Professional Documents
Culture Documents
2nd
year ELECTRICAL & ELECTRONICS ENGG. Bearing roll
no. B050288ee of NATIONAL INSTITUTE OF
TECHNOLOGY, CALICUT has undergone project training
in the areas of “MANUFACTURING OF TURBO
GENERATOR” at BHEL, R.C.Puram, Hyd-32 under my
guidance from 4.5.07 to 3.6.07
His conduct is satisfactory.
DEBABRATA BALA
Dy. MANAGER
EM PRODUCTION
BHEL – R C PURAM
HYDERABAD-32
ABSTRACT
Today energy is the basic necessicity of our life like water and food.
energy has its pivotal role because of its flexibility to be converted into
other forms.
For generating the electrical energy alternators are needed. The alternators
two parts (1) Rotor (2) Stator. It works on the principle of Faraday’s law. D.C.
current is given to the rotor winding due to which it produces magnetic field.
There is a relative motion between the magnetic field and stator conductors,
for his loads but in the most populated areas, it is more economical and
power to all or most of the users in specific areas. Such a utility company can
make use of very large alternators, which are inherently more efficient and for
this reason alternators with as much as 500 – 1000 MW are now in service. In
recent years of growing concern about efficient use of energy has made users
generate their own power. It seems likely that the number of smaller user
and required amount of energy is 200000 MW. Every year there is increment
needed.
will briefly discuss the basic theory of its operation and typical characteristics,
methods and also different types of insulation methods and after all the
Czechoslovak assistance.
These plants have been at the core of BHEL’s efforts to grow and
power sector regional centres, besides project sites spread all over
India and abroad and also regional operations divisions in various state
BHEL manufactures over 180 products and meets the needs of core-
and reliability.
BHEL has installed equipment for over 62,000 MW of power
generation-for Utilities.
Supplied over one million Valves to Power Plants and other Industries.
its-own R & D centres BHEL has acquired ISO 9000 certification for its
Management (TQM).
BHEL presently has manufactured Turbo-Generators of ratings upto
560 MW and is in the process of going upto 660 MW. It has also the
for thermal power generation, gas based and combined cycle power
Malta, Cyprus, Oman, Iraq, Bangladesh, Sri Lanka and Saudi Arabia.
is, today, a name to reckon with in the industrial world. It is the largest
over 180 products and provides systems and services to meet the
needs of core sections like : power, transmission, industry,
number of project sites spread all over India and abroad, enables
# Stator
- Stator Frame
- Stator Core
- Stator Windings
- End Covers
# Rotor
- Rotor Shaft
- Rotor Windings
- Rotor Retaining Rings
# Bearings
# Cooling Systems
# Excitation System
STATOR
1.1STATOR FRAME
It is the heaviest component and hence a rigid frame is required due to
and winding. It has radial and axial ribs having adequate strength and
efficient cooling. Guide bards are welded or bolted inside the stator
permeability and low hysterysis and eddy current losses. The sheets
Stator laminations are coated with synthetic varnish; are stacked and
interacts with the core, the entire core is built of thin laminations. Each
which are placed within end plates for making the stack.
The segments are punched in one operation from electrical sheet steel
lamination having high silicon content and are carefully deburred. The
stator frame. The segments are staggered from layer to layer so that a
Wh α β max 1.6 ft
We α β max ² f ² t²
In order to reduce the hysterysis loss, silicon alloyed steel, which has
Steel - 95.8 %
Silicon - 4.0 %
Impurities - 0.2 %
From the formula it is seen that eddy current loss depends on the
PREPATION OF LAMINATIONS
Initially the material comes in the form of rolled sheets and then it is cut
in trapezoidal form for reducing the copper losses since the material is
very costly.
1. Compounding tools.
1. COMPOUNDING OPERATION :
In this method the stamping with all the core bolt holes, guiding slots
two operations. In the first operation the core bolt holes and guiding
slots are only made. This operation is known as Blanking and the tools
winding slots are punched using another tool known as Notching tool
are
done. Nearly 500 tons crank press is used for this purpose.
c) Deburring operation :
d) Varnishing :
ASSEMBLY OF CORE
stator frame. The entire core length is made in the form of packets
material that are welded to provide radial ducts. The segments are
are reached. The complete stack is kept under pressure and located
nonmagnetic steel and are insulated from the core and the pressure
teeth thus, ensuring a firm compression in the area of the teeth. The
leakage flux.
rectangular core key bars are inserted into the slots provided in the
back of the core and welded to the pressure plates. All key bars,
except one, are insulated from the core to provide the grounding of the
core.
1. For Resin rich insulation system the laminations are stacked in the
frame itself.
2. For Resin poor insulation system (VPI) cage core of open core design is employed.
3.
STATOR WINDING
Stator winding is the one which induces emf and supplies the load.
Generally two layer lap winding, chorded to about 5/6 pitch which
practically eliminates 5th and 7th harmonics from the flux wage or open
circuit induced emf wave is used. The stator coil is made up of number
mechanical properties
Generally diamond pulled multiturn coils are used for low capacity
degrees. The transposition is done to ensure that all the strips occupy
individual strips due to the slot cross field and ensures that no or only
that deformations due to the thermal stresses are eliminated. The high
layers of resin poor mica tape are applied over the bars. The thickness
Slot Discharges:
Slot discharges occur if there are gaps within the slot between
the surface of the insulation and that of the core. This may cause
iron.
Within the slots, the outer surface of the conductor insulation is at earth
the enclosed copper. Surface discharge will take place if the potential gradient
are
10) (I) Remove heating clamps and take out the bar halves
from former.
a) Tape the bar with Resin poor fine mica paper tape on
tape)
After the manufacture of stator half coils (Roebel bars), they are
arranged in the core slots as per the design. First bottom layer of
bars is placed and then top one. Between them stiffner made up
factor top and bottom bars are brazed. Due to that at the ends a
has a transposed coil in each phase such that the flux distribution
frame and also rest on the foundation plate. The end covers are
PHASE CONNECTORS:
low specific current loading. The phase connectors are wrapped with
resin rich mica tape. After curing the connectors are attached to the
RTDs. They are placed at various sections of the core and winding.
temperature.
R= Ro (1+ ∝ T)
T = temperature difference in C.
INSULATION SYSTEMS
The system consists of flakes of mica in the form of tape and with the
mica folium tape is continuously wrapped in the slot position and in the
under heat & pressure. In this system B stage epoxy mica tape
material has limited shelf life and requires controlled condition of lower
temperature storage.
automation.
Till early fifties bitumen mica insulation system was in vogue with most
Generators.
BHEL INSULATION SYSTEM FOR TURBO GENERATORS
BHEL had Bitumen insulation system for low & medium rating TGS
and switched over to resin rich Thermo setting type as a step towards
The experience with Bitumen system has been generally satisfactory &
outage due to insulation failures has been considerably low, yet these
Large & medium range motors are provided with following insulation
system.
mica paper tape on overhang with a final layer of polyester shrink tape.
insulation system.
main insulation consists of resin poor epoxy mica paper tape all over
overhang portions.
provide avoid free monolithic insulation all over the winding. The
insulation thicknesses are slightly higher than those used for resin rich
increased reliability
1.Epoxy Resin content is about 8%. 1.Epoxy Resin content is about 40%.
Setting process.
4. Reduction in time cycle for this 4. It is very long process and time
process. Consuming.
DR. MEYER brought the VPI system with the collaboration of WESTING HOUSE in
the year 1956. Vacuum Pressure Impregnation has been used for many years as a basic
process for thorough filling of all interstices in insulated components, especially high
voltage stator coils and bars. Prior to development of thermosetting resins, a widely used
insulation system for 6.6kv and higher voltages was a Vacuum Pressure Impregnation
system based on bitumen bonded Mica flake tape main ground insulation. After applying
the insulation, coils or bars were placed in an autoclave, vacuum dried and then
impregnated with a high melting point bitumen compound. To allow thorough
impregnation, a low viscosity was essential. This was achieved by heating the bitumen to
about 180°C at which temperature it was sufficiently liquid to pass through the layers of
tape and fill the interstices around the conductor stack. To assist penetration, the pressure in
the autoclave was raised to 5 or 6 atmospheres. After appropriate curing and calibration,
the coils or bars were wound and connected up in the normal manner. These systems
performed satisfactorily in service provide it was used in its thermal limitations. In the late
1930’s and early 1940’s, however, many large units, principally turbine generators, failed
due to inherently weak thermoplastic nature of bitumen compound. Failures were due to
two types of problems:
1. Tape separation
2. Excessive relaxation of the main ground insulation.
Much development work was carried out to try to produce new insulation systems, which
didn’t exhibit these weaknesses. The first major new system to overcome these difficulties
was basically a fundamental improvement to the classic Vacuum Pressure Impregnation
process. Coils and bars were insulated with dry mica flake tapes, lightly bonded with
synthetic resin and backed by a thin layer of fibrous material. After taping, the bars or coils
were vacuum dried and pressure impregnated in polyester resin. Subsequently, the resin
was converted by chemical action from a liquid to a solid compound by curing at an
appropriate temperature, e.g. 150°C. this so called thermosetting process enable coils and
bars to be made which didn’t relax subsequently when operating at full service
temperature. By building in some permanently flexible tapings at the evolutes of diamond
shaped coils, it was practicable to wind them with out difficulty. Thereafter, normal slot
packing, wedging, connecting up and bracing procedures were carried out. Many
manufacturers for producing their large coils and bars have used various versions of this
Vacuum Pressure Impregnation procedure for almost 30 years. The main differences
between systems have been in the types of micaceous tapes used for main ground
insulation and the composition of the impregnated resins. Although the first system
available was styrenated polyester, many developments have taken place during the last
two decades. Today, there are several different types of epoxy, epoxy-polyester and
polyester resin in common use. Choice of resin system and associated micaceous tape is a
complex problem for the machine manufacturer.
Although the classic Vacuum Pressure Impregnation technique has improved to a
significant extent, it is a modification to the basic process, which has brought about the
greatest change in the design and manufacture of medium-sized a.c. industrial machines.
This is the global impregnation process. Using this system, significant increases in
reliability, reduction in manufacturing costs and improved output can be achieved.
Manufacture of coils follows the normal process except that the ground insulation consists
of low-bond micaceous tape. High-voltage coils have corona shields and stress grading
applied in the same way as for resin-rich coils, except that the materials must be compatible
with the Vacuum Pressure Impregnation process. Individual coils are interturn and high-
potential-tested at voltages below those normally used for resin-rich coils because, at the
unimpregnated stage, the intrinsic electric strength is less than that which will be attained
after processing. Coils are wound into slots lined with firm but flexible sheet material. Care
has to be taken to ensure that the main ground insulation, which is relatively fragile, is not
damaged. After interturn testing of individual coils, the series joints are made and coils
connected up into phase groups. All insulation used in low-bond material, which will soak
up resin during the impregnation process. End-winding bracing is carried out with dry, or
lightly treated, glass-and/or polyester-based tapes, cords and ropes. On completion, the
wound stator is placed in the Vacuum Pressure Impregnation tank, vacuum-dried and
pressure-impregnated with solventless synthetic resin. Finally, the completed unit is stoved
to thermoset all the resin in the coils and the associated bracing system.
After curing, stator windings are high-potential-tested to the same standard. Loss-
tangent measurements at voltage intervals upto line voltage are normally made on all
stators for over 1kv. A major difference between resin-rich and vacuum pressure
impregnation lies in the importance of this final loss-tangent test; it is an essential quality-
control check to conform how well the impregnation has been carried out. To interpret the
results, the manufacturer needs to have a precise understanding of the effect of the stress-
grading system applied to the coils. Stress grading causes an increase in the loss-tangent
values. To calculate the real values of the ground insulation loss-tangent, it is necessary to
supply from the readings the effect of the stress grading. For grading materials based on the
materials such as silicon carbide loaded tape or varnish, this additional loss depends, to a
large extent upon the stator core length and machine voltage.
In order to minimise the overall cost of the machine & to reduce the
time cycle of the insulation system vacuum pressure Impregnated System is used.
The stator coils are taped with porous resin poor mica tapes before inserting in the
slots of cage stator, subsequently wounded stator is subjected to VPI process, in
which first the stator is vacuum dried and then impregnated in resin bath under
pressure of Nitrogen gas.
Variant Description
Laminated rotors
Process:
1. General:
The jobs that are entering tank for Vacuum Pressurised Impregnation shall not have any
oil based coatings. Any such, rust preventive/ corrosion preventive viz., red oxide etc.,
shall be eliminated into the tank.
The jobs shall be protected with polyethylene sheet for preventing dust or dirt on jobs,
till it is taken up for impregnation.
Resin in the storage tank shall be stored at 10 to 12°C and measured for its viscosity,
viscosity rise.
Proper functioning of the impregnation plant and curing oven are to be checked by
production and cleared for taking up of job for impregnation
2. Preheating:
The job is to be loaded in the curing oven and heated. The temperature is to be
monitored by the RTD elements placed on the job and the readings are logged by
production. The time of entry into the oven, time of taking out and the temperature
maintained are to be noted. Depending on convenience of production the jobs can be
preheated in impregnation tank by placing them in tubs.
The impregnation tubs used for impregnation of jobs are to be heated in the
impregnated tank itself, when the jobs are preheated in the curing oven.
3. Impregnation:
Job insertion into preheated tub and insertion into tank
By the time, the preheating of job is completed, it is to be planned in such a way
that the heating of tub and tank heating matches with the job. This is applicable when the
job is heated in the curing oven separately. The preheated job is to be transferred into the
tub by crane handling the job safely and carefully with out damage to the green hot
insulation.
Insertion of tub with job into the impregnation tank
The warm tub with job is inserted into impregnation tank by sliding on
railing, in case of horizontal tank. The thermometer elements are to be placed at
different places on the job. The connection for inlet resin is to be made for
collection of resin into tub. After ensuring all these the lid of the impregnation tank
is closed. In case of vertical tank the job along with tub is slinged and inserted
carefully into impregnation tank without damage to insulation.
Drying the job in vacuum
The job is to be dried under vacuum. Drain out the condensed moisture/ water at the
exhausts of vacuum pumps for efficient and fast vacuum creation. Also check for oil
replacement at pumps in case of delay in achieving desired vacuum.
Heating the resin in the storage tank
The completion of operations of drying and the heating of
the resin in the storage tank are to be synchronised. The heating of
resin in the tank and pipeline is to be maintained as at preheating
temperature.
1) Process tests
2) Performance tests
PROCESS TESTS
made to detect the presence of local hot spots. Whenever there are
insulation or burns on the edges, high eddy current flow giving rise to
temperature rise in that zone. Any hot spots found are rectified by
is recorded.
resistance.
After laying of bottom bars in the stator core they are tested at for
2Un+7KV.
After laying of top bars they are tested for a voltage of 2 Un + 5 KV.
After laying of top and bottom bars, their balancing is done and then
PERFORMANCE TESTS
In this test the machine is run at rated speed with the help of prime
mover. The vibrations of the rotor and bearings are measured in three
directions- horizontal, vertical and axial. The vibrations must be within
balanced before the assembly. For balancing the rotor weights are
added to rotor.
In this test the machine is run at rated speed with the help of prime
In this test the machine is run at rated speed with the help of
prime mover. The output terminals of the stator are short circuited and
the excitation is slowly increased such that rated current flows through
When high voltage is done on the phase winding all other phase
earthed.
High voltage is applied to winding by increasing gradually to
required value and maintained for one minute and reduced gradually to
the earthed cable. The test is conducted to all phases and rotor
windings separately.
COOLING
i) Hysterisis loss
3. Mechanical losses
i) Frictional loss
compressibility.
Disadvantages :
Hydrogen.
indirect cooling for the stator winding. Director cooling of the rotor
AIR COOLING :
two axial flow fans arranged on the rotor shaft. Cold air is drawn by the
fans from the atmosphere through air filter the cooling air flow is
Flow path 1 is directed into the rotor end winding space and cools the
rotor winding, part of the cooling air flows past the individual coils for
cooling the rotor end winding and then leaves the end winding space
via bores in the rotor teeth at the end of the rotor body. The other
portion of the cooling air flow is directed from the rotor end winding
space into the slot bottom ducts axially from where it is discharged into
the air gap radially via a large number of radial ventilating slots in the
coils and bores in the rotor wedges. Along these paths the heat of rotor
Flow path 2 is directed over the stator end winding to the cold air
ducts and into the cold air compartments in the stator frame space
between the generator housing and the rotor core. The air then flows
into the air gap through slot in the stator core were it absorbs the heat
Flow path 3 is directed into the air gap via the rotor retaining ring. The
air then flows past the clamping fingers via ventilating slot in the stator
core into the hot air compartments in the stator frame being discharged
to the air cooler. The flow path mainly cools the rotor retaining rings,
the ends of the rotor body and the end portions of the stator core.
Flows 2 & 3 mix in the air gap with flow 1 leaving the rotor. The cooling
air flows radially outward through ventilating slots in the core within the
range of the hot air compartments for cooling of winding and core. The
Solid rotors are manufactured from forged alloy steel with suitable
magnetic properties. This type of rotor can withstand even upto speed
of 3000 rpm.
the teeth.
For directly cooled rotors, sub slots are provided for cooling Generator
rotor is made up of two parts (1) core, (2) lamination. The outer
for inserting the core inside the laminations the laminations are first red
heated at medium temperature for 15 hours in BELL FURNACE. After
that the core is shrunk fitted inside the laminations. Thus punched and
vacuum casting. It is forged from a vacuum cast steel ingot. Slots for
insertion or the field winding are milled into rotor body. The longitudinal
slots are distributed over the circumference such that two solid poles
are obtained.
centrifugal forces and short circuit torque’s call for a high quality heat
The rotor consists of electrically active portion and two shaft ends.
which hold the field winding. Slot pitch is selected so that the two solid
poles are displaced by 180 degrees. The rotor wedges act as damper
winding within the range of winding slots. The rotor teeth at the ends of
rotor body are provided with axial and radial holes enabling the cooling
air to be discharged into the air gap after intensive cooling of end
windings.
The rotor windings consist of several coils inserted into the slots and
series connected such that two coil groups form one pole. Each coil
each strip can be made upto 10.5 mm but here in BHEL we make only
upto 5.3 mm. The rotor bearing is made of silver bearing copper
ensuring an increased thermal stability. For ventilation purpose the
slots are provided on the coil and on inter strip insulation layer both.
The slot wedges are made of high electrical conductivity material and
thus act as damper windings. At their ends the slot wedges are short
circuited through the rotor body. The inter space between the overhang
CONSTRUCTION
into the longitudinal slots of rotor body. The coils are wound so that two
section and are provided with axial slots for radial discharge or cooling
air. All conductors have identical copper and cooling duct cross
section. The individual bars are bent to obtain half turns. After insertion
into the rotor slots, these turns are brazed to obtain full turns. The
series connected turns of one slot constitute one coil. The individual
coils of rotor are connected in a way that north and south poles are
obtained.
CONDUCTOR MATERIAL
INSULATION
fiber laminate.
The coils are insulated from the rotor body with L-shaped strips of
To obtain the required leakage paths between the coil and the rotor
body thick top strips of glass fiber laminate are inserted below top
wedges. The top strips are provided with axial slots of the same cross
winding is secured in the slots with wedges. The slot wedges are made
They are also used as damper winding bars. The slot wedges extend
beyond the shrink seats of retaining rings. The wedge and retaining
The spaces between the individual coils in the end winding are filled
plates held by HGL high glass laminate plates separate the different
The centrifugal forces of the rotor end winding are contained by single
high strength steel in order to reduce stray losses. Each retaining ring
with its shrink fitted. Insert ring is shrunk on to the rotor body in an
snap rings.
The rotor retaining rings withstand the centrifugal forces due to end
windings. One end of each ring is shrunk fitted on the rotor body while
the other end overhangs the end windings without contact on the rotor
winding.
The shrunk on hub on the end of the retaining ring serves to reinforce
the retaining ring and secures the end winding in the axial direction at
The shrunk seat of the retaining ring is silver plated, ensuring a low
contact resistance for induced currents. To reduce the stray losses and
have high strength, the rings are made of non magnetic, cold worked
materials.
The cooling air in generator is circulated by two axial flow fans located
on the rotor shaft one at each end. To augment the cooling of the rotor
the air expelled from the discharge parts along the rotor.
The blades of the fan have threaded roots for being screwed into the
rotor shaft. The blades are drop forged from an aluminium alloy.
BEARINGS
soft metal called Babbitt so that rotor doesn’t get harmed even if it
comes in contact with Babbitt. Inside this Babbitt there is a very thin
such that the measuring point is located directly below the babitt.
vibrations.
oil piping on either side of the non-drive end bearings are insulated
• Closed circuit air cooling with water or air coolers mounted in the pit.
The fan design usually consists of two axial fans on either made of
before assembling and the third and final routine tests will be
U2 = Ut + 1 KV
2. The next test is to be carried out after placing all the coils in the
While clamping care should be taken to see that the pressing rings
and other equipment are insulated from the winding and rotor body,
equipment.
Megger.
insulation condition.
5. After driving the central wedges only in position, measure the
test with a value of 1.10 Ut for 10 sec, i.e., just reaching the value
9. Finally, just before the dispatch of the finished rotor measure the
MEASUREMENT OF D.C.RESISTANCE :
supply. And measure the resistance and the temperature using RTD.
MEASUREMENT OF IMPEDANCE :
Z = V/I
V = voltage in volts;
I = current in amps;
between voltage v/s current. In this, there is no perfect value for the
1) After bars manufacturing bars are tested at four times the rated
voltage.
Ut = 4* Urated
actual current and line current. When the insulation is perfect and
3) After lying bottom, top and eyes joining, High voltage test is
CARRIED OUT :
Bars are subjected for Inter strip and Inter half shorts tests.
Ring flux test is carried out on the stator core before winding is
put in the slots. The rated flux density is generated in the stator core by
generation of heat. The stator core is observed for the temperature rise
through its surface by using RTD’s. If there is any hot spot found in the
MEASUREMENT OF D.C.RESISTANCE :
stator terminals. Measure the resistance and repeat the step for Y and
upto 5% is acceptable.
MEASUREMENT OF LEAKAGE REACTANCE :
XL = √ (Z² - R²)
Where Z = U/ ((√3) * I)
R = P/(3* I²)
XL = Z = U/((√ 3) * I) Ω
to it. Run the megger and note down the Insulation resistance value
than 1 MΩ
Remove the RTD terminals i.e. open the RTD terminals and
connect to the multimeter. Note down the resistance value of RTD. For
WINDING :
(Cg).
capacitance.
a standard capacitor.
1) High Voltage applied to one of the phases and remaining
Cx = capacitance to be measured.
Cn = standard capacitor
G = galvanometer
C4 = variable capacitance
R4 = standard resistor
C4.
Cx = (Cn * R4*(R3+100)/(N*(R3+s) uf
C4 and Cn are in uf
RATED SPEED:
The machine is rolled and run at rated speed after ensuring the
temperatures.
The machine is run at rated speed and drive motor input voltage
The excitation is reduced and cut off. The speed is reduced and
cooled down. The stator winding temperature should be less than 60°
The machine is run at rated speed and the motor input voltage
and current are noted and machine is excited gradually in steps, cat
20%,40%,60%,80%,90%,95%,100%,105%,110% and 120% of rated
Shaft voltage
Bearing vibration
RTD’s readings
The excitation is reduced, cut off, the speed is reduced, and the
voltage.
When the rotor shaft rotates inside the stator there will be some
grounded and it will again come back to the pedestal, to the bearings
through the earth. It will become a cyclic process. This voltage has to
be reduced otherwise, the rotor will get heated. For this bearing
AC voltmeter across the two ends of the rotor at 100% rated voltage.
the input leads and readings of voltage and current are noted down
Z = V/I
V = voltage in volts;
I = current in amps;
the machine.
(Machine at rest):
measured separately before and after high voltage test using Megger
as Absorption Coefficient.
This Absorption Coefficient for High Voltage test should be > =1.3
(MACHINE AT REST):
The High Voltage is applied to windings by increasing gradually
to required value and maintained for one minute and reduced gradually
to earthen wire. The test is conducted on all the phases and rotor
winding separately.
When High Voltage test is done on one phase winding, all other
is earthed.
Up = Excitation voltage
noted down.
at 1’
selected.
windings up to 5 % is acceptable.
MEASUREMENT OF D.C.RESISTANCES AND INSULATION
RESISTANCE OF RTD’s:
From the test data Short Circuit Ratio is calculated using the
formula.
(iv) Cooler
The 3 phase pilot exciter has a revolving field with permanent magnet
bridge and fed to the field winding of generator rotor through dc lead in
the rotor shaft. A common shaft carried the rectifier wheels, the rotor of
main exciter and permanent rotor of the pilot exciter. The shaft is rigidly
main and pilot exciters. The generator and exciter rotors are thus
shaft bore. This also compensates the length variations of leads due to
thermal expansion.
RECTIFIER WHEELS:
their mechanical design and differ only in the forward direction of the
diodes. The dc from rectifier wheels id fed to the dc leads via radial
the shaft circumference between the rectifier wheels and 3-phase main
exciter. One 3 phase conductor is provided for each diode. The
The 3 phase pilot exciter is a 6-pole revolving field unit. The frame
enclosure. The magnets are braced between the hub and external pole
shoe with bolts. The rotor hub is shrunk onto free shaft end.
the frame are poles with field and damper windings. The field winding
bolts over compression rings. The 3 phase winding is inserted into the
slots of the laminated rotor. The winding conductors are transposed
within the core length and end turns of the rotor winding are secured
with steel bands. The connections are made on the side, facing
rectifier wheels. The winding ends are run to a bus ring system to
which the 3 phase leads leading to the rectifier wheels are also
connected. After full impregnation with synthetic resin and cooling, the
AVR :
controller and field forcing limiter for the main exciter field current, a set
control setting, the field forcing limiter limits the output current of
thyristor set assigned to control system, to the value allowed for field
forcing.
CONCLUSION :
CONSTRUCTION :
end. The stator may be fixed either to be base frame of the main
shafting or a static auxiliary excitation unit is used for exciting the field
rectifier and fed into the field winding of main machine via the
excitation leads which pass through the hallow shaft of the main
machine.
ROTOR :
The rotor is fitted on the shaft extension of the main machine and
The rotor hub is of welded construction and called the laminated core
modules are welded between the arms of the rotor spider within the
ROTOR WINDING :
The 3-phase rotor winding inserted in the slots of the laminated core is
end leads of the individual windings are on the A end and connected to
the u,v,w and neutral bus rings arranged at the same end. Both
winding overhangs are bound with heat setting glass fiber tapes to
The rectifier accommodated inside the rotor core and rotor winding
comprises six diode assemblies and the protection circuit. The diode
formed cooling fans containing one disc type diode secured by means
of a clamping plate. As the heat sinks are electrically live, they are
insulated from the rotor hub to which they are fixed. A contact face
links to the appropriate bus ring on the 3-phase side. The connections
clamping plates.
face of the heat sink, should be observed. The dc bus rings carry the
means of insulating mounts. The two bus rings, each have a terminal
lug for the copper bars which are connected to the excitation cable of
The excitation cables are led through the insulated hollow shaft of the
main machine and are provided with special cable lugs at the shaft
openings.
VARISTOR :
The varistor discs are clamped between the bus rings by means of
insulated screws. Electrical contact between the varistor discs and the
them.
MAIN EXCITER :
in the frame are the poles with the field and damper windings. The field
field current.
The rotor consists of stacked silicon steel laminations forming the rotor
The winding conductors are transposed within the core length and the
The stator slots form indentations in the air gap boundary. Therefore
as the rotor flux moves across the stator teeth the change in
of the stator teeth. But due to the laminated construction, the resultant
burring system to which the 3 phase leads loading to the rectifier wheel
the pilot exciters and has forced oil lubrication from the turbine oil
converted to dc. The main components of the rectifier wheel are the
fig. The arrangement of the diode is such that the contact pressure
diode failure. Anode based diodes are used in positive arms and
fuses, Each diode is mounted in each light metal heat sink and thus
connected in parallel associated with each diode with HRC fuse, which
When high voltage surges occur, the capacitor gets charged until
normal conditions occur. When a low voltage surge occurs, the charge
The dc current from the rectifier wheels is fed to the DC leads arranged
PILOT EXCITER :
Some of different types of pilot exciters are salient pole, inductor type,
Alcomax. The permanent magnet pieces are bolted to a steel hub and
held in place by pole shoe. The bolts are made from non-magnetic
of the output voltage and reduce electrical noise, the pole shoes are
skewed one pole pitch over the stator length. Stator core is constructed
from a stack of low loss sheet steel laminations assembled within the
fabricated steel frame. Radial and axial cooling ducts are provided at
intervals along the core length to allow cooling of core and windings.
The coils are connected to give rated 3 phase voltage output and
and “manual channel” for field current regulation. Each channel has its
startup and shut down of the machine. The set point adjuster of the
FIG
The two self-ventilated thyristor sets for voltage control (AUTO) and
detector. The terminal voltage of the generator is also fed to the error
the amplifier is fed to the gate pulse generator where the pulses are
generated. These gate pulses are given to the gate terminals of the
the thyristor bridge. The rectified signal from the thyristor bridge is fed
assembling. The larger the rotor the more the balancing is needed.
# Static balancing
# Dynamic balancing
STATIC BALANCING :
In static balancing, the rotor is put on two plain rails. The shaft at the
these rails without friction. Then the eccentric force is balanced. The
static balance is only useful to bring the centre of gravity very near to
the axis of the shaft but for an exact balancing dynamic balancing is
needed.
DYNAMIC BALANCING:
It helps to find not only forces but also torque are on the shaft when the
of the axis of the center of the gravity from the axis of the rotation.
on the either side of the axis of the rotor are determined. The
either side of the axis of the rotor is not the same then the difference of
the weights are added to the required side of the axis. In this way, the
rotor is balanced.