Investigation of Primary Dimension Determining
Method for High Voltage Cable-Wound Generator
GE Baojun, DONG Chuanyou, TAO Dajun, LIN Peng, Sheng Boyao
Harbin University of Science and Technology
Harbin, China
E-mail: Gebj@hrbust.edu.cn, dcy131086@163.com
Abstract—High voltage cable-wound generator, the stator
winding of which is made of high voltage cables, is a new type of
generator. And its stator structure is different from that of
classical generator, so the designment of the primary dimension
of high voltage cable-wound generator is not same as
conventional generator too. In this paper, the primary dimension
determining method for High voltage cable-wound generator is
investigated based on the primary dimension determining
method of conventional generator, and the specific determining
process of primary dimensions of high voltage generator is
explained with an example.
Keywords-high voltage cable-wound generator; electric
machine design; primary dimension
I. INTRODUCTION
In February 1998, ABB corporation declared that a high
voltage generator (Powerformer) has been developed
successfully, which could directly be connected to the power
network, and it was installed in Foundation Porjus centre
hydro-power [1] in the north of Sweden. Subsequently, the
research institutions of China began to study of high voltage
cable-wound generator in 2001 year and it was called energy
converter, high voltage generator or power generator[2][3].
The stator windings of high voltage generator is made of
high-voltage cross-linked polyethylene (XLPE) cable, the
section of which is circular and the electrical field distribution
around it is uniform. So the output voltage can achieve grid
voltage level, which makes the high voltage generator can be
linked with the transmission grid directly [4] [5]. Cables are
used as stator winding of high voltage generator and the slots
are composed of circles interact linked. The stator structure of
high voltage generator is different from conventional generator
greatly, and the determining method of primary dimensions for
conventional generator is not suitable for high voltage
generator. Now, there are many papers studying on high
voltage generator at home and abroad, for example, reference
[6] investigates the stability of high voltage from the heating of
stator winding, it is found that the time constant of high voltage
generator is longer than that of conventional and the over-load
capacity of the winding heat load is larger than conventional
generator, reference [7] calculates and analyzes the leak
reactance of high voltage, reference [8] studies the impact of
Project Supported by National Science Foundation of China (50577012) and
Innovation Found Project for Graduate student of Heilongjiang Province
(YJSCX2009-030HLJ)
Ge Baojun was born in 1960.He received PH. D. degree from Harbin Institute of
Technology, Heilongjiang Province, China. Dr. GE is now a Professor of Harbin
University of Science and Technology. He mainly studies on basis theory and
application technology of large electromechanical energy conversion device
DONG Chuanyou was born in 1981. He is a postgraduate student now and studies
on the electromagnetic calculation of large synchronous generator.
978-1-4244-4813-5/10/$25.00 ©2010 IEEE
high voltage on the stability of power grid with dynamic
simulation, reference [9] introduces the short-circuit tests of
high voltage generator, reference [10] analyzes the steady-state
and fault of double winding high voltage generator, reference
[11] establishes the model of the internal single phase to
ground fault of high voltage generator. Reference [12] presents
the process of the development of high voltage generator
prototype though, and primary dimensions, results of
electromagnetic calculation of prototype are also presented, the
determining process of primary dimension is not analyzed at
length, therefore it is necessary to study the method of
determine the primary dimensions for high voltage
cable-wound generator systematically.
In this paper, primary dimensions determining method for
high voltage cable-wound generator is investigated according
to the mechanical and electric characteristic of high voltage
cables, and the determining methods of stator inner diameter,
stator external diameter and stator core length are presented,
the specific determining process of primary dimensions is
explained with an example.
II. METHOD OF THE PRIMARY DIMENSIONS OF
CONVENTIONAL GENERATOR
The generator primary dimensions include the outer
diameter of stator core D1 , the inner diameter of stator core
Di1 and the core length lef . For multi-pole generator, the
general method is to determine the polar distance firstly, and
then calculate the diameter of the stator core with equation (1).
2 pτ
Di1 = (1)
π
where， p is the number of pole pairs, and τ is the polar
distance (cm).
A. Choice of polar distance τ
According to difference cases, the following methods are
used to select polar distance initially:
1) According to the curve by manufacturing practice and
the empirical formula
S
τ = K1 N (2)
2p
where, D1 is coefficient, and D1 = 9.0 − 12.5 (medium
capacity) or 8.3-10.7(the maximum is taken for large capacity
and high speed).
 2) According to the allowed maximum circumferential 1.95 (large-capacity). Taking C into equation (8), we can get
speed of the mechanical strength the length of stator core.
Due to the calculated value τ (cm )is equal to the value
III. DETERMINATION METHOD OF PRIMARY DIMENSIONS
vN ,the circumference speed of the rotor(m) calculated under
FOR HIGH VOLTAGE GENERATOR
the rated speed, therefore, polar distance and the runaway
speed have the following relationship: As High voltage generator is based on cable windings, when
determining the primary dimensions of high voltage
vr cable-wound generator, in addition to taking into account the
τ= (3) traditional motor design requirements, it also needs to take into
Kr
account the stator windings of cable bend radius. At the same
when f≠50Hz: time, due to the winding technology of high voltage generator
windings is different from the traditional generators, stator core
vr 50 length should not be too long taking into account convenience
τ= (4)
Kr f of cable embedded.
A. Determination of stator core inner diameter and core
where, vr is the circumference speed of the rotor under the
length of High voltage generator
runaway speed, which can be obtained by table searching; K r
High voltage generator windings generally use concentric
is the Runaway coefficient, which is the ratio of generator unit windings. Suppose slot number per pole at one phase is q ,
runaway speed and rated speed. then the indicated polar distance indicated by slot number is
3) According to the requirement of GD 2 3q . Then the innermost coil span of concentric winding is
SN 2q + 2 , and the polar distance is:
τ = 13K 2 4.5 15 (5)
p 3q 3q 3
τ= Dd ≈ Dd = Dd (9)
where, S N is the generator rated capacity; K 2 is the 2q + 2 2q 2
coefficient, K 2 = f (lef τ ) . where, Dd is diameter of end connection of concentric
4) According to the design requirement of direct-axis Winding
transient reactance parameters（ X d′ ）and the temperature rise Stator inner diameter is determined by the method for the
allowable for stator windings traditional generator.
SN 2 pτ
τ = K1 K 2 (6) Di = (cm) (10)
2 p X d′ π

where, K1 is coefficient; K1 = f (lef τ ) ； K 2 is a coefficient The length of stator core:

about speed, which can be obtained in table. E
lef = (11)
When the inner diameter of stator core is confirmed, its outer 4.44 fK dp NBδ τ
diameter can be determined from empirical formula.
The Stator windings of High voltage cable-wound generator
D1 = Di + Kτ (7) uses high-voltage cross-linked polyethylene (XLPE) cable as
the stator windings. To ensure the strength of cable insulation,
where, K is the empirical coefficient, which can be obtained cable bend diameter should be as large as 30 ~ 40 times of
by table. cable diameter [7].
B. Determine of the stator core length Dd = (30 ~ 10)Φ d (12)
The inner diameter of stator core is determined after the
determining of polar distance τ , then lef can be calculated Di =
3p
Dd =
(90-120)p
Φd (13)
by mean of following formula. π π
S where, Φ d is XLPE cable diameter.
lef = 2
N
(8)
D n C
i N Once the polar distance τ is determined, the stator core
C = KABδ inner diameter can be determined, then the lef can be
determined according to Eq.8.
0.16
⎛S ⎞ B. Determination of stator core outer diameter for High
According to empirical formula C = K ⎜ N ⎟ , where K is
⎝ 2p ⎠ voltage generator
a coefficient, K =1.46-1.86(medium capacity)， K = 1.58 ~ Stator slot opening width and height are determined should
take into account the impact of slot leakage reactance. The
actual circular slot diameter is about 1.5 mm lager than the TABLE I. TALBLE1 HIGH-VOLTAGE CROSS-LINKED POLYETHYLENE
(XLPE) CABLE PARAMETER
stator cable outer diameter, which can be determined stator slot
width according to cable outer diameter.
Specification Insulation
Voltage class(kV)
Stator slot width: (mm2) Thickness(mm)

R2 = Rs 2 + 0.75 (14)
3.6/6 1*25 2.5
R1 = Rs1 + 0.75 (15)
6/10 1*25 3.4
where, R1 ， R2 are diameters of two kinds of cables, as
shown in Fig. 1. 8.7/15 1*25 4.5

B. Determination of the High voltage cable-wound generator

R2 R1 stator diameter
Bs 0 Cross-linked polyethylene-linked cable’s diameter is:
H s0 25
Hs Φd = 2 + 2.5 × 2 = 11(mm)
π
Figure 1. Figure 1 High voltage cable-wound generator Stator Slot structure Then according Eq.13 ， High voltage cable-wound
generator stator inner diameter can be calculate：
Depth of stator slot:
(90-120)p
H s = H s 0 + 2 N 2 R2 + 2 N1 R1 (16) Di = Φd
π
where, N 2 and N1 are the number of circular slots with (90-120)
= × 3 ×11
radius of R2 and R1 respectively, H s 0 is slot opening π
height = 945(mm)

Stator diameter: C. Determination of High voltage cable-wound generator

core length
Bδ Di
Hj = (17) The High voltage cable-wound generator core length is
4 pB j expressed as following formula:
where, B j is stator yoke flux density S
lef = 2
N

Yoke flux density is generally between 1.0~1.1T, and the
height of yoke should be guaranteed a certain value in order to
ensure adjustment of the stator core. Therefore, the outer
diameter of high voltage generator stator core can be
determined by the following formula:
D1 = Di + 2( H s + H j )
IV. EXAMPLE
A High voltage cable-wound generator with 6 poles, rated
voltage of 10.5kV and rated capacity of 750kW is taken for an
example, and the primary dimensions of High voltage
cable-wound generator is determined according to the above
method.
A. Selection of cable dimensions
The cable insulation level is analyzed according to the cable
voltage test and breakdown test. The cable dimensions
parameter is listed in the table. 1.
The 3.6/6kV cable can be used in this High voltage
cable-wound generator according to the Tab.1 and previous
High voltage cable-wound generator prototype cable winding
design experience, of the High voltage cable-wound generator
a. The wire cross-sectional area of this specification winding is
25mm 2，its insulation thickness is 2.5mm.
D n C
i N
1000
= 2
0.96 × 1000 × 3.3
= 328(mm)
where C = 3.3
(18) D. Determination of the High voltage cable-wound generator
stator outer diameter
According to empirical data, the stator standard diameter of
High voltage cable-wound generator with 6 poles, rated voltage
of 10.5kV and rated capacity of 750kW is D1 =118cm.
Because of its size is larger than the classical generator stator
size, the stator outer diameter cannot be chosen standard size
but next following frame size, which D1 =143cm.
V. CONCLUSIONS
• Cables are used in High voltage cable-wound generator
as its stator windings. Stator inner diameter of high
voltage cable-wound generator can be designed bigger
than that of conventional generator with the same
capacity because of restrictions of cable bend diameter,
and the length of stator core is shorter of high voltage
generator than that of conventional generator.
• The maximum bend radius of cables must be remarked
 in the determination of stator inner diameter according
to polar distance, it is because that cables are used in
high voltage cable-wound generator as its stator
windings.
• The bigger number stator frame is chosen in the
process of determination of stator external diameter for
high voltage cable-wound generator because of low of
the coil space factor and big of stator dimensions of the
high voltage generator.
REFERENCE
[1] Mats, Leijon, “PowerformerTM ——A radically new rotating machine”,
ABB Review, 1998, no. 2, pp. 21-26.
[2] Ge Baojun, Zhang Dakui, Liang Yanping, “Powerformer and Its Recent
Development”. Transactions of China Electrotechnical Society, 2005,
vol. 20, no.1, pp. 26–30 (In Chinese).
[3] Ge Baojun, Liang Yanping, Zhou Chuiyou, Song Fuchuan, Wang
Zhimin, Li Fahai. “Powerformer——a Nascent Electric Power
Generation Equipment for the 21st Century”. Automation of Electric
Power Systems, 2004, vol. 28, no. 7, pp. 1–4 (In Chinese).
[4] Dettmer R, “The heart of a new machine [Powerformer, cable-wound
stator machine]”, IEE Review, 1998, vol. 44, no. 6, pp. 255-258.
[5] Metwally, I A. Radwan, R M. Abou-Elyazied, A M, “Powerformers: a
breakthrough of high-voltage power generators”, IEEE Potentials, 2008,
vol. 27, no. 3, pp. 37-44
[6] Lindahl, S. “Improved control of field current heating for voltage
stability machine design-PowerformerTM”. Power Engineering Society
Winter Meeting, Columbus, USA, Jan, 2001, vol. 1, pp. 209-214.
[7] GE Baojun, ZHANG Dakui, LIANG Yanping, et al. “Analysis and
Calculation of Stator Leakage Reactance of Powerformer”. Power
System Technology, 2005, vol. 29, no. 3, pp. 15-22 (In Chinese).
[8] Aumuller, C.A. Saha, T.K. “Investigating the impact of Powerformer on
voltage stability by dynamic simulation”. IEEE Transactions on Power
System, 2003, vol. 18, no. 3, pp. 1142-1148.
[9] STEFAN G Johansson, BERTIL Larsson. “Short-Circuit Tests on a
High-Voltage, Cable-Wound Hydropower Generator”. IEEE
Transactions on Energy Conversion, 2004, vol. 19, no. 1, pp. 28-33.
[10] MARGUERITE Touma-Holmberg, KAILASH Srivastava. “Double
Winding, High-Voltage Cable Wound Generator: Steady-State and Fault
Analysis”. IEEE Transaction on Energy Conversion, 2004, vol. 19, no. 2,
pp. 245-250.
[11] SU Guoxia, GE Baojun, TAO Dajun, et al. “Modeling and Analysis of
Internal Single Phase to Ground Fault in Powerformer”. Electric
Machines and Control, 2007, vol. 11, no. 6, pp. 584-588 (In Chinese).
[12] Ge Baojun, Wang, Xiaowen, Tao Dajun, et. al, “Development of
Powerformer prototype”, Electric Machnies and Control, vol. 12. no. 4,
pp. 370-373. (In Chinese).
[13] Bai Yannian. Design and calculation of hydraulic generator. Beijing:
China Machine PRESS, 1982 (In Chinese).
[14] Chen Shikun. Electric machine design. Beijing:China Machine Press,
2002 (In Chinese).
[15] Yang Xilai. “The Electromagnetic Design and Parameter Calculation of
Powerformer by Fem”. Harbin University of Science and Technology,
2005, pp. 9–13 (In Chinese).
[16] MA Wenzhong, LI Yaohua, KONG Li. “Research on the Characteristic
of the Winding Cable in High Voltage Motor”. High Voltage
Engineering, 2006, vol. 32, no. 3. pp. 24 (In Chinese).