Design Problem :

Design the armature of the turbo-generator descr

ibed
i n the following specifications :

Output KVA = 8 300

Number of Phases = 3
Terminal Voltage = 1 0 500 V
p .f. of the load = 0.87
Frequency = 60 Hz
Type of drive = steam turbine
Speed, rpm = 2 000 rpm
Inherent regulation = within 25 % rise when
full
load is thrown off
Exciting voltage = 120 V
Permissible temperature = 45 C ( by thermo
meter )
rise after 6 hours,
full load run
Ventilation fan = independently dri
ven
( not part of generato
r)

C A L CU L A T I O N S
 Item 1 : Number of Poles
P = 120f = 120 ( 60 ) = 3. 6 say 4 poles
N 2000

Item 2 : Peripheral Speed ( fpm )

Assume v = 17 000 fpm

Item 3 : Diameter of rotor

D r = v ( 12 ) = 1 7 0 0 0 ( 1 2 ) = 3 2. 4 6 8 i
n
π (N) = π ( 2000 )
U s e 3 3 i n. ( f o r a i r g a p a l l o w a n c e )

Item 4 : Line Current

I= S = 9 000 = 4 5 6. 3 8 2
A
√3 VL √ 3 ( 1 0. 5 )

Item 5 : Phases Connection ( Star or Delta )

Star Connection

Item 6 : Volts per phase

Vo = VL = 1 0, 5 0 0 = 6 0 6 2. 1 7 8
V
√3 √3

Item 7 : Specific Loading

Referring to Article 7 1 by using extrapol
ation
with midrange value

5 000 850
10 000 900
8 300 q
 8 300 – 10 000 = x - 900
8 300 – 5 000 = x - 850
- 1 700 x + 1 445 000 = 3 300x – 2 970 000
X = q = 883

Item 8 : Current in armature conductors

( F r o m I t e m 4 ) I = I C = 4 5 6. 3 8 2 A

Item 9 : Armature ampere - turns per pole

( T I ) a = T q ; T = π D = π ( 3 3 ) = 2 5. 9
18
2 P 4
( TI ) a = T q = 2 5. 9 1 8 x 8 8 3
2 2
( TI ) a = 11 442 . 797

Item 10 : Length of air gap at center

A s s u m e d B g ‘’ = 3 0 0 0 0 l i n e s p e r i n 2
S = 1 . 2 5 q T = 1 . 2 5 ( 8 8 3 ) ( 2 5. 9 1 8 )
B g ‘’ 30 000
S = 0. 95 3

Item 11 : Internal Diameter of Stator ( armature )

D = 32. 468 + 1 = 33. 468
S a y 3 4 i n.

Item 12 : Pole Pitch

T = 2 5. 9 1 8 ( F r o m i t e m 9 )

Item 13 : Pole Arc

Distributed Winding

Item 14 : Percent of armature covered by pole

 Distributed Winding

Item 15 : Number of inductors per phase

Z = π D q = π ( 33 ) ( 883 )
3I 3 ( 4 5 6. 3 8 2 )
Z = 6 6. 8 6 1 s a y 7 2

number of conductor / slot = 3(72) =

3
72
slot per pole / phase = 72 = 6
(3x4)
I t e m 1 6: T o t a l n u m b e r o f I n d u c t o r s
Z= 3Z = 3( 72 ) = 216

I t e m 1 7: N u m b e r o f a r m a t u r e s l o t / p o l e / p h a s e
n= 6 ( from item 15 )

I t e m 1 8: T o t a l n u m b e r o f s l o t s i n a r m a t u r e
= 72 slots

I t e m 1 9: S l o t p i t c h
ʎ = T = 2 5. 9 1 8 = 1. 4 4 0
Cn 3(6)
c o r r e c t e d q = C I = 3 (4 5 6. 3 8 2) = 9 5 0. 7 9 6
1. 4 4 0

I t e m 2 0: N u m b e r o f c o n d u c t o r p e r s l o t
conductor per slot = 3

I t e m 2 1: F l u x p e r p o l e ( n o l o a d )
Ø= E x 1 08 b u t d = k’ k ; k’ = s i n β= 1 8 0o = 1
0
√ 3 ( 2. 2 2 ) d f Z 2 3(6)
K’ = s i n 1 7 0 = 0. 9 9 6 = 1 8 0o - 100 = 1 7 0
2 d = k’ k
K = sin [ 6 x ( 10 ) ] d = 0. 9 9 6 x 0. 9 5 6 = 0. 9 5 2
2
6 x sin ( 1 0) Ø= 1 0 5 0 0 x 1 08
2 √ 3 ( 2. 2 2 ) ( 0. 9 5 2 ) ( 6 0 ) ( 7 2
)
K = 0. 9 5 6 Ø = 6 6. 3 9 8 x 1 06 m a x w e l l s
I t e m 2 2: A v e r a g e f l u x d e n s i t y o v e r p o l e p i t c h ( o p e n c i
rcuit )
B g” = 3 0 0 0 0 M x p e r i n2
Item 23 : Axial length of armature core ( gross )
Ia = Ø = 6 6. 3 9 8 x 1 06 = 8 5. 3 9 5 s a y 8
5 in
B g” T 3 0 0 0 0 ( 2 5. 9 1 8 )
C o r r e c t e d B g” = 8 5 ( 3 0 0 0 0 ) = 2 9 8 6 1 . 2 3 3
M x p e r i n2
8 5. 3 9 5

Item 24 : Axial length of armature core (net)

ln =0.92(Ia) = 0.92(85) =78.2 in

Item 25 :Type of winding

Single layer

Item 26 : Current density in armature conductors

= 1 600 000 = 1 600 000 = 1 682.801 Amp
p e r i n2
q 9 5 0. 7 9 6

Item 27 : Size of Conductor

a r e a o f c o n d u c t o r = I c = 4 5 6. 3 8 2 = 0. 2 7 1 i n2
1 682.801
i n s u l a t i o n t h i c k n e s s = 5 0 + ( 1 0 5 0 0 ) = 2 4 0. 9 1 m i l s = 0. 2 4
091 in
55

s l o t w i d t h = s = ʎ s i n 0 c = 1. 4 4 0 s i n 4 0 0
1. 15 1. 15
s = 0. 8 0 5 i n w h e r e c0 = 4 00 ( f r o m 3 00 – 4 00 )
`

w i d t h o f c o n d u c t o r = 0. 8 0 5 - 2 ( 0. 2 4 0 9 1 ) - 2 ( 0. 0 1 6 ) = 0.
291 in

t o t a l t h i c k n e s s o f c o n d u c t o r = 0. 2 7 1 = 0. 9 3 1 i n
0. 2 9 1
using 4 flat copper strips / conductor
t h i c k n e s s o f w i r e = 0. 9 3 1 = 0. 2 3 3 i n
4
d i m e n s i o n w i l l b e = 4 x 0. 2 9 1 x 0. 2 3 3

Item 28 : Slot width

s = 0. 8 0 5 i n ( F r o m i t e m 2 7 )

Item 29 : Slot depth

d = 2 ( 0. 2 4 0 9 1 ) + 1 5 ( 0. 0 1 6 ) + 1 2 ( 0. 2 3 3 ) + ( 3 ) + (
1)
8 2
d = 4. 3 9 3 i n

Item 30 : Apparent tooth density (no load ) at center of

tooth

B t” = π B g” ʎ l a
2 t ln
 b u t t = π ( D + 4 ) = π ( 3 3 + 4 )- 0. 8 0 5 = 0. 8 0 9
slots 72

B t” = π ( 2 9 8 6 1 . 2 3 3 ) ( 1. 4 4 0 ) ( 8 5 )
2 ( 0. 8 0 9 ) ( 7 8 . 2 )

B t” = 9 0 7 5 1 . 4 8 8 l i n e s p e r i n 2
Item 31 : Flux density in armature core
A s s u m e 5 0 0 0 0 l i n e s / i n2

Item 32 : Radial depth of armature core below slots

Rd = 6 6. 3 9 8 x 1 06
2 ( 5 0 0 0 0 ) ( 7 8. 2 )
U s e R d = 8. 4 9 1 i n s a y 9 i n f o r a l l o w a n c e

Item 33 : Weight of iron in core

f o r vo l u m e o f i r o n i n c o r e, V
V= π ( 2 ( R + d ) + R d n l n
w h e r e R = D / 2 = 3 3 / 2 = 1 6. 5 i n
V= π ( 2 ( 1 6. 5 + 4. 3 9 3 ) + 8. 491 ) 8. 491 ( 7 8. 2 )
V= 1 0 4 8 7 8. 1 0 3 i n
a i r d u c t a r e a = 0. 0 0 5 ( 1 0 4 8 7 8. 1 0 3 ) = 5 2 4. 3 9 1 i n
r e d u c e g r os s d e p t h = 5 2 4. 3 9 1 = 2. 7 0 2 i n
π ( 4 1. 7 8 6 + 2 0 )
= 2 ( R + d ) = 2 ( 1 6. 5 + 4. 3 9 3) = 4 1. 7 8 6

computing for weight of iron

x = R + d = 1 6.5 + 8. 4 9 1 + 4. 3 9 3 = 2 9. 3 8 4 i n
y = R + d = 1 6.5 + 4. 3 9 3 = 2 0. 8 9 3 i n
z = R = 1 6.5
airduct in arm stamp
= ( π / 4 ) ( 1. 2 5 )2 ( 1 0 ) ( 7 2 ) = 8 8 3. 5 7 3
weight of iron in core
 = 0.28 l n ( x2 - y 2 ) π – a i r d u c t i n a r m s t a m p
= 0. 2 8 ( 7 8. 2 ) [ ( 2 9. 3 8 4² ) – ( 2 0. 8 9 3 ) π – 8 8 3. 5 7 3 ]
= 1 0 0 1 9. 1 5 4 l b s

I t e m 3 4: W e i g h t o f i r o n t e e t h
w t = 0. 2 8 l n [ π ( R + d ) – ( s x s w x d )
= 0. 2 8 ( 7 8. 2 ) [ π ( 2 0. 8 9 3 - 1 6 . 5 ) – ( 7 2 x 0. 8 0 5 x 4. 3 9 3 )
= 8 2 1. 2 9 2

I t e m 3 5: T o t a l c o r e l o s s, i n c l u d i n g t e e t h, o p e n c i r c u i t
f o r t e e t h, B t” = 9 0 7 5 1. 4 8 8
f r o m f i g 6 7, w a t t s / l b / c y c l e = 0. 1 3 2
w a t t s / l b = 0. 1 3 2 ( 6 0 ) ( 0. 8 7 ) = 6. 8 9 0
l o s s e s i n t e e t h = 6. 8 9 0 ( 8 2 1. 2 9 2 ) = 5 6 5 8. 7 0 2 W
f o r c o r e, fl u x d e n s i t y = 5 0 0 0 0 a n d f r o m f i g 6 7
w / l b / c y c l e = 0. 0 4 5
w / l b = ( 0. 0 4 5 ) ( 6 0 ) ( 0. 8 7 ) = 2. 3 4 9
l o s s e s i n c o r e = 2. 3 4 9 ( 1 0 0 1 9. 1 5 4 ) = 2 3 5 3 4. 9 9 3
W
T o t a l l o s s e s = 5 6 5 8. 7 0 2 + 2 3 5 3 4. 9 9 3 = 2 9 1 9 3. 6
95 W

I t e m 3 6: L e n g t h o f a r m a t u r e w i n d i n g
2 ( 8 5. 3 9 5 ) + 2. 5 ( 2 5. 9 1 8 ) + 2 (1 3. 8) + 6
= 2 6 9. 1 8 5 s a y 2 6 9 i n

I t e m 3 7: R e s i s t a n c e p e r p h a s e
area of conductor
= 0. 2 7 1 i n2
1 i n² = 1 2 7 3 2 3 9. 5 4 5 c m i l s
= 0. 2 7 1 ( 1 2 7 3 2 3 9. 5 4 5 )
= 3 4 5 0 4 7. 9 1 7 c m i l s
= 269 ( 18 )
3 4 5 0 4 7. 9 1 7
 = 1 4. 0 3 3 x 1 0-3 o h m s

I t e m 3 8: I R d r o p p e r p h a s e ( f u l l l o a d c u r r e n t )
= ( 4 5 6. 3 8 2 ) ( 1 4. 0 3 3 x 1 0-3 )
= 6. 4 0 4 v s a y 6 v

I t e m 3 9: T o t a l a r m a t u r e c o p p e r l o s s ( f u l l l o a d c u r r e n t )
I R = 3 ( 4 5 6. 3 8 2 )² ( 1 4. 0 3 3 x 1 0-3 )
= 8 7 6 8. 5 7 0 W

I t e m 4 0 – 4 1: A m o u n t o f c o p p e r l o s s t o b e r a d i a t e d f r o m
c o r e.
Approximate temperature cannot be calculated until al
l losses
i n c l u d i n g t h o s e i n t h e r o t o r f i e l d h a v e b e e n.

I t e m 4 2: I X d r o p ( e n d )
I=269-2(85+25.918) x2.54
4
I=29.949
I x = ( 4 5 6. 3 8 2 ) ( π/2 ) ( 3 √ 2 ) ( 3. 5) ( 0. 9 5 2 ) ( 6 0 )
( 6 x 3 ) ² ( 4 ) ( 2 9 . 9 4 9 ) ( 1 x 1 0-8)

I x = 2 3 6. 0 0 9 s a y 2 3 6 V

I t e m 4 3: F u l l l o a d d e v e l o p e d, v o l t s p e r p h a s e w i n d i n g
P e d = 2 3 6 Θ = 2 9. 5 4 1 O E d = 6 1 8 6. 9 0 5
% V R = 6 1 8 6. 9 0 5 – 6 0 6 2. 1 7 8 x 1 0 0
6 0 6 2. 1 7 8
= 2. 0 5 7 %