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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING
INDEX 1. Introduction 1.1 Gas- turbine generator; general aspects 1.1.1 Advantages and disadvantages of gas turbine power plants over diesel and thermal power plants 2. Description for stage I 2.1 Gas turbine 2.2 Excitation 3. Description for stage II 3.1 Gas turbine 3.2 Heat recovery steam generator 3.3 Steam Turbine 3.4 Excitation 3.5 Estimated generator data
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Gas turbine generator 4.1 Generator assembly 4.1.1 Stator 4.2 Rotor construction 4.3 Bearings 4.4 Hydrogen cooling 4.4.1 Cooler frame 4.4.2 Cooler tubes 4.4.3 Tube sheets 4.4.4 Water boxes 4.4.5 Gaskets
KPIT, EEE, Rajahmundry
4.5 Generator ventilation 4.5.1 Ventilation System 4.6 Generator lubricants 4.7 Seal oil system 4.8 Grounding and neutral ground transformer
5. Insulation 5.1 Nature of Insulation 5.2 Selection tests 5.2 Water cooling winding 5.3 Analysis tests (Recommended) 5.4 DC leakage
6. Case study 6.1 Generator dismantling and Rotor Thread out. 6.2 Inspection report on 112MW GT generator stator fault at GTPS 6.3 Analysis 6.4 Conclusion 6.5 References
CHAPTER 1 INTRODUCTION
1. Introduction:
Andhra Pradesh Gas Power Corporation Ltd., (APGPCL) is a company promoted by Andhra Pradesh State Electricity Board (APSEB) in association with industries in the private and public sector to supplement power supply from the grid. The Pioneering effort has come into being weft 31.10.88 paving way for many more Gas based stations around the region. It was among the first companies to be permitted in the private sector after the electricity laws in the country restricted entry only to government bodies and/or government owned companies in to power generation and before the opening up in 1991. Gas Turbo Power Generation, Vijjeswaram owned by M/S.APGPCL exists in an island amidst the Godavari water of the western delta canal and navigation canal branching out from the great river Godavari at Sitampet village of kovvur mandal in West Godavari District of A.P.
The objectives of the company are:
y y
Supplementing power from grid. Meeting the demands of energy of the participating industries without restrictions.
Enabling cheaper and reliable and source of power to all its participating industries than what a captive generation plant would give them. Ensuring appreciations on the investment made by the company.
GTPS has generation capacity of 272MW in two stages. Stage1 is of 100MW and Stage2 is of 172MW. The Company installed a 100MW Gas based Combined cycle Power Plant comprising two Gas Turbines.
They have a generation capacity of 33MW each and one steam turbine generator of 34MW capacity with natural gas as main fuel. M/S.BHEL had
undertaken to execute the most recent combined cycle plant indigenously built 33MW Gas Turbine Generator units for the first gas project in Andhra Pradesh at Vijjeswaram. The company successfully commissioned first phase of the plant containing two gas turbines generators and one steam turbine generator on 31.08.90, 02.02.91, 17.03.92 respectively.
The second stage installed capacity is 172MW with total capacity is 272MW in combined cycle as a natural gas prime fuel. The plant containing 1no.112MW Gas turbine of GE, USA make, model frame 9E and 1no.60MW steam turbine of GE, USA make at site conditions. The plant engineering and design was done by M/S Toshiba plant kansetsu, Japan. The gas turbine was commissioned on 22.12.1997.
The GTPS is the first gas based power plant come up in South-India and commissioned its first gas turbine in the year 1990.
The fuel for gas turbine is natural gas/clean liquid fuel viz., Naphtha/HSD. The gas resources of KG basin are near to supplement the short fall of natural gas or as a base fuel supplied by M/S HPCL either from Kakinada/Gummaladoddi(60/25km away from GTPS)
The water required for condenser cooling for both the stage1 and Stage2 is available from the Sir Arthur Cotton Barrage on river Godavari.
1.2 Gas- turbine generator; general aspects: A windmill was probably turbine to produce useful work, where in there is no precompression and no combustion. The characteristic features of a gas turbine include a compression process and a heat addition (or combustion) process. The gas turbine represents perhaps the most satisfactory way of producing very large quantities of power in a self-contained and compact unit. The gas turbine may have an ample future using conjunction with the oil engine. For smaller gas turbine units, the inefficiencies in compression and expansion process become greater and to improve the thermal efficiency it is necessary to use a heat exchanger. In order that a small gas turbine may compete for economy with the small oil engine or petrol engine it is necessary that a 5 KPIT, EEE, Rajahmundry
compact effective heat exchanger be used in the gas turbine cycle. The thermal efficiency of the gas turbine alone is still quite modest 20 to 30% compared with that of modern steam plant 38 to 40%. It is possible to construct combined plants whose efficiencies are of the order of 45% or more. Higher efficiencies might be attained in future. The following are the major fields of application of gas turbine. 1. Aviation. 2. Power generation. 3. Oil and gas industry 4. Marine propulsion The efficiency of gas turbine is not the criteria for the choice of this plant. A gas turbine is used in aviation and marine fields because it is self-contained, light weight not requiring cooling water and generally fit into the overall shape of the structure. It is selected for power generation because of its simplicity, lack of cooling water, needs quick installation and quick starting. It is used in oil and gas industry because of cheaper supply of fuel and low installation cost. The gas turbines have the following limitations: 1. They are not self starting. 2. Low efficiencies at part loads. 3. Non-reversibility. 4. Higher rotor speeds. 5. Low over all plant efficiency. In the last two decades, rapid progress has been observed in the development and improvement of the gas turbine plants for electric power production. The major progress has been observed in the following direction: i. ii. iii. Increase in unit capacities of gas turbine units. Increase in their efficiency. Dropping capital cost.
1.2.1 Advantages and disadvantages of gas turbine power plants over diesel and thermal power plants:
Advantages over diesel power plants: y y y y y y y y y y The work development per kg of air is large compared with diesel power plant. Less vibration due to perfect balancing. Less space requirements. Capital cost is considerably less. Higher mechanical efficiency. The running speed of turbine is comparatively large. Low installation and maintenance costs. The torque characteristics of turbine plants are far better than diesel plants. The ignition and lubricant systems are simpler. The specific fuel consumption does not increase with time in gas turbine plant as rapidly as in diesel plants. y Poor quality fuels can be used.
Disadvantages: y y y y Poor part load efficiency. Special metals and alloys are required for different components of the plants. Special cooling methods are required for cooling the turbine blades. Short life.
Advantages over steam power plant: y No ash handling problem. y Low capital cost. y The gas turbine plants can be installed at selected load center as space requirement is considerably less where steam plant cannot be accommodated. y Fewer auxiliaries required. y Gas turbines can be built relatively quicker. y They require much less space and civil engineering works and water supply. y The gas turbine as peak load plant is more preferable as it can be brought on load quickly and surely.
y The components and circuits of a gas turbine plant can be arranged to give the most economic results in any given circumstances which is not possible in case of steam power plants. y For the same pressure and initial temperature condition the ratio of exhaust to inlet volume would be only 03.95 in case of gas turbine plant as against 250 for steam plant. y Above 550 C, the thermal efficiency of the gas turbine plant increase three times as fast the steam cycle efficiency for a given top temperature increase. y The gas turbine can work quite economically for short running hours. y Storage of fuel is much smaller and handling is easy.
CHAPTER 2 DESCRIPTION OF STAGE 1
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2. Description for stage I:
2.1Ratings of Equipment at Stage-I TURBINES & GENERATORS: DETAILS MAKE MW PF KVA SRATOR: VOLTS: AMPS: ROTOR: VOLTS: AMPS: SPEED FREQUENCY COOLANT CONNECTION INSULATION 61/174 221/598 3000 50 AIR STAR CLASS B 61/174 221/598 3000 50 AIR STAR CLASS B 3000 50 AIR STAR CLASS B 11000 2099.5 11000 2099.5 11000 GAS TURBINE-I BHEL/HYD 33 0.8 40000 GAS TURBINE-II BHEL/HYD 33 0.8 40000 STEAM TURBINE BHEL/HYD 34 0.8 40000
2.1Gas turbine: A gas turbine power plant consists of a Gas Turbine with compressor mounted on the same shaft or coupled to the turbine, the combustion chamber, an alternator coupled to the turbine itself and auxiliaries such as starting device auxiliary lubrication pumps, oil system and duct system etc.
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The compressor (17 stage axial) from the atmosphere sucks in the air through the filter, which removes dust from the air. At the output of the compressor the air is available with high pressure. The compressed air is fed into the combustion chamber.
Fuel (Natural Gas) is injected into the combustion chamber and burnt in the stream of air supplied from the compressor. The products of the combustion comprising of mixture of gases at high temperature (around 15000C) and pressure are passed through the gas turbine. These gases in passing over the turbine blades (3 Stages Turbine) expand and thus result in motion of rotor. Due to the expansion of the mixture in the turbine the temperature falls from 15000C to 5580C. Since the rotor of the turbine is coupled to the rotor of the alternator thus electrical power is generated.
Diesel engine is used for the starting of the compressor and the compressor and it is mounted on the same shaft as that of the turbine. Once the unit starts part of the mechanical power output of the turbine drives the compressor then the diesel engine will be cutoff. Lub oil circulation is used to provide lubrication for the bearings of the turbine and generator. The speed of the turbine is 5100 rpm then the speed will be reduced to 3000 rpm by using load gear box. The outlet gas temperature of the gas turbine is around 5500C.
The outlet gas flow of the gas turbine is controlled by two dampers. One is called as guillotine damper another is diverter damper. In open cycle operation the outlet gases of the turbine are vented to the atmosphere through by-pass stack (30 meter). The By-pass stack and Main stack operations are controlled by Diverter damper. In case of combined cycle operation it is passed through the HRSG to recover heat energy of the exhaust gases to the extent possible. The outlet gas temperature is around 1000C and it is released into the atmosphere through main stack (60 meter).
Water is collected from the de-aerators through the HPBFPs at a pressure of 90kg/cm2and at a temperature of 1100C into the HP economizer-I & II and is converted to steam in the HP drums by using the heat energy of the exhaust gases of the gas turbine. 12 KPIT, EEE, Rajahmundry
This steam is further passed through the super heater-I & II, to remove the moisture content in the steam and to produce the dry saturated steam.
Similarly the water collected from de-aerators tank through LPBFPs with a pressure of 9kg/cm2 and is passed to the LP economizer and produces the LP steam. The above procedure is adopted for the gas turbine-II also. The HP and LP steam of the two gas turbines are fed to the steam turbine. The steam passes through the turbine blades in 49 stages. 1 to 40 is related to HP steam and 41 to 49 are related to LP steam. Then the rotor will rotate and it is coupled to the generator. Thus electrical power is produced. The exhaust steam of the steam turbine is condensed in the condenser by cooling once through cooling system. By using ejectors vacuum is created inside the condenser, due to this vacuum the outlet steam of the steam turbine is sucked into the condenser. The condenser extraction pumps extract the condensate. This passed into the gland steam condenser and then through the condensate pre-heater. The temperature of the condensate is raised and it is passed into the de-aerator for reuse.
2.2Excitation:
The type of excitation is used brush less excitation system. In this system permanent magnet generator (PMG) is coupled on the same shaft of the generator. This is called pilot exciter. The output of the pilot exciter is connected to the AVR. AVR produces an automatically controlled rectified voltage. This is fed to the main exciter field system. Main Exciter produces AC voltage. The main exciter is also coupled on the same shaft of the generator. A rotating bridge circuit is attached on the shaft. The output of the main exciter is given as an input for the bridge circuit. The output of bridge circuit is DC voltage & is fed to the rotor of the main generator. The generator produces Electricity at 11KV at its terminals.
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CHAPTER 3 DESCRIPTION OF STAGE 2
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3.Description for stage II: GENERATORS & GAS TURBINES:

DETAILS FUEL GAS TURRBINE(112MW) NATURAL GAS/NAPTHA/HSD/MIX ED FUEL SPEED OUTLET TEMPERATURE KVA ARMATURE VOLTAGE AMPS CONNECTION FREQUENCY SPEED COOLING PF EXCITATION EFFICIENCY LOAD AT 3000rpm 554 C 151000 11.5KV 7581A Y 50 3000 HYDROGEN 0.8lag BRUSHLESS FULL 98.5% 3000rpm 135C 81300 11.5KV 4082A Y 50 3000 TEWAC 0.8lag BRUSHLESS 98.52% STEAMTURBINE(60MW) STEAM
3.1 Gas turbine:
A gas turbine power plant consists of gas turbine with compresser mounted on the same shaft or coupled to turbine, the combustion chamber and alternator coupled to the turbine itself and auxiliaries such as starting device auxiliary lubrication pumps, oil system, fuel system and duct system etc.
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The compressor sucks the air from atmosphere through the filter, which removes dust from the air. At the output of the compressor, air is available with high pressure. The
compressor air is fed into the combustion chamber. Naphtha, high speed diesel and natural gas are mixed at the ratio desired by the operator within the limits, according to the fuel availability and loading. Fuel is injected into the combustion chamber and burnt in the stream of air supplied from the compressor. The products of the combustion, comprising of mixture of gases at high temperature and pressure are passed through the gas turbine. These gases when passing over the turbine blades expand and thus result in motion of rotor. Due to the expansion of the mixture in the turbine, temperature falls from 1500 degrees C to 558 degrees C. Since the rotor of the turbine is coupled to the rotor of alternator, thus electrical power is generated. Three phase induction motor is used for the starting of compressor and is mounted on the same shaft of the turbine. Once the unit starts part of the mechanical power output of the turbine, drives the compressor then the three phase induction motor will be cut off. Lube oil circulation is used to provide lubrication for the bearings of the turbine and generator. Since there is no need of load gear box, turbine and generator will rotate at the same speed.
3.2 Heat recovery steam generator:
The outlet gas temperature of the gas turbine is around 550 degrees C. This heat energy is recovered by passing the Flue gases through the heat recovery steam generator. DM water is collected from the deaerator tank at high pressure through high pressure Boiler feed pumps and it is circulated through the tubes, these tubes are passed through the HRSG compartment then the heat energy of the Flue gases is transferred to the water then the water is converted into high pressure steam before it leaves the HRSG compartment. Similarly, the water is collected from the deaerated tank at low pressure through the low pressure boiler feed pumps and produce low pressure steam.
The outlet gas flow of the gas turbine is controlled by two dampers called as guillotine and diverted dampers. In open circuit plants, the outlet gas of the turbine is released to the atmosphere. In case of combined cycle, it is passed to the HRSG compartment. The 17 KPIT, EEE, Rajahmundry
outlet gas temperature of the HRSG is around 145 degrees C and is released into the atmosphere through the main stack.
3.3 Steam Turbine: The HP steam is fed in the HP stages of the turbine. The steam is inducted in the LP stages of the turbine through the nozzles. This produces the motion of the rotor. The rotor is rotated at a speed of 3000 RPM. This rotor is coupled to the rotor of the generator and thus produces electrical power. The exhaust steam of the steam turbine is condensed in the condenser by cooling in once through the cooling system. The condensate is extracted by the condensate extraction pumps and it is supplied into the deaerated tank.
3.4 Excitation: The type of excitation is used here in brushless excitation system for STG. In this system a pilot exciter is coupled on the same shaft of the generator. The field of the pilot exciter is controlled by AVR. AVR produces an automatically controlled rectified voltage to the field of pilot exciter. Thus pilot exciter produces AC voltage. A rotating bridge circuit is attached on shaft of pilot exciter. The output of the bridge circuit is a DC voltage and it is fed to the rotor of generator. The generator produces at 11.5 KV ac at its terminals.
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ESTIMATED GENERATOR DATA Reactance data( per unit) Saturated synchronous (xdv) Direct Axis 2.1955 2.1955 0.2726 0.3582 0.1952 0.2546 (x2v) (x2i) (xov) (xoi) (XLM,OEX) (XLM,UEX) (xq) (xqv) (xqi) 0.1835 0.2409 0.0883 0.1099 0.2035 0.2035 0.5868 0.1888 0.2494 Quadrature Axis (xqv) (xqi) 2.1120 2.1120
Unsaturated synchronous (xdi) Saturated transient Unsaturated transient Saturated Sub transient Unsaturated Sub transient Saturated negative sequence Unsaturated negative sequence Saturated zero sequence Unsaturated zero sequence Leakage reactance, over excited Leakage reactance, under excited Field time constant data (sec at 125 C) Open circuit Three phase short circuit transient Line to line short circuit transient (Tdo) (Td3) (Td2) (xdv) (xdi) (xdv) (xdi)
4.0339 0.5008 0.7733 0.8901 0.0230 0.0321
(Tqo) (Tq)
0.3677 0.3677
Line to neutral short circuit transient (Td1) Short circuit subtransient Open cicuit subtransient (Td) (Tdo)
(Tq) (Tqo)
0.0230 0.0715
Armature dc component time constant data(sec at 100 c) Three phase short circuit Line to line short circuit Line to neutral short circuit Armature winding sequence resistance data (per unit) Positive Negative Zero Rotor short time thermal capacity, (I2)t (R1) (R2) (R0) 10 0.0045 0.0199 0.0077 (Ta3) (Ta2) (Ta1) 0.2875 0.2875 0.2378
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Turbine Generator combined inertia constant Three phase armature winding capacitance Armature winding dc resistance (per phase) Field winding dc resistance Field current at rated KVA, armature voltage & PF
6.37KW sec/KVA 0.985 0.0018 at 100 0.2606 at 125 1603.7020 A
Field current at rated KVA, & armature voltage & 0 PF lagging (FOR SYSTEMS STUDY ONLY NOT ALLOWABLE OPERATING POINT) 1900.9969 Amperes)
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CHAPTER 4 GAS TURBINE GENERATOR
4.Gas turbine generator:
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The generator package consists of generator, hydrogen control equipment, CO2 control equipment and the collector ring compartment. Access to the bearing sections of the generator is provided through doors in the load coupling compartment and in the collector ring compartment.
4.1 Generator assembly: The hydrogen cooled turbine generator is completely enclosed such that the hydrogen gas cannot escape. Hydrogen gas acts as the cooling medium. The ventilation system consisting of gas coolers, fans is self contained and thus it prevents the entry of dirt and moisture. The excitation system used is separately excited system. The separately excited rotating field driven by the turbine is supported by bearings located in the end shields mounted on the generator frame. The generator operates continuously so that there wont be any interruption in maintaining constant internal hydrogen and purity, and for supplying cooling water and lubricating oil. Hydrogen circulation is one by rotor fans. The generator construction will withstand all normal conditions of operation and three phase short circuits and their associated applied loads. The generator casing is used to design the destructive effects of an instantaneous hydrogen detonation to the generator casing and enclosed parts.
4.1.1 Stator:
y Stator frame and spring mounting: The stator frame consists of a gas-tight cylindrical casing of welded plate construction, reinforced internally in the radial direction by stationary web plates and in the axial direction by spring bars and braces. A series of floating web plates are welded to key bars which supports the stator core. The spring bars are supported by the fixed web plates. The spring mounting of the core isolates both radial and tangential magnetic vibration of the stator core from the outer frame and results in low frame vibration and quiet operation. The stator frame is supported on the foundation by feet 23 KPIT, EEE, Rajahmundry
attached to the bottom of the frame. Heavy end shields which contain the generator bearings are bolted to the ends of the frame. The frame also serves as the support and enclosure for the coolers. All end shield coolers and hand holes are carefully sealed to prevent leakage of hydrogen from the generator.
Figure 4.1 y Stator core:
The stator core is made up of segmented, annealed, insulated punching of preferred grain oriented, high quality silicon steel to give minimum electrical loss. The punching are assembled in an interleaved manners on keys machined integral with the key bars and are separated in to packets by space blocks to provide ventilation ducts. The punching are stamped from thin steel sheets and contain open end slots for the armature bars with dovetail slots for wedges to hold the armature bars in place . Other dove tail slots at the back of the punching are for assembly and locking of the segments on the key bars. Assembled punching is clamped in to a stiff cylindrical core by pressure applied through ductile cast iron end flanges by means of the stator key bars. Pressure is applied to the teeth by non-magnetic steel fingers located under the end flanges by means of the stator key bar. Pressure is applied to the teeth by non-magnetic steel fingers located under the end flanges. In order to reduce the heating from end leakage flux and its associated electrical losses occurring at the ends of the stator core the end packets of punching are stepped back to increase the gap between the punching and the rotor. Teeth in the end packed of punching are split radially to restrict the flow of circulating currents. 24 KPIT, EEE, Rajahmundry
Figure 4.2
Stator Winding:
The stator winding consists of insulated bar assembled in the stator slots joined at the ends to form coils and connected in the proper phase belts by bus rings. Each phase is split into groups of coils 180degrees apart. The stator bars are composed of insulated copper conductors transposed by the Roebel method so that each occupies, for an equal length along the bar, every radial position in the bar. This arrangement avoids circulating current loss which would otherwise be present under load conditions due to self inductive distribution of magnetic flux in the coil slot. Mica pal insulation system is applied to form the main ground wall of insulation over the stator bar, which is composed of several layers of mica tape bounded with a thermosetting binder. The result is a high density, high dielectric strength system which has high tensile strength throughout the operating temperature range. The bars with a composite build-up of layers of tape applied are placed in a Tank and subjected to vacuum pressure and heating cycles to remove the volatiles, compact the system to eliminate voids and cure the binder.
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Stator coil ends are covered with an outer layer of tape to bind and protect the mica insulation, after which they are sprayed with epoxy paint. These end turns are securely restrained by the binding bands, which are molded fiber glass rings supported from the stator core flanges. Conformable materials are bonded with thermosetting resin. The armature bars are held in the coil slots by Texolite wedges driven into the dovetail slots.
4.2 Rotor construction: Construction of generator rotor is machined from single alloy steel forging which has passed extensive tests to assured that the forging meets the required physical and metallurgical properties. Longitudinal slots, machine radially in the body, contain the field coils, sub slots, machine under the slots, and supply cooling gas to radial hole, in the field coils. The field coils are held in the slots against centrifugal force by steel wedges. These wedges are individually fitted and driven into dovetail openings machined in the rotor slots. Rotors fans providing ventilation for the generator are assembled near the ends of the rotor. The rotor is closed externally by the gas which passes under the rotor end winding, through the rotor sub slots and radially outward to the gap through holes in the field coils and slot wedges.
4.3Bearings: The rotor is supported and rotates in elliptical journal bearings mounted in the generator shields. The journal bearing is a ball seated type
and consists of a split ring casing. The casing is held by bearing bracket and clamped by the pinch fit of the mating ball seat in the bearing bracket cap. The two halves of the
casing are also bolted and doweled together. The casing is split horizontally to facilitate assembly and
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disassembly. The bearing and shaft steal housing at the collector end of the generator are insulated from the generator to prevent the flow of shaft current.
Figure 4.3
End Shields: The components that are contained in the outer end shields are generator rotor bearings, hydrogen shaft seals, and oil passages for supplying oil to the generator bearings. These end shields surrounded are split on horizontal centerline to facilitate their removal. The joints between the shields halves and between the shields and stator frame re fitted and provided with grooves for the insertion of sealing compound to seal the gas in the machine. Inner end shields are located between the ends of the armature windings and the outer end shields to separate the gas discharged from the fans from the gas entering the fans. Seal rings are attached to the inner end shields to prevent gas leakage from the fan discharge back to the fan inlet. Shaft Seals: The escape of hydrogen from the generator along the shaft is prevented by a shaft seal attached to each outer end shield, inboard of the bearing. This arrangement permits
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inspection of the generator bearings without removing gas from the machine. For shaft seal design, see text for Shaft Sealing System. The shaft seal housing at the collector end of the machine is insulated from the generator frame to prevent the flow of shaft currents. Field Winding and Retaining Rings: The field winding consists of rectangular copper bars, fabricated into coils. Several turns in one pair of slots around one pole form a coil. Several coils are assembled around each pole to form the winding. The individual turns are insulated from each other. The coils are insulated from the slot wall in the body portion by molded slot armors. To provide maximum ventilation and cooling, the end portions of the field coils are left bare except for turn insulation on alternate turns. Molded ring insulation is provided between the coils and the retaining rings, and Textolite blocking is provided in the end windings to separate and support the coils and restrict their movements under stresses from temperature and rotational forces. End turns are held in place against centrifugal force by heavy retaining rings machined from high strength, heat-treated alloy steel forgings which are shrunk and locked onto the centering rings. The centering rings are forged integral with the shaft. Generator collector rings and brushes: A. Collector and Collector Connection Current is supplied to the field windings through the collector rings which are connected with the winding through insulated copper bars assembled in the boredout center of the rotor forging and connected electrically to the field winding. At one end of the connection bars, terminal rods, or studs, assembled in radial holes in the rotor shaft, connect the winding with the bars; at the other end, the bars are connected to the collector.
The collector is built-up assembly consisting of forged steel shell, a molded mica shell for insulation, and four grooved, forged steel rings.
The mica is molded and baked on the steel shell and the collector rings are shrunk over the mica. A binder of molded fiberglass supports the mica insulation KPIT, EEE, Rajahmundry
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between collector rings and at the end of the shell. The complete assembly is shrunk on the generator shaft.
The mica shell insulates the collector rings from the steel shell and therefore, from the shaft. Because of the large shrink fit between the rings and shell, it is very nearly impossible to remove the rings without destroying the mica. For this reason the entire collector assembly should be treated as a unit and no attempt should be made to remove an individual ring.
Figure 4.4: Collector Assembly
For maintenance instructions pertaining to the collector, refer to the Maintenance section of this Service Manual.
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B. Brush Rigging
The brush rigging on the generator utilizes constant-pressure type brush holders. By means of a coiled spring, constant pressure is maintained on the top of the brush as it wears down. The coiled spring is permanently attached to a back plate, forming a back plate and spring assembly. Also attached to the back plate is a disconnect clip which engages the brush pigtail terminal and a connection plate which is inserted in the contact clip of the brush holder support.
Assembled to the coiled spring is a roller and clip assembly. The coiled spring is positioned in the recess at the top of the brush and the roller clip is fastened to the rivet hole of the brush.
One separate insulated handle is furnished for the assembly and removal of the brush back plate and spring assembly. This handle serves all the brushes of the brush riggings. When not used, the handle should be removed from the brush back plate and spring assembly, and stored in a safe and readily accessible place.
C.Shaft grounding Brushes
Shaft grounding brushes are supplied on turbine-generator units to prevent damage to bearings by electrical discharge through the bearing oil films. They also serve to complete the circuit for generator field-ground detector relay.
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Figure 4.5: Brush holder Assembly Shaft-to-ground voltages occur on units with static excitation systems. The output of the three-phase full-wave bridge rectifiers is not pure dc, but it contains a 360 Hz ripple of appreciable magnitude. Under certain conditions, this ripple can cause currents to flow through the capacitive circuit consisting of the field insulation, the bearing oil film, and the distributed capacitance of the excitation system transformers and rectifiers.
Shaft grounding brushes provide a low-impedance path to ground so that current due to static excitation voltage ripple flows harmlessly to ground, bypassing the bearings.
The grounding brush assembly consists of a yoke carrying two or more constant pressure brush holders and is located at the turbine end of the generator shaft.
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Note that the collector-end bearing on the generator is deliberately insulated from ground to prevent the flow of current due to a loop-type voltage along shaft and through bearings which may be produced by minor dissymmetry in the generator stator magnetic paths. Therefore, the grounding brush must never be located on the collector end of the generator.
The brushes used in this grounding assembly are the same as those used on the collector rings. The yoke should be electrically connected t the same station ground as the generator frame.
4.4 Hydrogen cooling:
Four hydrogen gas coolers are mounted vertically within cooler support rails inside cooler towers located at the four corners of the generator frame.
Ventilating system for a typical Hydrogen-Cooled Generator Figure 4.6
Each hydrogen coolers section consists of a pair of water headers (water boxes), tube sheets, round tubes with plate fins, all supported by frame. The cooling water circulates in the tubes with two or more passes as determined by the arrangement of partitions in the water boxes. The gas to cooled flows over the finned surface in a direction to obtained
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counter flow between the gas to cooled flows over the finned surface in a direction to obtain counter flow between gas and the water i.e. the hot gas enters on the water outlet pass and the cold gas leaves from the water inlet pass. The ventilation for the turbine generator consists of four cooler sections, arranged symmetrically in the gas steam within the gas tight generator casing. The sections should be piped in parallel for water flow. A vertical cooler has an extended tube sheet at the top And a gland packed hydrogen seal at the bottom tube sheet.
4.4.1 Cooler frame:
The frame is of welded steel construction and consists of two channel shaped side plates forming a box like structure with end plates at each end. Strength is provided by a diagonal pipe braces welded to the corner bars and extending across the two open sides of the frame. Rubber baffles are mounted on the side of the cooler to prevent by passing of gas, forcing the gas to flow through the finning surface. For proper cooler performance, it is essential that the amount of gas by passing the cooler be kept at a minimum. This cooler is supported by the extended tube sheet resting on top of the cooler tower.
4.4.2 Cooler tubes: The cooler tubes are of condenser tube quality as described by ASTM. The extended surface on the tube consists of continuous to a fin with a shoulder formed at the tube holes for the stacking as required. Both ends of each tube are roller expanded into the tube sheets standard condenser tube expanded for rerolling tube joints may purchased from one of the various suppliers of this type of tool or may be purchased through the general electrical company. The expander should be sized to suit the outside diameter of the tube and wall thickness. The length of the rolled joint should equal approximately 90% of the tube sheet thickness measure from the front face of the tube KPIT, EEE, Rajahmundry
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sheet. The rolling should never extend beyond the back face of the tube sheet. Since this will produce a circumference ridge in the tube, resulting in a condition that may produced early tube failure. 4.4.3 Tube sheets:
In addition to the normal functions, the tube sheets of the vertical hydrogen cooler support the cooler at the extended edges and provides Hydrogen scaling between cooler and generator current with the Hydrogen seals at tube sheets then is access to the tube ends, terminating repair and cleaning without removing the Hydrogen cooler from the generator. The gas seal at the floating end is provided by a compressed ring gas cut which bears on the edge of the floating end tube sheet. The edges of the floating end tube sheet of the machine accurately to provide good sealing surface. If these surfaces scratched or gouged, there should be repair by filing of storing until snoop. Deep graves may be filled with soft solded before filing smooth.
The upper tube sheet of the vertical cooler has a pumping grave type sheet. The sealing compound and method of use is same as for the generator and plate. The lower sheet uses a gland type seal. In vertical cooler the frame is bolted or welded rigidly to the top tube sheet (fixed end) and the bottom tube sheet (floating end) has guide pins which fits into clearance holes in to the frame on this type.
4.4.4 Water boxes:
The water boxes or headers and cover are bolted to the tube sheets with bolts or studs which thread into bottom- tapped holes in the tube sheet. Jack bolts in the covers facilitate removal of the covers. Four corners of the lower water boxes are fitted jamb nuts, which hole the lower water boxes in place when the cover is removed. 4.4.5 Gaskets:
These are provided in the joints between covers and water boxes and between water boxes and tube sheets. Before leaving the factors, the coolers are tested at KPIT, EEE, Rajahmundry
34
150% of the specified working pressure and this test value is stamped on the name plate, i.e. T188P stamped on the name plate indicates a test pressure of 180 psig.
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4.5 Generator ventilation: 4.5.1 Ventilation System: Rotor fans circulate hydrogen gas within the generator. They are the axial flow type with individual blades fastened to fan hubs nearer the end of the rotor. The gas which is passed through the fans is controlled by an inlet nozzle. Hydrogen is forced by the fans into the gas gap and also to the stator core. The stator core is axially divided into sections by the web plates and outer wrapper. In some sections cold gas is forced from the outer of the core toward the gas gap through the radial gas ducts and in other sections it passes from the gas gap towards the outside of the core through the radial ducts. Cooling gas is passed through tubes or ducts in proper way and hot gases are directed to the coolers. After the removal of heat cold gas is returned to the rotor fan & re-circulated. The inward and outward gas flow in the stator core results in a uniform cooling of the core and windings. Then excessive heat is avoided and stresses caused by temperature are being reduced.
4.6 Generator lubricants: A lubricant (sometimes referred to as "lube") is a substance (often a liquid) introduced between two moving surfaces to reduce the friction between them, improving efficiency and reducing wear. It may also have the function of dissolving or transporting foreign particles and of distributing heat. A lubricant's ability to lubricate moving parts and reduce friction is the property known as lubricity. One of the single largest applications for lubricants, in the form of , is prote in motor vehicles and powered equipment. Typically lubricants contain 90% base oil (most often petroleum fractions, called mineral oils) KPIT, EEE, Rajahmundry
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4.7 Seal oil system: To keep the hydrogen inside the generator, various places in the generator are required to seal against hydrogen leakage to atmosphere. The seal oil itself actually a portion of the lube oil, diverted from the lube oil system. It is then fed to a separate system of its own with pump, motor, hydrogen detraining or vacuum degassing equipment, and controls to regulate the pressure and flow. The seal oil pressure at hydrogen seals is maintained generally about 15 psi above the hydrogen pressure to stop hydrogen from leaking past the seals.
Once of the critical component of the seal oil system is the hydrogen degasifying plant. The most common method of removing entrained hydrogen and other gases is to vacuum treat the seal oil before supplying it to the seals. This is generally done in the main seal oil supply tank. As the oil is pulled into the storage tank under vacuum through a spray nozzle, the seal is broken up into the fine spray. This allows the removal of dissolved gases. In addition there is often re-circulate oil back to the tank through a series of spray nozzles for continuous gas removal.
Returns to the bearing oil drain. As a safety feature there is often a dc motor driven emergency seal oil pump provided. This motor will start automatically on loss of oil pressure from the main seal oil pump. This is after passing through the generator shaft seals, the oil goes through the detraining sections before it to ensure that the generator can be shut down without risk to personnel or the equipment.
4.8Grounding and neutral ground transformer: The bulk of transformers are three phase transformers. If you have a load that is balanced (equal across all three phases) then you can use a transformer with no ground and save yourself a wire. If you are supplying three distinct different loads, then you need to prove a path for the difference between the three loads to flow through. That path is the neutral path. If you supply an unbalanced load without a neutral path, then when one phase draws KPIT, EEE, Rajahmundry
37
power
it
changes
the
power
available
to
the
other
two
phases.
The best way to ground a power system is to obtain the system neutral through a generator or transformer with a wye-connected winding. However, a system neutral may not be available, particularly in many older low voltage systems and a significant number of existing medium voltage systems. To avoid a high cost of replacing a source transformer, an existing delta-connected system can be grounded using a star/ open delta or star/ delta transformer. During a line-to-ground fault condition, the zero sequence currents can flow into the ground at the point of the fault, and back through the neutral of the grounding transformer, hence providing facility to monitor & limit ground fault current. However Neutral Grounding Resistors are used for system grounding through Neutral Grounding Transformer & generators. A neutral grounding resistor limits the fault current, which is sufficient enough to operate protective relays, yet prevent unwanted fault damage.
Figure 4.7
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39
CHAPTER 5 INSULATION
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5. Insulation:
5.1 Nature of insulation: The insulation system of generator incorporates many different materials to protect the field winding, the stator winding. The major part of the system which is involved in most test problems is basic insulation ground wall, of the stator windings. The dielectric strength necessary for this ground wall is achieved from the use of mica in various forms. Generators that are built with asphalt-mica insulated windings have had a history of moisture absorption. If required, the winding should be given a dry out before the start up in order to achieve a satisfactory level of insulation resistance. This was done primarily to the inherent nature of asphalt-bonded insulation, which in a humid atmosphere will absorb moisture enough to markedly lower the megger readings. Present day epoxy mica insulated windings rely on mica as always however epoxy-mica insulation has added advantage of very stable bonding designs to provide stability dimensional control of the wall. It has high mechanical strength and practically impervious to water, oil and other contaminants to which the insulator might be exposed under abnormal conditions. Since epoxy-mica system have been introduced, it has become unnecessary to dry out the generator windings for the above mentioned cause. The function of the insulation depends on the integrity of the bonding of mica and other materials. This organic bonding of course sensitive to excessive temperatures beyond the design point, even for a short period of time can cause deterioration of in some of the supporting materials, thus weakening the system. This is particularly true if carbonization takes place in some of the organic auxiliary materials.
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The primary function of the insulation to contain the voltage of a particular part of the winding, and it is designed so that the rated voltage stress on the insulation will be reasonable and acceptable. If excessive high voltage is applied to the windings, the voltage stress causes heating within the insulation, and the magnitude of voltage. Time of application can result in damage of course at a high enough level of voltage can result in dielectric puncture which produces an immediate breakdown. Maintaining the compactness and integrating of the system is essential. For high strength level of ground wall, and any overheating, voids, mechanical damage or other abnormalities can produce weakness. This weakness can be of such a degree insulation might continue to perform at rated voltage quite satisfactorily but fail under voltage surges that the generator would be subjected to in operation. It is thus not reasonable to expect reliability from generator where insulation is satisfactory only for rated voltage. If voltage break down occurs in insulation while the generator is carrying load there is a high probability that considerable damage can occur to the components of the generator. This can very well be serious enough to acquire complete restacking and rewinding. Since such break down usually occur at an inopportune time, from the point of view of the user, it is quite desirable to establish a test program that will assure satisfactory insulation strength and that can be accomplished at the users convenience. It is practical to perform a visual inspection on all components of the insulation, and thus electrical verification at the strength of the system is quite desirable.
5.2 Selection tests: Tests on equipment in the factory are prescribed by ANSI standard and performed by the manufacturer before shipment. If the user elects to perform additional tests on new equipment at the power station start up, this is also covered by published ANSI standards and is 85% of the manufactures test at shipment. During the life of the equipment there are various occasions when it may be described to test on a planned periodic basis following some disturbance or micro operation in conjunction with repairs. 42 KPIT, EEE, Rajahmundry
It is unrealistic to expect that a uniform selection of tests can be used at all times and under all conditions for evaluation of gas insulation. It should be recognized that the age and importance of the equipment, its operating cycle and the conditions surround the test, as well as time available and equipment available for performing the tests, must all be considered in establishing a test series. Of those tests available, each of the following may serve a separate purpose, some of which are more indicative than others. Regardless of the degree of elegance of the test, the complexity of the equipment used, the fact remains that complete assurance of insulation strength cannot be given based on tests made at or below rated voltage. The only sure way to determine if insulation will hold a certain voltage is to apply the voltage and note the results.
5.3 Water cooling windings: Water cooling hi-pot is to be conducted; it may be accomplished with or without cooling water in the windings. With water in the winding the leakage current through water column will require greater kilovolts ampere output from the test set than if the winding was dry. Also, if water is contained in the winding; it should be circulated to prevent over heating of the hoses. There is no danger during this test of the breakdown through the water to ground within the range of recommended hi-pots voltage as long as conductivity remains within normal operation limits. However, if the water is tangent in the hoses the conduction current will heat the water and could produce boiling and subsequent damage to the hoses. If the winding has been drained and dried, air at atmospheric pressure should be preset in the winding hi-pot. Air under a partial vacuum is a poor dielectric and may cause a failure to ground through the air column inside the cooling water hoses during the hi-pot test. Single admitting atmospheric air to the winding will eliminate this problem. If it is desired to conduct the DC hi-pot test it will be necessary to drain and the winding. 5.4Analysis tests (Recommended): Insulation resistance is by far the simplest and easiest of the available tests to determine the integrity of insulation. It is made with an instrument commonly known as MEGGER either hand operated, motor operated or electronic. One of these types is usually available in most shops and test labs. The instrument generates a constant terminal voltage; thus, 43 KPIT, EEE, Rajahmundry
any current flow reduces the scale reading, which is calibrated in mega ohms. The results of this reading indicate only the presence or absence of conducting paths through or around the insulation system. The dense nature of epoxy mica insulation system has eliminated paths through the insulation, however, water cooled windings have introduced a path from windings to ground that that very vitally influences the insulation resistance reading that might be obtained. The multiple connecting hoses from the winding to the liquid header from many parallel paths; and if the winding is filled with water, these hoses in parallel contributes enough conductivity to reduce the insulation resistance reading to a level below the normally accepted limits. On water cooled windings, after the continuous check in the factory, the water is evacuated and the winding is done by using vacuum. This permits a recheck of the insulation resistance at destination prior to start up in order to verify that no damage has been done to the insulation. Subsequently if the purchaser has occasions to recheck the insulation resistance after the water has been added, it is necessary to remove the water from the winding. This is accomplished by drying, following surging air through the winding. Under this condition it will be difficult to completely dry the winding, and thus the megger reading will be somewhat lower than the normal values but can be used to check for major damage of the insulation. An index commonly used in interpretation of the megger reading is known as the DIELECTRIC ABSORPTION, which is obtained by continuing the reading for a longer period of time. If the test is continued for a period of about 10 minutes, the megger will have an opportunity to polarize or charge the high capacitance of the rotor insulation wall, and the indicated resistance reading will increase if the insulation is clean and dry. Thus, a minute reading is frequently made for optimum results. The ratio of the 10 minute reading to the one minute reading has been identified as POLARISATION INDEX. Polarization index values of 2.5 or higher might be expected on the stator and 1.25 or higher on the field. The simplicity of operation and availability of equipment lead to the common use of a megger as the first step in most insulation evaluations.
44
The following will serve as a very quick check that would eliminate the time required to drain the winding , with water in winding, the megger reading is likely to be as low as half to one mega ohm (1/2 to 1M ) which normal.
The value of resistance is low because of the leakage current through the water in hoses. However, the megger reading will still verify that the insulation does not have a complete breakdown or short to ground. Subsequent checks
With similar conductivity of water can be compared to an initial reading with water in the winding for assurance that no major change has taken place.
The insulation resistance reading has for years been the most convenient measure of the surface moisture condition of a winding at startup. A very low megger reading
and also a low polarization index winding is heated to eliminate moisture, the insulation resistance reading will vary. In practice, the impervious of nature of epoxy mica
systems has practically removed the need for dry out and on new machines a dry out run is required.
5.5 DC Leakage:
It is term used to designate another type of insulation resistance measurement. This is made with a variable voltage test set in which voltage can be applied to the insulation in series of steps. And the leakage current through the insulation measured at each voltage. The involves somewhat larger a and more complicated equipment
than the megger but provides more intelligence as to the nature of the insulation level. It has higher capability and can thus maintain the selected voltage constant while leakage current is measured at the desired voltage point. The test has been used extensively in older electrical equipment, particularly involving insulation systems that are subject to moisture absorption. Air cooled machines are subjected to the changes in humidity in the cooling air. In hydrogen cooled machines, the ambient is quite dry and the winding is protected against moisture absorption. Even if a fault does exist in the insulation wall in a very dry atmosphere, as long as the fault is clean and dry, no appreciable dc leakage 45 KPIT, EEE, Rajahmundry
current will be obtained. It is thus entirely possible that the dc leakage test will fail to indicate a fault in a hydrogen-cooled generator. Since epoxy-mica systems do not absorb moisture into the ground wall under normal conditions, the test is still less meaningful. Water-cooled windings that multiple parallel hoses from winding to ground can have leakage current through the water in the hoses as high as 50 mill amperes during a highpotential test, thus many times greater than the total leakage through the insulation, making it impossible to interpret the results. If the hoses are dry, the dc leakage test can be evaluated to look for other leakage paths over the surface of the insulation or through openings to ground. The maximum dc voltage applied should be limited to twice the RMS value of the rated ac voltage of the generator.
Analytical Tests (Customers Option) 1. DISSIPATION FACTOR of the insulation may be measured as a part of an overall evaluation program to determine insulation condition. This measurement also known by other terms as POWER FACTOR or TAN DELTA and is a parameter to establish the efficiency of the insulation. As voltage is increased, if voids or separation exists, or certain semi conductive material is present in the insulation, the dielectric behavior changes. A perfect insulation would be a true capacitance, with 0 PF and no internal losses. An increase in dissipation factor as a function of voltage or dissipation factor TIPUP indicates the rate of increase in ionization, internal losses and heating.A specific dissipation factor does not by itself give a measure of insulation strength. The rate of change in the slope of the curve, voltage at which the tipup occurs, etc., can provide information of value in determining insulation quality.This is usually conducted in a voltage range up to about rated line-to-ground voltage and thus does not subject the insulation to any overstress. 2. RADIO NOISE, SLOT DISCHARGE 3. CORONA START VOLTAGE These items are frequently used in part of the program of evaluation of an insulation system, but neither of them is by itself a particular
46
measure of insulation strength. These are of value in determining trends, and in overall quality control measures. Components to be tested: The component of the turbine-generator set that is normally involved in an electrical test program is the generator stator.
The rotating field is, of course, also subject to insulation failure, and such failure could result in a forced outage. In most cases, however, the field circuit is ungrounded, except for the addition of a ground detector relay; and thus if a single breakdown occurs, it does not result in a power surge through the fault, with the associated consequential damage. The practice in most operating companies is to do much less testing on the field than on the stator. In most cases the testing has consisted of possibly a megger test to verify the insulation resistance level and impedance or other test to search for shorted turns. There are factors that might indicate that this should be reevaluated, however, such as the rapidly increasing size of units, with the commensurate increase in dollar value of forced outage time, together with the increased voltage being used on recent fields. It might be considered good insurance to apply more effort and a more sophisticated test program in the future to promote a high level of reliability of the field winding and associated excitation equipment. The exciter falls in the same general category as the field as far as the scope of the test program.The program for protection of other auxiliary equipment such as pump motors on the seal oil or stator liquid cooling equipment usually consists of routine maintenance such as visual inspection, lubrication, etc., and does not normally include an electrical test program.
Preparation and testing: A. Insulation is very sensitive to change in temperature and this is reflected in the insulation resistance reading as obtained by a megger or similar equipment. Thus, for successive tests to be comparable, the data should be compared at the same temperature.
47
B. Any application of voltage for measuring winding conditions is dependent on a clean, dry winding to obtain optimum results. If moisture, wet paint or other contaminants are present, the test data will likely reflect the abnormal condition, since many such materials may provide a conducting path to ground. C. Liquid-cooled stators using water for the coolant have an additional dielectric leakage path in the columns of water through the connecting hoses. AC over voltage tests can be performed either with water circulating in the winding or with the winding drained and dried. DC overvoltage tests normally require that the winding drained and dried. Drying is usually accomplished by blowing air through the winding after draining the bulk of the water. D. The stator winding should be isolated or separated from other connected equipment such as power transformers and station bus. E. It is also desirable to separate the three phases of the winding from each other so that one phase can be tested at a time. Normally both ends of each phase are brought outside the generator through bushings. For test, both ends of the phase in question should be tied together. During the test, the other two phases that are not involved should be grounded. F. Instrumentation such as temperature detectors, both resistance type and thermocouples, which are located within or adjacent to the winding with leads brought to a terminal board outside the generator, should be grounded during the test. G. As far as safety is concerned, there are many established variations of safety regulations and usually each operating company has a set of rules, and these should be observed in accordance with the location and conditions of the test. In any event, some common rules would apply. The equipment to be tested, the high voltage test set itself and any connecting high-voltage leads should be enclosed with a safety tape to prevent stray personnel from entering the area. Enough guards should be posted in the area to provide observation of the winding and equipment, be alert for winding failures and abnormal conditions, and also to prevent personnel from entering the winding. 48 KPIT, EEE, Rajahmundry
The nature of an over voltage test is to search out weakness, and it is essential to obtain a voltage level high enough to satisfy this requirement, but it is equally important that the test voltage does not appreciably exceed the scheduled test level. Normal instrumentation used on the test equipment is subject to damage or erroneous reading, and since there is usually involved more than one multiplication factor due to scale selectors, instrument transformer ratio, etc., there is room for error in the applied voltage. One excellent way of verifying the applied voltage and simultaneously guarding against overvoltage is the use of a sphere gap to calibrate the test set and to serve as overvoltage protection during test. This is particularly valuable with portable high-voltage equipment, which is always subject to damage in handling. For use of a sphere gap test, the test equipment and the high-voltage lead should be energized first, connected only through the sphere gap and a discharge resistor to ground. The chart of sphere gap setting is guide for determining the spacing in connection with the test to be used. More detailed information is covered in a descriptive brochure, GEI41580, which takes into consideration sphere size, humidity and ambient conditions, and it is suggested that this be consulted before performing the test. After the gap setting has been verified by raising voltage to discharge across the gap, the gap may then be opened an additional 10 to 20% of voltage to permit the test to be performed on the generator without arcing across the gaps. This would provide a margin against overvoltage.
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CHAPTER 6 CASE STUDY
50
6. Case study:
GT Generator has tripped on Generator Differential and overall Differential protection on 31.05.2007 at 16:40 Hrs. The insulation resistance of stator winding was measured with 1000v megger and the results are as follows:
Generator Specialist from GEPSIL has reported at site on 01.06.2007 FN. After investigations, GEPSIL declared the unit under breakdown and advised to carry out the following activities to bring back the Unit in to service 6.1Generator dismantling and Rotor Thread out. y y y y y y y y y y y y Removal of Hoods Disassembly of brush rigging Decoupling of Turbine Generator Dismantling of Bearing covers Dismantling of Bearings and oil Deflectors Dismantling of pipelines Dismantling of Hydrogen seals Dismantling of top half end shields Dismantling of winding covers Preparation for Rotor thread out Dismantling of fan blades Rotor thread out.
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y y
Inspection and blue matching of seals , replacement if necessary Inspection of bearings, DPT, UT and dimensional checks, replacement if necessary
y y y y
Inspection of oil reflectors and replacement if necessary Inspection and cleaning of Hydrogen coolers Assembly of Hydrogen Coolers DPT of fan blades
Inspection of Stator winding and finding faulty Bar/Bars. Conducting ELCID Test.
y y y y y y y y y y y y y
Isolating and lifting of the faulty bars. Conducting of Hipot test of remaining winding Lifting of faulty bars, if any Preparation of list of materials for stator partial rewound. Preparation and cleaning of stator for partial rewind. Conducting ELCID Test. Pre-assembly Hipot test of new bars. Lying of new bars in slots after receipt of spares. Assembly of nipple springs, wedges etc., Brazing of joints. Insulation of joints. Braking of the winding Final testing of stator (IR, PI, winding resistance, Tan ,DC leakage, Hi pot, ELICID)
Testing and inspection of Generator field (IR, PI, DC Resistance, AC impendence, RSO).
y y
Rotor thread in. Generator assembly y y Preparation and a thread in of Generator rotor. Transfer on to bearings. 52 KPIT, EEE, Rajahmundry
y y y y y y y y y y y y y
Assembly of winding covers. Assembly of top end shields. Assembly of oil deflectors. Assembly of Hydrogen seals. Turbine Generator alignment. Turbine Generator coupling. Assembly of bearings. Assembly of piping. Assembly of brush rigging. Assembly of hoods.
Air leak test. Turning gear. Commissioning of the unit.
APGENCO and APGPL requested GPSIL to mobilize site immediately tocarry out the job. APGENCO and APGPL requested GEPSIL to arrange required space on top priority with in ten days.
6.2 Inspection report on 112MW GT generator stator fault at GTPS, Vijjeswaram: y y y GTG Generator tripped on differential fault at 16-40hrs on 31-05-07. Generator rotor was threaded on 07-06-07. Fault was observed between 5 and 6Oclock position at end winding portion of 10T and 11T and 24B to 27B at turbine end. All these bars are melted. y y y Base line ELCID test was conducted on 07-06-06 and core found healthy. Bars in the vicinity got heat affected. After lifting top bars from 3 to 33 and bottom bars from 22 to 33, the following damages were observed on 10-06-07. y Bottom bars melted due to fault;-24B, 25B, 26B and 27B on end winding on turbine end.
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Heat effected bottom bars:-12B to 23B and 28B to 35B on End winding on turbine end.
Top bars melted due to fault:- 10T and 11T on end winding on turbine end
Heat effected top bars:- 8T to 9T and 12T to 14T on end winding on turbine end.
y y
TE Radial rings # 3&4 were burnt between 5 to 6Oclock position. TE Binding bands #3 was burnt to extent of 95% and became weak. Binding bands #4 were burnt to extent of 65% between 5 to 6O clock position.
As the binding bands are the major structural member of the end winding support system, the damaged binding bands are to be replaced. To facilitate the replacement of binding bands all bars are to be lifted.
Full stator rewind is recommended. Hence full stator rewind kit without connection rings are to be procured for reliable operation.
Carbon has deposited every where in stator and rotor during this fault. Generator field has to be thoroughly cleaned by removal of retaining rings. For this full retaining ring insulation kit, field patch repair kit and rotor paint etc., to be procured.
6.3 Analysis:
Failed bars were identified electrically in the circuit. Fault was observed at end winding portion of 10T & 11T and 24B to 27B at turbine end. All these bars were melted. The 11T bar is a neutral bar, as figured out from the winding diagram attached. Others bars are in between the phase. This indicates of a voltage transient of some sort being a primary cause. Also, since there was no damage to the core it also confirms that short was phase to phase and not phase to ground. The low insulation resistance value that was observed is due to carbon generated during the fault. 54 KPIT, EEE, Rajahmundry
Bars were inspected very carefully while still in the slots for any evidence of the origin spot. Each and every bar was carefully removed and laid down on the ground to find which two-melted together first are and which one over heated consequentially. Possible cause in similar failures have been a missing block, loose ties of end winding, inspection of the unit carried out by GE Generator specialist during major inspection in February 2005, details no missing block, loose tie on end winding on both sides. Electrical test carried out during the inspection reports healthiness of the insulation system. Absence of alarms or indication of abnormal operation after inspection carried out in 2005 also indicates good condition of the machine.
6.4 Conclusion:
A careful review of all data for possible cause was done. End winding assembly of the generator was tied and secured. No electrical, mechanical or operational abnormality was observed prior to the fault. Test carried out during major inspection in February 2005 also indicated healthy end winding assembly and insulation system. Damage due to fault was contained as all generator protections were operated in time.
Thus, Failure of this magnitude can be attributed to a voltage transient in the system (which is connected to infinite bus) imposed on the winding during operation.
References: 1.) A Practical Study Report on Generator Rewinding At GTPS Vijjeswaram. 2.) Standard handbook of machine design, Joseph Edward Shigley, Charles R. Mischke, Thomas Hunter Brown. 3.) Gas Turbine Performance by P.Waish, Paul Fletcher. 4.) Gas Turbine Engineering Hand book by Meherwan, P.Boyce. 5.) www.wikipedia.org 6.) www.ieeexplore.ieee.org 55 KPIT, EEE, Rajahmundry
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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

The objectives of the company are:

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

CHAPTER 2 DESCRIPTION OF STAGE 1

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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

2. Description for stage I:

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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

CHAPTER 3 DESCRIPTION OF STAGE 2

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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

3.Description for stage II: GENERATORS & GAS TURBINES:

3.1 Gas turbine:

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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

3.2 Heat recovery steam generator:

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

4.0339 0.5008 0.7733 0.8901 0.0230 0.0321

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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

6.37KW sec/KVA 0.985 0.0018 at 100 0.2606 at 125 1603.7020 A

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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

CHAPTER 4 GAS TURBINE GENERATOR

4.Gas turbine generator:

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GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

Figure 4.1 y Stator core:

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING

KPIT, EEE, Rajahmundry

GAS TURBINE GENERATOR FAILURE AND STATOR REWINDING