Sterling Generators Pvt. Ltd.

Sterling Generators Pvt. Ltd.

(A Shapoorji &Pallonji Company)

ISO 9001 : 2008 & ISO 14001 : 2004 Certified Organization Warmly Welcomes You All
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Sterling Generators Pvt. Ltd.

Basic Principle of Alternator By Pradipta Srichandan Sr Manager

Faradays Disc

BASIC COMPONENTS OF ALTERNATOR

MAIN STATOR MAIN ROTOR

EXCITER STATOR
EXCITER ROTOR ROTATING RECTIFIER ASSAMBLY AVR

Generator Overview
AVR

Exciter Rotor
Exciter Stator Cooling Fan

Main Rotor Main Stator RRA Assembly

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Alternator Yoke
Yoke

Parts of an Alternator

Salient-Pole Synchronous Generator

Stator

Cylindrical-Rotor Synchronous Generator

Stator

Cylindrical rotor

Principle of Operation

Multiple Pole Rotor

Brushless Alternator Rotor

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SINGLE BEARING

DOUBLE BEARING

Excitation Leads

14

PMG

15

Exploded view of PMG

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STAR CONNECTION
Neutral Connection

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Differential CT
CT

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Terminal Block
CT

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PFC & AVR

Alternator

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Electronics components
PFC

Isolation Transformer

AVR

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Droop CT

22

AVR EA 321

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AVR

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Rotating Rectifier Assembly

Diodes

Positive

Varistor

Negative

ROTATING RECTIFIER ASSEMBLY

AVR supplies excitation current to the exciter stator Exciter stator generates a AC Voltage in Exciter Rotor Exciter rotor generated AC Voltage is converted to DC current for main field This AC to DC conversion is done by a Three phase bridge connection with 6 diodes This rectification arrangement gives better exciter utilization Low ripple output Surge suppressors should also be included in the system as filtration arrangement

FLEX PLATE COUPLING

Hub
Flex Plates

Nose Pilot

GENERATOR ALIGNMENT
flywheel housing

flywheel

Single bearing generator

fan Flex plate

bearing
rotor

shims

Salient-Pole Synchronous Generator

1. Most hydraulic turbines have to turn at low speeds (between 50 and 300 r/min)

2. A large number of poles are required on the rotor

d-axis
N

D 10 m q-axis
S S

Nonuniform airgap

Turbin e

Hydro (water)

Hydrogenerator

Direct & Quadrature Axes

d-axis
Stator winding N Uniform airgap Stato r

q-axis

Rotor winding Roto r S

Turbogenerator

Damper Windings

Three Phase Stator Connection

A
A B

Three Phase STAR Connected

Three Phase DELTA Connected

COIL NUMBERING T1
T4 T7

T10 T9 T12

T11

T8

T5 T2

T6 T3

4/6 WIRE ALTERNATORS

T1

T0 T4

T6
T5 T3 T2

SERIES CONNECTION
T1
T4

T0

T7 T10

240 V
T11

415V
T8 T5

T12

T3

T6

T9

T2
High Voltage Low Amps

PARALLEL CONNECTION
T1
T7 T0 T10 T6 T3 T9 T4 T11

139 V 240 V
T8 T2 Low Voltage High Amps

T12

T5

INSIDE ALTERNATOR

FUNDAMENTAL CONSTRUCTION

How Alternator works

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ALTERNATOR.
A.C. GENERATORS OR ALTERNATORS (AS THEY ARE USUALLY CALLED) OPERATE ON THE SAME FUNDAMENTAL PRINCIPLES OF ELECTROMAGNETIC INDUCTION AS D.C. GENERATORS. ALTERNATING VOLTAGE MAY BE GENERATED BY ROTATING A COIL IN THE MAGNETIC FIELD OR BY ROTATING A MAGNETIC FIELD WITHIN A STATIONARY COIL. THE VALUE OF THE VOLTAGE GENERATED DEPENDS ON THE NUMBER OF TURNS IN THE COIL. STRENGTH OF THE FIELD. THE SPEED AT WHICH THE COIL OR MAGNETIC FIELD ROTATES.
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Types of AC Generators
There are two types of AC generators:
1.) the stationary field, rotating armature;
2.) and the rotating field, stationary armature.

Small AC generators usually have a stationary

field and a rotating armature (Figure 5). One important disadvantage to this arrangement is that the slipring and brush assembly is in series with the load circuits and, because of worn or dirty components, may interrupt the flow of current.

Principle of Operation
The operation of a synchronous generator is based on Faraday's law of electromagnetic induction, and in an ac synchronous generator the generation of emf's is by relative motion of conductors and magnetic flux. These machines can be used as either motors or generators but their predominant use is in generation. There are a number of sources of energy used to turn the turbines:(a) Gas (c) Combined cycle (e) Hydro (g) Wave (b) Steam (d) Nuclear (f) Wind (h) Photovoltaic

Sterling Generators Pvt. Ltd.

ALTERNATOR WORKING PRINCIPLE

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BASIC SYSTEM

Principle of Operation
The revolving-field type alternator has a stationary armature and a rotating magnetic field. The generated voltage can be connected directly to the load without having to pass across the slip rings and brushes.

The voltage applied to generate the rotating field is a small DC voltage (called a field excitation voltage)

Figure 1

Basic AC Generator

Figure 3: Simple AC Generator

DC Generator

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Sterling Generators Pvt. Ltd.

PRINCIPLE OF OPERATION
SELF EXCITED, SELF REGULATED MACHINES
OUTPUT Reference Sensing AVR Power Output of AVR

MAIN STATOR

EXCITER STATOR

MAIN ROTOR
ROTATING RECTIFIER ASSEMBLY

EXCITER ROTOR

CLOCKWISE ROTATION FROM DRIVE END

MAIN STATOR

EXCITER STATOR

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SEPARATE EXCITATION BRUSHLESS SYSTEM

Single Phase Alternator

A single-phase alternator has all the armature conductors connected in series The stator is two pole. The winding is wound in two distinct pole groups, both poles being wound in the same direction around the stator frame. The rotor also consists of two pole groups, adjacent poles being of opposite polarity.

Single Phase Alternator

The two poles of the stator winding are connected to each other so that the AC voltages are in phase, so they add.

As the rotor (field) turns, its poles will induce AC voltages in the stator (armature) windings. Since one rotor pole is in the same position relative to a stator pole as any other rotor pole, both the stator poles are cut by equal amounts of magnetic lines of force at any time. As a result, the voltages induced in the two poles of the stator winding have the same amplitude or value at any given instant.

Principle of Operation
Its characteristic feature is that the armature rotates through a stationary magnetic field, and the generated AC is brought to the load by means of slip rings and brushes.

The revolving-armature alternator is found only in alternators of small power rating and is not generally used. This is because a rotating armature requires slip rings and brushes to conduct the current from the armature to the load.

Principle of Operation
In constructing a synchronous machine a point to note is that the stator is fixed and the poles rotate.
2-pole Cylindrical Rotor

There are two categories of Synchronous machines: (a) those with salient or projecting poles (b) those with cylindrical rotors
A Cylindrical Rotor

VOLTAGE & CURRENT GENERATION

Rotor
Magnetic field

N S
Stator
Coil

WAVE GENERATION
N N S S N S N
V 0 L T A G E

TIME

Alternating current (AC) flows

Three Phase Alternator

The three phases are independent of each other.

One point from each winding can be connected to form a neutral and thus make a wye connection.
The voltage from this point to any one of the line leads will be the phase voltage. The line voltage across any two line leads is the vector sum of the individual phase voltages. The line voltage is 1.73, (3 ), times the phase voltage. Since the windings form only one path for current flow between phases, the line and phase currents are equal.

Principle of Operation

4-Pole Salient Rotor

A Salient Pole Rotor

Three Phase Alternator

The frequency of the AC generated by an alternator depends upon the number of poles and the speed of the rotor When a rotor has rotated through an angle so that two adjacent rotor poles (a north and a south) have passed one winding, the voltage induced in that one winding will have varied through a complete cycle of 360 electrical degrees.

A two pole machine must rotate at twice the speed of a four-pole machine to generate the same frequency.

The magnitude of the voltage generated by an alternator can be varied by adjusting the current on the rotor which changes the strength of the magnetic field.

THREE PHASE GENERATION

N S
V O L T A G E

TIME

Three Phase Alternator

The three-phase alternator has three single-phase windings spaced so that the voltage induced in any one is phasedisplaced by 120 degrees from the other two.

VB VA

120O 120O 120O

V O L T A G E

A B C

VC
The voltage waveforms generated across each phase are drawn on a graph phase-displaced 120 degrees from each other.

3 phase AC

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Three Phase Alternator

A three-phase stator can also be connected so that the phases form a delta connection.

In the delta connection the line voltages are equal to the phase voltages, but the line currents will be equal to the vector sum of the phase currents. Since the phases are 120 degrees out of phase, the line current will be 1.73, (3 ), times the phase current. Both "wye" and the "delta" connections are used in alternators.

Three Phase Alternator

A two pole alternator produces one electrical cycle for each complete mechanical rotation.
A four pole alternator will produce two electrical cycles for each mechanical rotation because two north and two south poles move by each winding on the stator for one complete revolution of the rotor.

f = (nRotor)(p/2)/60 = (nRotorp)/120
where nRotor is the speed of the rotor in revolutions per minute, p is the number of poles f is the electrical line frequency produced by the alternator.

The speed of the rotor must be divided by 60 to change from revolutions per minute to revolutions per second.

Three Phase Alternator

SELF EXCITATAION BRUSSLESS & REGULATED SHUNT SYSTEM

SEPARATE EXCITATION BRUSH SYSTEM

Advantages
Permanent magnet replaced by an electromagnet

Output voltage can be adjusted without changing

prime mover speed by regulating DC supply to main field Disadvantages

Two Carbon brushes are required to be used

WHY PERMANENT MAGNET?

Improved performance under severe harmonic

loads Sustain 300 percent rated current for ten seconds to assure circuit breaker tripping

Advantages
A small alternator named Exciter is used to avoid the

brushes Main field, exciter armature & rectifier are mounted on same shaft Excitation supply comes to exciter field instead of main field DC power required for excitation is much lesser Disadvantages
This is an open loop system & input to exciter does not

vary for variation in output voltage

 In order to give correction in the exciter input

according to the voltage output, AVR are being used

Different types of AVRs are being used in DG sets Analog Digital

Three Phase Alternator

In an alternator the output voltage varies with the load.

There are two voltage drops.{ IR & IXL }

The IXL drop is due to the inductive reactance of the armature windings.

Both the IR drop and the IXL drop decrease the output voltage as the load increases.

The change in voltage from no-load to full-load is called the voltage regulation of an alternator. A constant voltage output from an alternator is maintained by varying the field strength as required by changes in load.

OPEN CIRCUIT CHARACTERISTICS

Field Regulator

ZZ FL

Zs Zs

Ea

V Ea

a.c.

Armature Circuit

DC
Source

F Z L

Ea

Zs

Field Current

To obtain the open circuit characteristics the machine is driven at rated speed without the load. Readings of the line-to-line voltage are taken for various values of field current. The voltage, except in very low voltage machines, is stepped down by the means of a potential transformer.

WORKING PRINCIPLE
THE HELP OF RESIDUAL MAGNETISM.

I. INITIALLY THE MACHINE BUILDS UP VOLTAGE WITH

II. THE AUTOMATIC VOLTAGE REGULATOR (AVR ) WILL SENSE THIS LOW VOLTAGE AND COMPARE IT WITH THE SET REFERENCE VOLTAGE LEVEL AND PROVIDES SUCH POWER AS IS AVAILABLE FROM THE MAIN STATOR WINDING. III. AS PER REQUIREMENT AVR WILL INCREASE THE EXCITATION VOLTAGE LEVEL TO EXCITER STATOR TO PRODUCE GREATER MAGNETIC FIELD STRENGTH.
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III. RESULTING INCREASED OUTPUT VOLTAGE FROM THE

EXCITER ROTOR.
III. THE

OUTPUT FROM THE EXCITER ROTOR IS RECTIFIED BY THE ROTATING DIODES WHICH ADDS TO THE FILED STRENGTH AND INCREASES OUTPUT VOLTAGE FROM THE MAIN STATOR.

III. IN THIS WAY VOLTAGE IS PROGRESSIVELY BUILT UP

UNTIL THE SENSED VOLTAGE IS SAME TO SET REFERENCE VOLTAGE.

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79

AVR Model- AS 440

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AVR Model-SX460

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MX341

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MX321

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AVR : AUTOMATIC VOLTAGE REGULATOR

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85

86

WHY AREP [AUXILLIARY] WINDING?

Ability to sustain short circuit current
Improved motor starting Characteristics Better Voltage Regulation even under unbalanced

Loads

LAM

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Insulation Measurement

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Diode Check

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Field Flashing for building up Residual Magnetism

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QDCT

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DROOP CT
Droop CT is normally connected in the second ( Y )

phase Output of the CT secondary is connected to the AVR , and the AVR gets the load information through this input Helps the AVR to maintain voltage as per the Droop curve in solo mode Helps for load sharing according to droop curve during parallel mode Generally disabled during solo mode by single/parallel selector switch/ relay If enabled in solo mode causes generator output voltage to drop as per droop curve

Synchronization System

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Classification of Voltage
Safe Working Voltage-Upto 50 V

Low Voltage -

Upto-1000V Medium Voltage- 1000-33KV High Voltage 33- 220 KV Extra High Voltage Above 220

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TVD

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Class of Insulation
Total Temperature Rise :

Class Y -

90 Deg C Class A - 105 Deg C Class E - 120 Deg C Class B - 130 Deg C Class - F - 155 Deg C Class H 180 Deg C Class - C 230 Deg C
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Classification of Insulation

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IP6X The first number designates protection against solid objects. IPX8 The second number designates protection against water.

INGRESS PROTECTION

copyright 2006 Bronzelite

Rev. 1

INGRESS PROTECTION

IP Rating IP1X IP2X IP3X IP4X IP5X IP6X

Solid Object Size > 50mm (1.97) diameter > 12.5mm (0.49) diameter > 2.5mm (0.098) diameter > 1.0mm (0.039) diameter dust-protected dust-tight

copyright 2006 Bronzelite

Rev. 1

INGRESS PROTECTION

IP Rating IPX1 IPX2 IPX3 IPX4 IPX5 IPX6 IPX7 IPX8

copyright 2006 Bronzelite

Type of Water vertical dripping dripping (up to 15o tilt) spraying (up to 60o angle) splashing from any direction jets from any direction powerful jets from any direction temporary immersion continuous immersion
Rev. 1

Deration factor of Alternator

Altitude in Meter 1000 M Deration Factor 1.0

1500 M
2000 M 2500 M

0.96
0.93 0.91

3000 M
3500 M 4000 M

0.88
0.85 0.82

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Deration due to Power Factor

Lagging P.F 1 (Unity ) Deration Factor 1

0.9
0.8 0.7

1
1 0.92

0.6

0.84

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Deration due to Amb Temp

Amb Temp in C 10 Derating Factor 1.1

20
30 40

1.08
1.04 1.0

45
50 55

0.96
0.93 0.91

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2.) Hysteresis Losses

The heat produced by this friction is called magnetic hysteresis loss. After the heat-treated silicon steel is formed to the desired shape, the laminations are heated to a dull red and then allowed to cool. This process, known as annealing, reduces hysteresis losses to a very low value. To reduce hysteresis losses, most AC armatures ar e constructed of heat-treated silicon steel, which has an inherently low hysteresis loss.

2.) Hysteresis Losses

Hysteresis losses occur when iron cores in an AC generator a

re subject to effects from a magnetic field. The magnetic domains of the cores are held in alignment wit h the field in varying numbers, dependent upon field strength. The magnetic domains rotate, with respect to the domains not held in alignment, one complete turn during each rotation of the rotor. This rotation of magnetic domains in the iron causes friction and heat.

3.)Mechanical Losses
Rotational or mechanical losses can be caused by bearing f

riction, brush friction on the commutator, and air friction (called windage), which is cau sed by the air turbulence due to armature rotation. Careful maintenance can be instrumental in keeping bearing friction to a minimum. Clean bearings and proper lubrication are essential to the reduction of bearing friction. Brush friction is reduced by ensuring: proper brush seating, proper brush use, and maintenance of proper brush tension. A smooth and clean commutator also aids in the reduction of brush friction. In very large generators, hydrogen is used within the generator for cooling; hydrogen, being less dense than air, causes less windage losses than air.

Efficiency
Efficiency of an AC generator is the ratio of the useful

power output to the total power input.

Because any mechanical process experiences some losses,

no AC generators can be 100 percent efficient.

Efficiency of an AC generator can be calculated using

Equation.
Efficiency =(Output /Input )x 100

Example:
Given a 5 hp motor acting as the prime mover of a g

enerator that has a load demand of 2 kW, what is the efficiency of the generator?
Solution: In order to calculate efficiency, the input and

output power must be in the same units. As described in Thermodynamics, the horsepow er and the watt are equivalent units of power. Input Power = 5 hp x 746W hp=3730 W Output Power = 2 kW =2000 W Efficiency =(output/input)x100= (2000 W /3730 W)= 0.54 x 100 =54%

Sterling Generators Pvt. Ltd.

Thanks
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