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Temperature Distribution of 250 MW Hydro
Turbine Synchronous Generator at Continuous
Overloading Conditions
C. Carunaiselvane1*, Student Member IEEE, Thanga Raj Chelliah2, Member IEEE and Deepak Khare3
Hydropower Simulation Laboratory, Department of Water Resources Development and Management,
Indian Institute of Technology, Roorkee, India.
cc@wr.ittr.ac.in1 thangfwt@iitr.ac.in2 kharefwt@iitr.ac.in3
Abstract— Hydrogenerators are usually operated at over-
load condition during the period when excess water, within
permissible silt content, would be available in the river. The
period may be extended to many weeks under extensive
conditions e.g. six weeks in case of Karcham Wangtoo
Hydropower Station (India) at 20% overloads. High-power,
low-speed, direct-driven Hydro Turbine Synchronous
Generators (HTSGs) apply their own cooling techniques to
withstand temperature rise at various load points. This paper
presents the temperature distribution of a 250 MW CB
870/300-28 HTSG running under distinct stages of long time
interval overloads. The machine modelling and simulations are
carried out by means of three-dimensional commercial finite-
element analysis (FEA) software package MagNet 7.5. The
analysis is initiated with a basic electromagnetic design of CB
870/300-28 using FEA solver. Then, extended to the
investigation of thermal distribution via a coupled thermal and
fluid-dynamical model based on ThermNet 7.5. The simulated
thermal metaphors at continuous overloads are presented and
validated with a case study of 250 MW HTSG. The utility of
these generalized results of thermal distribution guarantees the
desirable operation of this kind of machine. Moreover, this
paper shows the feasibility to design HTSG which intends to
operate at continuous overloads.
Keywords— Finite element analysis, finite element method,
large hydro turbine synchronous generator, MagNet/ThermNet,
overloads and thermal analysis.
I. INTRODUCTION
The megawatt generators are constituent in any hydro-
generating unit for the conversion of sustainable mechanical
energy of the turbine into utilizable electrical energy. The
two major components of these megawatt hydrogenerators
are the rotor and the stator with radial and tangential
electromagnetic forces acting on them [1]. Rotor is the
rotating assembly in which the mechanical torque of the
turbine shaft is applied. Most commonly, the hydro plants of
above 5 MW are equipped with salient pole synchronous
alternating current type machines. These large salient pole
generators are relatively low speed machines in the range of
80-375 rpm with large number of rotor poles [2]. In general,
the direct-driven large hydro generators operating at low
speed and high torque are of increased the size and weight
[3]. The capacity of these hydrogenerators are selected or
designed based on the maximum runaway speed that a
turbine attains when subjected to governor failure. Most
importantly the inbuilt rotor inertia to provide an satisfactory
governing [4]. Over change in time, these salient pole hydro
generators synchronized with large grids have undergone
considerable changes in reduction of size and power delivery
[5]. These developments in construction methods of the large
hydro generating unit commercially increased the demand
for small size hydro-generators to deliver large capacity of
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power [6],[7]. In other words, operating an existing generator
above rated loads under extensive conditions.
Whenever the megawatt hydrogenerators are operated
beyond their nominal value, the energy losses also amplify
simultaneously leading to alarming temperature rise and
insulation breakdown [1]. Over the period of time, many
researches and findings were influenced in these areas such
as, insulation breakdown for machine winding, ventilation
and cooling system [7], enhanced material [8]-[11] and
cutting-edge manufacturing technology [12]-[13]. Besides
these aspects, the key factor for operating a rotating machine
beyond rated loads is the necessity to calculate accurate rise
in temperature at every parts of electric generator [7].
Moreover, the lifespan, safety and efficient operation of the
large-scale electric machines are highly influenced by these
temperature rise [13],[14]. In-order to compute the rise in
temperature and its distribution over electrical machines the
lumped-parameter thermal network is adopted
conventionally [15]. Similarly, for a simulative stable
temperature field analysis a trending as well as widely used
technique is the Finite Element Method (FEM) [16],[17].
Many explorations were successfully done and presented
using these multi-physics tools. The explorations were
executed over various aspects of the machines. In specific
and unique, insulation aging and skin effect simulations on
stator [17] and damper bars and pole shoes on rotor surface
[8]. In addition, the thermal behavior of the machine when
subjected to any specific operation [17].
A. Problem Description and Importance of Present Work
During construction of a 1000MW (4x250MW)
hydropower project, the Project Developer felt the need to
make provision for 20% continuous overload operation of
the project when sufficient water is available and placed the
orders of hydro generating equipment capable of 20%
overload. The project has been in operation for the last about
five years with 20% overload running of machines during
monsoon period when excess river flow is available. The
generation upto 20% overloading has been achieved
successfully. In order to see the temperature distribution in
stator and rotor of hydrogenerator (operating at rated and
overloads) for safety for this type of operation, the present
work uses FEA and validates its simulation results with
onsite measurements. Effectiveness of cooler performance at
overloads is also investigated.
B. Organization of Paper
This paper emphasis and overviews the criteria that can
be used to design a 250 MW-class HTSG through coupled
electromagnetic and thermal fluid-dynamical FEM. The
presented generator was designed and modelled using
Magnet 7.5 FEA solver package in Section II. Moreover, the
major acting sources of heat in the heat transfer analysis are
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the electromagnetic losses. So a trivial literature on the losses
and the boundary conditions are also discussed in Section III.
The temperature distribution of various components of the
generator is obtained using 2-D and 3-D FEM analyses with
the support of FEM tool in Section IV. Furthermore, in the
same Section the thermal analysis is extended by subjecting
the generator to distinct stages of overloads and compared
with the case study of a typical 250 MW x 4 hydropower
plant in India. In precise, this paper endorses the feasibility
of appropriate machine design and thermal analysis of a 250
MW-class HTSG. The analysis performed in this paper is a
generalized one so that the results are suitable for any large
hydrogenerator having similar air-cooling system.
II. MODELLING OF 250 MW SYNCHRONOUS
GENRATOR
In this section, a complete electromagnetic model of a
250 MW HTSG is designed using FEM tool. The schematic
of the whole constructional view of the HTSG is shown in
Fig.1.
The stator slot windings are double layer with the wave
type distribution. The q slots per pole per phase of the large
hydrogenerator can be expressed as
z N (1)
q= =
2 pm d
where, z is the number of stator slots, p the number of
pole-pairs, and m is the number of phases, respectively and
N/d means N coils divided into d coil groups. The whole coil
distribution repeats z/N times.
In order to validate the proposed HTSG, the model is
simulated choosing an appropriate solver option and the
generated voltage pattern at no load is shown in Fig. 2. The
RMS value of the terminal voltage, i.e., 15.5 kV, is obtained,
which corresponds to the nominal design parameter. These
analysis and findings substantiates that the designed HTSG’s
design parameters and its nominal value corresponds to one
another.

Generated voltage (kV)

20

10

-10
Solid Model

-20

0 0.02 0.04 0.06 0.08 0.1

Time (sec)

Fig 2. Generated stator output voltage at no load.

III. THERMAL ANALYSIS OF 250 MW SYNCHRONOUS

GENRATOR
The performance and safe operation of the machines with
Initial 3D Mesh Model

high-power density are vastly derived from its thermal and

electromagnetic characteristics [21]. The thermal
characteristics are also significant as many other
characteristics, as this analysis outcomes the maximum
allowable operating range of any machine.
A. Loss calculation
Fig 1. Constructional Schematic of 250 MW scale HTSG The loss determination under actual operating conditions
is endorsed opportunity to measure the temperature rise of
The presented model replicates the CB 870/300-28 the cooling medium and frames of the machine. The
generator which is an existing 250 MW synchronous calculation and analysis of temperature field involve a wide
generator operated widely at large hydropower stations in range of knowledge on losses that are responsible for heat
India. This machine is of three phase, 28 poles and 348 stator transfer. Losses in large electrical machines can be
slot configuration (Appendix) is modelled and simulated categorized as given in Table I.
using MagNet 7.5 an electromagnetic 2D/3D field simulation
software, under steady-state and transient conditions. In TABLE I. LOSSES IN HTSG
Acronym Expansion Machine part Factors
MagNet, any model is designed with their physical Friction in the
dimensions in 2D as well 3D either by program modes or Mechanical Bearings and
Pmech bearings and a term
through applying their graphical coordinates [19]. The Loss rotor
called wind age
MagNet 7.5 2D/3D program modes calculate the Stator and rotor
Current and resistance
electromagnetic parameters for any designed machine model Pcu Copper Loss in the stator and rotor
windings
using FEM. The solver program takes into account the circuit
Various parts of Machine’s design
impact of slot windings, iron losses and magnetic material’s Pst Stray Loss
machine imperfections
nonlinearity [19]. The model was created with a dense Fundamental
meshing to cause a fine solution and long computational time Stator and rotor
Pfc Iron Loss frequency AC flux in
cores
[20]. The designed model’s 2D/3D solution works with the core
maximum nodes, mesh elements and high resolution, which
is automatically shaped by means of adaptive mesh
The calculation of these losses involves different
generation inbuilt technique and is shown in Fig.1.
methodologies and equations, the copper losses are typically

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calculated by well-defined analytical equations as in Eq.2
[15] in which Rs is stator winding resistance and Irms is stator
rms current. Whereas, the calculation of iron losses is
possible only for the models that own hysteresis (Phy) and
eddy current (Pec) components and can be expressed as in
Eq. 3 [22] at alternate flux density B̂ at frequency f.
= 3 × R s × I rms
2 (2)
P cu
= + = k hy Bˆ β f + k ec Bˆ 2 f
P fc P hy P ec
where khy and kec are the hysteresis and eddy-current
constants and are obtained from data sheet curve fitting.  is
the Steinmetz constant which is often approximated as 2.
In the case of FEM tool implementation these losses are
obtained by the inbuilt program within the solver and are fed
as input for coupled thermal fluid dynamic analysis.
B. Thermal Boundaries
As per IEEE C-50-12 and other standards such as
IEC:60034 and also IS:4722 the effective operating
temperature of a salient-pole air-cooled synchronous
generators are 40oC for open ventilated cooling system and
25oC for totally enclosed water to air cooled system. If the
cooling air ambient temperature exceeds the stated
temperature, then the maximum permissible temperature will
be based on temperature rise on reference temperature
(40oC/25oC) of the insulation class. Moreover, NEMA
specifies the permissible temperature based upon a reference
ambient temperature of 40°C at full load. According to the
resistance method followed by NEMA, the temperature rises
for a machine with class F insulation and service factor1.15
is calculated to be 115°C. Summing the reference ambient
temperature of 40°C to along with calculated temperature
rise the maximum operating temperature is 155°C.
It is also established that for any insulation the aging
occurs when operated above a certain threshold temperature.
From literatures the aging occurs cumulatively double the
temperature for each 10oC temperature rise. By description, a
generator with class F insulation operating at its rated
temperature for 20,000 hours will lead to drop its mechanical
strength by 0.5 times. Considering all these factors,
limitations are provided in the FEM tool in terms of applying
appropriate boundary conditions.
C. FEM Thermal Analysis
In-order to calculate the temperature field of hydro-
generators precisely, it is vital to estimate the power losses
and equivalent conductivity of the simulation model using
MagNet 7.5. The solving methods exploited by this FEM
tool are Newton Rapson and Successive Substitution
methods for solving 2D/3D models, respectively. The solver
is assessed through meshing and is characterized by the h
adaptation for 2D and p adaptation for 3D models and the
outcomes are presented in 2D/3D Static, Time-Harmonic and
Transient formats. Fig.3 shows the field distribution/flux
linkage of the targeted HTSG under the rated operating point
at an arbitrary time instant.
The FEM tool can also handle problems with automated
design optimization and provides thermal simulations and
vibration analysis. Anyhow, for a detailed thermo-electric
analysis, an additional product of MagNet 7.5 called
ThermNet 7.5 is incorporated. It is linked with MagNet 7.5
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for coupled thermal-electromagnetic field simulations. The
field simulation is conducted by means of a direct coupled
field solution providing the full set of thermo-electric
relevant effects.
Stator
Winding
Stator Core
Stator Teeth
2 (3)
Rotor
Winding
Rotor Core
Fig.3. Flux pattern of 250 MW scale HTSG with part
IV. TEMPERATURE DISTRIBUTION OF A 250 MW HTSG
In this section, the simulation of electromagnetic
parameters using FEM analysis is discussed in detail. To
verify the simulation results, a case study on a 250 MW
HTSG is carried out. Furthermore, comparative study is
carried out between the machine considered in case study
and FEM analysis subjected to HTSG operate at different
overloading conditions.
A. Case Study
The hydropower plant considered for this case study
works with four generating units equipped with synchronous
generator delivering the rated power capacity of 250 MW
each. The scope of the case study is to substantiate the
adequacy and safety of the electrical machine i.e the HTSG
for continuous generation of 10% and 20% overloads i.e. 275
MW and 300 MW respectively. The criteria for checking the
adequacy and safety aspects in this case study are
particularized to the rise in temperature with respect to the
guaranteed parameters as well as the corresponding standards
and grid codes. Like the most widely practiced cooling
systems these HTSGs are also furnished with a closed air
circulating cooling system. Moreover, arranged with
additional surface air coolers positionedd symmetrically all
around the outer limits of the stator frame. In India, these
surface air coolers shall have an adequate cooling capacity to
maintain the temperature of the air leaving the cooler at 35oC
or less. It may be noted that as per Indian Standard, the
present practice is to specify a class F insulation system for
stator and rotor windings, end connections, main & neutral
leads. The specifications and thermal limits of class F
insulation were discussed in Section III.
In this context, the temperature distribution and
temperature rise analysis of the test hydrogenerating unit is
carried out for continuous 52 days. The analysis is focused to
52 days, because the plant was operated continuously at
120% load. Moreover, it is noted that when the water flow in
the river is significantly high the plant was operated with
wide variation in power delivery during this period. Thus a
comprehensive analysis has been done on the temperature
rise attained by the HTSG serving particular generating unit.
A continuous running plot of day wise minimum and
maximum temperature sensed by sensors when operated at
rated load from 1st day to 11th day and 20% overload from
12th day to 52nd day are shown in Fig.4.
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TABLE II. COLOUR SCALE ANALYSIS OF COOLING WATER SYSTEM

Primary
Secondary
Inlet Outlet
Date Flow flow
temp. temp.
m3/h 0 0 m3/h
C C
Day 19 1032 14.0 15.6 873
Day 33 1031.829 16.5 18.2 874.2188
Day 34 1021.123 16 17.8 863.5416
Day 35 1022.859 15.6 17.4 875.2604
Day 41 1031.829 15.9 17.7 874.2188

Heat run test of the hydropower unit at rated and

overloads conducted at the time of commissioning is
summarized in Table III. At commissioning, test was
(a) Stator winding temperature conducted based on the calorimetric method of efficiency
measurement at various load points as per IEC 60034-2-2.
Perusal of the report furnished by the project developers
indicates that the weighted average efficiency meets the fail-
safe requirements by 99.0 %. From the foregoing analysis, it
is evident that the performance of the HTSG at various loads
including 300MW has been highly satisfactory and they are
adequate and safe for 300 MW of power delivery. In
addition, a comparison between the heat run data and the
design data has been done and tabulated in Table IV.
TABLE III. GENERATOR HEAT RUN TESTS AT 250 MW, PF=0.90
Generator parts Maximum
Sl.No Unit Value Average
temperature value
o
1 Stator Winding C 95-100 97.5 100
o
(b) Stator core temperature 2 Stator Core C 73-75 74 75
o
3 Stator Teeth C 66-70 68 70

TABLE IV. COMPARISON BETWEEN HEAT RUN DATA AND DESIGN DATA
Temperature rise (K)
Actual data
Sl.No Generator parts As per (Load heat run data)
Contract Considering Considering
avg. value max. value
1 Stator Winding
above cold air 70 66.5 69
temperature
2 Stator Core w.r.t
60 43 44
cold air
3 Stator Teeth w.r.t
-- 42 44
cold air

(c) Stator teeth temperature

(d) Rotor winding temperature
Fig.4. Day wise temperature plot of 250 MW HTSG equipped
hydrogenerating unit
Similarly a colour scale analysis of the temperature rise
in air cooler and cooling water system on particular day in
which the maximum temperature was observed has been
presented in Table II.
B. FEM Analysis
The thermal simulations have been executed in view of
the ambient temperature as 40oC. The results are illustrated
as temperature distribution and temperature rise metaphors in
Fig.5. The temperature is measured at four parts of machine
such as stator winding, stator core, stator teeth and rotor
winding at 50 Hz supply as like as the practical tests. The
simulations have been performed considering three arbitrary
loading points such as rated load, 10% overload and 20%
overload under corresponding Problem ID. The rotor of the
HTSG FEM model was treated as torque driven and was
governed at three different load points in such a way that the
machine can deliver an output power of 250, 275 and
300MW, respectively as shown in Fig.5.
Comparing the FEM simulation graphical temperature
metaphors, it is conceivable to realize that the losses are
highly dissipated from the stator winding than other parts and
is mainly due to copper losses. It is observed from the rise in
temperature investigation that the manufacturer provide
maximum permissible temperature rise for rotor than other

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rise at distinct stages of overloads. A comparative colour

scale analysis between the case study and FEM analysis is
tabulated in Table V. Though all the dimensions, materials
and boundary conditions of the HTSG used for the case
study are similar to those of the bench-scale machine used in
FEM analysis. It may be noted that in some aspects they
both differ from each other like chemical properties of
materials used, exact structure of the machine, etc.
Therefore, the results are also compared between case study
Problem ID: 1
and FEM analysis with the rise in temperature at arbitrary
load points in addition and presented in Table VI.

Problem ID: 2

(a) At 10% overload

Problem ID: 3

Problem Torque driven Output

ID rotor (kNm) power (MW)
1 11140.82 250
2 12254.11 275
(b) At 20% overload
3 13368.13 300
Fig.5. Thermal distribution metaphors of 250 MW scale HTSG Fig.6. Comparison between case study and FEM analysis

parts of the machine. From the case study and FEM Comparison between the results obtained from case
simulation the maximum temperature rise is observed at the study and the FEA analysis is shown in Fig. 6. The minor
stator windings than the rotor core. Likewise, the stator core errors existing between both the results may be due to
and teeth maintain an almost equal quantity of temperature thermal convection resistance and the position error of
TABLE V. TEMPERATURE DISTRIBUTION COMPARISON BETWEEN CASE STUDY AND FEM ANALYSIS
Temperature distribution (oC)
Machine parts Case study FEM Analysis
at 100% load at 110% load at 120% load at 100% load at 110% load at 120% load
Stator Winding 109 110.43 112 110 111.5 113
Stator Core 79.5 81 82.5 80 81.5 83
Stator Teeth 80.86 82.38 83.9 81.3 82.82 84.34
Rotor Winding 89 91.25 93.23 88.5 90.615 92.73

TABLE VI TEMPERATURE RISE COMPARISON BETWEEN CASE STUDY AND FEM ANALYSIS
Temperature rise (K)
Permissible temperature rise as
Case study FEM Analysis
Machine parts per contract with E&M supplier
at 100% at 110% at 120% at 100% at 110% at 120% at 100% at 110% at 120%
load load load load load load load load load
Stator Winding 64 75 74 65 76 75 70 75 80
Stator Core 38 43 48 38.5 43.5 48.5 70 75 80
Stator Teeth 39 44 49 39.4 44.4 49.4 70 75 80
Rotor Winding 45.23 50.23 55.23 44.7 49.7 54.7 80 85 90

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