1.

INTRODUCTION TO TURBO GENERATOR

A synchronous generator is the core of any generating power plant. A synchronous generator is a rotating electromagnetic device that converts mechanical energy into electrical energy by taking the mechanical input from a prime mover (Gas turbine or Steam turbine) and magnetic energy from excitation. Generators driven by steam or gas turbines have cylindrical/ round rotors with slots into which distributed field windings are placed. These round rotor generators are usually referred to as turbo generators and they usually have 2 or 4 poles. Generators driven by hydraulic turbines have laminated salient pole rotors with concentrated field winding and a large number of poles. The different electromagnetic or active parts of a generator are as follows: Stator core Stator coils/ bars Stator winding Output leads, brushings and conductors Rotor excitation leads Rotor coils Rotor winding

Stator core:
The stator core serves the two fold function of providing the mechanical support for the stator coils and carrying effectively the electromagnetic flux generated by the rotor winding. In order to minimize hysteresis and eddy current losses the entire core is built of thin laminations. Each lamination layer is made up from a number of individual segments.

Stator coils/ bars:

The stator coils are the individual entities, which are placed in the slots of the stator core and finally connected to each other as per a pre-designed scheme to form a three phase winding. The prime purpose of the stator bars is to carry the load current at minimal winding losses. These coils are provided with high voltage stresses. Depending upon the size and rated voltage of the machine different types of stator bars are designed.

Stator winding:
The stator winding is a short pitch; two-layered type made of individual bars. The bars are located in slots of rectangular cross section, which are uniformly distributed on the circumference of the stator core. In order to minimize the losses, the bars are composed of separately insulated stands transposed by 360 degrees. To minimize the stray losses in the end winding, the standards of the top and bottom bars are separately brazed and insulated from each other.

Output leads, brushings and phase connectors:

Output leads are taken out from the exciter end of stator from the top and supported on an insulated glass fabric plate. Six terminals are brought out, three for phase and three for neutral connections. The phase connections are connections between the stator winding phase bars /coils to the output lead brushings.

Rotor excitation leads:

The excitation leads provide electrical connection between rotor winding and output from brush less exciter.

Rotor Coils and winding:

The construction of the rotor winding consists of placement of pre-formed rotor coils as per the winding scheme in the slotted rotor body, providing necessary insulation both in the straight position and overhang, making connections of the excitation leads, wedging of the straight part and mounting of the retaining rings.

2. TURBO GENERATOR

Fig2.1Turbo Generator
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2.1 History of turbo generator:

A turbo generator is a turbine directly connected to electrical generator for the generation of electric power. An electrical generator is a machine which converts mechanical energy to electrical energy Generators are based on the theory of electromagnetic induction, which was discovered by Michael Faraday in 1831, a British Scientist. Faraday discovered that if an electric conductor, like a copper wire, is moved through a magnetic field, electrical current will flow(be induced) in the conductor. So the mechanical energy of the moving wire is converted into the electric energy of the current that flows in the wire.

2.2 Components of turbo generator:

The generator consists of the following components Stator Rotor Bearings Ventilation and Protection System Cooling System Insulation Vacuum pressure impregnation system Exciter Base frame

2.3 Principle of operation:

Turbo generator or A.C. generators or alternators operates on the fundamental Principles of FARADAYS LAWS OF ELECTROMAGNETIC INDUCTION in them the standard construction consists of armature winding mounted on stationary element called stator and field windings on rotating element called rotor The stator consists of a cast-iron frame, which supports the armature core, having slots on its inner periphery for housing the armature conductors. The rotor is like a flywheel having alternating north and south poles fixed to its outer rim. The magnetic poles are excited with the help of an exciter mounted on the shaft of alternator itself. Because the field magnets are rotating the current is supplied through two
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slip rings. As magnetic poles are alternately N and S, they induce an e.m.f and hence current in armature conductors. The frequency of e.m.f depends upon the no. of N and S poles moving past a conductor in 1 second and whose direction is given by Flemings right hand rule.

3. STATOR

3.1 Stator Frame:

The stator frame is of welded construction, supports the core and the windings. In consists of air duct pipes and radial ribs, which provide rigidly to the frame. Footings are provided to support the stator on the skid. The stator frame should be rigid due to the various forces and torque during operation. The welded stator frame consists of the two end plates, axial and radial ribs. The arrangement and dimensioning of the ribs are determined by the cooling air passages, the required mechanical strength and stiffness. The end covers are Aluminum alloy castings. The stator frame is fixed to the skid with the help of hexagonal bolts. The skid is temporarily fixed to the concrete foundation through bolts.

3.2 Stator Core:

Stator core is stacked from the insulated electrical sheet laminations and in the stator frame from insulated dovetailed guide bars. Axial compression is from clamping fingers, clamping plates and non-magnetic clamping bolts which are insulated from the core. In order to minimize the hysteresis and eddy current losses of the rotating magnetic flux, which interacts with the core, the entire core is built up of lamination, each layer of which is made from a no. of individual segments. The segments are punched from the silicon steel. In the outer circumference the segments are stacked in insulated trapezoidal guide bars, which hold them in position. The guide bar is not insulated to provide for grounding the core. The laminations are hydraulically compressed and heated during the stacking procedure. The complete stack is kept under pressure and fixed in the frame by means of cells.

The core packed into the stacking frame is pressed firmly together between the end plates of the machine frame and fixed in this position by welding the axial ribs of the core and end of the plates of frame. End fingers on the inside diameter of the end plates transmit the pressure to the teeth of the core. The compressive force produced prevents the laminations and teeth from vibrating. An eye is welded to each end plate for attaching suitable lifting gear with adequate lifting capacity for transporting the complete machine. All the forces that occur during normal operation or on short circuits are transmitted from the stator yoke to the frame via the seating plates and into the foundation.

3.3 Stator Winding:

The winding is a double layer multi turn lap winding. The half coils are made up of electrolytic copper strips insulated with mica based epoxy insulation of suitable thickness to give a long and uninterrupted service. Each strip is staggered to 360degrees and it passes through all the sides of the coil. This process is called transposition. The purpose of transposition is to avoid the circulation currents due to eddy current and also to avoid corona losses. The straight parts of the half bar are coated with conductive varnish to prevent corona discharges in the slot. The end winding is specially shaped to form a basket with an inviolate shaped over hang of the bars. The straight portion of the winding is secured by means of wedges driven into the slot position. The resistance thermometer elements are placed in the core teeth at carefully selected points to measure the temperature rise of the machine. Epoxy glass laminated brackets support the end winding. Epoxy glass laminated spacers to give a rigid structure to withstand the short circuit forces of the three-phase winding are connected to the connecting strips, which are also insulated and secured in position. Six output terminals are brought out from the rings of the insulated covers.

Fig 3.1 Wound Stator

Fig 3.2 Stator Winding

3.4 End Covers:

The end covers are the castings of the aluminum alloy and are bolted to the side plates of the stator frame. The inlet passage is specially designed with built in guide vanes, which ensure uniform distribution of the air to the fan. Air ceiling is provided around the shaft and at the parting plane of the top and bottom parts of the end covers so that suction of oil vapor from the bearings does not take place.

3.5 Location of Bars:

A semi-conducting wrapper of graphite paper in the slot protects the bar. The stator winding is protected against the effects of current forces in the slot section. To ensure tight seating of the bar at the slot bottom, a slot bottom-equalizing strip of stress path is inserted. A top ripple spring is arranged between two compression strips to exert a continuous pressure on the bars. The bars are shaped so that, cone shaped end windings are obtained. In order to reduce the stray losses a small cone taper of (13-20deg) is used. On the wide sides of the bars spacers of insulating material are inserted at regular intervals.

3.6 Enclosure:
The enclosure consists of the inner and outer components. The inner components comprises of the winding covers, which from an angular enclosure of top and bottom parts and is designed as required for particular degree of protection, as indicated in the dimension drawing or in the Technical data. The ventilating circuit is of the double-ended symmetrical arrangement.

3.7 Electrical Connections of Bars and Phase Connection:

Brazing makes electrical connection of Bars: Electrical connection between the top and bottom bars, one top bar being brazed to the associated bottom bar. The coil connections are wrapper depends on the machine voltage. After tapping, an insulating varnish is applied.

3.8 Phase Connectors:

The phase connectors consist of flat copper sections, the cross section of which results in a low specific current loading. The connections to the stator winding are of riveted and
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soldered type. The phase connectors are wrapped with resin rich mica type, which contain synthetic resin having very good penetration properties. The phase connectors are then cured at a certain temperature, with the shrinking tapes contracting so that a void free insulation is obtained.

3.9 Output leads:

The beginning and ends of three phase windings are solidly bolted to the output leads with flexible. The output leads consist of flat copper sections with mica insulation. To prevent eddy-current losses and inadmissible temperature rises: the output leads are brought out.

Fig 3.3 Phase connectors and rings

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3.10 Insulating materials used in the stator winding:

Usage Material description conductive Specifications foam HL657

A foam insulation for slot bottom Semi layer of stator coil Slot bottom insulation Inter layer insert Top insulation Spacers in overhang Bandage ring spacers Slot wedge Fillers for Slot Merge spacer Slot Merge spacer fleece

Semi conductive fleece Glass mat (compressible) Glass mat (compressible) Glass mat (compressible) Glass mat (compressible) Glass mat (Hard) Glass mat (Hard) Glass mat (Hard)

HL656 HM693 HM693 HM693 HM693 HM694.52 HM693 HM694.5

Stiffeners between top & bottom Glass mat (repressed in a SN763353 layers Interlacing for ring and stiffeners hydraulic fixture) Glass Sleeve SCHL559 GSBD552

Typing of spacers b/w collector Glass tape rings Insulation of rings Shrink and protection layer Adhesive varnish for tape ends Bandage rings Fine mica paper glass tape Polyester shrink tape Adhesive varnish

GSBD552 L611 KIL 875.2 +

Polyester resin + glass PG822 ravings GSSTR588 HM 694.5

Terminal boards

Glass mat (hard)

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4. ROTOR

The rotor is forged from a homogeneous steel ingot of specially alloy steel properly heat treated to meet the required mechanical, metallurgical and magnetic properties. Axial slots are milled through out the active length of the rotor body to accommodate the conductors. The slots are dovetailed at the top of housing the wedges.

4.1 Rotor shaft:

The rotor shaft is forged from a vaccum cast steel ingot. The high mechanical stresses resulting from the centrifugal forces and short circuit torque call for high quality heat-treated steel. The rotor consists of an electrically active portion and two shafts end. Approximately 60% of the rotor body circumference has longitudinal slots, which hold the field winding. Slot pitch is selected so that 1800 displace the two solid poles. The rotor wedges act as damper winding within the range of winding slots. The rotor teeth at the ends are provided with the axial and radial holes, enabling the cooling gas to be discharged into the air gap after, intensive cooling of the end windings.

4.2 Rotor Winding:

The field winding consists of several series connected coils inserted into the longitudinal slots of the rotor body. The coils are wound so those two poles are obtained. The solid conductors have a rectangular cross-section and are provided with axial slots for radial discharge of the cooling gas. The individual conductors are bent to obtain half turns. After insertion into the rotor slots, these turns are combined to form full turns of the series

connected turns of one slot constituting one coil. The individual coils of the rotor winding are electrically series connected so that one north and one south magnetic pole are obtained.

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Fig 4.1 Rotor shaft

Fig 4.2 Laminated Rotor before winding

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4.3 Rotor Slot Wedges:

To protect the winding against the effects of the centrifugal force, the winding is secured with wedges. The slot wedges are made from an alloy high strength and good electrical conductivity, and are also used as damper wedged bars. The retaining rings act as short circuit rings to induced current in the damper windings.

4.4 Cooling of Rotor Windings:

Each turn is subdivided into four parallel cooling zones. One cooling zone includes the slot from the center to the end of the rotor body, while another covers half the end winding to the center of the rotor body. The cooling air for the slot portion is a limited into the slot bottom ducts below the rotor winding. The hot gas at the end of the rotor body is then discharged into the air gap between the rotor body and stator core through the radial openings in the conductors and in the rotor slot wedges. The cooling air for the end windings is drawn from below the rotor-retaining ring. It rises radically along the individual coils and is then discharged into the air gap.

4.5 Rotor Retaining Rings:

The rotor retaining rings with stand the centrifugal forces due to the end windings one end of each ring is shrunk on the rotor body, while the other end of the ring overhangs the end winding without contact on the shaft. The shrunk on the hub at the free end of the retaining serves to reinforce the retaining ring and secures the end winding in the axial director at the same time. The shrink seat of the retaining ring is silver plated, ensuring a low contact resistance for the induced current. To reduce the stray losses and have high strength, the rings are made of non-magnetic core worked materials.

4.6 Slip Rings:

These are made of forged steel and shrunk on either side of the rotor between the end cover and the bearing. The mica splitting is used to insulate the slip rings from the rotor body. The excitation to the rotor winding is taken from these slip rings. The connection leads are suitably insulated and taken through slots milled on the surface of the rotor. Wedges are

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provided to keep the leads in position. A helical groove is machined on the outer surface of the slip rings to have better dissipation of heat, thus minimizing the brush wear.

4.7 Rotor Fan:

The generator cooling air circulated by the two axial flow fans located on the rotor shaft at either end. To augment the cooling of the rotor winding the pressure established by the fan works in conjunction with the air expelled from the discharge ports along the rotor shaft. The blades are screwed into the rotor shaft. The blades are forged from an aluminum alloy. Threaded root fastening permits the blade permits the blade angle to be changed.

4.8 Rotor Balancing:

The rotor is balanced with the help of sophisticated balancing machine. The balancing weights are provided in the hubs under retaining rings and in the fans. The rotor is dynamically balanced and subjected to an over speed of 20% for 2min.

4.9 Radial Bolt:

The field current lead located in the shaft bore is connected to the terminal lug through a radial bolt. The radial bolt is made from steel and screwed into the field current lead into the shaft bore.

Fig 4.3 Rotor over hang Portion

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5. BEARINGS
5.1 Principle of operation:
In steam turbines, the rotating shaft is supported on two journal bearings, and is axially located by a thrust bearing. Both these types of bearings in steam turbines work with a hydrodynamic oil film formed between the two mating surfaces. The hydrodynamic action can be explained as follows. The rotor pulls the oil into the space between the two mating surfaces. Because of the viscosity of oil, the layer of oil closest to the shaft drags in the next layer, which drags in the next layer, and so on. This action forms an oil film between the rotating shaft and the stationary bearing surface.

Now if the stationary surface is inclined such that the gap between the moving part and the stationary part gradually reduces along the direction of movement, then the dragged-in oil gets compressed, and a pressure film is built up. This pressure film takes the normal load on the moving part. The friction is only because of the shear in the oil, and the heat generated is also only because of this shear. The heat is carried away by the oil flow. It may be noted that the pressure built up depends upon the viscosity of the fluid. If, for a given bearing configuration, a fluid of less viscosity is used, pressure built up will be less, and the load carrying capacity will be less. The generator rotor is supported at two-journal bearing. The bearings consist of a bearing pedestal and bearing shell is split into two halves to facilitate assembly. The bearing pedestals are iron castings and the bearing shells are the steel castings. The bearing pedestals are providing with a spherical seating surface and bearing shell rests into with its outer spherical surface. The inner surface of the bearing shell is provided with spherical grooves and cast with Babbitt metal.

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5.1.1 Bearing Oil Supply: The oil required for the bearing lubrication and cooling is obtained from the turbine oil supply system supplied to the lubricating groove in the bottom-bearing sleeve. The upper bearing sleeve consists of a wide overflow groove through which oil is distributed over the shaft journal and fed to the lubricating pump.

5.1.2 Bearing Temperatures: One double-element resistance temperature detectors monitor the temperatures of each bearing. The resistance temperature detector is screwed in the position on side of the low bearing sleeve from outside with the detector extending to the Babbitt liner.

5.2 Ventilation and protection equipment:

5.2.1 Ventilation Arrangement: The turbo generator is cooled by air circulated by means of two axial fans. Air coolers cool the air after circulation. The air is drawn through suction ducts by axial fans mounted on either side of the rotor. The warm air flows out through the exhaust at the bottom of the stator frame.

5.2.2 Space heaters: These heaters are used to circulate warm air inside the turbo generator and during outages to prevent condensation of the moisture inside the machine. They are of strip type and robust design. The heating elements are enclosed in a steel sheet with specific rating of 15W per sq. inch of the surface. They are so designed that they may be fixed in the suction ducts of the turbo generator. The heaters are completely covered in order to prevent the accidental contact with the heat units.

5.2.3 Resistance Temperature Detectors: The resistance temperature detectors are made up of Platinum resistance elements. The detectors are placed in a groove cut in a rectangular glass laminate and embedded in different positions like stator teeth, stator core, and slots. There are 12 active and three spare elements distributed in different locations in 3 different planes, 5active plus 3 spare elements
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are placed in stator slots, 4 active are placed in stator core, 3 are placed in teeth to measure the hot and the cold air temperatures. The resistance thermometers are fixed in the exhaust hood of the stator frame and the end covers. The leads from these resistance thermometers are brought out and connected to the terminal board. The leads coming from the spare elements are brought up to the terminal board and left inside the machine. These resistance temperature detectors operate on the principle that the resistance of the elements will change depending on the temperature coefficient of the element. The change in resistance can be accurately measured in a bridge circuit. A graph is drawn showing the variation of resistance with temperature, which is used to know the temperature rise under different operating conditions of the turbo generator.

5.2.4 Fire Detectors: For the protection of turbo generator against any possible fire hazards 12 fire detectors relays are provided on either side of the stator winding. These relays have a set of normally open contacts. The set of contacts will close when the temperature surrounding the first relay exceeds 80deg Celsius. The other relay set of contacts close when the temperature exceeds 1000. These contacts are wired up to the terminal board provide on the stator frame for the resistance temperature detectors. Both the sets of contacts are used for automatic fire alarm shutting down of the turbo generator system and for the release of CO2 gas from the Carbon dioxide system.

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6. INSULATING SYSTEMS

6.1Resin rich system of insulation:

Conductor cutting and material used is same as in resin poor system. Transposition is done same as that of resin poor system. Stacking of coils is done. In this case high resin glass cloth is used for preventing inter half shorts. Putty work. Nomex is used as transposition pieces. Putty mixture is a composition if mica powder, china clay and SIB 775 Varnish. Straight part baking is done for 1hour at a temperature of 160OC and a pressure of 150kg/ sq.cm Then bending and forming is done. Half taping with resin rich tape is done for over hangs and reshaping is done. To ensure no short circuits half testing of coils is done. Initial taping and final tapings is done with resin rich tape to about 13-14 layers. Final baling is done for 3hrs at a temperature of 160OC in cone furnace. Gauge suiting is done. Conductive/ graphic coating (643) and semi-conductive coating 642 are done. High voltage testing is done at four times that of rated voltage and tan testing, inter strip, inter half testing are done. Finally glass taping and epoxy gel coating are carried out.

Advantages of resin rich system of insulation: Better quality and reliability is obtained. In case of any fault (phase-ground/phase-phase), the repair process is very easy. Addition of excess resin will be avoided because of using resin rich mica tape.

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6.2 Resin poor system of insulation:

Advantages of resin poor system of insulation: It has got better dielectric strength Heat transfer coefficient is much better Maintenance free It gives better capacitance resulting in losses due to which the insulation life will be more The cost is less and it is the latest technology Reduction in time cycle and consumption MW is also less and it gives high quality. Disadvantages of resin poor system of insulation: Dependability for basic insulation materials on foreign countries If any short circuit is noticed, the repairing process is difficult

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7. VACUUM PRESSURE IMPREGNATION

Siemens electrical machines quality is highly dependent on the vacuum pressure impregnation insulation system. All the high voltage machines, pole coils irrespective of size and shape are being impregnated under vacuum and pressure of self developed Siemens patent resin systems. The stringent quality tests on the resin mixtures and strictly following the vacuum pressure impregnation and systematic cooling and heating cycle of resin mixture and sophisticated automatic control systems made the insulation systems for better and better quality for more than 30 years, made Siemens pioneers in this field. The insulating materials used by Siemens for wedges are resin poor and accelerator treated. For example Main insulation tapes, mica paper tapes, overhang protective tapes, shrink tape and glass mates HM693 are treated with accelerator.

After impregnation, they become hard and experiments were conducted for voltage endurance at room temperature and at evaluated temperature continuously for more than 3 years. Though the mica tape can withstand 20kv per mm, the extrapolation has been done at 4kv/mm and life expectancy is around 100yrs. With an operation stress level of less than 4kv/mm, factor of safety is considerable. The Vacuum pressure impregnation system was brought by Dr.Meyer with the collaboration of westing house in the year 1956. The resins used were of polyester. Siemens developed the present Vacuum pressure impregnation system with epoxy resin and treated accelerator on tapes. The mica tapes used for Vacuum pressure impregnation systems are ROGS 275, ROGS 275.1 and ROV 292. ROGS 275 tapes are with glass cloth baking up to 13.8 kV voltage levels ROV 292 mica paper tapes are with polyester fleece above and more penetration of resin. ROGS 275.1 tape is special glue varnish for tropical countries like India and Brazil to resist higher humidity. The glue being used for main insulation tape is X2026 and for conductor insulation is X2027.

The resin used for Vacuum pressure impregnation is ET 884, a mixture of epoxy resin E1023 (lekuther m x 18) and hardener H1006 in 1:1.2 ratio by weight. In kwu, the components are mixed in 1:1 ratio. E1023: The resin is in drums of 220 kgs weight. It is in crystal form at temperature of 14 or 20deg.C the container is resin is available in drum the reason is faster heating in furnace
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the resin in liquid state shall not come out of the container. The drums are kept in oven and heated up to 1000 C for about 18hrs. If the resin is not fully in liquid condition, it can be heated up to 1250C. The storage tank is filled with resin first depending on the volume and ratio of mixture at a temperature of 600 C through hose pipes. Resin filling is being done by creating 0.2 bar vacuum in the tank.

7.1 Resin Mixture:

The mixing ratio of resin to harden is 46:54 parts. The resin mixture required for the siemens Impregnation tank is 27000lts. A job of 1.9m height and 4.5m diameter can be impregnated. Size of the tanks: Main impregnation tank = 4.5m (pie) x 3.0m ht. There are 3-inch vessels for different sizes jobs impregnation. Vessel (1) 3.8m pie x 2.25m ht. Vessel (2) 3.0m pie x 2.3m ht. Vessel (3) 2.0m pie x 2.3m ht.

Three Storage tanks of each resin capacity 9000 litres are in the operation for storing. The resin mixture cooling and heating cycle is by circulating the resin through the heat exchangers. Oil heated by water is being used for heat exchangers.

The Vacuum pressure impregnation cycle is as per WIV 114.1 standard. The job is kept in an oven for a period of 12hrs at a temperature of 70OC. Six no. of thermocouples are inserted on the back of the core and measured the temperature. Job insertion in the impregnation tank is at 70oc. The lid of the impregnation tank will be in open condition. The vessels are kept clean. Resin available is wiped out by Methylene. Traces of resin shall not be allowed on the inner side of the tank. It reacts with humidity and scale formation will takes place. These components obstruct the filters also. The resin at the time of cleaning is carefully removed by wiping with rubber sheets. Keeping the vessel in slant position on the ground also cleans the inner vessels. After ensuring the perfect cleaning, the tank should be allowed for further operation. The job is inserted in the tank the temperature monitoring thermocouples are placed on the back of the core. The lid is allowed to come down by hydraulic motor. Silicon grease is applied on the surface of tank where the lid is touching.
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A rubber gasket is also provided on the rim not to allow any leakage. Air pipes are closed and vacuum pumps will be started. Vacuum creation 0.35 torr for 2 hrs: The job temperature is to be maintained always above 65OC, if found less, tank can be heated up. In practice, the vacuum can be created in 2 hrs. Siemens adept before starts of 2nd shift (3.0 pm), they create 0.35 torr vacuum and it will be continued till next day morning 1st shift (6.00 am) min. requirement is 2hrs.During this time the resin cooling is being carried out to reach 10deg.C and heated up automatically to 70deg.C.

7.2 Impregnation:
The resin mixture is to be heated to 70deg.C. Every day morning a 20ml sample will be taken to laboratory tests. Viscosity will be measured at 70deg.C. It should not be more than 45 CD +10%. Anew resin will beat 15 CP. New resin and hardener mixture is to be added if the viscosity is more. The resin filling is being completed in 25 minute. At this time, the vacuum reduces to 0.5 Torr 1 Torr level. The resin is to be allowed to settle for 15 min. The level of resin is above 100mm over the job. Pressuring 3 bar: With the hydrostatic pressure of the resin, only surface of the insulation can be filled with resin. To have an effective penetration up to the end of a barrier, pressure is to be created to 3 bar (2 bar over atm. Pressure of 1 bar). Gelling time: The polymerization of resin and accelerator take place at this time. At 65OC, the time required is 170 min. The insulation gets hardened. Curing 14 hr at 140 O C: The resin is to be pumped back to the storage tank. The job is to be removed from the tank and allowed for dripping. It is kept in oven at 140deg.C for min of 14 hrs. The accelerator B1057.1 is to be placed at 4 corners of the oven. In curing process the accelerator vapors will react with surface resin and cures.

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7.3 Characteristics of VPI insulation system:

Higher mechanical bond Void free insulation High dielectric strength, low dissipation factor, hence longer electrical life. Better heat transfer Higher thermal stability, ensures class-F under running conditions Less maintenance Cost effective Low inflammability, hence limited damage during abnormal operations. High resistance to oil, acid, alkali and moisture. Manufacturing cycle is less Frame size is small, machine cheaper. Elastic response to thermo-mechanical stress, machine suitable peak load operation

7.4 Vacuum Pressure Impregnation process:

Four stages of Vacuum pressure impregnation cycle vacuum drying: Temperature Pressure Duration Drying check Impregnation: Resin temperature: 60oc +/- 2oc Resin filling Resin level Settling time : ~ 20 min : ~ 100 mm above : ~ 10 min : 60oc +/- 3oc : 0.2 millibar : ~ 16-18 hrs : 0.06 mbar drop in 10min

Resin (epoxy bisophenol a) & hardener ratio 1:1 Pressurization: N2 pressure Rising : ~ 4 bar : ~ 80 min

Holding time : ~ 2 hrs Post curing: Temperature of job Duration : 140oc +/- 5oc

: ~ 20 hrs
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Fig 7.1 Vacuum Pressure Impregnation Plant

Fig 7.2 Wound Stator at VPI Plant

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8. EXCITERS
8.1 Design features and different types of exciters:
The exciter consists of Rectifier wheel Three-phase main exciter Three-phase pilot exciter The three-phase pilot exciter has a revolving field with permanent-magnet poles. The three-phase ac is fed to the field of the revolving-armature main exciter via a stationary regulator and rectifier unit. The three-phase ac induced in the rotor of the main exciter is rectified by the rotating rectifier bridge and fed to the field winding of the generator rotor through the dc lead in the rotor shaft. A common shaft carrier the rectifier wheels, the rotor of the main exciter and the permanent magnet rotor of the pilot exciter. The generator and exciter rotors are thus supported on a total of three bearings. Mechanical coupling of the twoshaft assemblys results in coupling of the dc leads in the central shaft bore through the multi contract electrical contact system.

Rectifier wheels: The main components of the rectifier wheels are the silicon diodes, which are arranged in the rectifier wheels in a three-phase bridge circuit. A plate spring assembly produces the contact pressure for the silicon water of the diodes. One diode each is mounted in each light metal heat sinks and then connected in parallel. Associated with each diode is a fuse, which serves to switch off the diode from the circuit if it fails. Each arm of the diode bridge is provided with one RC block. The three-phase connection between the armature and diodes is obtained through copper conductors arranged on the shaft circumference between the rectifier wheels and the main exciter. One conductor is provided for each arm of the diode bridge. The conductors originate at a bus ring system of the main exciter.

Three-phase pilot exciter:

It has a frame, which accommodates the laminated core with the three-phase winding. The rotor consists of a hub with mounted poles. Each pole consists of separate magnets, which are housed in non-magnetic metallic enclosure.

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 Three-phase Main Exciter: It is a revolving armature unit, the frame poles with the field and the damper winding. The field winding is arranged on the laminated magnetic poles. The rotor consists of stacked laminations, which are compressed through bolts over compression rings the three-phase winding is inserted in the slots of the laminated rotor. The winding conductors are transposed with in the core length and the end turns of the winding are secured with the steel brands. The winding ends are run at bus ring system to which the three-phase leads leading to the rectifier wheels are also connected. After full impregnation with epoxy resin and curing, the complete rotor is shrunk onto the shaft.

Fig 8.1 Overhang Brushless Exciter (Stator and Rotor)

Fig 8.2 Conventional Brushless Exciter

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9. TESTING OF TURBO GENERATOR

9.1 Objective of testing:

Testing is the most important process to be conducted on a machine after it is designed. The testing of machine is necessary primarily to establish that the machine performance complies with the customer specifications. Tests ensure that the piece of equipment concerned is suitable for and capable for performing duty for which it is intended. Testing is done under condition simulating closely as possible to those, which will apply when the set is finally installed with a view to demonstrate to purchasers representative its satisfactory operation. Test provides the experimental data like efficiency, losses, characteristics, temperature limits, etc. for the use of design office, both as confirmation of design forecast and also as basic information for the production of future designs. Introduction: Testing is an activity, which basically evaluates a component, and or a product (built up of component assemblies) as to whether it has the technical capability that has been built into it by way of design, materials, and technological processes employed while manufacturing and workmanship.With ever increasing rating of the modern turbo generators and reliability of service expected, testing at manufacturers works has become of paramount importance. The machine performance is evaluated from the results of the equivalent tests. Advantages of testing: Provides quality assurance. Meets the requirements of legal & contract requirements. Ensures process capability & develops checklist. Have an approved procedure. Check the equipment before use. Calibrate the test equipment & instruments. Ensure interlocks of the equipment Provides data for optimization of design Provides quality assurance Meets the requirement of legal and contract requirements. Reduction in rework cost. Ensures process capability and develops checklist.
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Increases confidence levels in manufacture. Establishes control over raw materials. Helps in building of safety and general operation and manual.

9.2 Performance tests on turbo generator:

With the increasing trend on standardization every country has its National Standards covering a wide range of subjects, In India; the Indian Standards are valid and applicable. The machines produced at Hyderabad fully conform to Indian and also International Standards and many machines are being exported to various countries. The performance tests on turbo generators include the following

Measurement of Insulation resistance. Measurement of ohmic resistance of windings in cold state. Applied H.V. tests. Measurement of vibrations and mechanical losses. Measurement of no load characteristics. Measurement of short circuit characteristics. Determination of excitation on load and checks of voltage rise (regulation). Measurement of leakage and potier reactance. Measurement of losses and determination of efficiency. Heat run tests. Retardation test.

Test Procedure: During manufacturing of Turbo-generators the following stage tests are to be carried out on individual components to ensure quality of the product and to reduce last minute delay during acceptances tests. The standards for these tests will differ from plant to plant. Stator: Checking up of Resistance temperature detectors while core building. Ring flux test. Tan delta measurement on stator winding after impregnation. H.V. test on coils during manufacturers and assembly. Capacitance measurement.

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 Rotor: H.V. test on excitation connecting leads. H.V. & inter- turn insulation tests on field coils during the winding process. Impedance measurement field coils.

Over-speed test: Over-speed test involves mechanical running of the rotor at the prescribed % overspeed for the stipulated period of time. It is later subjected to a very close mechanical inspection to investigating into the effects of over speed if any. The rotor is balanced to the required levels as per standards. This brings us to measurement of characteristics and losses of the generator.Measurement or determination of efficiency of the machine is an important step. For determination of efficiency, losses measurement on the drive system is to be done and derive machine losses by subtracting drive motor losses. Determination of efficiency: Having measured the losses, the efficiency can be estimated from the formula. Efficiency =(input losses / input = output / (Output + losses) Tolerance on guaranteed efficiency is 0.1 (1-efficiency) when measured by summation of losses method. Measurement for leakage & potier reactance: Leakage reactance is measured on the stator alone when winding is completed. The procedure involves supplying the winding from a 3-phase variable voltage source and measuring currents voltage and power at the stator terminals. Depending on the source capacity upto 0.25In may be passed. Potier reactance as per accepted standard practices is taken as 0.6 to 0.65 of total leakage reactance. It can alternatively be calculated from the zero power factor test measurements. Line-to-Line sustained short circuit test: The negative phase sequence reactance is can be determined from the line-to-line sustained short circuit test.

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Negative phase sequence reactance (X2) = P / 3. (Ik2)2 Where P = Power measured and Ik2 is negative phase sequence current measured during lineto-line sustained short circuit test. Line to line and to neutral sustained short circuit test: From this test zero phase sequence reactance can be determined. Zero phase sequence reactance (Xo) = Vo / Io. Where Vo = Voltage from measured in open phase voltage and Io is current measured in line to neutral during line to line sustained short circuit test. Retardation test for determination of Moment of Inertia: The machine speed and time are noted during free coasting down of the machine. Moment of inertia = (4 x 365000 x P x T)/ N2 Kg-m2 Where: P = Power input in kW to keep machine at rated speed. N = Rated Speed in rpm. T Time in seconds from curve. (Tangent drawn at rated rpm)

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10. TESTING DURING MANUFACTURING PROCESS AND ASSEMBLING OF TURBO GENERATOR

Tests on turbo generators are classified under the following headings, which is also the order in which these are performed during the course of manufacture. Tests on the materials and components during the manufacture so as to control the quality of the materials in process also known as Process tests. Performance tests on the machine to prove the performance of the generator in accordance with the required standard. .

Fig 10.1 Turbo generator under testing 10.1 Tests during manufacturing process:
Tests on rotor winding Tests on stator coils. Balancing and over speeding of rotor.

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Tests on Rotor winding:

The rotor coils and their insulation are subjected to a high stress when in normal operation. Thus a thorough inspection of these is necessary before putting them in the rotor slots as otherwise any replacement of the faulty insulation or cell would necessitate removing the coil binding rings and the wedges, which is a cumber job. A series of graded voltage tests are conducted on the rotor cell and coils dusting assembly and also when finished to test its electrical strength against likely creep age to ground or inter turn breakdown.

Tests on Rotor Coils:

Between turns: The rotor coils turns are made up of a number of turns which are formed in halves and then assembled with their inter turn insulation and boned with an adhesive in the steam heat press. Although the normal working voltage per turn is very small, a turn to test of 240 volts is done to exercise quality control. Top turn trough: The insulation the top and bottom of the rotor slot provides adequate and safe creep age distance between copper and rotor steel, in case of slotted copper 500 volts for one minute to test the top trough. Collecting leads: A high voltage equivalent to the shipping test plus 1500v is applied to the collector leads when fitted in bore with studs of seals fitted but before connecting to the windings.

Tests on stator coils:

As per the standards the stator winding has to be subjected to a shipping pressure test of (2 x line voltage +1kv). This power frequency voltage applied for one minute. In order that machine when found with stands this final voltage test and any faulty coil is eliminated during various stages of coil manufacture and winding. Because of the continued application of HV tests overstress the winding insulation, the voltage is reduced in various stages. Tests between parallel strips: This is a test of strip insulation provided for eddy emf, on low voltage at the order of 350V for 3 seconds is applied.

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 Coils in manufacturing and Winding Sections: When the coils are first tested, a voltage of 8kV in excess of shipping pressure test is applied, and this voltage tests are repeated. Tests on Thermocouples: 1000V Megger test is applied to the thermocouples.

Balancing and over speeding of rotors:

Balancing: One of the most important preliminaries to testing is that of balancing the rotors. Before over speeding, the rotor is dynamically balanced, in cold as well as hot conditions. A set of run up and run down is taken sure those critical speeds are well away from the running speed. Over Speeding: In order to check the soundness of all parts and fitting on rotor assembly, the rotor is run at an over speed of 14% for five minutes or 30% for one minute.

10.2 Performance tests on assembled machine:

The machine is assembled and erected at the heavy rotating plant test bay for test. The performance tests on assembled machine are as follows: Dry out insulation resistance of rotor & stator windings: Before starting with running tests, the stator windings are dried out by circulating current in the winding from an external dc source Input of power is so controlled as to limit the temperature of the end windings to a maximum of 800C by thermometer. Progress of dry out is observed by one minute insulation resistance reading with 1000v Megger. With the application of heat, the insulation resistance will initially drop and then will rise again over a period of time and finally becomes approximately constant temperature. Ration of ten-minute reading, i.e. polarization index, when more than 2 gives an indication of good dry out. Insulation resistance readings of rotor winding to ground are taken.

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 Resistance of machine windings: Measurement of cold winding resistance, both for stator and rotor must be very accurate since it forms the basis of calculating rise in temperature of rotor winding under cold and hot conditions by resistance method. All precautions are taken to ascertain correct temperature of the winding white measuring cold resistance. Since the winding resistance of turbo generator is quite low: a modified form of wheat stone bridge i.e. Kelvins double bridge does away with the necessity of accounting for the resistance of loads. Resistance between phases for stator and between slip rings for is recorded along with the cold winding temperature at the time of measurement. Phase sequence test: The phase sequence test is to check the agreement of the terminal markings that have been specified using the Phase Sequence Indicator.

Before running the machines ensure: Lubricating oil is flowing through bearings and the gear box. All the instruments are working Roll the machine and check all the parameters. Slowly raise the speed to one-sixth rated speed. Observe slow roll vibrations, temperature and oil flows. Raise the speed to one-third rpm slowly and record the vibrations, temperature and oil flows. The vibrations are measured at rated speed on both the bearing housings (pedestals) in horizontal, vertical and axial directions with the help of vibration meters, which are internally connected to the monitor and the vibrations, are noted in the form of graphs. The temperature of stator is monitored by monitoring resistance temperature detectors embedded in core, tooth and winding. Now raise the speed to two third the rpm by observing all the parameters, critical speed and record them. The machine is rolled and run at rated speed after ensuring the bearing oil and left at rated for stabilization of bearing temperatures.

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11. MANUFACTURING DETAILS OF TURBO GENERATOR

Manufacturing details of 2-pole and 4-pole turbo generator:

S.NO. COMPONENT 2-POLE TG Manufactured from Cold Rolled Non-Grain Oriented (CRNGO) steel laminations of thk. 0.5/0.65mm Stator Lamination segments are assembled in a half lapped way Core laminations are secured using core bolts and guide bars, core back rings Ventilation spacers for separating packets and provide cooling to stator core No skew in the stator slots Single turn Roebel Bar design Transposition of conductor strips in the bar (360 / 540 deg) is required Brazing of end connecting strips required on both ends Overhang involute shaping of the bar is done manually on a universal former More cycle time for manifacturing one bar Lap Winding No. of brazings are more More cycle time for completing stator winding No. of tyings more in the overhang zone Overhang support system using Hardened Glass Laminates
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STATOR CORE

STATOR BARS

STATOR WINDING

4-POLE TG Manufactured from Cold Rolled Non-Grain Oriented (CRNGO) steel laminations of thk. 0.5/0.65mm Stator Lamination segments are assembled in a half lapped way Core laminations are secured using core bolts and guide bars, core back rings Ventilation spacers for separating packets and provide cooling to stator core Stator slots are skewed by one slot from one end to other end. Multi turn diamond pulled coil Transposition of conductor strips in the bar is not required Brazing of end connecting strips required on both ends Overhang involute shaping of the coil is done on maxie puller machine Less cycle time for manifacturing one coil Lap Winding No. of brazings are less Less cycle time for completing stator winding No. of tyings less in the overhang zone Overhang support system using Hardened Glass Laminates

Cylindrical rotor machined from solid Steel forging Open slots Concentric winding Cost of rotor for same rating will be high Rotor will be rotating at 3000rpm. Hence solid steel forging is required for rotor body Copper is 0.1% Silver bearing Copper (bare)

ROTOR CORE

Inter turn insulation to be provided ROTOR COILS & WINDING Complex system for overhang support system (overhang bracers made from HGL) Cupro Nickel wedges used for rotor as the rotor is rotating at high speed (3000 rpm) Cycle time for Coil manufacturing and rotor winding is more Axial fan for cooling Direct air cooling for Rotor Indirect air cooling for Stator Cost is more

Cylindrical Laminated rotor (Made of CRNGO steel laminations assembled and shrunk fit on to steel shaft) Open / Semi closed slots Concentric winding Cost of rotor for same rating will be low Rotor will be rotating at 1500rpm. Hence Laminated rotor can be used for rotor body Copper is 0.1% Silver bearing Copper (bare / Double Layer glass (DAGLASS) insulated) Inter turn insulation to be provided for bare strips and not required for DAGLASS copper Simplified system for overhang support system (overhang bracers made from Glass mat) HGL wedges can be used as the rotor is rotating at low speed (1500 rpm) Cycle time for Coil manufacturing and rotor winding is less Radial fan for cooling Indirect air cooling for Rotor Indirect air cooling for Stator Cost is less by 20% compared to same rating 2pole TG. There is a limitation in the design of sub-transient reactance compared to that of 2-pole TGs.

COOLING

COST

Fault current is limited by higher sub-transient PERFORMANCE reactance compared to that of 4-pole TGs.

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Manufacturing details of 30MW 2-pole and 4-pole turbo generator:

30 MW -2POLE STG GENERATOR DETAILS: DESIGN STANDARD SHORT CIRCUIT RATIO INSULATION COOLING PHASE POLES RPM FREQUENCY STATOR CORE: LENGTH OUTER DIA INNER DIA SLOTS SLOT TYPE STATOR WINDING: SLOTS/POLE(FULL PITCH) SLOTS/POLE/PHASE SHORT PITCH COILS METHODE OF WINDING ROTOR CORE: LENGTH OUTER DIA SLOTS SLOT TYPE ROTOR WINDING: SLOTS/POLE COILS COILS/POLE METHODE OF WINDING 30 MW-4POLE STG

IEC 60034 0.53 CLASS B AIR COOLED 3 2 3000 50 HZ 2040 2040 902 36 OPEN TYPE

IEC 60034 0.491 CLASS B AIR COOLED 3 4 1500 50 HZ 1740 2100 1274 84 OPEN TYPE

18 6 15 36 LAP WDG WITH SINGLE PARALLEL PATH 2080 800 24 OPEN TYPE 12 12 6 CONCENTRIC WINDING

21 7 17 84 LAP WDG WITH FOUR PARALLEL PATH 1720 OUTER DIA-1240/ INNER DIA720 48 OPEN TYPE 12 24 6 CONCENTRIC WINDING

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EXCITER DETAILS: TYPE DESIGN STANDARD KW RATING VOLTS AMPS

BRUSH LESS IS 4722 224 280 800

BRUSH LESS IS 4722 130 210 620

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12. CONCLUSION

The training at BHEL Hyderabad helped us in improving our practical knowledge and awareness regarding Turbo Generator to a large extent.Here we came to know about the technology and material used in manufacturing of turbo generators. Besides this, we also visualized the parts involved or equipments used in the power generation.Here we learnt about how the electrical equipments are being manufactured and how they tackle the various problems under different circumstances. At least we could say that the training at BHEL Hyderabad is great experience for us and it really helped us in making or developing our knowledge about turbo generator and other equipment used in power generation. The technology research and investigations division of BHEL is currently investigating the technical and logistical merit of performing offline quadratic-rate partial discharge tests on the stator winding insulation of its hydro & turbo generators. A series of laboratory based insulation research studies on stator bars have been conducted to gain a better understanding of the various partial discharge phenomena involved. Results thus far obtained from these tests have provided valuable insight into the discharge activity of operation.

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BIBLIOGRAPHY

A Text book of electrical technology by B.L.THERAJA. A Text book of electrical machines by P.S.BIMBRA. www.bhel.com www.seimens.com www.indiamart.com

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