MANUFACTURING OF TURBO GENERATOR

INDEX

Introduction to turbo generator Stator Rotor Excitation System Cooling system Generator Technical Data Testing Of Turbo Generator Conclusion

INTRODUCTION TO TURBOGENERATOR
A turbo generator is a turbine directly connected to electric generator for the generation of electricity. They are mostly used as large capacity generator driven by steam/gas turbine. The turbo generator is invented by Blathy Otto an electrical engineer of Hungary, in 1912. Later it was developed by Michael Faraday a British scientist.

PRINCIPLE OF OPERATION

Faradays Law : E.M.F. (Voltage) is induced in a closed path due to change of flux linkages and is proportional to rate of change of flux linkages. The change in flux linkages can be caused by change in flux in a stationary coil or by motion of coil with constant flux

or both.
E=N d/dt

MAIN COMPONENTS USED IN TURBO GENERATOR

STATOR ROTOR

EXCITATION SYSTEM COOLING SYSTEM

STATOR
The stator consists of following parts
STATOR FRAME STATOR FRAME STATOR WINDING STATOR END COVER BUSHINGS GENERATOR TERMINAL BOX

STATOR FRAME

Rigid fabricated cylindrical frame and is the heaviest section in the

generator, withstands weight of core & winding, forces & torques during operation. Provisions for H2/CO2 filling

Provision for temperature measurements Provision for H2 coolers

STATOR CORE

The stator core is made from the insulated electrical sheet lamination to
minimize eddy current losses. It ensure perfect link between the core and rotor.

The purpose of stator core is to carry the magnetic flux generated by

rotor winding.

STATOR WINDING

The stator winding of Turbo Generator is three phase two layer lap
winding. Each stator slot accommodates two stator bars.

The bar consists of a large number of separately insulated strands which are transposed by 540 degrees.

STATOR END COVER

The ends of the stator frame are closed by pressure containing end shields The end covers are made up of non-magnetic material (Aluminium castings).

The end shield used at the turbine end and exciter end side is different in
construction for 500MW and 250MW.

BUSHINGS

The beginning and ends of the three phase windings are brought out from the stator frame through bushings, which provides for high voltage insulation.

The bushings are bolted to the stator frame at the exciter end.

ROTOR
It is Rotating part of turbo generator. It has Longitudinal slots for housing

field winding.
The slot pitch is selected so that two solid poles are obtained with a

displacement of 180 degrees.

The Rotor consists of the following parts

ROTOR SHAFT

ROTOR WINDING ROTOR RETAINING RINGS FIELD CONNECTION

ROTOR SHAFT

It is the rotating part of rotor.

It is the axis around which the major rotor rotates. Maintenance of the rotor shafts is scheduled on a frequent basis. Bearings

and bearing mounts are replaced after a predetermined number of hours of

use.
ROTOR WINDING

The rotor of turbo generator accommodates field winding. The field winding consists of several series connected coils inserted into the longitudinal slots of rotor body.

The conductors are made up of copper with a silver content of approximately of 0.1%, having rectangular cross section and radial
discharge.

The individual bars are bent to obtain half turns. After insertion into the

rotor slots, these turns are brazed to obtain full turns. The series connected turns of one slot constitute one coil.
ROTOR RETAINING RINGS

To protect end winding of rotor from flying out from the rotor due to
centrifugal forces rotor retaining ring is used.

Retaining rings are made from high tensile non-magnetic alloy steel forgings.

FIELD CONNECTION

The field current is supplied to the rotor winding through radial terminal bolts and two semicircular conductors located in the hollow bores of the exciter and rotor shafts.

The field connection provides electrical connection between the rotor winding and exciter

EXCITATION SYSTEM
BRUSHLESS EXCITATION

The main parts of brushless excitation system are as follows

PILOT EXCITER MAIN EXCITER RECTIFIER WHEEL

The three phase pilot exciter has a revolving field with permanent magnet poles. The armature winding is housed on the stator. The three phase a.c. generated by the pilot exciter is rectified and controlled by automatic voltage regulator to provide variable D.C. for exciting the main exciter.

The three phase main exciter has stationary field with revolving armature.
Thus three phase a.c. power is produced in main exciter which is rectified by rotating rectifier bridge and is fed to the field winding of the rotor

(turbo generator) through dc leads.

PILOT EXCITER

PILOT EXCITER

Three phase pilot exciter is 16 pole revolving field units.

The stator accommodates three phase armature winding and magnetic

poles are placed on the rotor. Thus rotating flux is produced which cuts the stationary armature conductors and three phase a.c. is generated.

MAIN EXCITER

The three phase main exciter is a 6 pole armature type unit.

The stator frame accommodates the field winding. The field winding is placed on the magnetic poles. armature consists of stacked lamination and the three phase winding is inserted into the slots of the laminated armature

The

RECTIFIER WHEEL

Components in the rectifier wheel are as follows

SILICON DIODES ALUMINIUM HEAT SINK

FUSES

RC CIRCUIT

The main component in the rectifier wheel is silicon diodes which are arranged in rectifier wheel in three phase bridge circuit. The direct current from rectifier wheel is fed to DC leads and then to the field winding of the rotor.

COOLING SYSTEM COOLING METHODS FOR TURBOGENERATOR

AIR COOLED TURBO GENERATOR

In Air Cooled Turbo generator stator winding is indirectly air cooled

whereas the rotor winding and stator core is directly air cooled.

 This

type of cooling is applicable for rating of 30 MW- 60 MW

generators.

In this type of turbo generator there are vertically side mounted cooler in a separate housing.
HYDROGEN COOLED TURBO GENERATOR

H2 has a heat transfer coefficient 1.5 times and its thermal conductivity is 7 times that of air.

GENERATOR TECHNICAL DATA

PARAMETER MODULE RATED VOLTAGE RATED CURRENT

UNIT KV Amp. Bar

250 MW THRI 108/44 16.5 10291 4.0

500 MW THDF 115/59 21 16166 3.5

660 MW THDF 115/67 21 21334 5.0

800 MW THDF 125/67 27 20129 5

HYDR. PRESS. (g)

TESTING OF TURBO GENERATOR

To estimate the performance of generator, the TURBO GENERATORS are required to undergo some tests.
SHORT CIRCUIT TEST

Reduce the field current to a minimum, using the field rheostat, and then open the field supply circuit breaker. Short the stator terminals of the

machine together through three ammeters.

The short circuit characteristics is plotted from short circuit results by selecting X-axis as field current and Y-axis as % rated current.

From the Short Circuit test, we will get copper losses.

OPEN CIRCUIT TEST

Drive the synchronous machine at the synchronous speed using a prime mover when the stator windings are open circuited. Vary the rotor winding current, and measure stator winding terminal voltage. The open circuit characteristics is plotted from open circuit results by selecting X-axis as field current and Y-axis as% rated voltage.

From the open circuit test, we will get Iron Losses.

INTER STRAND TEST

This testing is basically done to check any short circuit between ant two

consecutive conductors of a bar.

For this test all the bare conductors at both the ends are separated from each other so that they do not short circuit.

Similarly all the conductors are checked for any short circuit.

HIGH VOLTAGE TEST ON ROTOR AND STATOR WINDING (MACHINE AT REST)

The test is conducted on all the phases and rotor winding separately.

When High Voltage test is done on one phase winding, all other phase
windings, rotor winding, instrumentation cables and stator body is earthed.

This test is done to check the insulation of the winding.

HELIUM TEST

Helium test is done to check leakage within the bar and at the brazed portions.

In this The helium gas at pressure of 11Kg/Cm^2 is passed through the bar.

CONCLUSION

As the turbo generators are high voltage machines which

are ranging from less than 1500 volts.

Hence the machine efficiency is accurate. Turbo generators are also more reliable in nature. As the production of sources are taken from the nonrenewable energy sources the cost is economic.