ELECTRCIAL ENGG. DEPT.

"DESIGNING AND TESTING OF ALTERNATOR"

Prepared By:
RANA NISHANT H. (106540309042) PATEL RAJAT M. (106540309016) SAIYAD SAJIDSHAH K. .(106540309025) PANCHAL VIJAY S. .(106540309051) RATHOD SIDDHARAJ D. .(106540309032)

Guided By:
MR. KARTIK K. PATEL (LECT.-EE DEPT.)

Industrial Guided:
MR. M.C.PATEL (OWNER-MAHAKALI MOTORS)

 Aim Objective Introduction Principle Types Of Alternator Theory Design Of Alternator Design Steps Of Rotor, Stator, Main Damnation, Efficiency Testing Of Alternator (Only Introduction)

Out Comes Of 5th Sem Project

Bibliography

 To Get Brief Knowledge Of Alternator &

Study Its Design, Testing Before Operation

 To Get Brief Knowledge About An Alternator.

Theory Design Steps Of Alternator. (5TH SEM)

To Know About All Factors affecting on Design. Testing Of Alternator.

 What is alternator?

An alternator is an electromechanical device that converts mechanical energy to electrical energy in the form of alternating current Most alternators use a rotating magnetic field with a stationary armature but occasionally, a rotating armature is used with a stationary magnetic field; or a linear alternator is used. The early machines were developed by pioneers such as Michael Faraday and Hippolyte Pixii.

 Faradays Law:The induced emf in a wire loop is proportional to the rate of change of magnetic flux through the loop.

 There are following types of Alternator: 1. Hydro alternator (rating up to 750 MW) 2. Turbo alternator (rating up to 1000 MW) 3. Engine driven alternator (rating up to 20 MW) 1. 2. 3. 4. 5. 6.

There are following types of Prime Movers: steam turbines Hydraulic turbines Diesel engines Gas Nuclear Wind

 Here we are present the theory steps of alternator and

also factor affecting on alternator. Basic Introduction about testing of alternator.

 Synchronous machines are designed to obtain the

following information. (i) Main dimensions of the stator frame. (ii) Complete details of the stator windings. (iii) Design details of the rotor and rotor winding. (iv) Performance details of the machine.

 (i) Specifications of the synchronous machine.

(ii) Information regarding the choice of design

parameters. (iii) Knowledge on the availability of the materials. (iv) Limiting values of performance parameters. (v) Details of Design equations.

 Stator

Stator winding
Rotor Rotor winging Poles Damper winding Bearings Brakes and jacks

Slip rings
Outer body

1. Cost 2. Durability

3. Compliance

 Then we cant calculate is all parts dimension Then we cant assemble its all parts. Then alternator not work properly Then we cant calculate all electrical parameters likes

voltage, current, frequency etc.

Then we cant calculate efficiency.

 Step

1 Rating of alternator
Q P Vlv Vph cos f ns p

1. Full load kVA

2. Full load power, kW 3. Line voltage

4. Phase voltage
5. Power factor 6. Frequency 7. Speed 8. Number of Poles

KVA output Q =(1.11 B av ac Kw *10-3)Va2L/ns Where, Q = output KVA B av = air gap flux density Ac = amp conductor per meter Kw = winding Factor Va = peripheral Speed (Va=pi*D*Ns) L = length Ns = sync. Speed

1. Specific magnetic loading

2. Specific electrical loading

3. Stator bore 4. Gross core length

5. Radial ducts : No width

6. Gross iron length 7. Net iron length

8. Pole pitch
9. Current per phase

 There are following points to affect in stator: 1. Type of Pole 2. Pole section 3. Radial length of pole 4. Turns per pole 5. Conductor : size, area 6. Full load current 7. Current density 8. Length of mean turn Stator 9. Voltage drop 10. Field copper loss 11. Peripheral speed

 Types of Poles:

Round Pole 2. Rectangular Pole Length of air gap: The increase in length of air gap, a larger value of field mmf is req. so increase the cost of machine.
1.

 No of armature slots:

Following factors should be considered for the selection of armature slots. 1. Balanced winding 2. Cost 3. Temperatures 4. Leakage reactance 5. Tooth ripples 6. Flux density

 Armature winding, coils & insulator:

Types of coils 1. Single turn bar 2. Multi turn Methods of Elimination of harmonics in voltages: 1. Distribution 2. Chording 3. Skewing 4. Fractional slot windings 5. Large length of air gap

 single layer winding:

-One coil-side occupies the total slot area -Used only in small ac machines

 Double layer winding:

-Slot contains even number (may be 2,4,6 etc.) of coilsides in two layers - Double-layer winding is more common above about 5kW machines

 Easier to manufacture and lower cost of the coils

Fractional-slot winding can be used

Chorded-winding is possible Lower-leakage reactance and therefore , better

performance of the machine Better emf waveform in case of generators

 Turns per phase:

Tph=Eph/4.44f Kw Conductor section: As=Iz/a Length of mean turn: Lml=2L+2.5+0.06kV+0.2 Stator core: De=*2Li*Bc

 Armature permanents:

Armature resistance 2. Armature leakages reactance

1.

Winding Number of Parallel Paths Number of Slots Slots per Pole per Phase Conductors per slot Conductor : size area 9. Current density 10. Slot size : width depth 11. Resistance per phase 12. Total copper loss
1. 2. 3. 4. 5. 6.

 Types of rotor:

Salient-ple type 2. Smooth-cylindrical type

1.
Height of Pole:

Hp=Hf+0.02 Where, Hf=total winding area/Df Hight of pole: Hs=2Dg

 There are flowing mmf are affecting:

1.
2. 3.

4.
5.

Mmf for air gap Mmf for armature teeth Mmf for core Mmf for poles Mmf for yoke

Design of field winding: Voltage across each field coil Winding height Field wingding depth
Pole pitch 0.1 0.2 Winding depth 25 35

0.4
-

45

Voltage across each field coil Field current Field turens Resistance of winding Cooling co efficent Temp. rise

 Losses in alternator

1.
2. 3.

4.
5. 6.

7.

Iron loss due to main field Iron loess due to parasitic fields Copper loss Eddy current loss Stray loss Friction and winding loss Excitation loss

 A single-phase alternator has

all the armature conductors connected in series The stator is two pole. The winding is wound in two distinct pole groups, both poles being wound in the same direction around the stator frame. The rotor also consists of two pole groups, adjacent poles being of opposite polarity.

 The two poles of the stator

winding are connected to each other so that the AC voltages are in phase, so they add. As the rotor (field) turns, its poles will induce AC voltages in the stator (armature) windings. Since one rotor pole is in the same position relative to a stator pole as any other rotor pole, both the stator poles are cut by equal amounts of magnetic lines of force at any time. As a result, the voltages induced in the two poles of the stator winding have the same amplitude or value at any given instant.

Poles 2 4 6 8 10 12

RPM for 50 Hz 3,000 1,500 1,000 750 600 500

RPM for 60 Hz 3,600 1,800 1,200 900 720 600

RPM for 400 Hz 24,000 12,000 8,000 6,000 4,800 4,000

14 16
18 20 40

428.6 375
333.3 300 150

514.3 450
400 360 180

3,429 3,000
2,667 2,400 1,200

Visual inspection (marking, completeness) Loss tangent test on installed stator winding Insulation resistances of windings, temperature sensors, space heaters, bearings DC resistances of windings, temperature sensors, space heaters Adjustment of magnetic centre of generators with sleeve bearings Measurement of rotor impedance Phase-sequence test Vibration severity measurement Check of voltage balance No-load characteristic, generator mode Short-circuit characteristic, generator mode Shaft voltage measurement (where design permits) Shock pulse measurement, if SPM nipple is provided High-voltage test Functional check of accessories Functional check of excitation system.

 Polarization Index Testing

Dielectric Absorption Testing

Pole Balance Tests Winding Resistance Testing Impedance testing Power factor testing (doble)

Wedge & end blocking Inspections

(a) Insulation test (b) Control function test* (c) Dummy load test* (d) Earthing protection test (e) Battery charger output test* (f) Step-load acceptance test* (g) Noise level measurement

 Overspeed test with generator on balancing machine No-load characteristic

Determination of iron and friction loss

Noise measurement at no-load Measurement of THF factor Moment of inertia in deceleration test Sudden short-circuit test

Temperature rise test at rated data or equivalent load test

Temperature rise time constants Load characteristics h = f(Pel) Regulation characteristics for different cos j Determination of nominal excitation current Determinations of synchronous machine characteristics (reactances, time

constants) Measurement of coolant flow rate

 This test is conducted to measure-winding resistance

of a synchronous generator when it is at rest and the field winding is open. The resistance is measured between two lines at a time and the average of the three resistance readings is taken to be the measured value of the resistance, RL from line to line. If the generator is Y-connected, the per-phase resistance is Ra= RL0.5

 he open-circuit test, or the no-load test, is performed

by 1) Generator is rotated at the rated speed. 2) No load is connected at the terminals. 3) Field current is increased from 0 to maximum. 4) Record values of the terminal voltage and field current value.

The OCC follows a straight-line relation as long as the magnetic circuit of the synchronous generator does not saturate. Since, in the linear region, most of the applied mmf is consumed by the air-gap, the straight line is appropriately called the air-gap line.

 The short-circuit test provides information about the

current capabilities of a synchronous generator. It is performed by 1) Generator is rotated at rated speed. 2) Adjust field current to 0. 3) Short circuit the terminals. 4) Measure armature current or line current as the field current is increased.

Ratio of the field current required for the rated voltage at open circuit to the field current required for rated armature current at short circuit. CR=f,c/If,sc

 The scope of the Operating and Maintenance Manual is agreed

with the customer on the basis of the General Terms of Delivery for Products of the Electrical Industry. The standard version of the manual comprises: Data sheet Test report Dimension drawing of generator Dimension drawing of cable connection Connection diagrams Erection instructions Subsupplier documentation Spare parts list Manufacturers declaration (CE)

 Failure of prime movers

Failure of excitation:
Failure of insulation in the stator or interconnecting -

cable can be further divided into: Interphase short circuits Single phase to earth fault inter turn faults Earth fault on the rotor