Afam Generator Design

Generator Generator Design
Mechanical/Electrical
Maintenance
Training Module
ALSTOM (Switzerland) Ltd ABCD

Generator
ABCD Mechanical/Electrical Maintenance Generator Design
We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly
forbidden.
Copyright© by ALSTOM (Switzerland) Ltd 2007
This is a training lesson. It provides overall information about the specific system
only.
All mentioned / attached values and settings are for information only. The values
might be changed during commissioning.
For actual values please refer to the Instruction Manual.
Power Plant Training Center

CSXA220089enB Page 2
Generator
Table of Contents
Module Objectives .............................................................................................................................. 6

Turbogenerator General...................................................................................................................... 7
Introduction ..................................................................................................................................... 7
Air-Cooled Turbogenerators ................................................................................................................ 8
Introduction ..................................................................................................................................... 8
Common Features of the Series WX, WY, WZ ....................................................................................... 9
Generator Size Versus Power Range .................................................................................................. 9
General Description and Design of Major Components....................................................................... 10
Turbo-Rotor ................................................................................................................................... 10
Rotor-Body..................................................................................................................................... 11
Rotor Winding................................................................................................................................ 11
Damper Winding ........................................................................................................................... 11
Retaining Rings .............................................................................................................................. 11
Retaining Rings (continued)............................................................................................................. 12
Axial Fan ....................................................................................................................................... 12
Fully Assembled Rotor .................................................................................................................... 12
Generator Stator ............................................................................................................................ 13
Fully Assembled Stator.................................................................................................................... 13
Stator Core .................................................................................................................................... 13
Stator Winding ............................................................................................................................... 14
Roebel Bars ................................................................................................................................... 14
The Micadur®-Compact Insulation System ....................................................................................... 15
Structure and Manufacturing........................................................................................................... 15
Bar Installation............................................................................................................................... 15
Impregnation Process ..................................................................................................................... 16
Fully Assembled Stator Core ........................................................................................................... 16
Stator Housing ............................................................................................................................... 16
Bearing Pedestals ........................................................................................................................... 17
Journal Bearings ............................................................................................................................ 17
Journal Bearings (continued)........................................................................................................... 18
Generator Test............................................................................................................................... 18
Cooling Air System Description ....................................................................................................... 18
Stator Cooling ............................................................................................................................... 19
Rotor Cooling ................................................................................................................................ 19
Generator Cooling......................................................................................................................... 20
Figure 1: Bearing Pedestals connected with the Housing and standing on Foundation........................... 21
Figure 1.1: Type WX … L................................................................................................................ 21
Figure 1.2: Type: WX … L............................................................................................................... 21
Figure 2: Bearing Pedestals free standing on Foundation..................................................................... 22
Type: WX … Z................................................................................................................................ 22
Figure 3: Bearing Pedestal free standing. These Generator will be shipped with the Rotor installed ........ 23
Figure 3.1: Type: WZ … Z .............................................................................................................. 23
Figure 3.2: Type: WZ … Z .............................................................................................................. 23
(Continued next page)

Generator
Table of Contents (continued)
Figure 4: Bearing Pedestals connected with the Housing and Bearing Pedestal free standing ..................24
Figure 4.1: Type: WY … L .............................................................................................................. 24
Figure 4.2: Type: WY … Z .............................................................................................................. 24
Figure 5: Power Range and Generator Frame Size Diagram for 50Hz.................................................. 25
Figure 6: Power Range and Generator Frame Size Diagram for 60Hz.................................................. 26
Figure 7: Type Key ............................................................................................................................ 27
Figure 8: Solid Forged Rotor with Machined Slots................................................................................ 28
Figure 9: Rotor with Field Winding in Place ......................................................................................... 29
Figure 10: Detail Rotor/Rotor End Bell with Bayonet Lock..................................................................... 30
Figure 11: Rotor Retaining Ring with short circuiting Ring and Bayonet Fitting ....................................... 31
Figure 12: Retaining Ring .................................................................................................................. 32
Figure 13: Assembled Fan ................................................................................................................. 33
Figure 14: Fully Assembled Rotor ....................................................................................................... 34
Figure 15: Stator with Housing........................................................................................................... 35
Figure 16: Stator Core in Housing...................................................................................................... 36
Figure 16.1: Placing the Stator Core into the Housing ...................................................................... 36
Figure 16.2: Welding the Stator Core to the Housing ....................................................................... 36
Figure 17: Housing ........................................................................................................................... 37
Figure 17.1: Closing the Housing ................................................................................................... 37
Figure 17.2: Principle of the Suspension Ring .................................................................................. 37
Figure 18: Stator ............................................................................................................................... 38
Figure 18.1: Stator Core................................................................................................................. 38
Figure 18.2: Core Plate .................................................................................................................. 38
Figure 19: Stator Core....................................................................................................................... 39
Figure 19.1: Stator Core ready for the Winding Installation .............................................................. 39
Figure 19.2: Stator Core Assembly.................................................................................................. 39
Figure 20: Stator Core with End-Winding ........................................................................................... 40
Figure 21: Roebel Bar ....................................................................................................................... 41
Figure 21.1: Roebel Bar Design ...................................................................................................... 41
Figure 21.2: Roebel Bar ................................................................................................................. 41
Figure 22: View of Roebel Bar before Applying the Main Insulation ...................................................... 42
Figure 23: Stator Bars........................................................................................................................ 43
Figure 24: Stator ready for Impregnation............................................................................................ 44
Figure 25: Cross Section Stator Slot with two Roebel Bars .................................................................... 45
Figure 26: Wound Stator of an Air-Cooled Generator ready for Insertion into the Tank for the VPI-
Treatment according the MICADUR-COMPACT Process ...................................................... 46
Figure 27: MICADUR-COMPACT Impregnation .................................................................................. 47
Figure 28: Completely Assembled Stator ............................................................................................ 48
Figure 29: Housing Types .................................................................................................................. 49
Figure 29.1: Housing Types WX … L/Z............................................................................................ 49
Figure 29.2: Housing Types WY … L/Z............................................................................................ 49
Figure 30: Housing Types WX, Cooler on Top..................................................................................... 50
Figure 31: Bearing Pedestal for the Types WX … Z, WY … Z and WZ … Z ........................................... 51
Figure 31.1: Cross-section of Bearing Pedestal ................................................................................ 51
Figure 31.2: Bearing Pedestal ......................................................................................................... 51

Generator
Table of Contents (continued)
Figure 32: Bearing Pedestal for the Types WX .. L and WY … L............................................................ 52

Figure 32.1: Cross-section of Bearing Pedestal ................................................................................ 52
Figure 32.2: Bearing Pedestal ......................................................................................................... 52
Figure 33: Pocket Type Journal Bearing.............................................................................................. 53
Figure 34: Generator in the Test Bay .................................................................................................. 54
Figure 35: Generator Cooling – Three Chamber System ..................................................................... 55
Figure 36: Generator Cooling – Four Chamber System ....................................................................... 56
Figure 37: Stator Cooling Air Flow ..................................................................................................... 57
Figure 38: Rotor Cooling Air Flow ...................................................................................................... 58

Generator
Module Objectives
Upon completion of this section, the student should be able to:
• List the major components of air-cooled turbogenerators and state the function
of each component using the drawings enclosed.

Generator
Turbogenerator General
Introduction
The synchronous generator is the most important machine used for generating
electrical energy.
The function of the turbogenerator is to convert the rotating mechanical power,
delivered from the turbine to the generator rotor, into electrical power, which is
available at the generator terminals. The turbogenerator will perform this duty
either continuously at rated power or under conditions of partial power or power
cycling.
The field winding in the rotor is fed with direct current (excitation current or field
current) producing the main electromagnetic field of the machine and driving it
across the rotor body, air gap and the stator core.
When the rotor rotates, the magnetic field also rotates. The field appears in the
stator as an alternating field, so that a voltage is induced in the armature (stator)
windings.
If the stator core is made of solid iron, the alternating field will produce eddy
currents, which would damp the field and cause high losses thus making the
generator inefficient. Therefore, the core is made of laminated segments of electric
steel sheets (magnetic steel).
The stator has a 3-phase winding system or three individual windings, which are
offset electrically from each other by 120°. As the rotating field passes through each
armature winding bar, the induced e.m.f. in each armature bar will reach
maximum and minimum values. Each phase follows the other in a time equivalent
to an electrical angle of 120°.
The basic features of a synchronous turbogenerator are the rotating magnetic-field

system and the 3-phase armature winding system, including the magnetic core.
• The field winding turns induce the magnetic field and are installed in slots
distributed around the cylindrical rotor body. A turbogenerator is a non-salient
pole generator.
• The 3-phase armature-winding system, in which the e.m.f. is induced, is
installed in slots around the inner diameter of the stator core.
The rotating part of the generator is called the rotor, while the stationary part
(armature) is called the stator. The turbogenerator block includes the stator,
bearings, rotor, and the exciter machine.

Generator
Air-Cooled Turbogenerators
Introduction
Air-cooled turbogenerators are used for producing electrical energy in industrial

and medium-size power stations. They can be driven by either gas or steam
turbines. ALSTOM started to develop in the early 1970 the WX...L and WY...L series
of air coold turbogenerators. The ratings of these machines cober the range 18 to
200 MVA. With these series of machines well established, ALSTOM started in 1988
to develop the new series WX...Z, WY...Z and WZ...Z.
Figures 1 & 3 Form feature of the series:

• Type WX...L Bearing pedestals connected with the housing and standing on
foundation.
• Type WX...Z Bearing pedestals free standing on foundation.
• Type WZ...Z Bearing pedestals free standing. These generators will be shipped
with the rotor installed. Stator housing and base frame are one
welded unit.
These series are designed for steam turbine installations.
Figure 4 • Type WY...L Bearing pedestals connected with the housing

• Type WY...Z Bearing pedestals free standing
These series are designed for Gas-Turbine installations.

Generator
Common Features of the Series WX, WY, WZ
• Compact, space-saving design

• For base-load and peak-load operation
• Easy maintenance, low maintenance cost
• Choice of cooling system
• Suitable of all excitation systems
The machines are constructed on modular principles so that many variations are
available by using standard components.
Generator Size Versus Power Range
Figures 5, 6 & 7

Generator
General Description and Design of Major Components
Turbo-Rotor
• Rotor design
• Rotor body
• Rotor winding
• Damper winding
• Retaining rings
• Axial fan
Generator
• Stator design
• Stator core
• Stator winding
• Stator housing
• Bearing pedestals
Cooling
• Rotor cooling
• Stator winding and core cooling
Turbo-Rotor
A number of parameters must be taken into account for designing a rotor:

• In 2-pole turbogenerators, the diameter of the active body and the retaining
rings are limited by the maximum centrifugal forces, which can occur during
abnormal operation conditions.
• Because of the dynamic behavior of the rotor at rated speed, and the several
critical speeds during run-up, the diameters and lengths of the various rotor
sections must be chosen so as to ensure that no important critical speed is close
to the rated speed.
• The coupling and the bearing journals diameters must be chosen so that they
can take the maximum torsional stresses which could occur during a 2-phase
sudden short-circuit or abnormal turbine operation.
ALSTOM's 2-pole turbogenerator rotors are designed in such a way, that the major
stresses which occur at over speed 120% and possible faulty operation still remain
below 66% of the yield point of the material used.

Generator
Rotor-Body
Figure 8 The rotor body and the drive-end coupling flange are machined from a mono,
high-quality alloy-steel forging. A number of longitudinal slots for the field winding
are machined into the active body.
Transverse slots are machined in the pole zones for compensation of the different
flexural stiffness in the cross sectional plane.
An area for mounting the axial fan is provided on both sides of the active body.
Rotor Winding
Figure 9 The rotor coils (field winding) are formed of hard-drawn rectangular hollow
conductors. The copper is alloyed with silver to increase its strength at high
temperatures. The coils are in the slots in such a way that the complete imbedded
winding can expand symmetrically from its fix-point in the centre of the rotor. These
design features ensure smooth operation during thermal changes. The coils are
direct cooled.
The insulating material used is heat resistant and non-distorting and complies with
the class F specification.
Damper Winding
Figure 10 The damper winding improves the damping properties for safe operation by
conducting the eddy currents induced under abnormal operating conditions such as
sudden variations in load or unsymmetrical load conditions. If a turborotor is not
provided with a damper winding, the eddy currents will circulate in the rotor body
surface, with produces a large amount of heat.
The damper winding is formed by the good electrical conducting slot wedges which
are short-circuited at their end by silver plated fingers and a silver-plated ring
installed in the retaining rings.
Retaining Rings
Figures 11 & 12 Retaining rings are critical components which must be able to with stand high
mechanical loading levels during standstill and operation caused by shrink-fit and
centrifugal forces respectively.
The materials used must posses a high yield strength to ensure a large margin of
safety against plastic deformation.

Generator
Retaining Rings (continued)
Figures 11 & 12 The material used for the retaining rings is a non-magnetic steel-alloy with a high
yield strength obtained by cold forming. The use of non-magnetic steel for the
retaining rings reduces the losses in the ring caused by eddy currents, and thus
avoids loosening of the retaining rings.
A retaining ring is fitted to each end of the rotor body in order to support the rotor
end-windings against the action of centrifugal forces. The retaining ring consists of
a main cylindrical barrel fitted at one end with an annular end disc.
The open end of the retaining ring is shrunk onto the end of the rotor body, and
usually has an additional bayonet coupling to restrain it in the axial direction. A
special key arrangement eliminates any possibility of tangential slip.
In order to prevent damage to the retaining ring due to deflection of the rotor under
its own weight, the retaining ring is fastened to the rotor body only at one end,
using the shrink seat mentioned above (cantilever principle). The outboard end of
the retaining ring is thus free to move in relation to the more heavily deflected shaft
end.
At the free end the end disc is shrink-fitted into the end of the barrel. Its purpose is
to counteract any non-uniform deformation of the retaining ring, which could result
from non-uniformity of the centrifugal load of the end winding.
Axial Fan
Figure 13 The generator is self-ventilated. Both ends of the rotor are provided with an axial
fan, which supplies the rotor and the stator with the required quantity of cooling air.
The fan is shrink-fitted to the rotor.
Fully Assembled Rotor
Figure 14 Standard Tests

In accordance with the international standards of the IEC and IEEE, every generator
is subjected to a series of tests, which includes the following rotor test:
• Winding resistance
• Mechanical balancing
• Over speed
• Insulation resistance
• High voltage

Generator
Generator Stator
Figures 15, 16 & The main parts of an air cooled generator stator are the:
17 • Laminated core
• Winding
• Housing
The laminated core together with the winding forms the active part of the stator in
which the electrical energy is generated.
The housing is a two part welded construction in which the core with windings is
suspended in the lower part.
The suspension of the assembled core is so designed that the vibration and thermal
expansion are taken up by the housing and are not transmitted to the foundation.
Fully Assembled Stator
Standard Tests
In accordance with the international standards of the IEC and the IEEE, every
generator is subjected to a series of tests which includes the following:
• Winding resistance
• Check of resistance thermometers
• Impedance measurement
• Phase-sequence
• Symmetry of currents and voltages
• High-voltage (high potential)
Stator Core
Figures 18 & 19 The stator core is built from a large number of punched out segments of low-loss
electrical silicon steel sheets, which are varnished on both sides for insulation.
The core is stacked separately outside the stator housing. The permanent
compression of the core between the ring-shaped alu-pressplates and the
pressfingers is provided by keys, set and welded to the lamination on the back of
the core.
Along the core there are a number of radial slots for cooling air.

Generator
Stator Winding
Figure 20 General
The stator winding is a three phase bar winding formed from insulated copper-
strips transposed by the Roeble method.
The winding is designed as a two layer winding with a short overhang (winding
head).
The bars are insulated with the Micadur®-Compact-insulation system.
The winding head is stiffened by lacing it with impregnated glass-fibre cords. It is
supported radially by triangular shaped brackets mounted to the core press plate.
To ensure radial rigidity and longitudinal elasticity.
Around the winding head on the stator NDE, ring connectors connect the two layer
winding to the 6 terminal leads.
Roebel Bars
Figure 21 The stator winding reaction field induces eddy currents in the bars. Due to the field
strengthening effect of the stator-core material these eddy currents lead to current
displacement towards on side of the stator-winding bar, resulting in increased
losses and hot-spots.
In order to avoid this current displacement effect, the individual copper strands are
transposed, giving a twisted form to the whole bar length.
The transposition of the strands in the bar ensures that each conductor is exposed
to the same magnetic flux and therefore the same eddy current is induced in each.
This transposed design is called the Roebel design.
Figure 22 The bar is built up of solid copper strands, insulated with varnish and covered with
a glass fibre. The strands are then transpositioned to form the Roebel bar, which is
pressed and baked over the straight core to exactly defined dimensions. Uneven
areas on the top and bottom, caused by the transpositioning of the strands, are
filled with a mica compound. After the ends have been formed to the desired
shape, the final insulation is applied.

Generator
The Micadur®-Compact Insulation System
The Micadur®-compact insulation system, a standard application for ALSTOM air-

cooled generators is a total-immersion impregnation process characterized by:
• Unusually high mechanical strength in all parts of the winding because the bars,
ring-connectors, core and supports are all impregnated at the same time.
• Uniform dielectric strength of the bars around the circumference.
• High thermal capacity; all insulating materials satisfy the requirements of
class F.
• Insulating materials are unaffected by moisture.
• Insensitive to oil and other contaminants.
• Insulation is flame-retarding.
Structure and Manufacturing
Figure 23 The formed coils are wrapped with porous mica glass tape in multiple layers
(determined by the rated voltage) to provide a durable ground wall insulation of
high dielectric strength. A final conductive corona protecting tape is applied over
the mica-glass to avoid corona discharge in the stator slot portion.
A special semi conductive varnish or tape coating is applied to the coil overhang
beginning at the slot exit. For high voltages a special stress grading sleeve is
applied over the transition between the semi conductive- and the slot conductive
corona protection.
Bar Installation
Figures 24 & 25 The unimpregnated coils are inserted in the stator core slots and firmly held in place
with the slot wedges.
The bar ends are then spaced by lacing highly resin absorbing fibre-glass cording
between the bars and between the bars and the overhang supports. After
impregnation and curing this support system, forms an extremely rigid winding
overhang structure with exceptional mechanical strength.
The ring-connectors and the bar connecting sleeves are installed.

Generator
Impregnation Process
Figures 26 &27 The completely wound and connected stator core is placed in a special tank for the
vacuum pressure impregnation and curing process (VPI).
In this tank the active stator assembly is subjected to:
• A: Heating and thorough vacuum drying prior to impregnation.
• B: Impregnation with well de-gassed varnish.
• C: Curing at elevated temperature.
Continues on-line monitoring of all essential process parameters during the VPI
process assures high quality.
Fully Assembled Stator Core
Figure 28 Standard Tests

In accordance with the internal standards of the IEC and IEEE, every generator is
subjected to a series of tests, which includes the following (stator tests):
• Induction test on the stator core, is performed prior to the installation of the
winding bars.
• High-voltage (high-potential)
Stator Housing
Figures 29 & 30 Design

The stator housing is a welded steel construction, split horizontally into two parts.
Function
• Taking up the stator-core
• Transmission of static and dynamic forces to the foundation
• Guidance of cooling air
• Accommodation of coolers taking up the coolers
Housing types
Depending on the type of turbine or the type of cooling and the cooler location,
various housings are used.

Generator
Bearing Pedestals
General
The bearing pedestal, with installed bearing, supports the generator rotor.
The pedestal is a welded construction and designed in such a way that the lube-oil
system can be connected on the left or right side.
The lube-oil is supplied by a central unit serving the whole turboset. A slight vacuum
is provided through the lube-oil return lines to give a slight under pressure in the
pedestals, thus preventing oil leakage along the shaft.
To avoid a current flow across the bearing, which could cause bearing damage, the
bearing is insulated.
Figure 31 Bearing pedestals for the type WX...Z, WY...Z and WZ...Z generator:
• The pedestals are free standing and bolted to the foundation or to the platform
on the lower part of the stator housing.
Figure 32 Bearing pedestals for the type WX...L and WY...L generator:
• The bearing pedestals are incorporated in the housing ends. Special labyrinth
seals together with a sealing air system prevent oil leakage into the generator.
Journal Bearings
Figure 33 General
The rotors are supported in plain journal bearings carried in bearing pedestals.
Pocket-type journal bearings combine a maximum of operational safety and
reliability with a minimum space requirement. They operate on the hydrodynamic
principle, which eliminates metal-to-metal contact of the running surfaces during
normal operation. This results in a long life, since there is practically no wear.
Design and Function

The bearing is split into two babbitt-lined bearing halves, which are bolted together
with body-fit bolts. Symmetrical oil-inlet pockets are machined into the babbitt
lining, which makes the bearing suitable for both directions of rotation.
The bearing is fitted in the pedestal by means of fitting-plates, which can be
adjusted with shims. An anti-rotation pin is located in the top fitting-plate.

Generator
Journal Bearings (continued)
Figure 33 Lube-oil supply

Oil enters the bearing via two inlets in the split section. The moment of oil is
determined by an orifice mounted in the oil inlet line outside the bearing pedestal.
All bearings, with the exception of the low-loaded ones. are supplied with high-
pressure jacking oil during start-up and turning gear-operation. This lifts the rotor,
prevents metallic contact between babbitt and journal, and greatly reduces the
starting torque
Generator Test
Figure 34 Special Tests

Running tests and special tests at standstill can be performed on request.
These tests can include:
• No-load characteristics, short-circuit characteristics
• Individual losses
• Determination of efficiency
• Sudden short-circuit test
• Heat runs
The records of tests based on such procedures are available.
Cooling Air System Description
Overview and Description

When a generator is in operation, unavoidable electrical and mechanical losses
occur in the form of heat. If this heat is not removed quickly and efficiently, the
temperature within the generator will rapidly increase. This will lead to a winding
insulation breakdown and ultimately to the destruction of the generator.
Air-cooled generators are self-ventilated. The cooling system has two symmetrical
circuits, corresponding to the two axial fans mounted at the ends of the rotor. The
two circuits are independent of the cooler arrangement used.
The cooling is designed as a closed circuit with air-to-water coolers. Special make-
up air filters on both ends of the generator are provided.
The coolers can be located in the housing either above or below the stator or they
may be incorporated in the foundation, depending on the type of generator or
special requirements.

Generator
Stator Cooling
The stator winding is cooled indirectly which means there is no direct contact
between the copper conductors and the cooling air. Part of the copper loss is
transferred through the insulation to the coolant (in the winding overhang) and part
of the losses is transferred to the stator-core. The stator core is dividend into a large
number of packets separated by special spacers which form radial cooling
channels. An adequate cooling surface is thus provided.
Depending on the generator size, the stator housing has either three or four
chambers in each half of the generator. Each chamber corresponds to a separate
cooling air flow.
The following description is based on a three-chamber arrangement.

From the fan, one part of the cold air is directed into the air gap where it joins with
air from the rotor end winding. It leaves the air gap through the radial cooling slots
in the stator core and enters the first chamber. From there the hot air flows back to
the coolers.
A second part of cold air is directed outwards, over the winding overhang and
through axial ducts to the second chamber. From there it flows inwards through the
radial cooling slots of the stator core into the air gap. A part of this air flows
towards the end of the rotor, joining the flow to the first chamber. The other part
flows towards the middle of the machine, mixes with the air emerging from the
rotor winding and flows outwards through the radial cooling slots in the stator core
into the hot chamber. From there the hot air flows back to the coolers.
Rotor Cooling
The rotor field winding is direct cooled, which means there is direct contact between
the copper conductors and the cooling air. The cooling air is circulated through the
hollow field-winding conductors.
From the fan a third cold air flow is taken to the rotor winding. The radius at the air
entry is smaller than at the point of exit. Therefore, the rotating rotor acts as a
radial fan, giving additional pressure to force the air through the hollow
conductors.
The cold-air enters the rotor between the retaining ring and shaft. It then enters the
hollow conductors near the slot ends. Each conductor has two inlet openings,
symmetrically placed on opposite sides: one opening admits air to the active (slot)
region, the other to the end-winding region. The cooling air for the active part flows
through the hollow conductors to the mid-plane of the rotor, then out through
radial openings in the conductors and slot wedges into the air gap. The air to the
end-winding flows through the hollow conductors of the winding overhangs to the
pole centerline, where it leaves the conductors and exits the rotor through slots in
the pole zones into the air gap.

Generator
Generator Cooling
Figures
35, 36, 37 & 38

Generator
Figure 1: Bearing Pedestals connected with the Housing and standing

on Foundation
Figure 1.1: Type WX … L
CSXA400637.cdr
Figure 1.2: Type: WX … L
CSXA400638.cdr

Generator
Figure 2: Bearing Pedestals free standing on Foundation
Type: WX … Z
CSXA400639.cdr

Generator
Figure 3: Bearing Pedestal free standing. These Generator will be

shipped with the Rotor installed
Figure 3.1: Type: WZ … Z
CSXA400640.cdr
Figure 3.2: Type: WZ … Z
CSXA400641.cdr

Generator
Figure 4: Bearing Pedestals connected with the Housing and Bearing

Pedestal free standing
Figure 4.1: Type: WY … L
CSXA400642.cdr
Figure 4.2: Type: WY … Z
CSXA400643.cdr

Generator
Figure 5: Power Range and Generator Frame Size Diagram for 50Hz
Ps/ Apparant power

MVA
21
200
150
18
100
16
50
14
Core lenght
0 1 2 3 4 5 L/m
Standards: IEC - B Frequency: 50 Hz

Power factor : 0.80
Size 14 16 18 21
Rotor diameter 700 mm 810 mm 920 mm 1060 mm
CSXA400644.cdr

Generator
Figure 6: Power Range and Generator Frame Size Diagram for 60Hz
Ps/ Apparant power

MVA
21
200
150
18
100
16
50
14
Core lenght
0 1 2 3 4 5 L/m
Standards: ANSI - B Frequency: 60 Hz

Power factor : 0.85
Size 14 16 18 21
Rotor diameter 700 mm 810 mm 920 mm 1060 mm
CSXA400645.cdr

Generator
Figure 7: Type Key
W Alternating current
X Generator for steam turbine; components
Y Generator for gas turbine; package
Z Generator for steam turbine; package; axis height variable
14 Rotor diameter code
16
18
21
L Direct air cooled rotor; bearing pedestal attached to housing
Z Direct air cooled rotor; bearing pedestal free standing
028
to Core length code
100
L Air cooled armature core
L Indirect air cooled armature winding
T Micadur R Compact insulation
... Micadur R Insulation
W X 18 L 054 L L T
CSXA400646.cdr

Generator
Figure 8: Solid Forged Rotor with Machined Slots
CSXA400647.cdr
Transverse slot
Winding slot
Fan seat
Journal bearing

Generator
Figure 9: Rotor with Field Winding in Place
Cross Section of Rotor Slot
Slot wedge
Hollow conductor
Slot insulation
CSXA400649.cdr

Generator
Figure 10: Detail Rotor/Rotor End Bell with Bayonet Lock
End bell Short-circuit Damping Slot wedge

ring finger
CSXA400650.cdr

Generator
Figure 11: Rotor Retaining Ring with short circuiting Ring and Bayonet
Fitting

Generator
Figure 12: Retaining Ring
Bayonet
connection End bell
Rotor body teeth
Slot wedge
CSXA400652.cdr

Generator
Figure 13: Assembled Fan

Generator
Figure 14: Fully Assembled Rotor

Generator
Figure 15: Stator with Housing

Generator
Figure 16: Stator Core in Housing

Figure 16.1: Placing the Stator Core into the Housing
Figure 16.2: Welding the Stator Core to the Housing

Generator
Figure 17: Housing

Figure 17.1: Closing the Housing
Figure 17.2: Principle of the Suspension Ring

Generator
Figure 18: Stator

Figure 18.1: Stator Core
Alu-pressplate Cooling slots
Keys
CSXA400660.cdr
Figure 18.2: Core Plate
Core Plate
CSXA400661.cdr

Generator
Figure 19: Stator Core

Figure 19.1: Stator Core ready for the Winding Installation
Alu-pressplate Press fingers
CSXA400662.cdr
Figure 19.2: Stator Core Assembly

Generator
Figure 20: Stator Core with End-Winding

Generator
Figure 21: Roebel Bar

Figure 21.1: Roebel Bar Design
CSXA400665.cdr
Figure 21.2: Roebel Bar
CSXA400666.cdr

Generator
Figure 22: View of Roebel Bar before Applying the Main Insulation

Generator
Figure 23: Stator Bars

Generator
Figure 24: Stator ready for Impregnation

Generator
Figure 25: Cross Section Stator Slot with two Roebel Bars
Slot wedge
Filler strip
Main insulation with

anti-corona tape
Conductor
Spacer
Stator core
CSXA400670.cdr

Generator
Figure 26: Wound Stator of an Air-Cooled Generator ready for Insertion

into the Tank for the VPI-Treatment according the MICADUR-
COMPACT Process

Generator
Figure 27: MICADUR-COMPACT Impregnation
13
15
18 14
7
22 23
15
4
16
1
3
2 11
19
21
20
8
17
5 9
10 12
24
6
CSXA400672.cdr
1 Impregnating boiler 13 Fan

2 Object to be impregnated 14 Air heater
3 Impregnating vat 15 Air valves
4 Inlet air bellows 16 Resin tank
5 Loading trolley 17 Cooling-heating apparatus
6 Resin pipe 18 Agitator
7 Inspection glass 19 Mixing paddle
8 Thermal insulation 20 Impregnating resin
9 Vacuum valve 21 Cooling-heating insulation
10 Vacuum pump 22 Connection for vacuum pressure
11 Nitrogen valve 23 Inspection glass
12 Liquid nitrogen tank 24 Resin valve

Generator
Figure 28: Completely Assembled Stator

Generator
Figure 29: Housing Types

Figure 29.1: Housing Types WX … L/Z
Figure 29.2: Housing Types WY … L/Z

Generator
Figure 30: Housing Types WX, Cooler on Top

Generator
Figure 31: Bearing Pedestal for the Types WX … Z, WY … Z and WZ … Z

Figure 31.1: Cross-section of Bearing Pedestal
Insulation
Bearing ring
Journal bearing
Jacking oil line
Oil inlet
Oil outlet
CSXA400677.cdr
Figure 31.2: Bearing Pedestal

Generator
Figure 32: Bearing Pedestal for the Types WX .. L and WY … L

Figure 32.1: Cross-section of Bearing Pedestal
Air
Fan
Sealing air line

Bearing yoke
Bearing Labyrinth seals
Rotor
Jacking oil
Bearing ring
CSXA400679.cdr
Figure 32.2: Bearing Pedestal

Generator
Figure 33: Pocket Type Journal Bearing
Helical
CSXA400681.cdr
Anti-rotation pin
Bearing top half
Fitting plate
with shims
Lube oil inlet pocket
Lube oil supply
Body fit bolt
Bearing bottom half

Jacking oil pocket
CSXA400682.cdr

Generator
Figure 34: Generator in the Test Bay

Generator
Figure 35: Generator Cooling – Three Chamber System
NDE
NS
3
Chambers
2
Helical
1
AS
DE
CSXA400684A.cdr

Generator
Figure 36: Generator Cooling – Four Chamber System
4
3
Chambers
2
1
CSXA400685A.cdr

Generator
Figure 37: Stator Cooling Air Flow
CSXA400300.CDR

Generator
Figure 38: Rotor Cooling Air Flow
CSXA400299.cdr


Afam Generator Design

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Generator Generator Design

ALSTOM (Switzerland) Ltd ABCD

Power Plant Training Center

Module Objectives .............................................................................................................................. 6

(Continued next page)

Power Plant Training Center

Table of Contents (continued)

(Continued next page)

Power Plant Training Center

Table of Contents (continued)

Figure 32: Bearing Pedestal for the Types WX .. L and WY … L............................................................ 52

Power Plant Training Center

Upon completion of this section, the student should be able to:

Power Plant Training Center

The basic features of a synchronous turbogenerator are the rotating magnetic-field

Power Plant Training Center

Air-cooled turbogenerators are used for producing electrical energy in industrial

Figures 1 & 3 Form feature of the series:

Figure 4 • Type WY...L Bearing pedestals connected with the housing

Power Plant Training Center

Common Features of the Series WX, WY, WZ

• Compact, space-saving design

Generator Size Versus Power Range

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General Description and Design of Major Components

A number of parameters must be taken into account for designing a rotor:

Power Plant Training Center

(Continued next page)

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Retaining Rings (continued)

Fully Assembled Rotor

Figure 14 Standard Tests

Power Plant Training Center

Fully Assembled Stator

Power Plant Training Center

Power Plant Training Center

The Micadur®-Compact Insulation System

The Micadur®-compact insulation system, a standard application for ALSTOM air-

Structure and Manufacturing

Power Plant Training Center

Fully Assembled Stator Core

Figure 28 Standard Tests

Figures 29 & 30 Design

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Design and Function

(Continued next page)

Power Plant Training Center

Journal Bearings (continued)

Figure 33 Lube-oil supply

Figure 34 Special Tests

Cooling Air System Description

Overview and Description

Power Plant Training Center

The following description is based on a three-chamber arrangement.

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Power Plant Training Center

Figure 1: Bearing Pedestals connected with the Housing and standing

Figure 1.2: Type: WX … L

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Figure 2: Bearing Pedestals free standing on Foundation

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Figure 3: Bearing Pedestal free standing. These Generator will be

Figure 3.2: Type: WZ … Z

Power Plant Training Center