1

SUMMER TRAINING REPORT

UNDER UPRVUNL
AT ANPARA THERMAL POWER PLANT
(17/05/2018 to 16/06/2018)

Submitted to:

Mr. Shailesh Chaurasia Mr. A.K. Nigam

Executive Engineer, EMD-I, ATPS Assistant Engineer, EMD-I, ATPS

Anpara Thermal Power Plant Anpara Thermal Power Plant

Sonebhadra, UP Sonebhadra, UP

Submitted by:

Sagar Kumar Pandey

B.tech. (2nd year), Electrical Engineering

Chandigarh University
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Acknowledgement
On completing the report of this nature. It becomes clear to the viewer that the
work would not have been possible without the support of others. It is my
pleasure to acknowledgement the help received fro those individuals. I am
greatly indebted to Er. D.K. Vigal (Executive Engineer), HRD Division, ATP
for allowing me to carry out six weeks of vocational training at this power
station under the able guidance of engineers and staffs.

I also acknowledge and extend my thanks to Er. Shailesh Chaurasia(Executive

Engineer), EMD-I, ATP for his through inspection and guidance during my
training session. More directly, Er. A.K. Nigam (Assistant Engineer), EMD-I,
ATP and associated staff took sincere pain day in and day out to clear me each
and every topic of my interest and provide me the finest technical details of the
systems used in power plant.

I shall be failing in my duty if I don’t express my gratitude to Prof. Inderpreet

Kaur (HOD, Electrical Engineering Department, Chandigarh University), who
helped me rise up to this level.

Last but not the least, I want to thank my parents and friends whose support has
been a constant source of encouragement to me.

Place: Anpara Sagar Kumar Pandey

Date: 16.06.2018 B. Tech(2nd year)
Electrical Engineering
Chandigarh University
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Contents
S. no. Topic Page no.
1. Acknowledgement
2. Contents
3. Abstract
4. Introduction
5. Basics
6. Unit Overview
7. Generator
8. Hydrogen Gas
System
9. Seal OIL System
10. Stator water cooling
system
11 Generator and
transformer
protection
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Abstract

This project report has been made with an objective to perform observational
study at Anpara Thermal Power Plant with special focus on areas covered
under Electrical Maintenance Division (First). Thus the report starts with a
brief introduction to Anpara Thermal Power Plant which covers method o
production of electricity electricity in thermal power plant. Also, establishment
related issues of thermal power plant are discussed. Further following deductive
method of report preparation, Anpara Thermal Power has been discussed in
details. Next subject of the report deals with unit overview which covers all
processes and systems of unit along with departments undertaking them.

After this, detailed analysis of generator and its subsystems used at ‘A’TPS is
done which covers seal oil system, stator water cooling system, hydrogen
cooling system for rotor and generator and transformer protection.

In this way, the report provides a bird’s eye glance to Anpara Thermal Power
Plant with special emphasis to systems under Electrical Maintenance Division
(First).
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Introduction

The site of Anpara Thermal Power Plant Station is situated at the border of
Uttar Pradesh and Chhattisgarh that is at the southernmost tip of district
Sonebhadra in Uttar Pradesh and at the left bank of Rihand reservoir along the
national highway no. 75E near village Anpara. The site is 3 km from the
existing Renusagar Power Plant.

Electricity generation in Thermal Power Plant

In the Thermal power plant, steam turbine is used as prime mover to drive 3
phase synchronous generator(alternator). This steam is produced by heating
water in boilers at high temperature and pressure using coal energy.

BOILER TURBINE GENERATOR

(Thermal (Mechanical (Electrical
Energy) Energy) Energy)

In India, about 65% of electrical power used is generated in thermal power

plants (including nuclear plants) and the rest comes from hydroelectric power
plants. Coal is the fuel for the most of the steam plants, the rest depend on the
oil/natural gas and nuclear fuels.
 6

A steam power plant basically works on Rankin cycle. For ideal Rankin cycle, 4
ideal processes which should take place are as under:

 For pump, the ideal process would be the reversible adiabatic

compression of liquid ending at the initial pressure.
 For steam boiler, this would be a reversible constant pressure heating
process of water to form steam.
 For turbine, the ideal process would be a reversible adiabatic expansion
of steam.
 For condenser, it would be a reversible a constant pressure heat rejection
as the steam condenser till it becomes saturated liquid.

The efficiency of Rankin cycle for thermal power plant is given as:

Cycle efficiency= (Wt-Wp)/Qt where Wt is work obtained from turbine, Wp is

work supplied to pump, Qt is heat supplied (Q2 is heat rejected).
 7

Site selection for thermal power plant:

The factors to be considered for selection of site for thermal power plant are as
follows:

 Easy availability of fuel and transportation of fuel.

 Availability of land and erection should be low.
 To be kept near the load center to reduce transmission loss.
 To be kept away from the urban areas due to pollution, smoke, noise, etc.
 Facility for disposal of ash.
 It should be installed near coals mines near to the harbour.
 The magnitude and nature of land to be handled.
 Easy availability of cooling water (near sea or river).

Coal used in thermal power plant:

Coal is categorised as follows depending upon fixed carbon, volatile matter, and
moisture content:

 Anthracite having 86% fixed carbon.

 Bituminous having 46 to 86% fixed carbon.
 Lignite having 30% fixed carbon.
 Peat having 5 to 10% fixed carbon.

Coal from mines is transported to CHP in railway wagons. It is unloaded in

track hoppers. For the purpose, each plant has Merry Go-Round (MGR) rail
transportation system. The loading operation of the coal rake takes place while
it is moving under the silo at the present speed of 0.8 km/hr. The loading time
for each wagon is one minute. For unloading of coal from the wagons, an
underground track hopper is provided at the power station end.

Anpara Thermal Power Plant

There are total 7 operational units, all of which are coal fired thermal power
stations. Anpara Thermal Power Plant has been made in 3 phases, Anpara A
(last unit commissioned in 1983) and Anpara B (last unit commissioned in
1994) by erstwhile UPSEB. In year 2007 Anpara C (last unit commissioned in
2012) was allotted to be constructed under Lanco Infrastructure and later run by
Lanco Power (2×600 MW). Under state government’s flagship, power
 8

generation company UPRVUNL, a new unit Anpara D has been installed. Units
are configured for generating 2×500 MW electricity and are manufactured by
BHEL. Project cost for Anpara ’A’ TPS is 721 crores , for ‘B’ TPS is 2060
crores and that of Anpara D is 7000 crores.

Details of Anpara Thermal Power Plant are as below:

Unit Section Capacity Manufacturer Date of Date of

No. Synchronization Commercial
Operation
1 Anpara 210 MW Bharat Heavy 26/03/1986 01/01/1987
A Electricals
Limited
2 Anpara 210 MW Bharat Heavy 28/02/1987 01/08/1987
A Electricals
Limited
3 Anpara 210 MW Bharat Heavy 12/03/1988 01/04/1989
A Electricals
Limited
4 Anpara 500 MW Mitsubishi 19/07/1993 01/03/1994
B Corporation,
Japan
5 Anpara 500 MW Mitsubishi 04/07/1994 01/10/1994
B Corporation,
Japan
6 Anpara 500 MW BHEL 31/03/2015 Sept- 2015
D
7 Anpara 500 MW BHEL Feb- 2016 Mar- 2016
D

For production of electricity major requirement is of coal and water. Coal is

obtained from open coal mines of various NCL projects mainly Kakari, Bina,
Khadia, etc.through MGR railway system. Maximum consumption of coal is
48.84 metric tonnes per day. Water requirement is met from Govind Vallabh
Pant Sagar reservoir formed by Rihand Dam.

Ash remained after burning is transported to Belwadah (14 km from ATP) in

the form of slurry through pipeline system. Also ash is stored in silos in dry
form which is supplied to J.P. Cement free of cost for cement and brick
formation.
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Various divisions in Anpara Thermal Power Plant are as under:

 Mechanical maintenance division.

 Coal handling division.
 Boiler maintenance division.
 Turbine maintenance division.
 Electrical and switchyard maintenance division.
 Ash handling maintenance division.
 Electrical maintenance division.
 Control and instrument maintenance division.
 Common auxiliary maintenance division.
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Unit overview
Various parts and systems of Anpara Thermal Power Plant (‘A’TPS) are as
follows:

Boiler: Boiler, in simple terms, can be called “Steam Generator”. It can be

defined as the unit where any liquid is boiled. It may also be defined as a device
that is used to transfer heat energy being produced by burning of fuel to liquid,
generally water, contended in it to cause its vaporisation. Temperature of boiler
may be as high as 18000C.

The following are factors essential for the efficient combustion usually referred
as ‘The Three Ts’:

(a) Time- It will take a definite time to heat the fuel to its ignition
temperature and having ignited, it will also take time to burn.
(b) Temperature- A fuel will not burn until it reaches its ignition
temperature.
(c) Turbulence- Turbulence is introduced to achieve a rapid relative motion
between the air and fuel particles.

Flowchart for water and steam circulation in boiler is as

under:-

BOILER FEED DOWN

ECONOMISER BOILER DRUM WATER WALLS
PUMP COMERS

FINAL SUPER PLATEN SUPER PRIMARY PLATEN WATER

BOILER DRUM
HEATER HEATER SUPER HEATER HEATER

A HP TURBINE REHEATER IP TURBINE LP TURBINE

CONDENSATE
BOILER FEED
EXTRACTION CONDENSER
PUMP
PUMP
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Superheater: The steam produced in the boiler is wet and is passed

through the superheater where it is dried and superheated by flue gases. It
increases the temperature of steam to superheated region. Superheater
system is used because the steam from the boiler drum contains water
particles. This steam cannot be directly impinged on the turbine blades as it
may cause severe damage to the blades. Also they may cause corrosion of
metallic parts. Generally there are four types of superheater used:

(a) Primary superheater

(b) Secondary superheater
(c) Tertiary superheater
(d) Final superheater

Reheater: Reheater is located in the furnace in its first pass of the fuel
gases. It is located just above the firing zone.

Reheater may be defined as an auxiliary, which is used to reheat the steam

coming from the turbine, having temperature 5400C, and the pressure
169kg/cm2. After having some work done on high pressure turbine at high
temperature and pressure, steam loses temperature. This temperature is again is
maintained in reheater by keeping the pressure constant.

Air preheater: Air is drawn from the atmosphere by forced draught fan and
is passed through air preheater to increase the temperature of air which is
further used for coal combustion. The flue gases are passed through air
preheater to heat atmospheric air before being exhausted by chimney. Preheater
applies either convention or regeneration principle.

Advantages of air preheater are as follows:

(a) Improved combustion

(b) Successful burning of low grade fuel
(c) Increased thermal efficiency
(d) Increased capacity of plants

Air preheater is of two type’s namely primary air preheater and secondary
air preheater.

Primary air preheater is an auxiliary located in the second pass of the furnace.
It is used to pre heat the air that is supplied to primary air fan. This air is
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supplied to the mills to keep the pulverised coal in dry condition i.e.it removes
the moisture content and hence avoids sticking of coal powder on the walls.

Secondary air heater is also similar in construction and function i.e. it is used
to preheat the secondary air which comes from FD fans. This whole air is
supplied to the furnace for efficient combustion of fuel.

Economizer: Economizer may be defined as a collection of tubes and heaters

which is used for heating the feed water from the feed heater pump, before it is
feed to the boiler. In this process, it poses resistance to the flow of flue gases
leaving the furnace to recover its heat and reduces their temperature. It
minimizes the consumption of fuel and increases the plant efficiency. It is
located in the second pass of the furnace, just before/above the air preheaters.
Water is approximately converted into the steam after passing through the
economizer.

Condenser: The purpose of condenser is to condense the exhaust steam from

a steam turbine into pure water, so that it is released in the steam generator or
boiler feed water. In the condenser, many tubes are provided in which water
flows continuously from the CV pump house after passing the condenser tube.
This water is reached to the CW pump house. After passing the L.P. turbine, the
steam is condensed and it is converted to water and this converted water is
stored in to hot well.

Condensate extraction pump: It is the pump driven by 6.6KV motor. It is

situated on the ground floor. It is used for sending the water from the condenser
hot well to deaerator. It increases the pressure of water as much as 27.8kh/cm2.
The 3 C.E.P. are provided in which 2 pumps are always in running condition
and one is spare.

Boiler feed pump: It is the highest pressure pump used in thermal power
plant. Its pressure is more than 150kg/cm2. The function of this pump is to
supply water at high pressure to the boiler during the startup,normal and
emergency operation. The system automatically maintains the proper flow of
water in the boiler drum to maintain its level. The boiler feed pumps must
develop the required pressure to overcome head and drum pressure.

Forced draught fan: FD fan is located prior to furnace. It forces air to flow
through furnace via preheater. This air helps in complete combustion of fuel.
 13

FD fan is an axial fan and has pitch control i.e. the pressure of the forced air is
controlled by rotating the blades of fans using oil control. FD fans are run by a 3
phase squirrel cage induction motor at 1490rpm. This A.C motor takes 6600V,
84.5A, 800KW supply. It is 94.5% efficient. Each unit has 2 FD fans.

Induced draught fans: ID fans induce a draught that helps in removal of

flue gases from the furnace. It also causes the flue gases to flow through ESP
and then out of chimney. ID fan is an axial fan made up of steel. It is driven by
3 phase squirrel cage induction motor at 744rpm. This motor uses 6600V,
138.5A, 1300KW supply and is 95.5% efficient. ID fan has Inlet Guide Vane
pressure control. Each unit has 2 ID fans.

Primary air fan: PA fan supplies primary air that carries the pulverized
coals from mills to furnace. Primary air passes to mills through 2 different
ducts. One duct carries air first to preheater and then to mills while the other
carries air directly to mills. Air through preheater is hot air while other is cold
air. Hot air helps in removal of moisture content from pulverized coal. PA fan is
a radial fan, runs at 1480rpm by an A.C. motor and has Inlet Guide Vane
control. Each unit has 2 PA fans.

Mills: Mill is very important unit of the plant. As it pulverizes the coal into the
powdered form which to be used in the furnace for production steam. Two types
of mills are used for crushing namely ball mill (used at ‘B’TPS) and bowl mill
(used at ‘A’TPS).

Ball mill uses 2.5-3 ton balls in cylindrical structure (2.5m radius) along with
coal for crushing system is rotated such that both coal and ball fall from a height
due to rotation. Air pressure from side makes powdered coal fly to furnace.

Bowl mill uses three impellers inclined at an angle of 1200 in a hemispherical

structure which on rotation grinds coal. Out of these two, ball mill has more
efficiency.

Turbine: Turbines form an important part of thermal power plant as they

convert energy of high pressure and high temperature steam into mechanical
energy. The high temperature and high pressure steam first expands in nozzles.
This reduces pressure of steam and increases its velocity. This high velocity
steam impinges upon blades of turbines forcing them to rotate. Hence the
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rotational or mechanical energy is achieved.

Fig: Turbine

The turbines may be classified as:

(a) Simple impulse turbine

(b) Reaction turbine
(c) Impulse-reaction turbine
(d) Condensing or non-condensing turbine

The specifications of turbine used in a 210MW unit are as follows:

(a) Rated power 210MW

(b) Rated steam pressure 130kg/cm2
(c) Rated steam temperature 5300C
(d) Rated steam flow 611.635 tons/hour
 15

(e) HPT exhaust pressure 25.75kg/cm2

(f) HPT exhaust temperature 3140C
(g) Type of governing Hydro-mech.
Nozzle governing
(h) Type of turbine Condensing, Tandem, Reheat, Impulse
Type
(i) No. of stages
1. H.P. cylinder 25
2. I.P. cylinder 40
3. L.P. cylinder 8×2

Turbines when allowed to run freely run at a very high speed of about
30,000rpm. This speed is not of much use and can cause damages to various
parts of assembly. Turbines when coupled to generator should not run at such
high speed. To avoid such situations, the compounding of turbines is done.

Compounding is of three types:

(a) Velocity compounding or Curtis turbine

(b) Pressure compounding or Rateau turbine
(c) Pressure-velocity compounding

The load on generator coupled to turbine may fluctuate. But the speed of
turbine must be maintained constant. This is obtained by governing turbines.
The performance of turbine depends, to a large extent, on the type of governing
done. Following methods of governing arte known:

(a) Nozzle control governing

(b) Throttle governing
(c) By-pass governing
(d) Combination of nozzle and throttle governing
(e) Combination of throttle and by-pass governing

LP turbine: The LP turbine is of auxiliary split, double shell design. A

double flow inner casing is housed in outer casing. The steam coming from the
 16

reheater is passed in to the inner casing via admission branches, which are
symmetrically arranged in the top and bottom halves of the outer casing. The
inner and outer shells are made of GS-17Cr MO V511 and GS-22MO4 steel
casting.

IP turbine: This turbine is of double flow type, triple shell welded casting.
The outer casing consists of the front and rear walls with two lateral
longitudinal support beams and upper part. The double flow inner casing is of
double shell construction. The casting (fabricated) is made up of steel st-37-2.

HP turbine: The high pressure turbine is of barrel type construction having

split inner shell, carrying the guide blades. The barrel type casing is without
any axial joint. The inner shell after assembly is supported inside the barrel
casing. Such turbines with barrel type casing are specially suitable for quick
start-up and loading. The inner and outer shell of the turbine is of GS-17Cr
MoV511 steel casting.

For power generation , various processes are carried out in power plant whose
stage wise description is as under.

(a) Water from 116kg drum is fed to superheater to form superheated steam.
(b) This steam is fed to HP turbine.
(c) After coming out of HP turbine it is fed to reheater.
(d) Steam from reheater goes to IP turbine.
(e) Steam from IP turbine goes to LP turbine for complete expansion. This
LP turbine’s output is connected to generator for power production.
(f) Steam from LP turbine is fed to condenser for cooling.
(g) Output of condenser goes to LP heaters via condenser pumps.
(h) Output from LP heaters goes to deaerator.
(i) Water from deaerator goes to HP heaters via boiler feed pumps.
(j) Output of HP heaters goes to economizer via feed water regeneration
station.
(k) Water from economizer is again fed to drum to complete cycle.

Besides this main water cycle, several other systems are also in operation
simultaneously for proper functioning of boiler system. For example, in coal
system, PA fans remove moisture from coal feed pulverized coal in boiler along
with oil for proper combustion of coal and formation of fire balls. FD fans
supply air to boiler for complete burning of coal. FD fans create positive
 17

pressure in boiler. ID fans help in removing ash from boiler via ESP by creating
negative pressure in boiler. Flue gases are excreted to chimney via ID fans. In
ESP, ash is passed through high voltage plates where it settles in form of cakes
on one plate which is further removed by hammering. After this, ash is mixed
with water to form slurry and is transported away. About total ash is
precipitated in ESP and only 0.2% is left in flue gases which is discharged in
atmosphere via chimney.
 18

Generator
In synchronous machines (generator or motor), the armature winding either
exports ac power (generator) or imports ac power (motor) whereas the field
winding is always energized from a dc source. Therefore, synchronous
machines are doubly excited energy conversion devices. An alternator may have
either rotating field poles and stationary armature or rotating armature and
stationary field poles.

But practically, for power generation, the field windings are on rotor and
armature windings are on stator due to following advantages:

(a) More economical: If high three phase current carrying armature winding is
placed on rotor, three slip rings with heavy insulation are needed whereas
for low current carrying field windings on rotor, only two slip rings with less
insulation are required.
(b) More efficient: For only two slip rings on rotor, losses in slip rings are
reduced.
(c) Better insulation: Stationary armature windings on stator may be insulated
satisfactorily for higher voltages.
(d) Efficient cooling: Stationary armature windings can be fooled more
efficiently.
(e) More output: Lower power field windings allow construction of lighter
rotor and hence permit high speed, thus increasing the output.
(f) Lesser rotor inertia: Field windings on rotor require less copper and reduce
rotor weight and hence its inertia.
(g) Rigid and convenient construction: Three phase armature windings at
stator may be more easily braced against electromotive forces when it is
placed in stator slots. In addition, water cooling of stator may be applied
more efficiently.
(h) More armature teeth strength: High current carrying armature windings
require deeper slots which are easily made on rotor. On the other hand, if
this armature winding will be at rotor, teeth will be narrower and weaker.
Strong teeth on stator lead to less noise and vibration.

For alternator, frequency of alternating current produced is given by following

equation: f=NP/120.
 19

Where ‘f’ is frequency of current generated, ‘P’ is number of poles and ‘N’ is
number of turns of coil of stator windings.

At ‘A’TPS, specifications of three phase synchronous generator used are as

below:

S.NO. PARAMETER SPECIFICATIONS

1. KW rating 210MW
2. VA rating 247MVA
3. Power factor 0.85
4. Phase 3
5. Phase connection Y-Y
6. Rated speed 3000rpm
7. Rated frequency 50hz
8. Stator voltage 15,750V
9. Stator current 9050Ampere
10. Stator coolant Water
11. Stator temperature 720C
12. Rotor voltage 310V
13. Rotor current 2600Ampere
14. Rotor coolant 97%pure H2 at 3.5kg/cm2
pressure
15. Rotor temperature 620C
16. Insulation class F
17. Make BHEL

CONSTRUCTION OF TURBOGENERATOR:
Construction of generator is essentially manufactured of component parts which
are assembled partly at manufacture’s works and partly at site. It is usual to
consider the machine in two major components:

STATOR
(a) Frame
(b) Magnet core
(c) Windings
 20

Further description of various parts of three phase synchronous generator

is as follows:

(a) Stator body: It is totally enclosed gas tight fabricated structure, suitably
ribbed internally to ensure rigidity. It is designed mechanically to withstand
internal pressure and forces as a result of unlikely event of explosion of
hydrogen air mixture without any residual deformation. Hydrogen gas
coolers are housed longitudinally inside the stator body. Rigid end shields
close the casing and support the fan shields and shaft shields. The end
shields are made in two halves in convenience during erection and
inspection. On both sides of body, foot plates are bolted for supporting
complete stator on the foundation.

(b) Stator core: The stator core is made up of insulated punching of sheet steel
with low loss factor. The stampings are assembled in an interleaved manner
on dove tailed core bars in order to damp out the oscillations so that
magnetic vibration of stator core are not transferred to foundation through
stator frame. Core bars are designed to provide elastic suspension of core in
the stator. For this purpose, slots are milled at regular intervals at support
points of core bars at circular ribs. The core consists if several pockets
separated by steel spacers for radial cooling of core by hydrogen to ensure a
tight and monolithic core, pressing the punching are effected in several
steps and when completely built, core is held in pressed condition by means
of rotary, non-magnetic steel press rings which are bolted to the end of core
bars. Additional support is provided to the teeth portion by means of non-
magnetic steel fingers held between the core and press rings. The press
rings are tapered on the face towards the core so that an even pressure is
applied over the end surfaces of the core when core bars are tightened. The
end zone heating is reduced by copper screens provided between the end
packets and press rings.

(c) Stator windings: Stator bars, bus bars and terminal bushings are designed
for direct water cooling. In order to minimize the eddy current losses, the
bars are composed of insulated strands, both solid as well as hollow which
are transposed by 3600 in the slot portion.
 21

The high voltage insulation is provided by thermosetting insulation using

epoxy mica paper tape (resin rich). With this insulation system, several layers
of this tape are applied to the formed bars continuously and half overlapped.
The number of layers i.e. the thickness of the insulation depends upon the
machine voltage. The bars are then pressed in a mould at fixed temperature.
The high voltage insulation obtained is characterized by excellent electrical,
mechanical and thermal properties. The insulation is also water proof and oil
resistant. To prevent corona discharge between insulation and slot wall, a final
coat of semiconductor varnish is applied to the surface of all bars within the
slot portion. All bars are additionally coated with stress grading varnish at
bends to avoid end corona, to control the electric field at the transition from
slot to the end winding and to prevent the creep age sparks. For protection
stator winding against the effect of current forces in slots, side fillers, bottom
spacers and top spacers below the slot wedge ensure permanently firm seating
of the bars in the slots during operation. The overhang portions of the coils are
securely lashed with turbine cord to bandage rings.

The stator bars are joined at each end electrically by brazing top and bottom
bars. The stator winding is connected inside the machine by connecting
bushings bars and brought out to nine bushing located in the box of welded non
–magnetic steel below the generator at excitation end.

ROTOR
(a) Rotor shaft: The rotor shaft is a single piece forging manufactured from
ignots which are cast by vacuum deposing process. The longitudinal slots
for insertion of field windings are milled into barrel portion. The slots are
distributed over the circumference so that two solid poles are obtained. To
ensure that only high quality and defect free forging are used, strength test,
chemical analysis, and ultrasonic tests are carried out during manufacture.
After completion of rotor assembly, the rotor is balanced at different speeds
in various planes and then subjected to an over speed test at 120% of rated
speed for two minutes.
(b) Rotor windings and retaining rings: The rotor winding comprises of
several coils which are inserted into the slots and series connected in such a
way that two coil groups enclosing one pole each are obtained. Each coil
consists of several series connected turns comprising two half turns each
 22

which are connected by brazing to the end winding portion. The slot wedges
consists of well conducting duralumin and are in contact with damper
segments at the ends which are silver plated and extended below the
retaining rings. The centrifugal portion it the rotor overhang windings are
taken up by single piece retaining rings. The retaining rings consist if non-
magnetic high strength steel in order to reduce stray losses. The retaining
rings with shrink fitted centering ring are shrunk on to rotor body in floating
position. Each retaining ring is secured in axial direction by a nut which is
threaded and then screwed on retaining ring in final position.
(c) Field connections: The field connection is supplied to the rotor windings
through two semi-circular copper bars arranged in the hollow bars of rotor.
(d) Bearings: The generator bearing are pedestal type with spherical seating to
allow self-alignment and are supported on a separate pedestal on slip ring
side and in LP casing on turbine side. The bearings have provision of
hydraulic shaft lifting during start-up and turning over operation.
(e) Shaft seals: In order to prevent the escape of hydrogen from the generator
casing along the rotor shaft, shaft seals supplied with oil under pressure are
used. The points where the rotor shaft emerges out of the stator casing are
provided with radial type seal rings. The seal ring is guided into the seal
ring carrier which id bolted on to stator and shield. The seal ring is lined
white metal on the bore. The shaft seal is provided with seal oil by a
separate closed circuit system. To ensure free movement of seal ring, the
shaft seals are provided with pressure oil for ring relief from governing oil
system through governing oil filter. In order to prevent the circulation of
shaft currents, the seal body and oil pipelines connection on the exciter side
are insulated from earth.
 23

Excitation system
1. Excitation power from generator via excitation transformer and
converter to rotor through field breaker.
2. Excitation built up from battery/aux mains, and automatically
disconnected when 70% generator voltage achieved.
3. Converter is split into several groups/blocks each block has its own pulse
output stage cooling fan and monitoring system. Failure of one block
gives alarm without interrupting normal operation. Failure of 2nd block
causes limitation to output/disconnection.
4. Voltage is connected by two channels.
In automatic channel having voltage regulator UN 2010, voltage value is
processed and compared with reference value. PID amplifiers in AVR
with adjustable gain and time constant permit to stabilize control circuit
easily.
Four limiters operate in parallel to the voltage regulator:
(A) Excitation current limiter UN1024 prevents thermal overloading of
rotor by lowering output value of voltage regulator with a delay and
thus the field current.
(B) Effect of load angle limiter UN1043 is reverse, since it increases
field voltage instantaneously for increased excitation, thus preventing
generator from falling out of step.
5. Measuring transducer UN0022 under excitation regulator XZ9302
wherever provided, works for second load angle. Stator current limiters
UN0093, UN0027 effect increase/decrease of field voltage depending
upon over or under excited operation and limit stator current.
6. Supplementary signal acting on AVR is supplied from stabilizer
equipment. Later serves to dampen active power oscillations.
7. Gate control set 1001 with subsequent line driver 0082 and intermediate
pulse-stage 0096 is duplicated for both auto and manual channels. In
manual channel, it is directly controlled from a digital reference value
unit whereas in auto, it is controlled by AVR.
8. Manual channel should be used only when auto channel fails or in
emergency.
9. Since redundancy is fully effective only if monitored, pulse monitor
0053 is connected to output of gate control set in both channels. If pulse
failure is recorded by 0053 of auto, automatic transfer of manual channel
 24

occurs. If failure of manual channel is recorded, alarm gets initiated in

control room.
10.To avoid surges on changeover, pulse position of both channels is
compared in ‘Pulse comparing stage 0040’ for manual channel follow
up. Matching is effected with a follow up control device with 0016 and
0510 directly acting of manual potentiometer.
11.Each converter block has its own pulse final output stage 0097. Here
they are further amplified for firing thyristors. To one block fails, pulses
are blocked in corresponding final stage. Power supply from AC/DC
converters and from station battery in case of DC/DC converter supply.
These are two supplies to both auto and manual channels. Besides this
each pulse final output stage is provided with its own power pack 0098.
12.Control and protection are supplied from station battery as well as from
station AC aux supply. Over voltage protection in the field circuit is
provided.
Protection of excitation transformer is by:
(a) Over current relay CTU62 with instant trip
(b) Over current relay CTU62 with delayed trip
(c) Temperature monitoring unit
 25

Hydrogen gas system

Hydrogen is used as cooling medium in large capacity generators in

view of its high heat carrying capacity and low density. Hydrogen
becomes highly explosive with certain proportions of air and hence
requires an elaborate arrangement for filling, purging and maintaining
it inside the generator.
The gas system is designed to carry out following functions:
(a) Filling and purging of hydrogen safely without bringing it in
contact with air.
(b) Maintaining gas pressure inside the machine at desired value at
all times.
(c) Indicating to operator at all times the condition of gas inside the
machine i.e. its pressure, temperature and purity.
(d) Continuous circulation of gas inside the machine through gas
driers in order to remove moisture.
(e) Indication of presence of liquid in generator housing.

Fig:- Hydrogen gas system

In hydrogen gas cooling system, the system draws gas supply from
hydrogen and carbon dioxide manifolds situated at a convenient
location at ground floor of the power station. The supply from the
 26

hydrogen manifold is connected to the generator bottom by suitable

piping which is further taken to the distribution header situated at the
top through a built in pipe inside the generator. The hydrogen is
filled into the generator casing from the top so that impure mixture of
hydrogen and carbon dioxide is discharged from the bottom. The
carbon dioxide is fed to the bottom of the generator casing and is
admitted into the generator from a number of points to have
extensive spread inside the machine. This arrangement is adopted so
that impure mixture with air or hydrogen is discharged from the top
of generator casing.

The piping is connected in such a way that during filling by carbon

dioxide, the air inside the casing escapes through the connection
from the top distribution header and air/hydrogen discharge valve to
atmosphere. Similarly when hydrogen is being filled, the carbon
dioxide will escape from the bottom of the generator through carbon
dioxide discharge valve to atmosphere. Two hydrogen driers are
provided to facilitate the removal of moisture if any from the
hydrogen by circulating it through the driers continuously and thus
maintaining hydrogen gas in desired dry condition. The circulation
through the driers is effected by the differential pressure of the fan
(turbine side) across which the drier is connected.

To detect presence of water/oil inside the generator casing and also

in two ends shields, liquid leakage detectors are provided in the drain
pipelines which are further connected to alarm circuit. In this way
safe operation of hydrogen gas system is ensured.
 27

Seal oil system

General description: Generator shaft seals are supplied with pressurized oil
to prevent escape of hydrogen at the shaft from where it comes out of the stator
and ingress of air into the generator. As long as the seal oil pressure in the
annular gap exceeds the gas pressure in the generator, no hydrogen will escape
from the generator housing. The shaft seals are supplied with required seal oil
from an exclusive closed loop oil circuit. The oil in seal oil system is same as
that used in the turbine/turbogenerator bearings and the turbine governing
system.

Most of the components of seal oil system are mounted on seal oil unit except
pre-chambers and seal oil storage tank which forms part of drain circuit. The
seal oil in seal oil tank is kept under vacuum to prevent deterioration of the
hydrogen purity in generator housing. The gases entrapped in oil are thus
removed so that the seal oil pumps draw only degassed oil.

To ensure the free floating condition of seal oil ring in seal body at high
machine gas pressures, the shaft seals are provided with ring relief oil. Supply
for ring relief oil is obtained from governing oil supply line through a simplex
filter and is admitted on the side of both shaft seals.
 28

Fig:- seal oil system

Components of seal oil system

(a) Main seal oil tank
(b) Seal oil pumps (1 ac and 1 dc)
(c) Two differential pressure regulators A and B
(d) Two seal oil coolers
(e) Two seal oil rings at both ends of rotor
(f) Intermediate oil storage tank
(g) Seal oil storage tank (SOST)
(h) Pre-chambers
(i) Seal oil vacuum pump

Seal oil pumps: For oil circulation, two screw type pumps are provided. In
the event of failure of AC seal oil pump in service due to mechanical or
electrical fault, the standby DC seal oil pump automatically takes over. It both
the pumps fail, the seal oil supply is taken over by turbine governing oil system
without any interruption. The additional backup with the turbine governing oil
system provides for increased reliability because all the safeguards to maintain a
constant turbine governing oil supply are available.

Differential pressure regulating valve “A”: A positive differential

pressure is required to ensure proper seaking of generator. With the seal oil
pumps in operation, the seal oil pressure is regulated by differential pressure
valve. Depending on the valve setting and the differential pressure required, a
larger or smaller amount of oil is returned to the seal oil tank so that the
required seal oil pressure is available at the shaft seals.

Seal oil coolers: The two seal oil coolers are each of full capacity. One is
always in operation, while the second one serves as standby. The seal oil flow
can be changed over from one cooler to other by means of valves provided at
their inlet and outlet ends.

Duplex filters: The seal oil filter is provided immediately after coolers. The
filters have fine mesh which prevent clogging and damage at shaft seals by
foreign particles entrained in the oil. By connecting two separate filters in
parallel, one of the filters can always be maintained in operation, supplying
filtered oil to the shaft seals. The changeover valve assembly at the filters
allows one filter to be taken out of service for cleaning without of oil flow.
 29

Prechambers: The oil drained from the hydrogen side of the shaft seals is
discharged into the generator prechambers. The prechambers receive the oil
flows which permit the escape of entrained gas bubbles and defoaming of the
oil. Downstream of the prechambers, the oil flow are combined and passed
through the intermediate oil tank. A float valve leeps the oil level in the tank at
a pre-determined level and it acts as a hydraulic seals by forming gas barrier,
prevents the ingress of hydrogen into seal oil tank. The oil from the intermediate
oil tank is returned into the seal oil tank together with the oil drained from the
air side of the shaft seals via a float valve. If an excessive amount of oil is
supplied to the seal oil tank a float valve allows some oil to return to the seal oil
storage tank.

Vacuum pump: The seal oil tank is evacuated by a rotary vacuum pump.
The vacuum pump should be in operation as long as the seal oil pump is
delivering oil.

Differential pressure regulating valve “B”: In case of emergency i.e.

failure of pumps, the shaft seals are supplied with oil from turbine governing oil
system in system in which non-degassed turbine oil is fed to the shaft seal. In
this case, a slow deterioration of hydrogen purity in the generator will take
place, necessitating the scavenging of hydrogen to improve its purity.

The small amount of hydrogen escaping from the generator together with the oil
does not present a danger to the generator surroundings, since the seal oil
storage tank is provided with an extractor to ensure continuous venting of the
tank. If the shaft seals are supplied with seal oil from turbine governing oil
supply, the supply oil pressure is controlled by differential pressure valve B.
Except for the valve seats and valve cone, the B valve is of the same design as
the A valve. The valve cone is arranged so that the valve opens for a downward
movement of the valve steam (occurring at falling oil pressure in the oil circuit).

Annunciation provided: The following annunciation are provided on the

instrumentation and signalling panel-

1. Level in the prechamber exciter end/turbine end (HIGH)

2. Level in intermediate oil tank (LOW)
3. Level in seal oil tank (HIGH AND LOW)
4. AC seal oil pump running
5. Vacuum in seal oil tank (LOW)
 30

6. Reserve seal oil pump running

7. Temperature of seal oil (HIGH)
8. Pressure of seal oil exciter end/turbine end (LOW)
9. Level of oil in seal oil storage (SOST) tank (LOW)
10. Automatic switching on of DC emergency oil pump
11. Power/control supply failure of AC seal oil pump motor
12. Power/control supply failure of DC seal oil pump motor
13. 240V AC instrumentation supply (FAILED)
14. Main/reserve seal oil pump (RUNNING/OVERLOAD)
15. Differential pressure of seal oil and hydrogen (HIGH AND LOW)
16. DC annunciation supply (FAILED)

Operation: Operation of seal oil system is described step by step as below:

(a) Oil from main seal oil tank flows through ac pump (normally) or dc pump
(in case of failure of ac pump).
(b) Oil from pumps goes to either of the coolers.
(c) Oil after passing through the coolers divides into 2 parts: turbine end and
excitation end.
(d) Oil from both the ends goes to rings and divides into 2 parts.
(e) One third of oil goes to hydrogen side and two third goes to air side.
(f) Oil from hydrogen is passed through pre chambers for defoaming and
escaping of entrapped gasses and is further flown to intermediate tank.
(g) Oil from intermediate tank flows to main oil tank together with oil from
air side.
(h) In case of failure of both the pumps, governing oil system takes control of
seal oil system through differential pressure regulator B.
(i) Both differential pressure regulators A and B are operated by gas
pressure.
 31

Technical data of seal oil system is tabulated under as:

S. No. Particulars Minimum Normal Maximum Unit

value value value
1. Type of shaft seals Single flowing ring type
2. Hydrogen pressure 3.3 3.5 3.7 Kg/cm2
3. Seal oil/hydrogen 1.0 1.5 1.7 Kg/cm2
differential pressure
0
4. Seal oil temperature at - 40 45 c
inlet
5. Quantity of seal oil - 38.5 - L/min
6. Quantity of seal oil Two third
flowing towards air
side
7. Quantity of seal oil One third
flowing towards
hydrogen side
8. Pressure of ring relief 0.5 Kg/cm2
oil above seal oil
9. Pressure of oil from 7.5 Kg/cm2
governing oil system
 32

Stator water cooling system

General Description: Stator water cooling system is used for

200MW/210MW/235MW machines. In this system, there is closed loop
circulation of demineralised water. Stator windings consist of both solid and
hollow conductors. Heat losses occur in stator windings, main terminal bushings
and phase connectors. Water is in direct contact with HV windings. Electrical
conductivity of cooling water is maintained below 2.5 µ mho/cm.

Water used is free from oxygen and may be distilled water, fully demineralised
water from boiler feed water treatment plant or condensate. Fully demineralised
water and condensate may only be used if no chemicals such as ammonia,
hydrazine, phosphates etc are present in water or condensate.

Heat of demineralised water is dissipated to secondary coolant in primary water

cooler.

Part of water is bypassed and treated in ion exchanger in parallel to stator

winding, magnetic filter and expansion tank and returned to suction side of
water pump to maintain electrical conductivity.

Base substance of exchanger resins are normally polymers containing groups of

diverse character featuring exchange activity. The cation exchanger contains
highly acidic groups while anion exchanger contains highly basic groups. The
exchanger resins are thus capable of accepting ions from DM water while
releasing equivalent amount of other ions (hydrogen ion from cation and
hydroxyl ions from anion exchanger). This exchange can take place between
equally charged ions. Therefore cation exchanger exchanges cation and anion
exchanger exchanges anion. This process takes place within a very short time
while DM water is passed through ion exchanger.

A combination of highly acidic cation exchanger and highly basic anion

exchanger constitutes a multitude of small demineralisation units resulting in a
high purity deionate.

The mechanical filters eliminate any foreign particles which may coke or erode
the hollow conductors. Difference of pressure at inlet and outlet of filter is
indicative of the degree of choking. The choked filter may be cleaned after
 33

using the standby without affecting the working of system. The magnetic filter
prevents any magnetic particle from entering the generator.

The water from the outlet of stator winding gets collected in an overhead
expansion tank which provides a constant level of water during normal
operation of the system. The hot water enters the tank through perforated pipe in
the form of spray and thus releasing any entrapped gas. A water jet ejector is
connected to expansion tank for creating vacuum for the purpose of removing
any traces of oxygen/hydrogen gas which may be present as a hydrogen leakage
into DM water stream. Level signalling device provided in expansion tank
monitors the level of distilled water and initiates a tripping command at low
level for stator water pump.

The quality of DM water flowing through the windings is measured by a system

of orifice plates, flow transducers, flow indicator and recorder. Signalling
contacts are available in flow switch, indicator and recorder which are set to
annunciate at low flow through the windings and initiates tripping of machine at
emergency flow on the principle of two out of three. Continuous monitoring of
conductivity of water is done by conductivity cell and suitable indicator and
recorder which annunciate alarm at high set value of conductivity. At very high
conductivity, the unit is tripped automatically.

In addition to above, the system is also provided with necessary instrumentation

for indicating/signalling of temperature and pressure at various points of the
system. Pressure interlocking of pumps is also provided.
 34

Fig:- stator water cooling system

Components of stator water cooling system

A. Centrifugal pumps(2×100% duty)
B. Distilled water coolers(2×100% duty)
C. Polishing unit
D. Mechanical filters(2×100% duty)
E. Magnetic filters(2×100% duty)
F. Gas trap device
G. Expansion tank
H. Control valves

Stator water pump: To ensure the continuous generator operation without any
interruption, two full capacity pumps are provided. Both pumps have equal
priority and are alternatively brought into operation. A changeover is possible at
any time without interruption. The standby pump is kept ready for service and is
automatically started in the event of failure of stator water supply which results
in fall of pressure below the set value in pressure switch installed in the circuit.

Stator water pumps are of single stage centrifugal type with spiral casing and
overhung impeller. The pumps suction is arranged in axial direction while the
discharge is directed radially upward. The spiral casing of the pumps is joined
to the bearing housing through a flange. The pumps impeller and the spiral
 35

casing are of stainless steel construction. The point where the pump shaft passes
through the pump casing is sealed by means of mechanical seals. The pump
shaft is supported in oil lubricated antifriction bearing. The pump is connected
to three phase 415V AC motor by a flexible coupling. Normally, the pump
motor set is installed at the zero meter level of power station.

Water cooler: The stator water cooler is a shell and tube type heat exchanger
suitable for vertical mounting in which DM water flows through the shell. The
shell is made up of magnetic stainless steel. Cooling water flows through the
tubes. Tubes are made up of copper/admirality brass. To have effective heat
transfer between the coolant and the cooled water, baffles made of brass are
provided across the tube nest to guide the water to be cooled in zig zag fashion.
The cooling water is led in and out of the cooler from the flanges provided at
the bottom of the cooler. Four thermometers are provided to serve the following
purposes:

(a) One thermometer each at inlet and outlet of cooled primary water to
measure inlet and outlet temperature.
(b) One thermometer each at inlet and outlet of secondary cooling water to
measure inlet and other outlet temperature.

Stator water filter (mechanical): The filter consists of cylindrical body

having separate inlet and outlet chambers. A perforated cylindrical body having
holes all along its length and periphery is surrounded by an assembly of 45
filter elements. The filter elements are kept in position by a helical spring which
is kept pressed by the cover. The filter elements consists of sound corrugated
brass sheet with a central hole and two sizes of wire mesh apertures, 0.224 mm
and 0.5 mm held in same assembly by the inner and outer brass rings.

Body cover and perforated cylinder is made up of stainless steel and filtering
element is made up of brass. Water enters first in filtering element and after this
goes to perforated cylinder from where it flows to the outlet chambers.
Mechanical impurities get collected on the wire meshes as the liquid passes
through the mesh holes from the inlet chamber to the delivery chamber through
the perforated cylinder. The filter is provided with nets and drain plugs. The
normal pressure drop across the filter corresponding to the rated flow is of the
order of the 0.1-0.2kg/cm2. As the particles get deposited on the wire meshes,
the resistance to flow increases and consequently pressure drop across the water
 36

filter increases. When the pressure drop increases to 0.4kg/cm2, cleaning is

recommended.

Stator water filter (magnetic): the magnetic filter is of permanent magnet

type designed to trap ferromagnetic particles, if present in the water system.
The capacity of the magnetic filter is 36 m3/hr. Maximum strength of magnetic
field in the circular air gap is of order of 4000 gauss.

The filter mainly consists of an upper and a lower body housing the permanent
magnet system comprising of magnets, pole does and pole rings.

The demineralised water before entering the windings passes through the
magnetic filter where it successively passes through two annular air gaps in
which ferromagnetic particles are filtered out because the latter are attracted to
the pole shoes and pole ring points in the zone of high magnetic field strength.

The filter is installed in the vertical position and is connected to the

corresponding piping flanges by means of bolts.

Expansion tank: The expansion tank is a hermetically sealed container

made of stainless steel. The DM water from the stator winding outlet header
discharges in to a section of tank through a perforated pipe. The tank is under a
vacuum of 250-300 mm of mercury under the influence of water jet ejector. In
the process of spraying under vacuum, the entrapped air/gas in the DM water
entering the tank, if any gets liberated and ejected out. The tank is provided
with a makeup connection from the power station DM water source. The inlet
of makeup connection to the tank is controlled by means of a float operated
level regulator which opens or closes depending on the level in the tank.

The stator water pumps draw water from the bottom of the tank for
recirculation. The tank is provided with the following instrument/components:

 A gauge glass to indicate the level of water in the tank.

 2 transducers for level signalling device to give high and low level alarm
signals.
 A vacuum gauge to indicate vacuum inside the tank.
 A float operated level regulator to regulate the makeup water.
 A drain valve to facilitate draining of the complete tank in case of
necessity.
 37

Flow measuring devices: In order to measure the flow of stator water,

orifice plate and 2 flow transducers are coupled to a suitable recorder. Also an
indicating type flow switch of proven design is provided for monitoring the low
flow in the stator windings.

Conductivity measuring devices: In order to measure the purity of stator

water in terms of conductivity, a conductivity measuring device is provided on
the pipeline. In case the conductivity increases above 13.6 mho/cm, alarm signal
appears and purity of water is improved by draining the impure water. In case
the conductivity still increases and reaches to 20 mho/cm, the tripping contacts
are provided for automatic tripping of the machine. Tripping is on the principle
of one out of 2 protection systems for which 2 conductivity measuring devices
are provided.

Temperature measuring devices: The temperature of stator water at the

inlet and outlet of stator winding is measured by means of resistance
thermometers installed on the water pipelines and these points are taken to the
generator temperature recorder. In addition, temperature switches are also
provided to give signals for high temperature.

Gas trap device: To monitor the leakage of hydrogen into the stator water, a
GAS TRAP has been provided in the stator water circuit.

Signalling and instrumentation panels: Two local panels are provided

for stator water system designed as signalling and instrumentation panels and
starting panel. Signalling and instrumentation panel houses necessary signals for
this system and is equipped with facia windows, power suppliers, accept-reset
test push buttons, hooter, flashers etc for annunciation. Starting panel is
provided with all the necessary controls for signalling and interlocking of stator
water pump motors. It is also provided with selection facility for trying with
UCB. Whenever tripping of the generator is recommended, two or three
separate sensors are provided so that the tripping is on the principle of one out
of two or two out of three protection systems.

Annunciation provided:
 Water level in the expansion tank (LOW)
 Water level in the expansion tank (HIGH)
 Temperature of cooling water at the inlet of stator winding (HIGH)
 38

 Temperature of cooling water at the outlet of stator winding (HIGH)

 Stator water flow (LOW/EMERGENCY)
 Stator water conductivity (HIGH/VERY HIGH)
 Stator water pressure (LOW)
 Power/control supply for stator water cooling pump A/B (RATED)
 240 V AC instrumentation supply (FAILED)

Working of stator water system (With reference to flow chart)

 To drive the pump, induction motor should start. Induction motor will
start when respective contactor (such as 4C for pump A and 5C for pump
B) will pick up.
 Contactor 5C would pick up when relays 26 R and 10 TR would pick up.
 Relay 26 R may be picked up in 3 ways- REMOTR STARTING (first
path through relay 37 R which is set for desired level of water in
expansion tank below which would not allow motor to start) from control
room, AUTOMATIC STARTING of pump B subjected to tripping of
main pump A (due to interlocking of both pumps i.e. contactor 4C opens)
or through relay 33 R which is set at low pressure in downstream line of
stator water cooling system due to decoupling of pump A and LOCAL
STARTING (on local panel).
 Relay 10 TR would pick up when relay 25 R would pick up.
 Relay 25 R is in the motor heating circuit through 11 TR. It would not
pick up when motor temperature is beyond the set value.
 Apart from starting circuit relay 26 R is also a part of tripping circuit
through relay 11 TR which is in turn temperature controlled.
 Motor stopping may also lead to 3 cases- REMOTE STOPPING (first
path) from control room, LOCAL STOPPING (on local panel) and
STARTING OF ADJACENT PUMP MOTOR in case of emergency.
 Apart from starting and tripping circuit discussed above, system is also
provided with several other controls such as voltage check relay, motor
trip multiplier, current measuring circuit, thermal overload relay, switch
fuse unit etc.
 39

Generator and transformer protection

General description: Generators are designed to run at a high load factor

for a large number of years and to permit certain incidences of abnormal
working. Normal service conditions are supervised by sensitive direct action
temperature detectors in order to prevent high working temperature which
would result in early ageing of insulating materials. In addition, mechanically
actuated devices are installed to detect vibrations, low pressure of lubricating oil
or failure of cooling media i.e. stator water and hydrogen. Further, transient
voltages or voltage surges are limited by lightening arrestors and surge
capacitors.

Abnormal conditions with internal or external faults are dealt with by protective
relays which are installed to provide high speed primary protection and delayed
selective backup protections. The requirements with regards to the inclusion of
various types of protective relays are not laid down in any internationally agreed
standard specifications. So called common standard practice may therefore vary
on certain points between different countries and also between different power
interpretations of fault statistics. However, it is commonly agreed that over
protecting a machine to give 100% security should not be pursued since the
inclusion of additional apparatus also increases the risk of possible failure.

By properly designing the protective system, the danger to personnel, the

damage at the point fault and the time taken to return a machine to service
reduces to minimum.

The large generators which require step up transformers are in majority of

cases, equipped with a neutral point resistor which provides an earth fault
current of 5 to 15 amperes in order to minimise burning of the core laminations.
The neutral of the generator system should not be isolated from earth because it
may give rise to excessive transient over voltage during earth faults (arcing
grounds). In case of generator transformer unit, stray voltage will appear at
generator neutral during earth fault in the HV network. This is due to the
capacitive coupling between the HV and LV windings of step up transformer.
The magnitude of stray voltage depends upon:-
 40

 Method of neutral earthling of HV network i.e. effectively earth end or

reactance earthed.
 Inter winding capacitance of step up transformer.
 The holmic value of generator neutral earthing resistor.

When the HV system is directly earthed, the voltage across the generating
earthing resistor during the HV earth fault will be small and can be disregarded.
However, if the HV network is reactance earthed (Peterson coil earthed), the
neutral displacement voltage of the generator can reach the normal setting of the
earth fault. This displacement voltage can be reduced or controlled by
decreasing the ohmic value of generator earthing resistor.

Earth fault normally occurs in armature slots. The damage at the point of fault is
directly related to the selected current rating of the neutral earthing resistor.
With fault current less than 20 amperes, negligible burning of iron core will
result if the machine is tripped with seconds.

If, however, earthing resistor is selected to pass a much higher earth fault
current i.e. more than 200 amperes, severe burning of the stator core will take
place necessitating restacking of laminations. Even when a high speed earth
fault differential protection is provided, severe damage may be caused due to
large time constant of field circuit and the relatively long time required to
completely suppress field flux.

Various types of protection systems used in generator are as follows:

Differential protection: Differential protection operates on the principle of

comparison of difference of input current and output current of a protected
zone. For this, one current transformer is provided at the input point and the
other current transformer at the output point of the protected zone and
difference of secondary currents of CTs are compared. One current sensing
relay is provided to sense differential current. This principle is used at ATP in
following protections.

(a) Generator differential protection

(b) Overall differential protection
(c) Unit auxiliary transformer differential protection
 41

Negative sequence protection: The currents in a three phase machine are

normally balanced but if a fault occurs on the supplied or supplying system, this
balance is disturbed. Single phase fault, two phase fault, phase rupture or
asymmetrical loading on the system can give rise to unbalanced current, hence
negative sequence. These current generate opposite rotation in machine stator.
Relative to the rotor, stator field therefore, rotates at double the power system
frequency and generate eddy current in the rotor. High frequency of this eddy
current causes heating of outer part of the rotor and winding. If the negative
sequence current is of high magnitude or if its persists for longer period of time,
rotor parts may be damaged due to overheating. At ATP, for negative sequence
protection, RARIB relay of ASEA make it provided which is a very sensitive
and high speed relay.

Inter turn fault: Inter turn fault are short circuits between the turns of coil
which may occur if the stator winding is made up of multi turn coils. Such fault
may develop owing to high current surges with a steep wave which may cause a
high voltage across the turns at the entrance of stator winding. At ATP, stator
coils are split into two equal parts and differential current protection is used to
know may inter turn fault.

Motoring protection: Motoring of a generator will occur if the driving

torque of a prime mover is reduced below the total losses of the generator unit.
Active power will be drawn from the network in order to maintain the
synchronous speed of the machine. If this is allowed to persist more than 10 sec,
serious overheating of the steam turbine blade may occur and machine may be
damaged. At ATP, for this purpose, an electro mechanical relay is provided
which is a directional power relay to sense any power reversal and actuate.

0-95% stator earth fault (protection by open delta method): In a

balanced three phase system connected in delta, zero voltage is obtained across
the open delta. If there is fault in any one or more phase, the voltage across the
open delta will appear which is sensed by voltage relay. This method is
employed in protective stator winding earth fault. At ATP, ASEA make voltage
relay is provided.

100% stator earth fault protection: Recently ASEA has developed a

very sensitive and high speed relay named RAGEA (used at ATP) to protect
100% stator winding from the earth fault. The principle employed is as follows:
 42

The relay consists of two voltage measuring relay with associated filtering
components and supervising relay factory wired as a unit. A ground fault
anywhere in the protected zone causes a significant change in measured voltage
in machine neutral. For the majority of the fault, the fundamental frequency
voltage will increase on neutral during a ground fault. But for windings faults
within about 5% of the neutral, the fundamental frequency voltage does not
increase sufficient to make a fault determination. However, fault in this area
cause the third harmonic voltage to change appreciably. Typically, a machine in
service will generate from 1% to 10% third harmonic voltage and about half of
this appears on neutral bus. A fault in neutral of the machine will reduce this
voltage to near zero. The 95 to 100% ground relay measure this reduction in
third harmonic voltage so as to identify faults in the area not protected by 0 to
95% conventional protection.

Relay filters reject the unwanted frequencies so as to provide substantial overlap

of the responsive fault area of two relay which comprises of RAGEA. When the
machine is out of service, 95 to 100% relay which measures the lack of third
harmonic voltage on the neutral will close its contacts. To protect this from
creating unnecessary alarm, this relay is monitored by a machining voltage pr
current relay which completes the alarm circuit only when the machine is
generating sufficient voltage for the ground fault protective system to function.

Loss of field/excitation protection: A complete loss of field excitation

may be obtained as a result of a fault in AVR equipment and open circuit or
short circuit in the main field. A reduced excitation causing excessive heating at
the end region of the stator core may be obtained during normal system
conditions when there is continuous tendency of increasing system voltage
(dropping to reactive VA). In that case, the normal AVR action will be to
reduce the field excitation. Reducing field excitation too much will ultimately
cause a loaded generator to fall out of synchronism. At ATP, for this protection,
ASEA has provided a solid state protection scheme RAGPC. This system
consists of a directional over current relay which senses the loss of excitation.

Generator pole slipping protection: At ATP, an electromagnetic relay is

used to protect the synchronous generators against the effect of pole slipping
caused by excessive load or insufficient field excitation. Pole slipping results in
generator slowing down and loss of synchronism.
 43

Generator back up impedance protection: This protection is provided

mainly as a backup short circuit protection to the differential protection of the
generators and to the line protection of the transmission system network. It is
used for generators with static excitation system which have strongly decreasing
over current characteristics compared to generators with a rotating excitation
system. The protection must be able to operate when the fault current is lower
than the rated current and in event of close-up faults when the output voltage
disappears. Conventional time lag over current relays does not operate for this
type of fault but the relays which measure impedance operate. At ATP, ASEA
make solid state circular impedance characteristics RAKZA relay is used which
operates even at 20% of rated current at generator voltage.

Overvoltage protection: If there is a sudden load throw off due to tripping

of generator circuit breaker or tripping of any outgoing feeder of switch gear
while the machine is running at full load and rated power factor, the subsequent
in terminal voltage will be limited by a quick acting automatic voltage
regulator. If the AVR is faulty or at this particular time, switched for manual
control of the voltage level, severe over voltage will occur. This voltage rise
will be further increased if over speeding occurs due to slow acting turbine
governor.

There is another case of over voltage. If the generating units have static
excitation system, the excitation is regulated to the generator through the PT
secondary. To protect the PTs from internal faults of PTs, miniature circuit
breakers are provided in the secondary of PTs. To due to any reason, the MCB
of PT connected to AVR trips, the AVR will sense the low excitation and will
try to increase the generating voltage of the machine resulting into over voltage.
Over voltage protection normally comprises of one over voltage relay with a
high resetting ratio and one definite time lag relay.

Voltage balance protection: At 3×210 MW ATP, four sets of potential

transformers are provided in each unit. If any of the PT becomes faulty, the
protection will operate and an alarm will appear for rectification of faulty PT.

Over flux (excitation) protection: When power transformers are over

excited, the leakage flow increases and this results in heavy hysteresis and eddy
current losses in non-laminated parts of the transformer. If the temperature rise
due to these losses is excessive, the insulation can be damaged and flash over’s
may occur.
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Protection system discussed above is depicted in the adjoining flow chart with
their appropriate locations.