STATOR GENERATOR BARS ELIMINATION

AS EMERGENCY SOLUTION FOR GENERATOR PROBLEM

Tri Tjahjonoputro, Buyung Arianto, Wasis Jati Waskitho

Indonesia Power, Tj. Priok Generating Business Unit

Abstract

Gas turbine generator 2.3 Tanjung Priok Combined Cycle Power Plant was fault. There was a short circuit on
stator winding bar phase R. Short circuit was caused by insulation failed. End winding junction of bar number 15
was melted. The result of this phenomenon is decreasing of some bars volume. Decision had already made;
eliminating the broken bars because it has lower risk than bar welding/ connecting. Two turns (4 bars) of
winding phase R was cut and so did another phase (S & T) for voltage balancing. The new bypass connection
was made to connect the normal winding. The result, 12 of 120 bars had already eliminated. Elimination of
these bars consequence at 10% drops of generator output voltage. Overcome this consequence; ratio changing
was made at Main Transformer’s tap changer to compensate the lower generator output voltage. The Main
Transformer’s output voltage became equal with transmission voltage. Tap changer ratio in Auxiliary
Transformer was also changed for gain an auxiliary voltage same as before. Resetting generator protection
relay and excitation system was done in order to match between old and new generator value and made
generator and gas turbine operation safer. Control and evaluation of generator operation after elimination
process have been made. Generator has been operating normal and safely although it was not in maximum
rate until now (5 months). We hope this paper can give inspiration to face the generator problem in other power
plants.

1. Introduction Rated current : 7698 A

Gas turbine generator GT 2.3 Tj. Priok CCPP was Rated frequency : 50 hz
fault. There was short circuited on phase R. It was Rated speed : 3000 rpm
caused by insulation failed. End winding junction Poles :2
on bar number 15 was melted. It resulted Phases :3
decreasing of bar volume in some bars especially Stator connection : star
in bar number 15. The circle of winding in DE side Excitation voltage : 310 V
got the carbon dust from the arching process in bar Excitation current : 1437 A
number 15. Cooling media : air
Simplified modeling of stator wiring :

Fig 1. End winding was melted

2. Objective
• To recover the generator condition as soon as Fig 2. Stator wiring
possible
• To decide what the optimal way to recover 4. Problem
generator End winding junction of bar number 15 was melted
• To anticipate the operation character after and it caused decreasing volume of some bars.
recovery Generator must operate in normal and safe
condition as soon as possible.
3. Generator GT 2.3 Priok CCPP
Specification of generator GT 2.3 Tanjung Priok 5. Solution
Rated apparent power : 210 MVA It was decided to eliminate bar number 15 in one
Rated active power : 168 MW turn (2 bars) because it had lower risk than bar
Rated power factor : 0.8 welding. We could account the effect of bar
Rated voltage : 15.750 kV (+/- 7.5%) elimination but it couldn’t for bar welding. The

HAPUA Workshop, 15-16 July 2008 1

special bypass connection was made to connect B = air gap flux density (T)
the normal winding. In other hand, management d = rotor diameter (m)
took the decision to order the new stator set to l = rotor length (m)
change existing stator. It needs at least 2 years n = rotational speed (s-1)
duration. k = machine construction coefficient

6. Basic Elimination wk p kd
Basic concept of elimination process is decreasing k =
the number of some winding bars. 4 bars (2 turns) 2
of phase R were cut and isolated. For voltage wk p kd
balancing, other phases were cut for the same k ' = 0 .9 ×
2
number of bars.
S ' = 0 .9 × k × A × B × d 2
× l × n
S = 0 . 9 × 210 MVA
'

S ' = 189 MVA

Rated current before elimination :
S = 3 ×V × I
S 210MVA
I= = = 7698 A
3 ×V 3 × 15.75kV

Rated current after elimination :

S 189 MVA
Fig. 3 Elimination Modeling I= = = 7698 A
3 ×V 3 × 14.175kV
The result of elimination process was voltage and
apparent power rating of generator decreased. 7. Elimination Process
Phase voltage equation : Elimination process need 34 time working days
(some of days use double shift). Two turns (4 bars)
φ
U ph = 2 × π × f × w × f w × ×l of winding phase R was cut also another phases
l for voltage balancing. Generator winding bars
Uph = phase voltage totally 12 bars were cut. Hipot testing was done
f = frequency (hz) before elimination process to ensure the condition
w = number of turns (turn) of winding bar in every phase. The broken bar was
fw = winding factor separated to ensure the condition of normal bars.
Ø/l = magnetic flux per unit length of rotor (Tesla) Eliminated bars were isolated but still in existing
l = rotor length (m) slot. Special bypass connection was made to
connect the normal bar.
For Y connection :
Vt = 3U ph
Vt = generator terminal voltage

Decreasing turns number 6/60 = 0.1

w' = w − 0.1w = 0.9 w
If the existing terminal voltage generator is 15.75
kV, so the new voltage after elimination (Vt’) is :
φ
Vt = 3× 2 × π × f × w × fw × × l = 15 . 75
l Fig. 4 Bypass connection
φ
Vt ' = 3× 2 × π × f × 0 .9 w × f w × ×l
l
V t ' = 0 . 9 × V t = 0 . 9 × 15 . 75
V t ' = 14 . 175 kV

The elimination process change the Rated

Apparent Power of generator :
S = k × A× B × d 2 × l × n
S = rated apparent power (MVA) Fig. 5 Connecting two bars &
A = electrical loading in stator (MA/m) eliminating two other bars

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Some materials for elimination process are : tin, Parameter Setting Changing of Protection Relay
bypass connection, insulation. Some tools for
process are heater, Hipot test tools. Hipot testing Protection Setting
was done after elimination process to ensure that Function Before After
all winding have normal insulation system. The Voltage Input 1.00 UN 0.90 UN
elimination process taken budget Rp. Overcurrent- 1.40 IN 1.10 IN
8,351,791,374.40 ,- (USD 907.000,-). It spent for Undervoltage 4.0 s 4.0 s
NPS I 0.08 IN 0.05 IN
materials and service.
NPS II 0.08 I2/IB 0.05 I2/IB
Overvoltage 1.40 UN 1.10 UN
8. Compensation of Elimination Inst. 0.2 s 0.1 s
Elimination process of generator made the Overvoltage 1.20 UN 1.076 UN
generator voltage output was decrease. Def. Time 3.0 s 6.0 s
Decreasing voltage of generator made the Table 3. Parameter Setting Changing of Protection Relay
electrical system change. Some equipment were
changed its setting for normal and safe operation Parameter Setting Changing of Excitation System
again.
Parameter Setting Setting
Original New
− Main and Auxiliary Transformer
Voltage Reference Value :
Tap changer ratio of main transformer was preset 100% 90%
changed to the highest ratio. This ratio changing maximum value 107.5% 95%
permitted the transformer synchronize with 150 kV minimum value 92.5% 85%
network. V/ hz limiter :
max overvoltage 115% 97%
Tap HV LV Ratio Position [U(p.u)/ f(p.u)]
1 162750 15750 10.33 X (new) Reactive Current Influence 5% 0%
Field Current Limiter : 105% 100%
2 158875 15750 10.09 thermal reference value
3 155000 15750 9.84 Stator Current Limiter :
thermal reference value
4 151125 15750 9.60 X (existing) - overexcited 130% 100%
5 147250 15750 9.35 - underexcited 105% 100%
Table 1. Main Transf.Tap changer position Table 4.Parameter Setting Changing of Excitation System

New range of voltage regulation after elimination is 9. Monitoring after Elimination

14.175 (+5/-3%). It means that range of voltage are Monitoring and evaluating activities have been
between 13.75 – 14.8 kV. Transformer tap on tap 1 doing after elimination. Generator was started on
position means that range of main transformer December 31st, 2007. Generator has been
output are between 142 – 153 kV. operating normal and safely until now, although it
Tap changer of auxiliary transformer was changed was not in maximum rate. Monitoring and
to the lowest ratio. The changing of tap ratio mean evaluation were done for some parameter such as
the auxiliary transformer can serve their loads (GT temperature winding and partial discharge value.
auxiliary) normally. The table 5 show the winding temperature at 90
and 100 MW load of generator.
Tap HV LV Ratio Posisi
1 16537.50 400 41.34 RTD 90 MW 100 MW

2 16143.75 400 40.36 Position (° C) (° C) %

3 15750 400 39.38 X (existing) Slot 2 95.28 99.26 3.98 4.18

4 15356.25 400 38.39 Slot 10 96.49 100.66 4.17 4.32
5 14962.5 400 37.41 X (new) Slot 18 96.07 100.27 4.2 4.37
Table 2. Auxiliary Transf. tap changer ratio Slot 26 95.87 99.92 4.05 4.22
Slot 34 95.71 99.58 3.87 4.04
The changing of that tap made the voltage output
of auxiliary transformer is 378 V. This voltage is for Slot 42 94.99 99.04 4.05 4.26
serve the auxiliary equipments which have 380 V Table 5. Increasing of winding temperature
voltage input.
Average temperature winding on 100 MW loading
− Setting of Generator Protection and Excitation is 990 C. Generator insulation use class F material
Consequence of elimination process that made (maximum temperature 1550 C). It means that
difference at generator impedance and voltage temperature winding operation is 550 C below the
rating constrained to change some parameter maximal value. Generator insulation will be life for
setting on generator protection relay and excitation 25 -30 years if the operating temperature is 300 C
system. below the maximum rate[3]. Generator has been

HAPUA Workshop, 15-16 July 2008 3

operating from January until now (June) with
average 100 MW loading. We haven’t been
operating the generator more than 100 MW for
safety reason.
Phase R = 0.78 nC
Phase S = 0.80 nC
Phase T = 0.69 nC
Fig 6. Partial discharge value
The nominal value of partial discharge after
elimination process saw the low value (under 1 nC).
Lower of partial discharge value mean better
condition of insulation level.
10. Benefits
Some benefits have been taking from elimination
project. The important thing is generator can
operate normal and safely for produce electricity.
Elimination project was an emergency project
because it just gain a result that operation of
generator was not in its rate. Management had to
order new stator set to change the existing stator
set and then the normal output parameter will be
back again. This ordering time process will take
time 24 months.
Generator has been operating from January until
now (June) with average 100 MW loading. If We
count the generator income with average load 100
MW from January until now (June) :
Rp
= 321 . 46 × 24 × 180 × 100 MW
kWh
= Rp 138 ,870 , 720 , 000 , −
= USD 15 , 094 , 695
Other benefit of this project was generator
operation increase the reliability of interconnection
system especially in Region 1 Java-Bali
interconnection.
11. Conclusion
− Decreasing volume of stator bars generator in
GT 2.3 Tanjung Priok CCPP occurred
because of end winding junction melting
− Stator bar elimination was done in generator
winding GT 2.3 to recovery its generator
HAPUA Workshop, 15-16 July 2008
− Elimination process consequence decreasing
generator output voltage and its apparent
power
− There were made new by pass connection to
connect the normal winding bars
− Decreasing generator output voltage were
compensated with the changing of tap
changing ratio of main and auxiliary
transformer
− Setting parameter of excitation and generator
protection were changed to synchronize with
new specification of generator
− Generator has been operating in normal and
safe condition from January until now (June)
− Elimination process was an emergency
solution because it can’t make the generator to
existing rate. Management had to order the
new stator set to return the generator output
rate.
12. Suggestion
Elimination process of stator winding bars is
applicable for other power plant if the
compensation factor for it process are feasible.
13. References
1. Power Plant Training Manual, Generator Vol. 1,
Tanjung Priok CCPP, ABB-Marubeni.
2. Generator Transformer For Gas & Steam
Turbine Generator (177 & 235 MVA),
Maintenance Manual, Marubeni-Hitachi Ltd.
3. Electrical Insulation for Rotating Machines
(Design, Evaluation, Aging & Testing), Greg C.
Stone, Hussein Dhirani, Ian Culbert, Edward A
Boulter, IEEE Press.
4. Electrical Machinery Fundamentals, Stephen J.
Chapman, McGraw Hill International Edition.
5. ABB Generator and Transformer Protection :
Lecture, ABB Network Partner AG.
6. GT 13E Setting Data for the Gen. Protection
Functions, No. GKW E 094 407, Tanjung
Priok CCPP, ABB-Marubeni.
7. Static Excitation System for Gas Turbine
Type : DDS-0/ 431. Tanjung Priok CCPP,
ABB-Marubeni.
14. Biographies
Tri Tjahjonoputro, Buyung Arianto, and Wasis
Jati Waskitho are employed by Indonesia Power,
Tanjung Priok Generating Business Unit,
Maintenance Department, based in Tj. Priok
Jakarta
Email address :
tri.tjahjonoputro@indonesiapower.co.id
buyung.arianto@indonesiapower.co.id
wasis.jw@indonesiapower.co.id
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