Professional Documents
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Gen Testing
Gen Testing
KANIHA
SHEET 1 OF 29
1. PLANT DETAILS :
The 500 MW generator is coupled to the 500 MW KWU
turbine.
The rated parameters of the generator are
listed in plant details (Section-1) of Testing schedule
for generator protection and generator bay. The design
and constructional features are outlined briefly below.
Generator manual supplied by the manufacturer may be
referred for details of above.
STATOR BODY :
The stator body is a totally enclosed gas tight
fabricated structure suitably ribbed internally to ensure
high
rigidity.
Hydrogen
coolers
are
housed
longitudinally inside the stator body. Rigid end shields
close the casing and support the fan shields.
STATOR CORE :
The stator core is made up of segmental varnish insulated
punchings of cold rolled grain oriented silicon gel and
is assembled in an interleaved manner on core bars.
Steel spacers for ventilating ducts are provided for
radial cooling of core by hydrogen.
The core is held
pressed by means of heavy non-magnetic steel press rings
which are bolted to the ends of the core bars.
Additional support is provided to the teeth portion. In
order to isolate the stator body and thus the foundations
from magnetic vibrations, the core bars are designed to
provide elastic suspension of the core in the stator
frame.
STATOR WINDING AND INSULATION:
The stator has a three phase, double layer short corded
bar type windings having two parallel paths. Each coil
side consists of glass insulated solid and hollow
conductors with cooling water passing through the latter.
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SHEET 3 OF 29
FIELD WINDING:
The field winding is made from hard drawn silver bearing
copper. The winding is held in position and by nonmagnetic rotating ring in the overhang portion. Gap
pickup method is used for direct hydrogen cooling of
rotor.
The main slot insulation is of glass cloth impregnated
with Epoxy resin. The inter turn insulation consists of
layers of prepped glass cloth glued to the bottom of each
conductor. The end windings are packed with blocks of
glass laminates to separate and support the coils and to
restrict their movement under stress. The end windings
are insulated from the retaining rings with the help of
glass epoxy molded segments.
SHAFT MOUNTED FANS
For circulating the cooling gas inside the generator two
propeller type fans are shaft mounted on either end of
the rotor body. Fan hubs are made of alloy steel forging
and are a shrunk fit on the rotor shaft. The alloy steel
cast fan blades are machined in the tail portion to suit
the fan hub and held in position with the help of conical
pins. The blades can be easily removed from or assembled
in the fan hub. Fan shields fixed to the end shields
guide the gas flow.
RETAINING RINGS:
The end windings are held in position by retaining rings
of floating type shrunk fit on the rotor body. The rings
are screwed to prevent axial movement by locking nuts.
SHEET 4 OF 29
SLIP RINGS:
The slip rings consists of helically grooved alloy steel
rings shrunk on the rotor shaft and insulated from it.
They are mounted on a single, common steel bush, which
has an insulating jacket pre-molded on it. The complete
bush with sliprings are provided with inclined holes for
self ventilation. The helical grooves cut on the outer
surface help improve the brush performance.
FIELD LEAD:
The slip rings are connected to the field winding through
semi-flexible copper leads and current carrying bolts,
placed radially in the shaft. Two semicircular hard
copper bars insulated from each other and from the rotor
shaft are placed in the central bore or the rotor joining
the two sets of current carrying bolts with special
profiled precision conical threads.
GAS COOLERS
Four longitudinally mounted gas
the stator body. They are made
with coiled copper wire wound on
as to expose maximum surface area
BEARINGS:
Generator bearings are of pedestal type with spherical
seating to allow self alignment and are supported on a
separate pedestal on slip ring side and in the L.P casing
on the turbine side, Bearing bush is of cast steel lined
with white metal. Oil catchers and deflectors are
provided to prevent axial leakage of oil. To prevent
shaft currents slip ring side bearing and connecting
pipes are insulated from earth.
SHEET 5 OF 29
SHAFT SEALS:
In order to prevent leakage of hydrogen from the
generator casing radial thrust type shaft seals are
provided on either side where the shaft extends out from
the generator. The seal consists of seal liner with
babbit pressing against the shaft caller of the rotor.
Seals are defined in testing schedule of seal oil system.
SHEET 6 OF 29
TURBO GEN.
588
MVA
500 MW
16166 A
21 + 1.05 KV
50 HZ
0.85(LAG)
YY
3.5 BAR
8 %
340 V
4040 A
MAIN EXCITER
-----3780 KW
6300 A
600 V
-------------------------
PILOT EXCITER
65 KVA
-----195 A
220 + 22 V
400 HZ
------------------
------
-------
SHEET 7 OF 29
2. TESTING OBJECTIVE :
TO TEST THE GENERATOR AND MAKE IT READY FOR SYNCHRONIZATION.
SHEET 8 OF 29
3.0 PROPOSAL
3.1
Tests
as
detailed
in
item-8
shall
be
carried
out
on
3.3
3.4
the
3.6
SHEET 9 OF 29
4. SERVICES REQUIRED
4.1
4.2
4.3
4.4
SHEET 10 OF 29
5.0
S A F E T Y PRECAUTIONS:
5.1
5.2
nature,
5.3
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6.
EMERGENCY PROCEDURE :
6.1
Shock treatment
available.
6.2
6.3
6.4
chart
and
first
aid
box
shall
be
SHEET 12 OF 29
7.
7.1
STATE OF PLANT :
Generator Erection complete and satisfactory.
erection test results/log sheets available for
following :
-
Erection of stator.
Measurement
of
insulation
resistances
of
All
the
various
SHEET 13 OF 29
7.2
Following
Testing/Commissioning
schedules
satisfactorily and results/records available :
completed
7.3
7.4
7.5
SHEET 14 OF 29
1.
3.
Excitation Circuit :
Fuses of PMG input to AVR and main exciter input from AVR
output are to be checked for their healthiness.
No trip
SHEET 15 OF 29
4.
Ensure that Gen PTS are racked in and Gen bus duct are in
pressurised
condition.
5. Systems :
i.
ii.
and
to
be
7.
LBB LINKS
to be kept out
8.
Interlock between
be defeated.
9.
GT differential protection
input CT Sec. Links.
be
disabled
by
shorting
SHEET 16 OF 29
7.6
7.7
7.8
to
3000rpm
after
following
the
SHEET 17 OF 29
8.0
TEST METHOD :
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
S.No
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
17.
Gen.Field
Current
(Amps)
Gen.
current
500
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
14000
15000
16000
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
Exciter
field
voltage
Exciter
field
current
Gen.
Termina
l
Voltage
AVR
control
Voltage
SHEET 18 OF 29
Find overall
Transformer.
8.2
1.
PROTECTION CHECKING:
Proving of Rotor Earth Fault protection (64E) :
i.
SHEET 19 OF 29
Iop =
Apms.
vi.
C.
D.
OPERATING CURRENT
GENERATOR CURRENT
SHEET 20 OF 29
condition,
relay
block
by
SHEET 21 OF 29
SHEET 22 OF 29
of
operated
current
and
Generator
current.
Switch
off
Excitation and trip field breaker. Normalise TB wirings and
relay settings.
G.
condition,
relay
block
by
SHEET 23 OF 29
SHEET 24 OF 29
Excite the machine and slowly raise the current till the
relay operates. Measure current at relay terminal 5 & voltage
across 7 & 8. Note the values of Operating
current
and
Voltage.
iii) Normalise Generator Transformer HT terminals. Open
Generator Circuit Breaker.
8.3
SHEET 25 OF 29
8.4
Exciter
field
voltage
Exciter
field
current
Gen.
current
S.No.
Gen.Fie
ld
Current
(Amps)
AVR
control
Voltage
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
1.
2.
3.
4.
96G :
1.
2.
avoid
SHEET 26 OF 29
3.
4.
SHEET 27 OF 29
8.6
SYNCHRONISING:
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
8.6.8
9.
COMPLETION CRITERIA :
SHEET 28 OF 29
9.1
COMPLETED AND
ON GENERATOR
SCHEDULE.
9.2
9.3
AND
SHEET 29 OF 29
10. APPENDICES
2.
Relay manuals