ENGINEERING TRAINING I

TOPIC

ALTERNATOR

SPEAKERS BACKGROUND

Name
Country of Origin
Department
Designation
Main Roles

: Gan Saik Ngai

: Malaysia
: EPDV, Jakarta
: Project Controller
: a) Project Management
: b) Electrical Design
2

CONTENTS
1.0 DIFFERENT VIEWS OF ALTERNATOR
1.1 Exploded View
1.2 Block Diagram
1.3 Schematic Diagram
2.0 PRINCIPLE OF OPERATION
2.1 Voltage Generation
2.2 Parallel Operations
2.3 AVR Settings
3

CONTENTS ( Continue )
2.4 4-Line Wiring Diagram of Generator
Board
2.5 Single Line Wiring Diagram of Main
Switchboard
3.0 PROTECTIONS OF ALTERNATOR
3.1 Over-Current Relay
3.2 Earth-Fault Relay
3.3 Reverse Power Relay
4

CONTENTS ( Continue )

4.0
5.0
6.0
7.0

3.4 Over / Under Voltage Relay

3.5 Over Temperature Relay
CALIBRATIONS OF PROTECTION
RELAYS
POWER FACTOR CORRECTION
SERVICING & MAINTENANCE
MECHANICAL DEFECTS
& ELECTRICAL FAULTS
5

CONTENTS ( Continue )
8.0 POWER CORRECTION
COEFFICIENTS
9.0 SELECTION & SIZING OF DIESEL SET
TO START ID FAN

1.0 DIFFERENT VIEWS OF

ALTERNATOR
1.1 Exploded Views
Diagram No.1

1.0 DIFFERENT VIEWS OF

ALTERNATOR
1.2 Block Diagram
Diagram No.2

1.0 DIFFERENT VIEWS OF

ALTERNATOR
1.3 Schematic Wiring Diagram
Diagram 3

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2.0 PRINCIPLE OF OPERATION

11

2.1 Generation of Output Voltage

Pilot exciter (PMG)
As the main exciter rotor
injects a constant AC
rotates around the main
power into AVR
exciter stator a 3-phase
AC power is produced in
AVR also receives
the main exciter rotor;
feedback AC power from
rectified (DC power) and
alternator output
then feed into main rotor.
These input signals are
Similarly 3-phase AC
processed by the AVR.
power is produced at
The resultant signal (DC
main stator when main
power) is then feed into
rotor rotates over the
the main exciter stator
main stator windings
12

2.2 Parallel Operations

Synchronising Kits
Synchronoscope
Double Voltmeter
Double Frequency
Double Lamps
Paralleling CT
Control knobs
Governor Switch
Voltage Trimmer

Metering
Voltmeter
Ammeter
PF meter
KW meter

13

2.2 Parallel Operation

1.
2.
3.

Conditions For Synchronising

Same voltage (380V)
Same frequency (50Hz)
Same phase (R,S,T)

14

2.2 Parallel Operations

Procedures for Parallel Operation
1. Run up Set No.1 to take load at 380V 50Hz 0.9 PF
2. Start Set No.2 : Voltage = 380V, Frequency=50Hz
3. At Synchronizing panel select Set No.2
4. Adjust V2 = V1 ( trimmer) & F2 = F1(Governor)
5. When lamps are totally dark and synchronoscope
at about 11.30, Switch on ACB for Set No.2
6. Adjust governor switch (Kw) and voltage trimmer
(Kvar) of Set No.2 to take desired values.
15

2.3 AVR Settings

Buttons

Setting Positions

Purpose

P1

Set voltage droop

( voltage / kw )
Set output voltage

P3

Fully anti-clockwise
(Min)
Fully anti-clockwise
(Min)
Center position

P4

Fully clockwise (Min) Set under-speed Protection

P5

Fully clockwise (Max) Set limit of excitation

P2

Stabilize output voltage

16

Procedures for AVR Settings

Single Operation
1. Check strap ST3 is connected to 50Hz
2. Adjust P2 (set voltage) to fully anti-clockwise ( Min
Output )
3. Adjust P3 (stability) in the center
4. Adjust P4 (under-speed protection) to fully clockwise (Min trigger Hz)
5. Start turbine/engine and adjust governor until frequency (speed) =
47.5Hz (1425rpm)
6. Turn P2 clockwise until output voltage = 380V
7. If output voltage fluctuates, adjust P3 to stabilize
8. Turn P4 slowly anti-clockwise (increase to trigger at 47.5Hz) until
output voltage drops significantly.
9. Readjust governor to achieve 50Hz
10. Apply rated load (kw) at PF=0.8
11. Adjust governor and voltage trimmer to achieve rated values

17

Parallel Operations
1.0 Check paralleling CT is connected to S1 & S2 at AVR
2.0 Adjust P1(voltage droop) in center position
3.0 Apply rated load (Kw) at PF = 0.8 lag. Voltage drop by 2 to
3%.
4. Adjust P2 (set voltage) to 380V, if necessary
5. Repeat Steps 1,2,3 & 4 for Set No.2
6. Parallel Sets 1 & 2
7. Adjust governors to share total loads
8. Adjust P1 of one machine to equalize circulating current until
both PF meters indicate almost same values.
18

2.4 4-Line Wiring Diagram of

Generator Board
(Diagram 5)

19

2.5 Single Line Wiring Diagram

of
Main Switchboard
(Diagram 6)

20

3.0 PROTECTIONS OF ALTERNATOR

3.1
3.2
3.3
3.4
3.5

Over-Current Relay
Earth-Fault Relay
Reverse Power Relay
Under-Over Voltage Relay
Over-Temperature Relay

21

4.0 Calibration of Over-Current Relays

and Earth-Fault Relays
Primary Injection Test
Secondary Injection Test

22

Over-Current Relay Setting

100 %

To Carry Without Tripping

(Full Load)

120 %

To Trip Within 1 Minute

(Overload)

150 %

To Trip Instantly

(Short-circuit)
23

Earth-Fault Relay Setting

10 % , 15% &
17.5%

To Trip Instantly

24

25

5.0 POWER FACTOR CORRECTION

5.1
5.2
5.3
5.4
5.5
5.6

What is power factor

Causes of low power factor
Disadvantages of low power factor
Power factor improvement method
Power triangle
Worked Examples
26

27

6.0 SERVICING & MAINTENANCE

6.1 Checks After Initial Start-Up
After 20 hours of operation re-tighten
all screws on the machine
Perform general inspection
Check all electrical connections
28

6.0 SERVICING & MAINTENANCE

6.2 Air Circulation
Daily perform visual inspection that the air
inlet and outlet grilles are not partially blocked
by any foreign materials

29

6.0 SERVICING & MAINTENANCE

6.3

Bearings ( Leroy Somer Alternators )

Lubricate bearings during operation

Regrease use: Lithium Standard NLGI 3
(Factory Lubrication : Shell Alvania G3)
Bearing
6226 C3 6232 C3 NU 1028
No.
MC3
Qty of
50 gm
70gm
35gm
Grease
Interval
3600 Hrs 1700 Hrs 2000 Hrs
30

6.0 SERVICING & MAINTENANCE

6.3 Bearings ( Continue )
Check for compatibility before using another
type of grease
Temperature rise in the bearings should not
exceed 50 Deg C above ambient temperature
Ambient temperature is taken at 40 Deg C
31

6.0 SERVICING & MAINTENANCE

6.4 Electrical Servicing
Cleaning Products for Winding
Normal Petrol ( no additives)
Toluene : Slightly toxic, inflammable
Benzene : Toxic, inflammable
Ciclohexare : Non-toxic, inflammable
32

6.0 SERVICING & MAINTENANCE

6.4 Electrical Servicing (Continue)
Cleaning Windings & Diode Bridge
Insulating components & impregnation system can
be cleansed using approved cleaning solvents
Apply solvent with brush; sponging frequently to
avoid solvent accumulation in housing
Dry the windings with dry cloth
Let traces of solvent evaporate before reassembling the machine
33

6.0 SERVICING & MAINTENANCE

6.4 Electrical Servicing (Continue)
BOQ to Rewind Alternator
BOQ to Overhaul Alternator

34

6.0 SERVICING & MAINTENANCE

6.5 Mechanical Servicing
WARNING : Cleaning the machine using water or high
pressure washer is prohibited. Warranty is cancelled.
Degreasing : Use a brush and detergent
Dusting : Use an air gun
Fitted With Air Filters : Clean filter elements regularly;
once a week.
After cleaning check windings insulation resistance

35

7.0 MECHANICAL DEFECTS

&
ELECTRICAL FAULTS

36

7.0 MECHANICAL DEFECTS

Bearing
Alternator
frame

Defects
Excessive overheating
( 50 Deg C above
ambient temp)
Excessive overheating
(40 Deg C above
ambient temp)

Vibrations

High Vibration

Noise

Abnormal Noise

Causes
Bearing not fully locked
End shields not correctly aligned
Overloading
Operating above rated voltage (>105%
of Vn)
Filter elements clogged
Coupling misalignment / play
Defective mounting
Rotor not balance (turbine / alternator)

Defective coupling
Defective shaft end
Loose/Fractured Fan
Inter-turn shorts

37

7.0 ELECTRICAL FAULTS

Fault

Action

No Voltage at Connect a 12no load on start Volt battery at

up
terminals Eand E+ (AVR :
to exciter field)
for about 3
seconds only

Effect

Cause/Check

Voltage build
up to rated
value and
maintain
Voltage does
not build up to
rated value
Voltage
disappear when
the battery is
disconnected

Lack of residual
magnetism
Faulty diode
Main exciter
rotor shorted
Faulty AVR
Main/exciter
field windings
open circuit

38

7.0 ELECTRICAL FAULTS (Continue)

Fault

Action Effect

Check/Cause

Voltage too Check the Correct speed

low
drive
speed
Speed too low

Main/exciter field
windings shorted
Diodes burnt
Increase drive speed

Voltage too Adjust

high
AVR

Faulty AVR

Adjustment
ineffective

39

7.0 ELECTRICAL FAULT (Continue)

Faults

Action

Effect

Voltage
Oscillates

Adjust AVR
If no effect
stability button

Voltage
disappear
during
operation

Check AVR,
surge
suppressor,
diodes and
replace
defective parts

Check/Cause
Check speed
Check loose
connections
Faulty AVR

Still no voltage Exciter winding

OC
Main field OC /
SC
Faulty AVR

40

7.0 ELECTRICAL FAULTS (Continue)

Fault

Action

Effect

Voltage :
No Load
OK
On Load
Too
Low

Run on no
< 10Volts
load and
check voltage
between E- &
>15Volts
E+ at AVR

Check/Cause
Check the speed and AVR P4
setting (under-speed
protection)
Faulty rotating diodes
Faulty main exciter rotor
Main field short-circuit

41

8.0 POWER CORRECTION COEFFICIENTS

42

8.0 POWER CORRECTION

COEFFICIENTS FOR GENERATORS
Purpose

: To correct the rated power of a

generator set to suit site conditions

Conditions :a)
Ambient Temperature
:b) Altitude
:c)
Power Factor
:d) Operating Duty

43

8.0 POWER CORRECTION COEFFICIENTS

STANDARD CONDITIONS
a) Ambient Temperature : Up to 40 Deg C = 1
b) Altitudes
: Up to 1000m
=1
c) Power Factor :i) 0.8 - 1 Lag
= 1.0
:ii) 0.7 Lag
= 0.92
:iii) 0.6 Lag
= 0.85
d) Duty
:i) MCR
= 1.0 ( Continuous )
:ii) Prime Power = 1.1 (for 1 hr)
44

8.0 POWER CORRECTION COEFFICIENTS

NOTES
Where more than one special condition is involved,
the total multiplication factor is the product of the
individual coefficients

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46

9.0

SELECTION & SIZING OF DIESEL SET

TO START ID FAN

1. What is starting KVA

2. Starters & K Factors
3. Worked Example

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48

THANK YOU FOR YOUR

ATTENTION

49