PRESENTATION ON

TURBOGENERATORS

03/27/2021 Gyanendra Sharma, NPTI Delhi

 GENERATOR MODULES TYPES MANUFACTURED AT
HARIDWAR
VARIANTS
# TARI - TURBOGENERATOR (SIEMENS DESIGN) 108/36 -115 MW
AIR COOLED 108/41- 130 MW
RADIAL COOLED ROTOR WINDING 108/46- 155 MW
INDIRECTLY COOLED STATOR WINDING

108/44
210/250/270MW

# THRI - TURBOGENERATOR (SIEMENS DESIGN)

HYDROGEN COOLED
RADIAL COOLED ROTOR WINDING
INDIRECTLY COOLED STATOR WINDING

03/27/2021 Gyanendra Sharma, NPTI Delhi

 GENERATOR MODULES TYPES MANUFACTURED AT
HARIDWAR
VARIANTS

115/59
# THDF – TURBOGENERATOR (SIEMENS DESIGN) 500/560 MW
HYDROGEN COOLED
DIRECTLY COOLED ROTOR WINDING
FLUID (WATER) COOLED STATOR WINDING

THW-210-2
THW-210-2A
THW-210-2B
THW-235-2
# THW - TURBOGENERATOR (RUSSIAN DESIGN)
HYDROGEN COOLED
WATER COOLED STATOR WINDING

03/27/2021 Gyanendra Sharma, NPTI Delhi

 STATUS OF SETS MANUFACTURED/ SUPPLIED

RATING TYPE OF ORDERS SETS

MW TG RECEIVED SUPPLIED
500 MW THDF 64 37
210/250 MW THRI 75 55
80/120/140/160 TARI 19 17
MW
200 / 210/ 235 THW 125 125
MW
100 MW THH 6 6

03/27/2021 Gyanendra Sharma, NPTI Delhi

 MW range of Generator
210MW 500MW 600MW 800MW 1000MW

Water Cooled
(THDF)

100MW 270MW 350MW

Hydrogen
Cooled
(THRI)

80 MW 160 MW 240MW
Air
Cooled
(TARI)

80 MW DESIRED MW CAPACITIES 1000 MW

Already manufactured Awaiting Orders

Future Ratings
03/27/2021 Gyanendra Sharma, NPTI Delhi
 GENERAL VIEW OF 500 MW TURBOGENERATOR

03/27/2021 Gyanendra Sharma, NPTI Delhi

 GENERAL VIEW OF 500 MW TURBOGENERATOR

03/27/2021 Gyanendra Sharma, NPTI Delhi

 GENERAL VIEW OF TURBOGENERATOR

03/27/2021 Gyanendra Sharma, NPTI Delhi

 VENTILATION SCHEME OF TURBOGENERATOR

- HOT GAS
- COLD GAS

03/27/2021 Gyanendra Sharma, NPTI Delhi

 VENTILATION SCHEME OF TURBOGENERATOR

- HOT GAS
- COLD GAS

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DESCRIPTION
OF
TURBOGENERATOR

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DESCRIPTION OF TURBOGENERATORS

STATOR
STATOR FRAME:

- Cylindrical Frame Housing fabricated from

structural steel consists of two flanged rings
and axial and radial ribs.
- Arrangement of ribs determined by cooling
gas passages and required mechanical
THDF
strength and stiffness.
- Frame within the range of phase connectors
of stator winding made of non magnetic steel
to prevent eddy current losses.
- Hydraulically tested with End Shields at 10 bar
to ensure capability of withstanding maximum
explosion pressures

03/27/2021 Gyanendra Sharma, NPTI Delhi

THRI
 DESCRIPTION OF TURBOGENERATORS

STATOR
END SHIELDS:

- Close the ends of the stator frame

- Horizontally split and have high stiffness THDF
- Contain generator bearings, shaft seals
and houses generator coolers on
Turbine End.
- Static and dynamic forces are
transmitted to the foundation via lateral
THRI
feet attached to the lower half end
shield.

TERMINAL BOX:

- Welded stainless steel structure for bringing

out six phase and neutral connections
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

STATOR
STATOR CORE:
Stator core built up of thin laminations made of
Electrical sheet steel.
- Each lamination layer is made up of number of
individual segments.
- Segments are staggered to obtain high
mechanical strength and uniform permeability.
- Laminations are debured and coated with
insulating varnish on both sides.
- Laminations are held by dovetailed core bars.
- Laminations are hydraulically compressed and
heated during stacking to obtain maximum
compression and eliminate undue settling.
- Stack of core is kept under pressure and located
in the frame by means of clamping bolts and
pressure plates.
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

STATOR THDF

SPRING SUPPORT OF STATOR CORE:

- Stator core is spring mounted in the stator frame

- Stator Core is supported in several sets of rings.
Each ring set consists of two supporting rings
and two core clamping rings
- Supporting ring is solidly pressed against core by
clamping ring.
-Tightening of clamping rings reduces gap
between ring segments and thus supporting ring
gets linked to the stator frame by three flat
springs, which resist transmission of double
frequency vibration to the stator frame.

THRI
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

STATOR
STATOR WINDING:
- Stator Winding is three phase, lap type.
- Stator bar consists of hollow and solid copper
conductors
-The strands are insulated and are transposed to
reduce the skin effect.
- In straight slot portion the strands are transposed
by 540 degree for mutual neutralisation of
voltages induced in individual strands & ensures
existence of minimum circulation current.
- Contact sleeves for Electrical connection of the
bars and water boxes with cooling water
connections are brazed to the bar ends.
- Stator winding bars are made up of micalastic
insulation
- Stator winding is connected to the connecting bus
bars to make a 3 phase winding. Connecting bus
03/27/2021 Gyanendra Sharma, NPTI Delhi
bars are connected to the terminal bushings.
 DESCRIPTION OF TURBOGENERATORS

STATOR
STATOR END WINDING SUPPORTING ARRANGEMENT:

THDF

THRI
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

STATOR
STATOR WINDING COOLING:
- Stator Winding is cooled with DM water which
flows through the hollow copper conductors.
- DM water enters the stator winding through
the stator water inlet header. Teflon tubes
connect the headers to the winding bars.
- DM water goes back to the Primary Water
Tank located at the top of the stator through
the stator water outlet header. THDF
- PW tank is kept under nitrogen pressure to
minimize contact of air with DM water.
-The DM water is made alkaline to prevent
corrosion of hollow copper conductors.
- Separate circuit is available for cooling of
Terminal bushings.
THW
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

ROTOR
ROTOR SHAFT:

- Forged from a vacuum cast steel ingot.

- Integrally forged flanged couplings
- Two third of the rotor circumference provided
with longitudinal slots for field winding. THDF
- Transverse slotting on poles to offset non
uniform slot distribution

THW

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DESCRIPTION OF TURBOGENERATORS

ROTOR
ROTOR WINDING:

- 2 Pole rotor winding

- Hollow conductors have trapezoidal cross-section
& are provided with cooling ducts of
semi-circular X-section
- Insulation material used for rotor is made from
glass fiber laminate- Class F insulation.
- Rotor slot wedges prevents winding from the
affect of centrifugal forces.
- Rotor retaining rings contain the centrifugal forces
due to the end windings.
-Field connections between rotor winding and
exciter winding are through Current carrying bolts,
D-lead and multicontact bands.
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

ROTOR
ROTOR COOLING:
- Rotor is Axially and Radially Cooled. Rotor slots have axial cooling ducts.
- Hollow conductors have trapezoidal cross-section& are provided with cooling
ducts of semi-circular X-section.
- Cooling gas is admitted into hollow conductors through milled openings
directly before the end of the rotor body and flows through the hollow
conductors to the centre of the rotor body.
- Hot gas is discharged into the air gap between rotor body and stator core
through radial openings in the conductors and the rotor slot wedges.
- Generator cooling gas is circulated by one axial flow fan located on the
Turbine end shaft journal.

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DESCRIPTION OF TURBOGENERATORS

HYDROGEN COOLERS
HYDROGEN COOLERS:
- 4 nos shell and tube type hydrogen coolers are
provided vertically in the Turbine End End
Shield
- Each cooler consists of Tube bundles, upper &
lower tube sheets, return water channel, inlet
and outlet water channel.
- Water flows through the tubes and hydrogen
flows through the shell.

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DESCRIPTION OF TURBOGENERATORS

BEARING
BEARING:
- Rotor is supported on 2 nos. sleeve bearings
- Bearings have forced lubrication.
- Jacking oil for initial lift is provided.
- Bearings are housed in the End Shields
- Bearing oil and jacking oil is fed through
pipes laid in the End Shield
- 3 nos spherical self aligning support seats are END SHIELD MOUNTED
fixed for self alignment of bearing during BEARING-THDF
operation.
- Bearing saddle is insulated from stator end
shield to prevent flow of shaft currents.
- Bearing is babitted on the ID to prevent
damage to the rotor journals.
- A tangential locator is provided to prevent the
bearing from turning in the saddle.
03/27/2021 Gyanendra Sharma, NPTI Delhi
JOURNAL BEARING-THW
 DESCRIPTION OF TURBOGENERATORS

SHAFT SEALS

SHAFT SEALS :
- Double Flow Shaft Seal arrangement is provided
for retaining hydrogen at rated pressure inside
the generator.
- Continuous film of oil is maintained between
the shaft and a non-rotating floating seal ring.
- Seal oil from two separate circuits is fed to
the seal liners i.e., Air side seal oil and
hydrogen side seal oil.
- Thrust oil is provided to prevent the seal liner
from sticking in the seal body.
- Continuous flow of oil to the seal rings is
maintained by the seal oil system comprising of
Seal Oil pumps, filters, Coolers, Seal oil tank,
Intermediate oil tank, Vacuum pump, Differential
pressure regulators etc.
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

SEAL OIL SYSTEM

SEAL OIL SYSTEM :

- Continuous flow of oil to the

seal rings is maintained by
the seal oil system
comprising of :
- Seal Oil Pumps ( AC and DC)
- Seal Oil Filters
- Seal Oil Coolers
- Seal oil Tank
- Intermediate oil tank
- Vacuum pump
- Differential pressure
regulators
- Piping, valves, instruments
& gauges etc.
03/27/2021 Gyanendra Sharma, NPTI Delhi
 DESCRIPTION OF TURBOGENERATORS

GAS SYSTEM
GAS SYSTEM :
- Gas system is provided to fill &
evacuuate the hydrogen gas
requiredfor cooling the stator
core and rotor winding.

Gas system consists of:

- CO2 bottle rack

- Hydrogen bottle rack
- Gas dryer
- Gas valve rack
- Hydrogen Purity analyser
- Moinsture Measuring System
- Piping, valves, instruments &
gauges etc.

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DESCRIPTION OF TURBOGENERATORS

PRIMARY WATER SYSTEM

PRIMARY WATER SYSTEM :

- Primary Water System is provided

to supply DM water for cooling of
stator windings and terminal
bushings.

Primary Water System consists of:

- Primary Water Pumps

- Primary Water coolers
- Primary Water Valve Racks’
- Primary Water Tank
- Primary Water Filters
- Water Treatment System
- Alkalyser unit
- Conductivity Transmitters
- Piping,
03/27/2021 Gyanendra Sharma, NPTI Delhi
valves, instruments & gauges etc.
 DESCRIPTION OF TURBOGENERATORS

EXCITATION SYSTEM
EXCITATION SYSTEM :

- Exciter provides the excitation

to the Generator rotor

- Exciter consists of the following:

- Three phase Pilot Exciter

- Three phase Main Exciter
- Rectifier wheels
- Exciter Rotor carrying the rectifier
wheels, rotor of main exciter,
permanent magnet rotor of
pilot exciter and exciter fan.
- Exciter coolers
- Stroboscope for fuse monitoring.
03/27/2021 Gyanendra Sharma, NPTI Delhi
 ERECTION AND COMMISSIONING
DOCUMENTS
OF
TURBOGENERATORS

03/27/2021 Gyanendra Sharma, NPTI Delhi

 ERECTION ITEMS PERTAINING TO GENERATOR

1. FOUNDATION PLATES
2. STATOR
3. ROTOR
4. END SHIELDS
5. SHAFT SEALS
6. BEARINGS
7. EXCITER- BED PLATE, EXCITER ROTOR, EXCITER
BEARING, PMG
8. SEAL OIL SYSTEM
9. GAS SYSTEM
10. PRIMARY WATER SYSTEM

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DOCUMENTS SUPPLIED FROM HARIDWAR

1. OPERATION AND MAINTENANCE MANUAL OF GENERATOR

2. ENGINEERING DRAWINGS OF MAJOR ITEMS
3. QUALITY LOG SHEETS DURING SHOP TESTING
4. PACKING LIST OF PACKAGES SENT FROM
HARIDWAR

DOCUMENTS MADE AVAILABLE BY OTHER GROUPS

5. ERECTION & COMMISSIONING MANUAL BY POWER SECTOR

6. QA LOGSHEET BY POWER SECTOR

03/27/2021 Gyanendra Sharma, NPTI Delhi

 AGENCY AT MAUNAFACTURING PLANT TO BE
CONTACTED IN CASE ANY TECHNICAL PROBLEM IS
FACED AT SITE ON THE EQUIPMENT SENT FROM
THE MANUFATURING PLANT

FIELD ENGINEERING SERVICE (FES)

FES/EME: FOR GENERATOR

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FORMATS FOR PROBLEMS RAISED BY SITES

1. MATERIAL SHOULD BE INSPECTED IMMEDIATELY ON

RECEIPT AND ANY NON CONFORMITY TO BE RAISED IN
“MDR FORMAT” – MATERIAL DEFICIENCY REPORT

2. IF ANY PROBLEM IS FACED ON ANY EQUIPMENT SENT

BY MANUFACTURING UNIT DURING ERECTION,
DETAILED FEEDBACK OF THE PROBLEM, PHOTOGRAPH
OF THE FAULTY EQUIPMENT ETC. TO BE REPORTED ON
“SAR FORMAT” – SITE ACTION REQUEST.

3. IF ANY PROBLEM IS FACED ON ANY EQUIPMENT SENT

BY MANUFACTURING UNIT DURING COMMISSIONING,
DETAILED FEEDBACK OF THE PROBLEM, PHOTOGRAPH
OF THE FAULTY EQUIPMENT ETC. TO BE REPORTED ON
“CAR FORMAT” – COMMISSIONING ACTION REQUEST.

03/27/2021 Gyanendra Sharma, NPTI Delhi

 IMPORTANT CHECKS ON GENERATOR
ON RECEIPT AT SITE

1. INSPECT STATOR WINDING OVERHANG/ CORE FOR ANY

DAMAGES DURING TRANSPORTATION
2. INSPECT ROTOR WINDING FOR ANY DAMAGES DURING
TRANSPORTATION.
3. CHECK CONDITION OF TERMINAL BUSHINGS FOR ANY
DAMAGE DURING STORAGE.
4. CHECK CONDITION OF EXCITER
5. CHECK CONDITION OF HYDROGEN COOLERS
6. CHECK OTHER PACKAGES ON RECEIPT FOR ANY
DAMAGE/ MISSING ITEMS.
7. STORE AS PER STORAGE REQUIREMENT.

03/27/2021 Gyanendra Sharma, NPTI Delhi

 ACTIVITIES ON GENERATOR DURING ERECTION

1. FIXING OF FOUNDATION PLATES

2. PLACEMENT OF STATOR ON FOUNDATION PLATE
3. MEASUREMENT OF IR OF ROTOR AND STATOR
4. INSERTION OF ROTOR
5. ALIGNMENT OF STATOR/ROTOR WRT TO CATENARY
6. CHECKING OF ERECTION AND SETTING CLEARANCES
7. ASSEMBLY OF TERMINAL BUSHING
8. ASSEMBLY OF EXCITER
9. ASSEMBLY OF HYDROGEN COOLERS
10. ASSEMBLY OF END SHIELDS
11. ASSEMBLY OF SHAFT SEALS
12. COMMISSIONING OF SEAL OIL SYSTEM, H2 GAS SYSTEM
AND PRIMARY WATER SYSTEM
13. AIR LEAKAGE TEST OF GENERATOR
14. BARRING GEAR
15. COMMISSIONING ACTIVITIES

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Thank You

03/27/2021 Gyanendra Sharma, NPTI Delhi