1

INTRODUCTION
WORKING PRINCIPLE OF GENERATOR

when there is a change in the flux linkages relative to a circuit, an emf is induced

The amount of emf induced is directly proportional to the rate of change of flux linkages

The direction of induced emf is such that it opposes the very cause producing it

FARADAYS I LAW

FARADAYS II LAW

FARADAYS III LAW

Components of Turbo Generators

1.stator

2.Rotor

3.bearings

4.Cooling system

5.Excitation system
3

STATOR
Stator core Stator frame Stator windings End covers

stator

STATOR FRAME
welding steel single piece construction in order to support the laminated core and windings

STATOR CORE

PREPARATION OF LAMINATIONS Compounding Blanking and notching

ASSEMBLY OF CORE

OPERATIONS IN MANUFACTURING OF LAMINATIONS

A .The cold rolled non grained oriented (CRNGO) steel sheets in the required shapes according to the size of the laminations are cut by the feeding the sheet into shearing press . B .Compounding operation or blanking &notching operation. C. Deburring operation D. Varnishing E. The prepared laminations are subjected to following tests: i) Xylol test-to measure the chemical resistance ii) Mandrel test-when wound around mandrel there should not be any cracks iii) Hardness test-minimum 7h pencil hardness iv) Ir value test-for 20 layers of laminations insulation resistance should not be less than 1 mega ohm

PURPOSE OF STATOR CORE

To support stator windings To carry the electromagnetic flux

generated by rotor winding. Hence selection of material for building up of core plays a vital role. The losses in the core are of two types: Hysteresis losses Wh a Fmax 1.6ft Eddy current losses We a Fmax2 f2 t2 In order to reduce the hysteresis loss silicon alloyed steel, which has the low hysteresis constant is used for the manufacture of the core. the composition of silicon steel is Steel-95.8% Silicon-4.0% Impurities-0.2%

STATOR COILS
1. Set the straightening and cutting machine using guide pilot 2. Cut the conductor strips as per requirement 3. Set the press for Roebel transposition 4. Assemble strips with respect to template and transpose 5.Assembling both halves of the coil sides to form i)One roeble half bar ii)Inserting insulation in straight part
9

6.Baking process 7. remove insulation at the ends of the strips and

testing for the inter strips and inter halves shorts 8. Set the universal former as per standards and bending the stator coils in roebel shape 9.Tapping process

10

Phase connections Resistance

Temperature detectors

11

Two types of coils Diamond pulled multiturn coil (full coiled) Roebel bar (half coil)

12

Stator Terminals

Connecting Rings Clamping Plates & Rings

HGL End Winding Support

Insulated Copper Bars are placed in the slots to form 3 winding

13

ROTOR
Rotor slot wedges Construction End winding braces

Rotor windings

Rotor retaining rings

Rotor shaft

Rotor

Rotor fans

14

ROTOR SHAFT

SINGLE PIECE SOLID ROTOR BODY

MILLING THE FIELD WINDINGS INTO THE ROTOR BODY

Rotor Slots

MACHINED ROTOR

15

CONSTRUCTION
Several series connected coils inserted into the longitudinal slots of rotor body. y CONDUCTOR MATERIAL y INSULATION

16

ROTOR SLOT WEDGES

Slot wedges are made of copper alloy featuring high strength +good electric conductivity Protect the windings against the centrifugal forces . Windings are secured in the slots with wedges

17

END WINDING BRACES ROTOR RETAINING RINGS ROTOR FANS

18

BEARINGS
 High mechanical stability and reduced vibration in operation  To prevent damage to the journals due to the shaft currents, bearings and oil

piping on either side of the non-drive end bearings are insulated from the foundation frame. For facilitating and monitoring the healthiness of bearing insulation, split insulation is provided

19

COOLING SYSTEM
There are various methods of cooling. They are i) Air cooling 60 MW ii) Hydrogen cooling 100 MW iii) Water cooling 500 MW iv)Hydrogen and water cooling 100 MW DISADVANTAGES OF HYDROGEN OVER AIR COOLING: a) Hydrogen is explosive when it combines with oxygen. b) Greater precautions are to be taken to avoid leakage of Hydrogen. c) Cost of cooling system is high compared to air cooling system
20

Flow path 1: is directed into the rotor end winding space and cools the rotor winding, part of the cooling air flows past the individual coils for cooling the rotor end winding and then leaves the end winding space via bores in the rotor teeth at the end of the rotor body. Flow path 2:is directed over the stator end winding to the cold air ducts and into the cold air compartments in the stator frame space between the generator housing and the rotor core. Flow path 3: is directed into the air gap via the rotor retaining ring. core.

21

Exciter is brushless and takes the form of the stationary field generators
Rotor of Brushless Exciter

Armature

Permanent Magnets

Diode Wheel

E/f Monitoring Slip Rings

Rotating Diodes & Fuses

22

EXCITATION SYSTEM COMPRISES OF

ROTOR ROTOR WINDINGS RECTIFIER VARISTORS MAIN EXCITORS ROTATING RECTIFIER WHEEL

23

24

25

QUERIES
26