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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
1 DESIGN OF SYSTEM
1.1 PURPOSE
The generator, synchronized to the grid, ensures the supply of active power and the
supply or absorption of reactive power.
1.2 DESCRIPTION OF SYSTEM
The present document concerns a generator with a power of 115 875 kVA, a
nominal voltage of 15 kV, rotating at a speed of 3000 rpm, cooled by air that has
been water-cooled.
Energy is carried off by two three-phase channels. The excitation is composed of a
rotating supply and rectifying system fixed at the end of the rotor.
1.2.1 Generator general description
The Generating Unit's main components are the generator (stator + rotor), the exciter (a
multiphase a-c machine + rotating diodes), the coolers and the bearings.
These components are skid-mounted.
Skid-Mounted Unit of outdoor "package type"
The skid is a welded structure consisting of I beams and heavy steel plates.
The skid's rigidity permits handling and transportation of the unit without altering the
alignment of its components. It also provides for the transmission of forces to the
anchoring points of the unit and hence to the foundations.
The internal space of the skid is partitioned so as to allow for a proper distribution of the
cooling air flow in the lower part of the generator.
The following components are mounted on the skid:
• the stator, which is mechanically secured to the skid through special supports. These
supports are designed to transmit the torque to the skid, and to prevent transmission
of vibrations coming from the stator magnetic core to the structure of the generator.
• the bearings which support the rotor
• the brushless exciter
• the instrumentation, accessories, wiring, terminals and lube oil piping
• the housing which is bolted onto the skid covers the whole generator as well as the
bearings and the exciter. The access to the bearings and exciter compartments is
ensured by lateral doors. This housing ensures the stator protection and the
distribution of cooling air. It is internally lined with soundproof material. The coolers
are fitted in the upper part of the housing.
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
1.2.1.1 Masses
− Base .............................................................................. 33 500 kg
− Stator ............................................................................. 97 700 kg
− Rotor (+ exciter rotor) .................................................... 34 400 kg
− Exciter .............................................................................. 1 800 kg
− Bearings .......................................................................... 6 400 kg
− Housing ......................................................................... 23 000 kg
− Coolers............................................................................. 5 400 kg
− Miscellaneous .................................................................. 4 800 kg
− Generator approximate total weight ............................. 207 000 kg
− Stator
− Number of slots ........................................................... 72
− Winding pitch ............................................................... 0 to 29
− Voltage ........................................................................ 15 000 V
− Current ........................................................................ 4.460 A
− Resistance per phase at 20°C ..................................... 0,00141 Ohm
− Number of terminal outputs .......................................... 6
− Insulation class ............................................................ F
− Temperature rise ......................................................... Class B
− Phases connection ...................................................... Star
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DESCRIPTION
− Rotor
− Number of poles .......................................................... 2
− Number of slots ........................................................... 24
− Excitation voltage ........................................................ 158 V
− Excitation current ......................................................... 1.811 A
− Resistance at 20°C ...................................................... 0,0625 Ohm
− Insulation class ............................................................ F
− Temperature rise ......................................................... Class B
− Tests
Dielectrics
− Stator 31 000 V for 1 min.
− Rotor 1.580 V for 1 min.
Mechanical
− Over-speed 3600 rpm. for 2 min.
− Curves
Sheets 4, 5, 6 et 7.
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DESCRIPTION
1.2.1.3 Base
The monobloc base assembly is a welded structure made of I shaped beams and
thick plates which support the stator, the bearings and the exciter.
This design also allows housing the magnetic core making up the magnetic circuit.
A tough and rigid structure is thus obtained to hold the magnetic core and winding.
This structure can resist the rotor magnetic attraction as well as nominal or spurious
torques.
Four trunnions facilitate handling and shifting of the assembly.
Base plates arranged under the generator assembly machined surfaces at the
location of the bearings and main heavy-equipment ensure the anchoring and
adjustment of the generator on the foundation sole plates.
Two of the support transversal beams are notched at their lower part to provide for
the installation of centering blocks embedded into the foundations and accessible
from the upper part of the base on Non-Drive End and through an opening in the
upper part of the base on Drive-End.
Two special locations constituted by bosses are provided for grounding on each
side of the base.
1.2.1.4 Magnetic core
The magnetic core is made up of silicon steel segmental laminations with high
permeability and low specific losses.
These laminations are punched, deburred and varnished on both sides. The
punchings are assembled in an annular, interleaved manner and are separated into
packets by radial vents through which the cooling air will flow. Keybars uniformly
distributed at the periphery of the core permit the precise stacking of the punchings.
After stacking, the core assembly is securely clamped between two heavy fingered
plates and is then blocked both axially and radially, thus forming a rigid core
structure with slots to receive the armature winding.
Given the magnitude of the alternating magnetic fields in the vicinity of the clamping
plates the following special provisions are made to reduce losses:
• The fingers of the clamping plates are non-magnetic.
• A flux shield of high conductivity material, usually aluminium, is mounted on the
clamping plates, thus forming a magnetic flux repulsion screen which protects
the clamping parts from the end-leakage flux between the stator and the rotor.
• The first packet of punchings has graded end-teeth to reduce losses due to the
front fringing flux.
The magnetic core is mechanically secured to the skid through special supports.
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DESCRIPTION
1.2.1.6 Rotor
The rotor main components are the solid rotor shaft, the field winding, the retaining
rings and the fans.
The body of the rotor - the shaft's central part - receives after machining and milling
the field and, according to the type, the damper windings whose ends are blocked
and secured by the retaining rings. Further, from the center, there are the fans and
the bearing sections of the shaft.
Solid Rotor Shaft
The generator rotor is machined from a single forging whose ingot is prepared in an
electric furnace, cast under vacuum and weighs about twice as much as the rough-
machined shaft. The mechanical stresses sustained by the rotor while the unit is
running are such that it requires the use of alloy steels, with yield and tensile
strengths of at least 650 and 800 MPa respectively.
These data are measured on test-samples taken from the periphery of the forging.
In addition, ultra-sonic examination verifies the homogeneity of the material and
checks the absence of non-metallic inclusions.
For the field coils, slots of appropriate depth are milled in the central body of the
rotor and are distributed so as to generate a magneto-motive force close to a
sinusoidal wave. These slots cover two thirds of the rotor periphery.
For the damper winding, additional shallow slots are milled on the remaining third of
the rotor periphery.
Since the field winding is fitted only over the two thirds of the rotor periphery, the
asymmetrical arrangement of the coils in the rotor causes a difference in the area
moments of inertia with respect to the main planes of the rotor. In order to avoid
vibrations of twice the rated frequency, this inequality is compensated by slots
milled perpendicularly to the axis of rotation in the unwound portions, so that the
rotor behaves as an isotropic body.
The rotor is designed in such a way that the first critical speed is far below the
synchronous speed, and the second critical speed far higher than the overspeed.
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1.2.1.11 Fans
Two axial fans with streamlined blades of heavy duty aluminium alloy are mounted
onto the rotor and ensure cooling air intake and circulation within the generator.
When fitting blades, apply "ROCOL" anti scuff lubricant to the bolt threads and to
the underside of the bolt heads.
Tightening torque for the M24 bolts: 360 Nm.
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DESCRIPTION
1.2.1.12 Bearings
The machine is equipped with two bearings:
One of them, on the side opposite the coupling (exciter side), is isolated from
ground by a dual insulation between the bearing mounting plate and the raising
block.
This insulation is provided to avoid currents in the shaft and damage to the journals.
It is also used for checking insulation of the whole before coupling.
The bearings are tilting pad type bearings with no stop.
Each pad is lined, for contact with the shaft, with an anti friction metal. Each bearing
is mounted on a spherical pivot providing a continuous adaptation of the position of
the pads with respect to the rotor journals. The pad support assembly is mounted in
a bearing body enclosed by a cover. The assembly is mechanically welded.
The bearing body acts as the oil reservoir.
Deflectors are provided for oil sealing on the shaft journals.
The bearings are lubricated with pressurized oil by the main lubrication system of
the turbogenerator shaft line.
An alternating current, high pressure oil injection unit located outside the machine is
provided for the two bearings. This unit is used for raising the shaft line during
startup and when the unit is slowed down.
An additional, direct current, emergency, high pressure oil injection unit is also
located outside the machine.
The bearing on coupling side is equipped with:
• One Resistance Thermo Detector which monitors the journal bearing
temperature.
• One Resistance Thermo Detector which monitors the bearing oil outlet
temperature.
• Two seismic detectors which monitor the bearing vibration.
• Two proximity sensors used for monitoring the shaft vibration.
The bearing on exciter side is equipped with:
• One Resistance Thermo Detector which monitors the journal bearing
temperature.
• One Resistance Thermo Detector which monitors the bearing oil outlet
temperature.
• One seismic detector which monitors the bearing vibration.
• Two proximity sensors used for monitoring the shaft vibration.
• One oil pressure switch + one pressure transmitter.
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1.2.1.15 Lighting
The bearing compartments of the generator unit are lighted by standard
230 V A.C protected incandescent lamps.
Each of these lamps is controlled by a switch and supplied with single phase
alternating current, with grounding in the compartment.
Emergency lighting is ensured by protected incandescent lamps supplied with 125 V
D.C. located in the bearing compartments
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REPERES NOMENCLATURE
A FRAME
B FIELD WINDING SUPPORT
C LAMINATED YOKES - LAMINATIONS
D FIELD COILS
E ARMATURE SUPPORT
F CLAMPING PLATES
G ARMATURE LAMINATION
H ARMATURE BAR
J DIODES AND FITTINGS
K CONNECTION TO THE RECTIFIERS
L END FLANGE
M AIR DUCT COVER
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DESCRIPTION
1.2.2.1 Masses
− Field (stator) ......................................................................... 410 kg
− Armature (rotor) .................................................................... 1 105 kg
− Miscellaneous ....................................................................... 998 kg
− Exciter approximate total weight ........................................... 2 513 kg
Field
− Number of poles ................................................................... 10
− Number of coiled poles.......................................................... 5
− Number of coil per pole ........................................................ 3
− Voltage ................................................................................ 45 V
− Current ................................................................................ 83 A
− Cold resistance ..................................................................... 0.385 Ohms
− Insulation class ..................................................................... F
− Mounting of poles ................................................................. in series
Armature
− Number of slots .................................................................... 63
− Number of conductors per slots............................................. 2
− Voltage ................................................................................ 158 V
− Current ................................................................................ 1 811 A
− Insulation class ..................................................................... F
− Mounting of phases .............................................................. in polygon
Tests
Dielectric tets
For the dielectric tests, it is necessary to short-circuit the 7 phases and the polarity
rings.
− Armature .......................................................................... 1 580 V for 1 min
− Field ................................................................................. 1 580 V for 1 min
Mechanical tests
− Over-speed ...................................................................... 3 600 rpm for 2 min
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1.2.2.3 Frame
The frame is built with cut or bent steel sheets. It ensures two main functions:
• it supports the field,
• it allows the exciter ventilation.
1.2.2.4 Magnetic core
It is composed of a stack of magnetic punchings.
Each punching is insulated by a thin enamel layer.
The outer periphery of the core follows the shape of the 10 poles and its center is
cut to enable the stacking on the ferrule.
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1.2.2.9 Diodes
On the internal side, the armature support holds 14 diodes.
The diodes are fixed on a clamping plate with an insulated wedge and a cooling
block.
The assembly of 2 diodes constitutes a branch of the rectifier-bridge (which includes
7 branches).
There are two kinds of diodes:
• the S1104-SVD27 diodes, positive polarity
• the S1104-SVU27 diodes, negative polarity
The diodes must be fitted in such a way as to connect the SVU diodes negative
polarity to the collecting ring branched to the negative connection of the rotor.
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1.8 APPENDICES