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SANTOSH BHARADWAJ REDDY
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ABSTRACT
Electrical power has become a basic necessity of our daily life. Maximum percentage of
total power generation is obtained by conventional power plants. Of these, steam, diesel and
gas turbine power plants are high-speed systems where always 3-phase alternators are used.
Generators play a major role in the production of electricity.
In large scale industries manufacturing generators, insulation design plays a vital role.
Insulation is known to be the heart of the generator. If the insulation fails, generator fails which
leads to loss of crores of rupees. The latest technology for the insulation in the world adapted
is “VACUUM PRESSURE IMPREGNATION” which is of resin poor thermosetting type.
This type is preferred as it is highly reliable and possesses good mechanical, thermal properties
and dielectric strength. As the quantity of resin used is less, the overall cost of insulation is
reduced.
In our project we have made a detailed study of the VPI system of insulation.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
CHAPTER1:
INTRODUCTION
TO
TURBOGENERATORS
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
INTRODUCTION:
Electricity does not occur naturally in usable form and it cannot be stored usefully in
large quantities. Therefore it must be generated continuously to meet the demand at all
times. It also improves the economy of a country.
A generator means an efficient & convenient way to generate electrical power by
conversion of mechanical energy to electrical energy in a rotating device.
Turbo generator means a generator directly coupled to a turbine which can be either
steam or gas. These are used for power production on large-scale basis.
1.1 PRINCIPLE:
DC GENERATORS:
In DC Generators, the armature rotates and the field system is stationary.
AC GENERATORS:
AC Generators are also known as Alternators. Here the field system rotates and the
armature is stationary.
CLASSIFICATION OF DC GENERATORS:
DC Generators can be broadly classified into three types.
1. Shunt Generators.
2. Series Generators.
3. Compound Generators.
CLASSIFICATION OF AC GENERATORS:
AC Generators can be broadly classified into two types.
1. Asynchronous generators.
2. Synchronous generators.
ASYNCHRONOUS GENERATORS:
Asynchronous generators are those in which the speed of rotor and flux are not
in synchronism.
E.g.: Induction motor.
SYNCHRONOUS GENERATORS:
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
Synchronous generators (or) alternators are those in which the speed of the rotor
and flux are in synchronism.
The 3-phase synchronous generators are widely used machines for power
production on large scale basis. These when connected to turbines are called turbo-
generators. Gas turbine generators and steam turbine generators are widely used for power
generation.
Synchronous generators can be classified into various types based on the medium used for
generation. They are:
Turbo-alternators.
• Steam
• Gas
Hydro Generators.
Engine Driven Generators.
Turbo generator mainly consists of 3 parts
1. Stator.
2. Rotor.
3. Excitation system.
1.3 STATOR:
Armature windings are mounted on a stationary element called the stator.
The main parts of a stator are:
1. Stator Frame.
2. Stator Core.
3. Stator Winding.
STATOR FRAME:
The stator frame is of horizontally split type and welded construction and supports the
laminated core and the winding. Ventilation holes are provided in the frame itself and
helps in cooling the machine
STATOR CORE:
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
The stator core is made up of stacked insulated silicon steel laminations. The core is
laminated to minimize loss due to eddy currents. Spaces are provided between the
laminations to allow the cooling air to pass through. The slots for housing the armature
conductors lie along the inner periphery of the core.
STATOR WINDING:
The stator winding is a fractional pitch double layer lap winding. The bars are
located in slots which are uniformly distributed on the circumference of the stator core.
1.4 ROTOR:
Field windings are mounted on a rotating element called rotor. The main parts of the
rotor are
1. Rotor Shaft.
2. Rotor Winding.
3. Retaining Rings.
4. Field Connections.
5. Bearings.
ROTOR SHAFT:
Rotor shaft is a solid forging into which slots for insertion of field winding are milled
using the Hellar machine. The longitudinal slots are distributed over the circumference so
that solid poles are obtained. It is then sent for red gel painting. .
ROTOR WINDING:
Rotor windings are made up of copper strips. Each individual conductor is placed over
a template and passed under the ventilation punching machine.
On both sides of the conductor 90° bending is carried out. The conductors are then
subjected for “Annealing”, Hydraulic pressing on both the bends and checking with gauge
is carried out. On both the ends of the conductor dovetailed punching is done. Air dry
varnish is applied and relief filing is done on both sides of the conductor. All the bars are
assembled on a dummy rotor and brazed to make one full coil.
After red gel painting, the rotor slots are checked for foreign matter presence and
windings are assembled. Footings assembly is carried out on both sides and diameter is
checked. Input lead is assembled into the rotor shaft on the exciter side. It is enclosed with
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
HGL (Hardened Glass Lamination) insulation and the two D-leads are separated and
surrounded with insulation and is checked for H.V. The output studs are assembled onto
the rotor for connections.
Wedging is carried out using high electrical conductivity material which act as
damper winding. Overhang braces are assembled in between the conductors to protect
from electrical short circuits. HV AC and Impedance tests are conducted.
RETAINING RINGS:
Assembly of retaining rings, the contact surface of which is sprayed with silver, is
carried out on both turbine and exciter side on the overhang part of the rotor body by
heating it to 250° C. Then the snap ring is released into the groove of the retaining ring.
Before assembling the retaining rings ensure the snap ring movement into the rotor groove
and lock it. After cooling the retaining rings, the rotor is subjected for HV and impedance
tests.
FIELD CONNECTIONS:
The two output leads which are brought out towards the exciter side are connected to
the excitation system and the field current is supplied to the rotor.
BEARINGS:
The rotor is supported in two sleeve bearings. The temperature of the bearings is
maintained with two RTD’s (Resistance Temperature Detector) embedded in the lower
bearing sleeve so that the ensuring point is located directly below the Babbitt. All bearings
have provisions to monitor the shaft vibrations. The oil supply to the bearing is obtained
from the turbine oil system.
These losses dissipate as heat and raise the temperature of the generator which affects the
insulation. Therefore it should be cooled to avoid excessive temperature rise. So the class
of insulation used depends mainly on the cooling system installed.
CHAPTER 2:
MANUFACTURING
OF
STATOR
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
MANUFACTURING OF STATOR:
The different stages involved in the manufacturing of stator are:
1. Lamination preparation.
2. Stator Core Assembly.
3. Stator Winding.
4. Stator Assembly.
2.1 LAMINATION PREPARATION:
The building up of the core using laminations plays a vital role to minimize the
magnetic losses which are of two types,
• Hysteresis Losses occur due to residual magnetism in the material.
• Eddy Current Losses occur due to the emf produced in the core.
In order to minimize the Hysteresis losses, silicon alloyed steel sheets are used for
building up of the core. These sheets are 4% Silicon Alloyed COLD ROLLED NON-
GRAIN ORIENTED (CRNGO).
The sheets have the following composition,
Steel : 95.8%
Silicon : 4%
Impurities : 0.2%
In order to minimize the Eddy Current losses, the core is built up of 0.5mm thick
laminations which are insulated from each other using CLASS-B type oil varnish.
The preparation of the lamination involves the following processes:
1. RECEPTION OF SILICON SHEETS:
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
The silicon roll sheets are received in the form of bundles.
2. EXAMINATION OF SILICON SHEETS:
The received silicon sheets are examined for the specified electrical, magnetic and
mechanical properties.
3. BLANKING:
It is the process where the required shape of the lamination is obtained by passing
on the rollers and cutting into required size. The specified dimension sheet obtained
from cutting process is called “Blanking” and the remaining waste material is called
“Perforation”.
4. NOTCHING:
This is the process where slots are punched into the blanked sheet. There are two
types of notching:
INDIVIDUAL NOTCHING: Each operation is carried out independently &
the probability of error is high.
COMPOUND NOTCHING: Processing the laminations at single stroke &
the probability of error is less.
5. DEBURRING:
Each lamination is processed for deburring operation i.e. removing the bur level
which prevents from short circuit. The acceptable limit of the bur
is 5 microns
6. VARNISHING:
This is done to insulate the lamination using “ALKYD PHENOL VARNISH”.The
laminated sheets are passed through a conveyor which has an arrangement to Sprinkle a
coat of varnish. The coating thickness should be 7 to 10 microns/side. The Varnish used
should be of correct viscosity which is measured using a din-four-cup.
After varnishing, laminations are passed through furnace where temperature is
Maintained at 300°C - 400°C.
6 . FIRE DETECTORS:
On the overhang portion, fire detectors are placed to detect occurrence of fire due to
short circuit.
6. PUTTY WORK:
The uneven surface formed during transposition are filled with nomex sheets to
prevent inter-half and inter-strip short Mica fleece is placed on the width of the bar and
PTFE (Poly Tetra Fluoro Ethylene) is wrapped on the straight portion.
7. STRAIGHT PART CONSOLIDATION:
The bar is subjected to a pressure of 150kg/cm² horizontally and vertically and
temperature of 160°C for 2-3 hours. The bar is consolidated such that there are no air gaps.
8. DIMENSION CHECK:
The dimension i.e. both width and height are checked using a guage.
9. TESTING:
The tests performed on the bar are inter-strip and inter-half. These tests are
performed using a lamp which is connected between a phase and neutral.
The two terminals are connected for:
Inter-strip -> between strips.
Inter-half -> between two coils of a bundle.
If the lamp glows, it indicates that a short circuit has occurred.
10. BENDING:
Bending process is carried out on the bending fixture. After bending, the bar is in
the shape of half diamond and is hence called as half diamond coil.
11. OVERHANG CONSOLIDATION:
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
Nomex pieces are inserted by applying rotopax and hardner from first bend to
third bend between the two coils of a bundle. Both the overhang portion and consolidated
using clamps and heating to a temperature of 60°C to 70°C for a duration of 30 minutes.
CHAPTER 3:
INSULATING MATERIALS
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
INSULATING MATERIALS:
Electrical insulating materials are defined as those which offer high resistance to the
flow of current.
In the electrical machines and transformers, the insulating materials applied to the
conductors are required to be flexible and have high dielectric strength and ability to
withstand unlimited cycles of heating and cooling.
ELECTRICAL PROPERTIES:
INSULATION RESISTANCE:
It is defined as the resistance between two conductors usually
separated by insulating materials i.e., one through the body and other over the surface of
the body.
DIELECTRIC STRENGTH:
The voltage across the insulating materials is increased slowly, the
way in which the leakage current increase depends upon the nature and condition of
material.
POWER FACTOR:
Power factor is a measure of the power losses in the insulation. It
should be low. It increases with the rise in temperature of the insulation. A rapid increase
indicates danger.
DIELECTRIC CONSTANT:
The property is defined as the ration of the electric flux density in
the material to that produced in free space by the same electric force.
DIELECTRIC LOSS:
The dielectric losses occur in all solid and liquid dielectrics due to:
a. Conduction Current
b. Hysteresis.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
THERMAL PROPERTIES:
• Specific heat thermal conductivity.
• Thermal plasticity.
• Ignitability.
• Softening point.
• Heat Ageing
CHEMICAL PROPERTIES:
• Resistant to external chemical effects.
• Resistant to chemicals in soils
• Effect of water.
MECHANICAL PROPERTIES:
• Density
• Viscosity.
• Moisture absorption.
• Hardness of surface.
• Surface tension.
• Uniformity.
CHAPTER 4:
INTRODUCTION
TO
INSULATION SYSTEM
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
4.2 THERMOPLASTIC:
Thermoplastic process is that where the resin softens on heating and hardens on
cooling.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
THERMOSETTING:
Thermosetting process is that where the resin once hardened cannot be softened
even on heating. Thermosetting is again divided into two types.
They are 1.Resin Rich System.
2.Resin Poor System.
CHAPTER 5:
VACCUM PRESSURE
IMPREGNATION
PROCESS
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
5.1 STEPS INVOLVED IN VPI PROCESS.
5.2 QUALITY CHECKS ON RESIN MIXTURE.
5.3 TESTING PERFORMANCE OF RESIN POOR SYSTEM
BEFORE IMPREGNATION PROCESS.
The stator coils are taped with porous resin poor tapes before inserting into the slots of
the cage stator. Subsequently wound stator is subjected to a special process called VPI
process in which first the stator is vacuum dried and then impregnated in a resin bath under
a pressure of Nitrogen gas. Then the stator is curried in an oven.
In olden days “Resin Rich System” of insulation was used where the stator coils are
wound with Resin Rich tape which contains 40% of resin. But for good dielectric strength
25% is required. The extra 15% of resin is to be oozed out which is a tedious process and is
carried out in medium. Hence it is not an ideal process and is not employed
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
Now-a-days “Resin Poor System” is employed where the stator coils are wound with
Resin Poor tape which contains 8% of resin. For good dielectric strength, the extra 17% of
resin is to be injected into the pores of the resin poor tape by “impregnation” and is done by
VPI Process.
RESIN MIXTURE:
The resin used in VPI process is ET884, a mixture of Epoxy Resin E1023 and
Hardener H1006 in 1:1.2 ratios by weight and the two components are mixed in 1:1 ratio.
The resin tank contains Resin Mixture (Epoxy Resin + Hardener) and catalyst for good
insulation system.
RESIN:
Resin is a polymer. The process of polymerization under condensation gives Resin.
The chemical name of resin is “DIPHENOL PROPANE” and its commercial name is
“BISPHENOL-A”. The chemical structure of Diphenol Propane is (C6H5OH)2C3H8.
HARDNER:
Hardner is used to solidify the resin. Hardner means Anhydride which means removal
of water (i.e. H2O) molecule.
CATALYST:
Catalyst is used to accelerate or decelerate the rate of a reaction. The catalyst used in
resin in the VPI process is “Zinc Napthenate”.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
VACUUM
VACUUM VACUUM PUMP
PUMP TRAP VALVE
VACUUM
NITROGEN NITROGEN
PRESSURE
SUPPLY LINE
IMPREGNAT
TANK VALVE
ION TANK
RESIN RESIN
SUPPLY SUPPLY
TANK VALVE
IMPREGNATION PLANT:
Horizontal Impregnation Chamber for higher capacity stators of steam turbine
or gas turbine generators and Vertical Impregnation Chamber for small capacity systems
such as Permanent Magnet Generator stators for brushless excitation systems, coil
insulation of small pumps and armature of motors etc. are used.
1) The insulating tape used in this system 1) The insulating tape material used in this
has only 8 % of resin. system has 40% resin.
2) This method follows thermosetting 2) This method follows thermosetting
process. process. .
3) There is a need for addition of resin from 3) Further addition of resin is not required
outside.. from outside.
4) Reduction in time cycle for this process. 4) It is very long process and time
5) No tests are carried out here at processing consuming.
stage. 5) Tests are carried out while processing
6) The cost of repairing is more. stage.
7) Processing of bars along with stator and 6) Repairing work is easy.
processing of exciter coils (along with 7) Processing of stator bars is only possible
exciter coil) are possible in resin poor in resin rich system.
.
8) The overall cost is less compared to resin 8) The total cost of this process is more.
rich system.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
CHAPTER 6:
PERFORMANCE TESTING
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
TESTING OF TURBOGENERATORS:
6.1 OBJECTIVES OF TESTING :
Testing is the most important process conducted on a machine after it is designed ,
to ensure that equipment concerned is suitable and capable for performing duty for which it
is intended & complies with the customer specifications.
Testing is done under conditions as closely as possible to those which apply when the
set is finally installed with a view to demonstrate the customer its satisfactory operation.
The tests provide the experimental data like efficiency, losses, characteristics, temperature,
limits etc, both for conformation of design forecast and as basic information for the
production of future designs. The machine performance is evaluated from the results of the
equivalent tests.
ADVANTAGES OF TESTING:
1. Provides data for optimization of design & quality assurance.
2. Meets the requirements of legal and contract requirements.
3. Reduction in rework cost.
4. Ensures process capability and develops check list.
5. Establishes control over raw materials.
PERFORMANCE TESTS:
The performance tests carried out on the turbogenerator are classified as:
1. Mechanical run test.
2. Routine tests.
3. Type tests.
MECHANICAL RUN TEST:
The generator should be run for 24 hours .this test is done to ensure that there are no losses
(friction and windage and the heat generated should be less. Vibrations occurring in the
generator are also detected.
ROUTINE TESTS:
These tests are carried out on a generator to ascertain that it is electrically and
mechanically sound. The routine tests are classified as:
a. Static test.
b. Running test.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
6.2 STATIC TEST:
Equipment:
i. Megger (1000v/2500v)
ii. Earthing rod and earthing wire or cable
When HV test is done on one phase winding, all other phase windings, rotor
winding, instrumentation cables and stator body are earthed. High voltage is applied to the
winding by gradually increasing to the required values and maintained for 1min and
reduced gradually. The transformer is switched off and winding is earthed by connecting it
to earthing rod connected to earth wire. The test is conducted on all the phase & rotor
winding separately.
HV test levels:
Stator winding: (2Ut + 1) KV =23 for 11KV machines
Rotor winding: 10Up volts (with min of 1500V and 3500V)
Where Ut = Rated Voltage of machine under test
Up = Excitation voltage
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
Tanδ Test:
Equipment:
i. Schering bridge.
ii. 50HZ HV transformer
iii. 100-1000PF Standard capacitor.
iv. Isolation shunt box.
v. High tension cable.
vi. Earth cable.
vii. Voltmeter.
viii. Megger (2KV)
ix. Null indicator
The test is conducted to check the presence of impurities in the insulation. Tanδ
value is significant factor for testing dielectric strength of the insulation. δ is loss angle
.
The stator body, is isolated from ground by placing insulation package between
body and phase connections to the Schering Bridge. HV supply is switched on and the
bridge 1.0 Un in steps of 0.2 Un. By varying the voltage, Tanδ value for each phase and
also for combined phases is noted down.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
Tanδ value should be generally less than or equal to 2%
Voltage regulation:
Voltage regulation is defined as the change in voltage from no load to full load
expressed as the percentage of full load. For a generator to be ideal and efficient, voltage
regulation should be less. There are four methods to find voltage regulation. They are:
i. EMF method .
ii. MMF method.
iii. ZPF method.
iv. ASA method.
CONCLUSION:
In view of the above, in the coming decades, the Indian grids will use more of
generators using VPI system of insulation. In the scenario of world market which demands
generators with less cost at the best possible time with better reliability VPI system of
insulation will provide viable solution compared to Resin Rich type of insulation system.
Manufacturing & Insulation System By VPI Process For Air Cooled Turbo Generators
BIBLOGRAPHY:
Electrical Machines:
Dr.P.S.BIMBHRA
Electrical Machines:
M.G.SAY
Document By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
More Papers and Presentations available on above site