhichin
turn are screwed to the nonmagnetic damper ring bolted to the stator frame.This solid copper
damperringoneoneithersideconsiderablyreducesreducesheatingontheendiron

RESISTANCETEMPERATUREDETECTORS:
Thestatorslotsareprovidedwithplatinumresistancethermometerstorecordandwatchthe
temperatureofthestatorcore,toothregionandbetweencoilsidesofmachinein
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operation.AccordingtoVDE0530/7,55allACmachinesratedformorethan5MVAorwith
armaturecoreslongerlongerthan1metreistobeprovidedwithatleast6resistancethermometers
orthermocouples,whichshallbebuiltinsidethestator,suitablydistributedaroundthe
circumferenceatthelikelyhottestpoints.Inthecaseoflongerlengthsitistorecommendedbythe
specificationtodistributetheresistancethermometersalongthelength.Thethermometershouldbe
fittedintheslotbutoutsidethecoilinsulation.Whenthewindinghasmorethanonecoilsideper
slotthethermometeristobeplacedbetweentwinsulatedcoilsides.Accordingtothesame
specificationsthelengthoftheresistancethermometersdependsuponthelengthofthecoreofthe
armature.

LENGTHOFTHELENGTHOFTHE

COREMETERRESISTANCE
(INMETER)THERMOMETER
(INCM)

Upto0.512.5

Over0.5to1.025.0

Over1.050.0

Theleadsfromthedetectorsarebroughtoutandconnectestotheterminalboardforconnectionto
temperaturemetersorrelays.
Theresistancetemperature(RTD)isaresistancelement.OperationoftheRTDisbasedon
the principle that the electrical resistance of a metallic conductor varies linearly with its
temperature.The resistance wire of these detectors are moulded into a fiber glass strip
approximately 2 mm thick and trimmed to slot width.All moulded strip detectors are non
inductively wound to cancel the extraneous voltage induced in them.Thus,by measuring
resistance(usually incorporating quick and fairly accurate Wheatstone's bridge)temperature can be
computedfromcalibrationcurvesuppliedwiththetestreport.
Thermometers for the remote measurement of temperatures of air at inlet and outlet(i.e. cold and
hot)havealsobeingprovidedwithinthestatorframe.

DESIGNFEATUREOFSTATOR:
1.Overhangportiongenuinelyshiftstosupportrings,whereitrests.
2.Endpacketofcorestampingsareputinsteps.
Simultaneouslyacutisprovidedonthesestamping.Themainmottobehindthisistoreduceeddy
currentlossesasatendsleakagefluxismaximum.

3.Forminganglesofallstatorbarsaredifferent.Thusitispossibletoconnectthemingiven
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particularfashion.Endbarshavegotdifferentlugtotakephaseconnectionoutit.

4.Onedesignfactorischordingofthepolewindings.Ifinthe36slot,4polemachine,anindividual
coilentersslot1andcomesinslot10,itwillhavespanned90mechanicaldegreesofthestator
circularstructure.Inthiscase90mechanicaldegreesis180electrical.Thusthetwosidesofthecoil
areinthesamerelativepositionontheadjacentnorthandsouthpolepositions.Thisisafullpitch
coilconstuction.
ThemoreusualACmachinecoilwillcoverlessoftheperipheryofthemachineandisthensaidto
befractionalpitch.Atypicalsituationmighthaveacoilenterslot1andleaveslot7.Thisthencovers
sixoutofapossiblenineslotpitches,andisa6/9or66.7%pitch.ThemajorityofACmachinesare
offractionalpitchtype,forwhichthereareafewimportantadvantages:

*Theendsofthecoilsareshorter,whichmeanslesscopperlossduetolesstotallength.
*Theendcoilscanbeformedmorecompactly.Theendbellswillneedlesswindingspace,resulting
inashorterunit.
*Thereisadistinctreductioninmachineharmonicsduetocancellationofhigherharmonics.Since
allACequipmentisdesignedtooperateonapuresinewave,thegenerationofharmonicsistobe
avoided.Thisisespeciallysowhenthefactorthatachievesitisotherwisedesirable.

*TRANSPOSITIONOFSTATORWINDINGS:
Wherethecurrentbyconductornecessitiesalargecrosssectiontobeused,theliabilitytoexcessive
eddy loss and heating makes it essential to subdivide the conductor into strips.This is due to fact
thattheconductorsorpartsoftheconductorsnearerthetopoftheslotshavelesserselfinductance
thatthosenearerthebottomoftheslot.Hence,thecurrentstendstoflowinthetopportionsofeach
conductor.To prevent such unequal distribution of current the large conductors in alternator
armaturearestranded,andeachstrandisinsulatedwithenamel.Eachconductorismadeupsothat
all strands occupy top,intermediate and bottom positions for equal distances.This is done by
twisting or transposition of coils.In a longcored turboalternator,the twisting may be carried out
threeorfourtimesinasingleslot.Theeffectsoftranspositionarethesameastwistingthebundleof
strands180degreeor360degree.Thisisaccomplishedwithoutsubstantiallyincreasingthewidthof
strands.Foramultiturncoil180degreetranspositionusuallysuffices.Forasingleturncoil,because
ofitsgreaterdepthat360degreetranspositionmaybenecessary.Theeffectistoequalisetheeddy
e.m.f.in all the laminations and to allow the layers to be paralled at the ends without producing
eddy circulating currents between the layers.The crossover is obtained by special shaping of
conductor.ThiskindoftransposedconductoriscalledROEBELBAR
Another type of transposition provides 180degree twist of the strand bundle in the end turn
positionofthewindingwheretheincreasewidthdimensionscanbetolerated.Thegroupofstrands
canbeinsulatedfromadjacentgroupsthroughoutthecoilsinclidedintransposition.

ENDCOVERS:
Endcoversoffabricatedsteeloraluminiumalloycastingsareemployedwithguidevanesoninner
sideforensuringuniformdistributionofcoolingairorgas.
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Incase1500rpmgenerators,endwindingsarefirstenclosedinglassepoxymouldedendcovers
andanoverallsteeloutercoverisprovidedoverthestator.

ROTOR
CONSTRUTIONALFEATURE:
InTurboGenertatortherearetwotypesofrotordesigns:

*Forgedsolidrotor
*Laminatedrotor

ThemainfunctionoftherotoristhattherotoractslikeElectromagentbytakingcurrentsfromthe
excitation systems. It is coupled to Turbine rotor to take the driving torque and thus produce a
flux,which leads to the generation of currents.The changes in the flux produced by the rotor
windingsinducesvoltageinthestatorwinding.Italsohastopwithstandhighpowertorqueproduced
by the by the turbine and the backward torque produced due to the generator current.For large
capacity generator is forged from a single piece ingot of steel alloyed with
nickel,chromium,maganese and vanadium,heated to obtain the required mechanical and magnetic
properties.The forgings must be homogeneous and flawless.The forging undergoes a series of
stringent quality control test like metallographic,ultrasonic and heat stability etc.before it is
acceptedforfurtherprocessing.
The rotor forging is planed and milled to form the teeth.About 2/3 oftherotorpolepitchis
slotted,leaving 1/3 unslotted (or slotted to lesser depth) for the pole centre.Longitudinal slots are
machinedradiallyintherotorbodytoaccomdatefieldwinding.Theslotpitchisselectedinsucha
waythattwosolidpolesdisplacedby180degreeareobtained.
Additionaldummyslotsandsubslots(underthemainslots)provideadequatepassageforthe
coolingairforrotorbodyandwinding.
Rotor shaftissubjected to assembly section in dust proofenclosure.Inthissectionwemount
insulation,windingdamper,connectingleadandretainingringontheshaftwithgreataccuracy.They
aredescribedhere:

1.ROTORSHAFT:
Detailsofshaftaregivenhere
Length:9m(app)
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Diameter:1m(app)
Material:Alloysteel
No.ofpoles:2

2.ROTORWINDING:
Rotorcoilsareofmultiturntype,manufacturedfromsemihard,silveralloyedcopperof
rectangularcrosssection,withventilationholespunchedinit.Twoindividualconductorsareplaced
oneovertheotherarebenttoobtainhalfturns.Furtherthesehalfturnsarebrazedinseriestoform
coilontherotormodel.
Thesolidpolesareprovidedwithadditionalslotsusedtoaccomdatefingerofdampersegment
actingasdamperwinding.

3.INSULATION:
Theindividualturnsareinsulatedfromeachotherbylargelayerofglassprepagstripsonturnof
copperandbackedunderpressureandtemperaturetogiveamonolithicinterturninsulation.Overall
windinginsulationwithrespecttorotorbodyisprovidedbyepoxyglasslaminatedtroughslocated
intheslots.
AtbottomofslotDshapedlinersareputtoprovideaplaneseatingsurfaceforconductorsandto
facilitateeasyflowgasfromonesidetoanother.Theselinersaremadefrommouldingmaterial.The
overhangportionareseparatedbyglasslaminatedblockscalledliners.Theoverhangwindingatre
insulatedfromretainingringsegmenthavingLshapedandmadeofglassclothimpregnatedby
epoxyresin.

4.ROTORWEDGE:
Therotorslotwedgesareusedtoprotectthewindingsagainsttheeffectofcentrifugalforce.This
slotwedgesaremadeofanalloyfeaturinghighstrengthandgoodelectricalconductivity.They
extendbelowtheshrinksealsoftheretainingrings.Theyareshortcircuitedunderretainingfor
shortcircuitinginducedshaftcurrent.Theslotclosingwedgelaminatewhichalsohavedrilled
holes.Thusthecoolingairenteringsubslotsradiallycomesoutthroughtheseholes,ensuring
effectivecoolingofrotor.

5.RETAININGRING:
Theoverhangportionoffieldwindingisheldbynonmagneticsteelforgingofretainingring
againstcentrifugalforce.Theyareshrinkfittedtotheendoftherotorbadybarrelatoneend,while
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theothersideofretainingringdoesnotmakecontactwiththeshaft.
Thecenteringringsareshrinkfittedatthefreeendofretainingringthatservestoreinforcethe
retainingring,securingendwindinginaxialdirectionatthesametime.
Theretainingringsaremadeofnonmagneticalloysteelforgingwithveryhighmechanical
properties.Thismaterialisstressandcorrisionresistant.Thematerialisworkedtoreducestray
losses.

6.FANS:
Twoaxialfanslocatedatthetwoendsofrotorshaftcirculatethecoolinginthegenerator.The
bladesarealuminiumalloydieforgings.Threadingsismadeinthefanbladesrootssuchthatthey
canbefixedintothethreadedpoolsprovidedontherotor.Thefanscirculaterequiredquantityof
coolingairatrequiredheadtoovercomethepressuredropinsidethegenerator.

7.EXCITATIONLEAD:
Theexcitationleadprovideselectricalconnectionsbetweenrotorwindingsandoutputfrom
brushlessexciter.Aflexiblecopperconnectorelectricallyjoinstherotorwindingstotheexcitation
leadsthroughradialcurrentcarryingstuds.Theradialstudisscrewedtofieldleadintheshaftbore
throughaholedrilledradiallyintheshaft.Thefieldleadsrunintheaxialdirectionfromtheradial
studtotheendoftherotor.Theyconsistoftwosemicircularconductorsinsulatedfromeachother
byanintermediateplateandfromtheshaftbytube.Theendsaresuitablydrilledtoaccomdatemulti
contactpinstoreceiveoutputfromtheexciter.

8.BEARINGS:
Bearingsplayanimportantroleintheoperationofthemachines.Thebearingshouldnotdevelop
anydefectevencontinuousoperationforyearstogetherandalsoshouldnotshowwearouts.Inthe
caseofturbogeneratorsplainbearingswithringsforoilcirculationareused.Largeturbogenerators
havebearingslubricatedbyoilcirculatingunderpressure.Theoilflowingoutofthebearingis
cooledbymeansofwatercoolersandaftercoolingthesameoilispumpedin.Thebearingmustbe
oiltightasanyleakageofoilfromthebearinghasthepossibilityofenteringthemachine,spoiling
itsinsulationandresultinginshutdown.
Topreventdamageduetoshaftcurrents,bearingsandoilpipingsoneithersideofthenondriveend
bearingsareinsulatedfromthefoundationframe.Forfacilitatingandmonitoringthehealtinessof
bearinginsulation,splitinsulationisprovided.

9.SLIPRINGS:
Excitationcurrenttotherotorwindingissuppliedthrough2shrunkfitslipringslocatedbeyondthe
mainpedestalbearingontheexciterside.Thesearemadeofsteel,adequatelyinsulatedfromrotor
bodyusingmicastripsinsulation.Actualexcitationleadsfromslipringstothewindingarecarried
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withintheshaftboreandareprovidedwithadequateinsulationofclass'B'type.Forbetterheat
dissipationthesurfaceofslipringshasbeenhelicalmachined.Selfventilationarrangementhasbeen
forsliprings.

10.BRUSHGEAR:
Inordertoeffectivelysupplytheexcitationcurrenttotherotorwinding,thebrushgearsarerobustly
designedwithradialtypebrushholders.Brushesofnaturalgraphitecompositionwithlowco
efficientoffrictionandselflubricatingpropertiesareused,whichensuresmoothandtroublefree
operation.Thebrushgearfreeoperation.Thebrushgeariseitherfixedontotheendofthestatorend
coversorbearingorismountedseparatelyonapedastal.
Dependingontherequirements,generatorsareprovidedwithonloadbrushchanginggears.The
advantagesofthisarrangementare:
*Constantspringtensionovertheentirebrushwear.

*Brushchangeoverwithoutstoppingthemachine.
*Safetyofthepersonnelduetoprovisionofinsulatedhandle.

SPECIALFEATURESOFROTOR
1.Rotorslotsaremadetappedtoincreasemechanicalstrengthofteethpart.
2.Windingsareconnectedinparticularfashiontocreateoppositepoleswhichisshownhere.
3.Inordertominimizewindagelosses,whichtendtobehighatturbine,thesurfaceofthefinished
rotoraremadeassmoothaspossible.

EXCITER
The basic use of given exciter system is to produce necessary DC for turbo generator
system.Principal behind this is that PMG is mounted on the common shaft which generates
electricityandthatisfedtoyokeofmainexciter.ThisexcitergenerateselectricityandthisisofAC
innature.ThisACisconvertedintoDCandthanfedtoturbogeneratorviac.c.bolts.Forrectification
purposewehavegotRCblockanddiodecircuit.
Themostbeatifulfeatureofthistypeofexciteristhatitautomaticallydecidesthemagnitudeof
currenttobecirculatedinrotorcircuit.ThishappenswiththehelpofA.V.R.system,whichmeans
automaticvoltageregulator.A feedback path is given to this system which compares theoritical
valuetopredeterminedandthenitsendsthecurrenttorotorasperrequirement.

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TESTING

1.TESTPROCEDUREFORHIGHVOLTAGETESTONSTATOR
WINDINGSOFTURBOGENERATOR:

SCOPE:
Thisprocedurecoversthehighvoltagetestonstatorwinding.

PURPOSE:
Thistestisconductedtocheckwhethertheinsulationisproperlyplacedornot.Theinsulation
placedoverthewindingsshouldbeinsuchawaythattheymakehalfoverlapswiththenext
wrappingofthetape.

THISTESTISEXCLUSIVELYCONDUCTEDTOTESTTHE
HEALTHINESSOFINSULATIONOFWINDINGS.

2.TESTPROCEDUREFORHIGHVOLTAGEONROTOR
WINDINGOFTURBOGENERATORS:

SCOPE:
Thisprocedurecoversthehighvoltagetestonrotorwinding.

PURPOSE:
Thistestisconductedtocheckwhethertheinsulationisproperlyplacedornot.

3.TESTPROCEDUREFORMEASUREMENTOFDC
RESISTANCEOFSTATORANDROTORWINDINGSOFTURBO
GENERATORS:
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SCOPE:
Thisprocedurecoversthemeasurementofdcresistanceofstatorwindings.

PURPOSE:
Thistestisconductedtomeasuretheresistancecontentpresentintheconductingmaterialof
statorandrotor.

TESTPROCEDUREFORMEASURMENTOFIMPEDANCEOF
ROTORWINDINGWITH5OAND500HzSUPPLY:

SCOPE:
ThisprocedurecoversthemeasurementofimpedanceofRotorwinding50and500Hz
source.

TESTEQUIPMENT:
1.50Hz(Powerfrequency)/500HzACsource.
2.ACvoltmeter(030,75,150Vand0150,300,450V)
3.ACAmmeter(05A)
4.Multimeter
5.Currenttransformer(50/5Aor100/5A)
6.Connectingleads

CALCULATIONS:

Z=V/IOHM
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WhereZ=Impedanceinohms
V=VoltageinVolts
I=CurrentinAmperes

With50Hz,thistestisdoneinfollowingconditions:
1.Rotoroutsidethestatoratstandstill.
2.Rotorinsidethestatoratstandstill.
3.Rotorinsidethestatoratspeeds1/3,2/3,3/3ofratedspeed.
500Hzsourceisusedonlyduringprocesstesting.

ACCEPTANCELIMITS:
IMPEDANCEWITH50Hz:
Astheimpedanceoftherotorwindingdependsonphysicalgeometryoftherotor,itisnotpossible
tofixatparticularvalueforacceptance.Butapeculiarcharacteristicthatimpedanceincreasewith
increaseofvoltagecanbeassured.Valueofincreaseislessincylindricalrotorsthaninsalientpole
rotor.
IMPEDANCEWITH500Hz:
Thismeasurementisonlytoobservethevoltagedropacrosseachpole.Differenceinvoltagedrops
upto2Visacceptableacrosstwoidenticalpoles.

5.TESTPROCEDUREFORMEASUREMENTOFLEAKAGE
REACTANCEOFTURBOGENERATORSTATORWINDING:

SCOPE:
Thisprocedurecoverstheleakagereactancemeasurementbofstatorwindingafter
completionofwinding.

PURPOSE:
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1.Todeterminetotalleakagereactance

(xb)

(xa)

2.Todetermineboreleakagereactance
3.Tocomputepotierreactance

(xd)

6.TESTPROCEDUREFORCAPACITANCEANDTAN$
MEASUREMENTOFSTATORWINDINGS:

SCOPE:
Thisprocedurecoversthemeasurementofcapacitanceperphasewithrespecttogroundandtan$of
thestatorwinding.

PURPOSE:
Togeneratereferncevalueforcomparisoninfutureatsite.

PRINCIPLE:
Thestatorwindingshavetwovaluesofcapacitances

C :Capacitancewithrespecttogroundcalledgroundcapacitance

1.

C :Capacitancewithrespecttootherwindingscalledmutualcapacitance.

2.

ThemeasurementofcapacitanceisdoneusingScheringBridgeandaStandardcapacitor.

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