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Investigation on the performance of a 277.8 MVA synchronous air-cooled

hydrogenerator through loss models

Conference Paper · January 2018

DOI: 10.1109/PICC.2018.8384790

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 Investigation on the Performance of a 277.8 MVA
Synchronous Air-Cooled Hydrogenerator Through Loss
Models
Karthik Desingu, Student Member, IEEE, Thanga Raj Chelliah, Senior Member, IEEE, Deepak Khare
Department of Water Resources Development and Management, Indian Institute of Technology Roorkee, India
(Email: karth.dwt2015@iitr.ac.in, thangfwt@iitr.ac.in, kharefwt@iitr.ac.in)

Abstract— Synchronous generators (SGs) are widely used in mGeno - Weight of rotating part of the generator
power generating plants including hydropower as it is easy to Pcomb - Calculated loss of the combined bearing
control, supports large amount of reactive power, and offers PUGB - Upper guide bearing losses
higher energy efficiency in comparison with asynchronous
generators. SGs are often overloaded through hydro-turbines by
α - Heat transfer coefficient
utilizing excess water flow in the river (e.g. 1000 MW Kancham
Wangtoo hydropower station (India) at 20% continuous
overloading condition for more than six weeks). This paper I. INTRODUCTION
investigates the efficiency of a 277.8 MVA SG, through its loss
models, under two operating conditions: (i) at rated load, (ii) at
20% overload. Temperature of cooling air inlet to the stator of SG
Among all electrical generators synchronous generator (SG)
is owing more attention for power production. In
(primary cooling) and the temperature of water inlet to the cooler hydropower plant up to 700 MW unit capacity SGs are
(secondary cooling) are considered for the analysis. Simulated preferred [1]. Cooling system in generators are of great
results are compared with a commissioned generator through the importance, which provides longer lifetimes of certain
on-site measurements. From the test results, it is observed that the components such as insulation, windings, etc. Furthermore, the
cooler performance (temperature of air leaving from the cooler) electric resistances of the windings are temperature dependent.
was poor at overloads which causes reduction in efficiency and This means that in order to keep the generator at its maximum
temperature-rise in stator windings of tested SG. efficiency, it should work in its normal design temperature
Index Terms-- Calorimeter, efficiency, temperature, losses,
range (60oC – 80oC) [2]-[4]. Hydro-power generators are
synchronous generator, cooler performance. equipped with a closed air circulating cooling system with
surface air coolers spaced symmetrically around the periphery
I. NOMENCLATURE of the stator frame. The air cooler including the cooling air
circuit of the generators is able to satisfy the required loading
ϑw ,W - Warm water temperature of the generator
conditions. SGs are often operated at over-load condition
Cm ,W - Mean specific heat capacity of the water during the period when excess water flows in the river to meet
ρK - Cold air density the power demand. While feeding generator of 250 MW
.
V - Volumetric water flow capacity with 120% of shaft power will lead to generate 300
ρ w ,W - Warm water density MW power and thereby increase in thermal energy losses. As
.
Q - Thermal losses the large hydro-generators are operated beyond the rated value,
Pfw - Ventilation losses (friction and windage) the energy losses also amplifies correspondingly that leads to
ρN - Rated air density alarming temperature rise and insulation breakdown [3]. During
PFe - Open circuit losses the past several eras, the researches and findings were
prominent in these areas such as insulation breakdown for
PSC - Rated stator I2R winding losses
N
machine winding, ventilation and cooling system. To ensure the
PLLN - Rated additional load losses
cooling performance of the SGs while operating above rated
I fg - Air gap excitation current
load, efficiency measurement is important. During the past
I fk - Short circuit excitation current
twenty years, the calorimetric method has been used quite
mI - Incline short circuit characteristic widely to determine the losses and efficiency of large hydro
Pf N - Rated excitation power generators [5]-[11]. Different implementations from closed-
Pbe - Electrical brush loss cycle water-cooled systems [12] to high-precision calorimeters
Pbm - Mechanical brush loss with seemingly complex arrangements [13] have been reported.
wb - Tangential width length of carbon brush In SGs, losses are classified into four categories: winding
lb - Axial length of carbon brush (copper losses), core (iron losses), mechanical, brush-ring
nb - Total number of brushes on both slip rings electrical losses. Through the loss models, total efficiency of the
Ab - Brush contact area SGs is obtained. In general, efficiency of large SG is about 98%
uSR - Circumferential speed of slip ring in total, including field-winding losses. This paper presents the
PTB - Thrust bearing losses

978-1-5386-2462-3/18/$31.00 ©2018 IEEE

 Fan 2
Collector of
cool air
Stator

Rotor Water
radiator

` Collector of
hot air
Rotor
Windings
Stator end
windings

Fan 1

Fig. 1 Hydro generator’s cooling systems [19]

efficiency and cooler performance of a 277.8 MVA air-cooled

A. Ventilation loss:
generator at rated and overload conditions. The generator
cooling-system is schematically shown in Fig. 1. The The heat transfer between a surface and the surrounding air is
measurement of air and cooling water temperature together measured according to IEC60034-2-2, considered with α =
with the records of the generated power are considered to 15W/ (m2.K).
analyze the performance of the generator. The losses transferred to the air are
.
The organization of the succeeding script is as follows:
Section III gives the introduction to power loss computation Q conv = α . A.Δϑconv (2)
model and calculation of efficiency of the generator. Section IV Where A = surface area in m2
gives the introduction to generator cooling system and onsite Δϑconv = Temperature difference surface/ air in K.
measured values. Section V discusses the results obtained from The dissipated power through water is
the loss models and their comparison with on-site . .
measurements and concludes the paper in section VI. Q = ρ .V .cm .Δϑ (3)
The above equation Δ ϑ is the difference between the warm
II. POWER LOSS CALCULATION water and cold water temperature of the generator
Since power losses of electrical systems are dissipated as . .
heat, they can be directly determined by measuring the QV = ρw ,W .V W .cm .(ϑw ,W − ϑk ,W ) (4)
generated heat. In calorimetric methods, there is a controlled Recalculated to rated density form cold air density, rated
medium (usually air or water) used to take over the heat revolutions and with convection losses is the mechanical power
produced by the tested device. Ideally, the heat is completely that are required as
absorbed by this medium[14]-[18]. The power dissipation 3
. .  f  ρ 
(Ploss) of the tested device can thus be determined as function of Pfw = ( QV + Q conv ).  N  .  N  (5)
the temperature rise ∆T between inlet and outlet water  f   ρk 
temperature, the mass density ρ and the flow rate ܸሶ of the B. Open circuit losses
coolant with Dissipated power through the water during open circuit losses
.
Ploss = C p .V .ρ .ΔT (1) is given as,
. .
where cp is the specific heat capacity of the fluid. QOC = ρw ,W .V W .cm .(ϑw ,W − ϑk ,W ) (6)
The following loss components are considered: (i) It is included the heat dissipated by the water due to ventilation,
ventilation losses in the machine, (ii) open circuit losses, (iii) excitation and convection losses. The final value has to be
short circuit losses, (iv) excitation losses, (v) electrical brush recalculated to rated voltage with the measured value to estimate
losses, (vi) upper and lower guide bearing losses, and (vii) the electrical power that is lost is represented below.
thrust bearing losses.
. ρk  f 
3
.   U 2
During each loss thermo-physical properties ϑw , W , C m , W ,   − I f .U f + Q conv  . 
N
PFe = Q sc − Pfw . . (7)
ρ K are measured.  ρN  fN    U 
 
C. Short circuit losses F. Combined bearing
The dissipated power through the water is calculated by using The axial thrust of the turbine due to its load does not affect the
(8) losses of the bearing itself. The dissipated power through the
. . water is
Q SC = ρw ,W .V W .cm .(ϑw ,W − ϑk ,W ) (8) . .
The recalculation of rated current is similar to earlier section QCB =ϑ w,W .V W .Cm ,W .(ϑw ,W −ϑk ,W ) (20)
. 3   I 2 The combined bearing losses are divided into the guide and
ρ  f  .
PSCN =  Q sc − Pfw . k .   − I f U
. f + Q  N  (9)
conv . 
thrust bearing losses according to the ratio of the weight of
 ρN  fN   I  generator rotating parts and the weight of turbine rotating parts.
 
In the combined bearing calculation 298 kW are considered for
The short-circuit losses are divided into the I2R losses at 75oC
the thrust bearing and 50 kW for the guide bearing. Then the
winding temperature and the stray losses
losses are divided into the amount of thrust generated by the
PSN = (1.I N )2 .R175 C (10) generator and the turbine. The lower combined bearing is
calculated from the measured values of the calculated ratio of
D. Excitation Thrust and Combined bearing.
In excitation loss, excitation demand at various levels power Ftotal = (mTurb + mGeno ).g (21)
deliveries has to be calculated for P = 0.8.PN, P = 1.0PN, and P . FGeno Pcomb
= 1.2PN at the power factor cos ϕ = 0.9 FGeno = mGeno .g , PTB = QCB . . (22)
The filed voltage and field current can be obtained by using (11) Ftotal PTBcalc
and (12) . . Pcomb
PTB = QCB − QCB . (23)
PTBcalc
U I = (U N .cos φ + I .R1 )2 + (U N .sin φ + I . X P )2 (11)
G. Upper guide bearing
I f = ΔI f + ( I fg + I fk .sin φ )2 + ( I f k .cos φ )2 (12)
The upper guide bracket transfers to the stator frame the forces
An exemplary calculation for P = 0.8.PN and cos φ = 0.9 is of its own weight and the horizontal forces due to the rotation
conducted in the following. of the rotating parts of the machine transmitted through the
S .0.8 upper guide bearing. The upper guide bearing loss was
I 0.8 = N , measured as similar to the ventilation losses, the devolution of
UN . 3
temperature. The dissipated thermal power through the water is
U I0.8 = (U N .cos φ + I 0.8 .R175 C )2 + (U N .sin φ + I 0.8 . X P )2 (13) given as
. .
QUGB = ρw,W .V W .cm,W .(ϑw,W − ϑk ,W ) (24)
I f0.8 = ΔI f0.8 + ( I fg + I fk0.8 .sin φ )2 + ( I fk0.8 .cos φ )2 (14)
.
Pf 0.8 = I 2 f 0.8 × R275 C (15) QUGB = PUGB
According to the IEC 30034-1[9], 10% of the total calculated
E. Brush losses losses are considered as tolerance. Based on those values the
The current is transferred from the stationary parts to the amounts of losses are added to the contractual losses. Which are
rotating parts through sliprings contacts formed by the 263.7kW for 110%, 246.3kW for 100% and 216.4kW for 80%
stationary brushes and rotating rings. During running, the The efficiency for a given load is
contact faces of the sliprings become coated with a carbon film. PN
This is a necessary condition for good current transfer and for ηN = (26)
PTN + PN
reducing the friction between brushes and sliprings. The
Voltage drop of a brush is generally 2V. PTN = Pfw + PFe + PSC N + PfN + PTB + PUGB + PLGB + PE N + PbeN + Pbm
PbeN = ΔU b . I fN for rated excitation current (16) (27)
The friction losses of a brush are calculated from its contact area IV. GENERATOR COOLING SYSTEM
and the circumference speed of the slip ring
Pbm = 0.6. Ab .uSR (17) The generator shall be provided with a closed, re-circulating
cooling system with surface air coolers spaced symmetrically
Ab = wb .lb .nb (18) around the periphery of the stator frame as shown in fig.1. The
uSR = 2π f M .rSR (19) cooling air flow is generated directly by construction of the
rotor hub and the rotor rim. Removing the heat from the stator
Mechanical brush friction losses are included in the excitation winding and stator core, and is recirculated into the cold-air
system losses. space through the air-to-water coolers. The air-to-water heat
exchangers recool the hot air discharged from the machine. The
heat extracted from the air is transferred to the cooling water
 and dissipated. The surface air coolers shall have the cooling 52.03Mvar, cos ߶m=0.9855 are considered for this analysis.
capacity, with 10 per cent margin, for dirty or plugged piping The density of water is calculated from the warm water
to maintain the temperature of the air leaving the cooler at 350C temperature [7]. The change of state of the water is described
or less, with the generator delivering continuous overload with the specific heat capacity as indicated by IEC60034-1. [3].
capacity at rated voltage and water entering the coolers at 250C The density of air is calculated according to ISO5801 [6].
[20]. The circulation of air shall be by means of rim ventilation
systems. The air shall circulate out of the openings in the stator V. LOSSES AND EFFICIENCY
frame, through the coolers, back into the top and bottom of the In this section generator performance is analyzed based on
rotor and the bearing areas. In order to inspect the operation of the hot and cold air temperatures together with the measured
this cooling-system, several temperature sensors had to be cooling water temperature. Measurements are covered over
integrated into the stator-core in order to measure its total time duration of 1248 operating hours in 52 days. Figure 6
temperature, which should not exceed 800C [19]. The shows the inlet and outlet cooling water temperatures of the
temperature measurements performed on the generator showed generator. The results shown in Fig. 7 and 8 are the inlet and
some deviations from the design temperatures, especially at outlet air temperatures of 250 MW SG with rated and 20%
rated and overloads. Onsite measured values including water overloading conditions. The variations in hot air and cold air
temperature, electricity, generator temperature, air and surface temperatures were mutually affected by each other. The results
temperature of 250 MW rated and 20 % overloading conditions in Fig. 7 indicates that the values of measured hot air
are shown in Table I-V. Electrical quantities Um = 16148, Im= temperatures are about to coincide overall operating conditions.
10968A, IFm=1822A, Sm= 306.8MVA, Pm= 302.3MW, Qm= - This implies the good uniformity of hot air temperature around
the generator, indicating good flow behavior of the circulating
TABLE I. WATER TEMPERATURE
air for 250 MW power generation. On the other hand,
Warm Water flow
Cold water noticeable differences exist between the measured temperatures
water .  m3 
ϑk ,W [ C]  VW   of the cold air existing from the air coolers for 20 % overloading
ϑw,W [ C ]
 
h condition (shown in Fig. 8). The surface air coolers shall have
sufficient cooling capacity to maintain temperature of the
Ventilation (V) 12.29 21.34 49.99
generator and it also maintains the air leaving the cooler at 35°C
Open circuit (OC) 14.82 27.32 91.74
or less, with respect to water entering the coolers at 0 to 25°C.
Short Circuit 1.0 IN
(1.0)
14.82 27.90 75.30 From the results (shown in Fig. 8), it is observed that the
Upper guide bearing temperature of air leaving the cooler was reached up to 38°C
14.80 27.04 1.18
(GB) and stabilized at 37°C during the operation of plant at 120%
Lower Guide Bearing
19.87 36.88 20.62
load. It is noted that cooling water temperature during this
(CB) period was observed as 20°C (maximum). Hence the difference
TABLE II. ELECTRICAL PARAMETERS between cold air leaving from the cooler and cooling water
Stator Stator Rotor Excitation temperature is observed as 18°C which is higher by 8°C as per
Frequency
voltage current voltage current
f [Hz] IEC 60085:2007. It indicates that cooling system needs to be
U [V] I [A] Uf[V] If[A]
checked by the operator to maintain the temperature at 35°C or
Ventilation
(V)
- - 49.98 less. Efficiency of a generator is determined using the losses
Open circuit described in section III. Ventilation, open circuit, short circuit
15808 - 97.73 1324 50
(OC) and bearing losses indirectly depended on the devolution
Short temperature and air flow. Individual losses are calculated based
Circuit 1.0 - 10229 83.52 1130 49.99
IN (1.0)
on the measured onsite cooler air and water temperature.
TABLE III. GENERATOR TEMPERATURE
Generator
Stator core Stator winding
cold air
ϑ S1[ C ] ϑW 1[ C ]
ϑ[ C ]
Ventilation (V) - - 29.70
Open circuit (OC) 58.26 - 36.00
Short Circuit 1.0 IN (1.0) - 70.28 36.71
TABLE III. AIR AND SURFACE TEMPERATURE
Upper Lower Lower
Upper air
surface air Surface
ϑU [ C ]
ϑUS [ C ] ϑ L [ C ] ϑ LS [ C ]
Ventilation (V) 20.57 25.96 28.73 32.54 Fig. 6. Inlet and outlet water temperature
Open circuit (OC) 21.86 27.36 29.30 39.32
Short Circuit 1.0 IN 44.69
22.08 31.43 29.70
(1.0)
 From the analysis, the open circuit loss of 679.4 kW is
300 120
calculated and brush losses of 2.6 kW is obtained. Efficiency of 250 MW
250 100
70

Stator power (MW)

Temperature( oC)
200 Stator Winding Temp. (oC) 80
60
150 Stator Core Temp. (oC) 60
Temperature ( ̊ C)

50

40 100 40

30 50 20

20 0 0
Cold Air Inlet Temp. (̊C) 0 10 20 30 40 50 60
10 Hot Air Outlet Temp. (̊C) No. of Days
0 Fig. 10 Stator core and winding temperature at 250MW
0 10 20 30 40 50 60 350 120
No. of Days
300 100
Fig. 7. Inlet air and outlet air temperature (250 MW) 300 MW Stator Winding Temp. (oC)
250

Stator power (MW)

80

Temperature (oC)
80
200
70
Stator Core Temp. (oC) 60
150
60
Temperature ( ̊ C)

40
100
50
50 20
40
0 0
30 0 10 20 30 40 50 60
20 No. of Days
Cold Air Inlet Temp. (̊C) Fig. 11. Stator core and winding temperature at 300MW
10 Hot Air Outlet Temp. (̊C) Table IV :Generator heat Test (250 MW)
0 Generator parts Unit Value Average Maximum
0 10 20 30 40 50 60 Stator winding o
C (95-100) 97.5 100
No. of Days Stator core o
C (73 -95) 74 95
Fig. 8. Inlet and outlet air temperature of cooler (300 MW) Thrust bearing o
C (56-64) 60 64
o
1 Upper guide bearing C (40-46) 43 46
o
0.995 Lower guide bearing C (39-46) 42.5 46
Air cooler
0.99 o
Temperature C (31-66) - -
0.985 cold/Hot
Efficicney

0.98 o
Air cooler water C (15-25) - -
0.975 TABLE V :GENERATOR HEAT TEST (300 MW)
0.97 Generator parts Unit Value Average Maximum
o
Stator winding C (103 -109) 103 109
0.965 o
Stator core C (78-96) 79 96
0.96 Efficiency at 250 MW Thrust bearing o
C (60-64) 62 64
0.955 Efficiency at 300 MW o
Upper guide bearing C (44-52) 44 52
o
0.95 Lower guide bearing C (41-48) 41 48
17 18 19 20 21 22 23 24 25 26 Air cooler Temperature o
C (27-71) - -
Air cooler water inlet Temp.( ̊C) cold/Hot
o
Fig. 9. Efficiency performance of 250 MW and 300 MW Air cooler water C (15-25) - -

TABLE VI: LOSSES IN SYNCHRONOUS GENERATOR

Lower Upper Rated
Open Short Combined Electrical
Ventilation Excitation Brush guide guide excitation
Load circuit circuit bearing brush Total
losses losses losses bearing bearing system Efficiency
losses losses losses losses (kW)
losses losses losses
Pfw (kW) Pfe (kW) PSC(kW) Pf0.8(kW) Pbm(kW) PTb(kW) PLGB(kW) PUGB(kW) PEN(kW) PbeN(kW)
Rated 537.0 679.4 536.1 375.0 2.6 277.2 58.1 16.7 35.4 4.3 2521.8 0.9909

120 % overload 649.2 888.6 600.5 399.2 2.9 330.1 66.1 20.6 41.27 5.2 3003.67 0.9903
120%
Overload at 3oC 0.9889
650.9 889.1 602.8 401.2 3.1 332.6 69.7 21.4 42.48 5.2 3012.4
increase in cold
air
SG at rated and 20% overloads are shown in Fig. 9. The overall
efficiency of the synchronous generator is calculated as 0.9909
for 250 MW, 0.9903 for 20% overload and 0.9889 for 20%
overload with 3oC rise in temperature. Power delivery of rated
and 20% overloads with stator core and stator winding
temperature are shown in Fig. 10 and Fig 11. Generator heat
test results for rated and 20% overloads are shown in Table IV
and V. The various power losses in synchronous generator at
rated and 20 % of overloads are tabulated in Table VI.
Compared to 250 MW, generator operate at 20 % of overload
(300 MW) losses are amplified. From the analysis, it is
observed that the maximum field current and stator current
were reached to 2090.14A and 10968A, respectively, at rated
and 120% rated loads. Since the current is the primary function
of overall temperature rise, it is clear that the efficiency of the
250 MW generator at normal loading condition is better than
overloads. At 20% overload, the generator performance is
slightly affected due to the increase in cooling air temperature.
This can be compensated by improving the performance of
cooler provided for the generator.
VI. CONCLUSION
The present study has investigated the performance of a
277.8 MVA SG at rated and 20 % overloads. The efficiency
of hydrogenrator was obtained through the
calorimetric/experimental test. With the measured results, the
effects of cooler performance at different loading condition
were analyzed. The investigation has led to the following main
conclusions: (i) the measured hot air temperatures lies
sufficiently below the normal design temperature range (60oC
– 70oC) for the generator operating at rated loading condition,
(ii) the hot air temperature maintains uniform flow behavior of
the circulating air, (iii) during the 20% overloading condition,
hot air temperature range lies between 70oC to 80oC. The
difference between cold air leaving from the cooler and the
cooling water temperature is observed as 18°C which is higher
by 8°C as per IEC 60085:2007. Due to this under performance
of cooler, machine efficiency drops out slightly (i.e. from
0.9903 to 0.9889). These test results shall be helpful to the
plant authorities to operate the machine in effective manner by
providing significant attention to cooling systems.
APPENDIX
Rated Output power 277.8 MVA
Max. continuous output power 305.8 MVA
Power factor 0.9 lag
Frequency 50±3% Hz
Rate line voltage 15.75±5% kV
Rated speed 214.3 rpm
Field voltage (at rated load) 300 V
Field current (at rated load) 1600 A
No. of poles 28
ACKNOWLEDGEMENT
The authors would like to thank THDC India Limited and
Jaiprakash Power Ventures Ltd., India for their support in
funding and supplying the data required for this research work.
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