PRESENTED BY :

UPENDRA DEEP
BHEL, HYDERABAD
 PRODUCT PROFILE OF ELECTRICAL MACHINES,
BHEL - HYDERABAD

ELECTRICAL MACHINES

SYNCHRONOUS MATCHING EXCITERS

GENERATORS
DC STATIC BLE

AIR COOLED CONV OH

H2 COOLED 3000 RPM

2-POLE 4-POLE

STGs GTGs STGs GTGs

Fr V,VI,VI-FA & IX 10 - 40 MW Fr I , III, V & VI
CROSS SECTION OF A GENERATOR
LOSSES IN A GENERATOR

- CORE/ MAGNETIC LOSSES

( CONSTANT WITH VOLTAGE)
- COPPER/ WINDING (ROTOR AND STATOR) LOSSES
( VARIABLE WITH LOAD)
- BEARING FRICTION AND WINDAGE LOSSES
( CONSTANT WITH SPEED)
 COOLING OF THE GENERATOR

-AIR COOLING (INDIRECT FORCED) : UPTO 25 MW

- AIR COOLING (DIRECT FORCED) : UPTO 150 MW

- HYDROGEN COOLING (DIRECT FORCED): UPTO 250 MW

- HYDROGEN WITH WATER COOLING OF STATOR: UPTO 500 MW

 TYPE OF COLING

• OPEN
•CACW
•COOLING
WATER
MODULE

Ventilation Scheme of Generator

 AIR COOLING SYSTEM FOR GENERATOR

ROTOR COOLING:
•Cold air is circulated in the machine by two shaft mounted
axial fans with screwed-in blades.
•A sophisticated cooling system is employed for cooling the
rotor
•Rotor windings are directly cooled by air
 AIR COOLING SYSTEM FOR GENERATOR
GENERATOR IS CACW COOLED
STATOR COOLING:
•Hot Air from the generator is sent to a heat exchanger where
it is cooled by water. Cold air is sent back to the generator
cold zones.
•The system is designed to ensure uniform temperature rise
through out the length of the stator.
•The temperature of the windings, core and teeth are
measured.
 MAIN PARTS OF GENERATOR
ROTOR: STATOR: AUXILIARIES:
1. ROTOR FORGING 1. STATOR FRAME 1. BEARINGS
2. ROTOR COILS 2.STATOR CORE 2. TERMINAL BUSHINGS
3. ROTOR WEDGES 3. STATOR WINDING 3. AIR FILTER / COOLER
4. RETAINING RINGS 4. END COVERS 4. ENCLOSURES
5. FANS
 STATOR FRAME

•FABRICATED STEEL STRUCTURE

•FUSION WELDING QUALITY STEEL PLATES

•AXIAL STIFFENERS FOR RIGIDITY

•RESILIENT MOUNTING OF STATOR CORE

 Location of

Stator Frame
output leads

Top Frame

Base Frame

Ventilation
Chambers
Hot/Cold
View of VPI wound stator
1. STATOR FRAME UPPER PART
2. STATOR FRAME LOWER PART
3. STATOR CAGED CORE
4. CAGED CORE FEET
5. CORE MOUNTING BEAMS
STATOR CORE
CUTTING OF STATOR CORE LAMINATION SEGMENT
STATOR CORE ASSEMBLY
ASSEMBLED CORE
 Stator Stator Connecting
Terminals Clamping Plates
Rings
& Rings

HGL End
Winding
Support

Insulated
Copper Bars
are placed in
the slots to
form 3 Ph
winding
 TOP BAR

BOTTOM BAR

STATOR COIL FORMATION

HIGH VOLTAGE
INSL. COPPER INSULATION
STRIPS
TRANSPOSITION
OF CONDUCTORS
ASSEMBLY OF STATOR WINDING
 SALIENT FEATURES OF DESIGNS OF BARS

 Roebel bars with 3600 transposition to

reduce eddy current losses
 Double glass lapped copper conductors.
 Resin poor VPI insulation.
 Corona protection of straight part insulation.
HIGH VOLTAGE INSULATION

 PROVIDING DIELECTRIC TO WITHSTAND THE VOLTAGE.

 MEETING THE ELECTRICAL, THERMAL,MECHANICAL

AND CHEMICAL STRESSES ARISING OUT OF MACHINE
OPERATION.

 MACHINE LIFE DEPENDS ON THE LIFE OF THE

INSULATION

 RESIN RICH/RESIN POOR DEPENDS ON THE

PERCENTAGE OF BINDER IN THE GREEN STAGE
INSULATION
 CLASSIFICATION OF INSULATING MATERIALS
CLASS OF MAXIMUM
INSULATION PERMISSIBLE TEMP.
LIMIT(°C)
A 105
E 120
B 130
F 155
H 180
C 225
MATERIALS
COTTON, SILK AND PAPER IMPREGNATED IN
DIELECTRIC LIQUID SUCH AS OIL.
COTTON,SILK AND PAPER IMPREGNATED IN
DIELECTRIC LIQUID FOR OPERATING UPTO
120°C
MICA,GLASS FIBRE,ASBESTOS WITH SUITABLE
IMPREGNATING MATERIALS FOR OPERATING
UPTO 130°C
MICA,GLASS FIBRE,ASBESTOS WITH SUITABLE
BONDING SUBSTANCES CAPABLE UPTO 155°C.
SILICON ELASTOMERS WITH MICA,GLASS
FIBRE,ASBESTOS WITH SILICON RESINS.
MICA,PORCELAIN,GLASS AND QUARTZ WITH
INORGANIC BINDERS
 M
F TE
O S
Y
R SY
O N THERMOPLASTIC INSULATION SYSTEM
T
IS TIO
H A SHELLAC MICA FOLIUMWRAPPED SYSTEM
L
SU
IN BITUMEN MICA FOLIUM WRAPPED SYSTEM

BITUMEN MICA TAPED & PRESSURE IMPREGNATION SYSTEM

THERMOSETTING INSULATION SYSTEM

RESIN RICH
RESIN POOR

BAR IMPREGNATION

FORM IMPREGNATION

TOTAL IMPREGNATION
 FINE MICA RESIN POOR GLASS TAPE

IT HAS THREE COMPONENTS

1. MICA - DIELECTRIC MATERIAL
2. GLASS - CARRIER
3. RESIN - BONDING MATERIAL (< 10 %)

THE PROCESS OF ADDING MORE RESIN TO THE MAIN INSULATION OF

STATOR WINDING AND CURING IT IS CALLED VACUUM PRESSURE
IMPREGNATION (VPI) PROCESS.
GLOBAL IMPREGNATED STATOR
-PREHEATING OF WOUND STATOR AT
60°C FOR MIN. 1 HOUR
-PLACING THE WOUND STATOR IN
TUB
-PLACING THE TUB WITH STATOR IN
IMPREGNATION TANK
-VACUUM DRYING AT 60°C, 0.2 mBAR
DURATION: ~16-18 HOURS
-RESIN ADMISSION:
RESIN TEMP : 60DEG. C +/- 2DEG. C
RESIN FILL : ~20 MIN
RESIN LEVEL : ~100 MM ABOVE JOB
SETTLING TIME : ~10 MIN.
-PRESSURISATION:
N2 PRESSURE : ~ 4 BAR
RAISING TIME : ~80 min.
HOLDING TIME : 2 HRS.
-RESIN WITHDRAWAL AND TRANSFER

PLACING THE TUB WITH STATOR IN IMPREGNATION TANK

-CURING OF IMPREGNATED STATOR:
TEMP. OF JOB : 140DEG. C +/- 5 DEG. C
DURATION : ~20 HRS
STATOR AFTER IMPREGNATION

TESTS ON VPI CURED STATOR :

- INSULATION RESISTANCE
- TAN DELTA
- H.V TEST
- PD MEASUREMENT
 AVANTAGES OF VPI INSULATION

* LONGER ELECTRICAL LIFE

* HIGHER THERMAL CONDUCTIVITY
* LESSER THICKNESS OF INSULATION HIGHER VOLTAGE STRESS.
*SMALL DISSIPATION FACTOR TIP-UP (VOID FREE INSULATION )
* BETTER ELASTIC RESPONSE TO THERMOMECHANICAL STRESSES
* INSENSITIVITY TO HIGH TEMPERTURE AND TEMP. CHANGES
(SUITABLE FOR GT APPLICATION)
* LOW INFLAMABILITY
* HIGHER RESISTANCE TO EFFECT MOISTURE
* HIGHER CHEMICAL RESISTANCE TO CORROSIVE GASES, LUBE OILS, ACIDS
& ALKALIS
* LESSER MANUFACTURING CYCLE OF M/C.
* HIGHER P/W RATIO. LOWER COST OF M/C.
 FEATURES OF GENERATOR STATOR

 2 Pole , 3000 rpm, 50 Hz

 Split casing of stator frame(VPI generators)
 Core built with low loss non-oriented sheet steel
(CRNGO) low hysteresis & eddy current loss.
 Stator packets separated by radial ducts for cooling
 Clamping of core by tension bolts to eliminate core
bulging
 Core consolidation done under pressure
 Stator winding insulation with resin poor micalastic
system
 Total wound stator behaves as single solid piece
 ROTOR

MATERIAL

• FORGING OF SPEC. 26NiCrMoV145

• HARDENED, TEMPERED & STRESS RELIEVED
• COMPLIANCE WITH TLV9123
 ROTOR

•ULTRASONIC TEST

•MAGNETIC PARTICLE EXAMINATION

•RESIDUAL STRESS MEASUREMENT

 ROTOR WINDING
MACHINED ROTOR

ROTOR COIL
RETAINING RINGS & WEDGES
ROTOR MACHINING
 FLUX IN AIR GAP

POLAR AXIS
NEUTRAL AXIS
DISTANCE

- 1/3RD OF THE ROTOR IS LEFT UNSLOTTED.

- MAGNETIC FLUX IN AIR GAP IS TRAPIZOIDIAL.
-IT CONTAINS A FUNDAMENTAL SINE WAVE AND HARMONICS WHICH IS
UNAVOIDABLE.
Rotor Rotor Slots

Machined Rotor
Rotor

Finished Rotor with Retaining Ring

 CROSS SECTION OF A ROTOR SLOT
ROTOR WEDGE

TOP INSULATION

SLOT WALL
INSULATION
TURN INSULATION

ROTOR COPPER
 FANS

•TO PROVIDE CIRCULATION OF COOLING MEDIUM

•FAN BLADES - ALUMINIUM ALLOY DIE FORGINGS

•THREADING IS MADE ON FAN BLADE

•15 Nos. BLADES PROVIDED

•BLADE ANGLE ADJUSTABLE AT WORKS & SITE

•ALL BLADES SECURED AT ITS ROOT WITH A THREADED PIN

 ROTOR WEDGES

•MATERIAL: CUPRO NICKEL DRAWN PROFILE

•MECHANICAL PROPERTIES

YIELD POINT = 520 N/mm2

•NON MAGNETIC MATERIAL

•GOOD ELECTRICAL CONDUCTIVITY>15 MEGA

SEMENS/METER

•PROVIDES PATH FOR ROTOR CURRENTS DURING

MOTORING
 RETAINING RINGS

•ALLOY STEEL FORGING

•MATERIAL X8 Mn Cr 18 18K

•MECHANICAL PROPERTIES

YIELD POINT = 1150 N/mm2

•NONMAGNETIC PROPERTIES

RELATIVE PERMEABILITY=<1.1

•MATERIAL IS STRESS CORROSION RESISTANT

 RETAINING RINGS

 SECURES OVERHANG WINDING

 ONE END IS SHRINKFITTED TO ROTOR BODY

 OTHER END OVERHANGS WITHOUT MAKING

CONTACT WITH ROTOR

 THIS ARRANGEMENT ENSURES THAT SHAFT
 DEFLECTION DURING OPERATION IS NOT
OBSTRUCTED BY THE RETAINING RING


 RETAINING RINGS

 FREE END OF RR IS REINFORCED BY

 SHRINKING A HUB ON INNER DIAMETER OF RR
 AMOUNT OF SHRINK FIT IS SO CHOSEN THAT
 RELEASING SPEEDS ON ROTOR BODY AS WELL

 AS HUB ARE BEYOND 120% RATED SPEED

Rotor

Complete finished rotor

 FINISH MACHINED ROTOR

 DYNAMICALLY BALANCED AT RATED SPEED IN A

 VACUUM BALANCING TUNNEL

 ACCURACY CLASS Q2.5

 OVER SPEED TEST AT 120% RATED SPEED FOR
 2 MINUTES
 BALANCE CONDITION CHECKED OVER ENTIRE

 SPEED RANGE FROM STANDSTILL TO 3000 RPM


ASSEMBLED ROTOR

ROTOR IN BALANCING
TUNNEL
 BEARINGS

 2 JOURNAL BEARINGS
 EACH BEARING CONSISTS OF A BEARING
 PEDESTAL AND A BEARING SHELL
 BEARING PEDESTAL IN TWO PARTS
 - BOTTOM PART & TOP PART
 BEARING SHELL IN TWO PARTS
 - BOTTOM PART & TOP PART

 SPHERICAL SURFACES FOR INNER DIA OF BRG

 PEDESTAL & OUTER DIA OF SHELL

 BEARINGS

 SELF ALIGNING PROPERTY OF BEARINGS

 EXCITER SIDE BEARING IS INSULATED FROM
 BASE AND PIPING TO PREVENT SHAFT
 CURRENTS
 EACH BEARING IS PROVIDED 2-DUPLEX RTDS
 BEARINGS
 INNER SURFACE OF BEARING SHELL PROVIDED

WITH BABBIT LINING

 BABBITT MATERIAL : WHITE METAL
 FORCED OIL LUBRICATION
 OIL SYSTEM COMMON WITH TURBINE
 BOTH BEARINGS ARE PROVIDED WITH HYDRAULIC

SHAFT LIFT OIL SYSTEM TO REDUCE FRICTION

FEATURES OF GENERATOR ROTOR

 ACTS AS THE ELECTROMAGNET TO GENERATE THE

FLUX.

 TRANSMITS THE MECHANICAL TORQUE FROM THE

PRIME MOVER/TURBINE TO GENERATOR.

 UNDER THE STATE OF CONSTANT TORSION DUE TO THE

FORWARD TORQUE BY THE TURBINE AND BRAKING
TORQUE FROM THE ARMATURE REACTION.
 SALIENT FEATURES OF ROTOR DESIGNS

 Solid rotor forging of Cr Ni Mo V alloy steel

 Silver bearing semi hard electrolytic copper
conductor for rotor winding
 Half coil technology for rotor winding to
achieve better forming and consolidation of
end winding
 Slot wedges of good electrical conductivity
shorted at the end by retaining rings. This
works as damper winding.
GENERATOR UNDER ASSEMBLY
 STATOR END COVERS

•AIRGUIDE RING

•LABYRINTH RING

•BOTH ARE HEAT TREATED ALLOY CASTINGS

•AIRGUIDE RING IS FIXED TO STATOR FRAME TO

GUIDE COOLING AIR FLOW INTO THE GENERATOR

• ILABYRINTH RING IS PROVIDED WITH SCRAPPERS TO

PREVENT INGRESS OF DUST AND OIL INTO THE GENERATOR
ASSEMBLY OF RESISTANCE TEMPERATURE DETECTORS

-IN STATOR WINDING, BETWEEN BOTTOM BAR & TOP BAR

- IN STATOR CORE
-IN HOT AIR AND COLD AIR ZONE
-IN BEARING SHELL

ALSO FIRE DETECTORS ARE MOUNTED ON BOTH SIDE OF THE

STATOR CORE TO DETECT ANY FIRE IN SIDE THE GENERATOR.
USE OF PLATINUM IN RTD (PT 100)

- HIGH TEMPERATURE COEFFICIENT OF RESISTANCE

-MORE PRECISION MEASUREMENT
-DIMENSION UN AFFECTED FROM –32°C TO 300° C
-LINEARITY OF MEASUREMENT
 SHAFT VOLTAGE AND BEARING INSULATION

TUR.FE GEN.FE
TUR.FE GEN.RE
BRG BRG
BRG BRG
COUPLING

GENERATOR
TURBINE

INSULATION

EARTHING BRUSH
EARTHING BRUSH