company name organization

110 MW 985-32 TGs
TYPE TGP 234260/2H
Presented by
Abhilash Chandra Aron
Consultant, Turbogenerators
May, 2004

company name organization

GENERAL
38 sets in operation all over India.
Oldest sets in operation since 1974 at
Kothaguddam and Bhatinda.
Originally a SKODA design, TGs were
manufactured at BHEL Hyderabad.

ACA - 110MW - 2 / 90

company name organization

ACA - 110MW - 3 / 90

COOLING vs. RATING
A/H = AIR / HYDROGEN
R = ROTOR: DIRECT RADIAL
I = STATOR: INDIRECT

TARI

THW / THDF
THRI
412
200 300 450

MVA

1000

A. C. ARON

C.4 / 90 THRI THW / THDF A.company name organization COOLING SYSTEMS STATOR SLOT ROTOR SLOT ACA -110MW . ARON 02 02 2000 .

ACA . Operation with one cooler out. Low maintenance. allowed.Stator core is directly clamped to body without any springs. Rotor copper is fully utilized.110MW . Rotor winding hot spot to average temp.company name organization MERITS High efficiencies. Machine cooling is highly optimized.5 / 90 . Simple construction. ratio is low. High I2 current withstand capability.

75 MVA Maximum output at 0 pf lag: 110 MVA Maximum output at 0 pf lead: 50 MVA Efficiency at rated output: 98.32% Hydrogen gas flow: 30 Cu M per sec.110MW .company name organization TECHNICAL SPECIFICATION 110 MW. 7220 A. Cooling water flow: 250 Cu M per Hr.6 / 90 . 0. 11 kV. Excitation:1428 A.80 pf. 381 V. 137. 2atg H2 Output with 1 of 3 coolers out: 96.25 MVA Output with air cooling: 68.5 MVA. ACA .

2 Rotor critical speed: 2150 rpm Rotor moment of inertia ‘J’: 13.110MW . ACA . With YY winding.company name organization TECHNICAL SPECIFICATION .78 ton M² Stator terminals: 6.7 / 90 .

Inlet cold H 2 max.5 Inherent voltage regulation: 39% xd”: 20.3 60 STATOR SLOTS VARIANT Short Circuit Ratio: 0.2 x In peak. Amplitude of sudden short circuit current including DC component: 9. Losses dissipated: 1500 kW CW max.8 / 90 .: 40°C ACA .company name organization TECHNICAL SPECIFICATION .7%. xd: 217% X2: 22. xd’: 30 %.7%.: 34°C. X0: 10.110MW .9%.

7 x In peak.: 42°C ACA .: 36°C.company name organization TECHNICAL SPECIFICATION . Losses dissipated: 1700 kW CW max. Inlet cold H2 max.4 Short 66 STATOR SLOTS VARIANT Circuit Ratio: 0.5% xd”: 16. xd’: 24.110MW . X0: 8. xd: 198% X2: 16.3%.9 / 90 . Amplitude of sudden short circuit current including DC component: 10.59 Inherent voltage regulation: 33.8%.7%.8%.

8 lag Rated EFFICIENCY 97% 96% 0 25 100 50 75 LOAD % ACA .0 pf 98% 0.company name organization EFFICIENCIES BOTH 60 SLOTS & 66 SLOTS 99% 1.10 / 90 A C ARON 21 NOV 02 .110MW .

110MW .11 / 90 A C ARON 16 NOV 02 .company name organization GENERAL ASSEMBLY 4050 3950 ACA .

2 1840 1840 ACA .12 / 90 A C ARON 16 NOV 02 .company name organization GENERAL ASSEMBLY .110MW .

company name organization ACA .13 / 90 110 MW TG 985-32 2280 70 985 1125 3200 Rotor:3280 A C ARON. 30 SEP ‘02 .110MW .

110MW . 18 SEP 02 .company name organization ACA .14 / 90 110 MW TG 985-32 VENTILATION DIAGRAM A C ARON.

6 0.110MW .4 110 100 80 LAG 60 40 MW 137.5 H2 2 atg H2 0.9 ROTOR HEATING LIMIT 0.5 55 27.company name organization CAPABILITY DIAGRAM 0.15 / 90 0 MVA 40 60 80 LEAD 82.5 110 82.5 A C ARON 15 NOV 02 .05 atg AIR THEORETICAL STABILITY LIMIT ACA .8 0.

440 1010 1335 110MW .company name organization ELECTRICAL CHARACTERISTICS 140 120 66 SLOT VARIANT OCC 11KV 100% STATOR VOLTS % 60 40 % In ARMATURE CURRENT SCC 20 100%=7216A 80 60 40 20 890 0 400 800 1200 1400 AMPS ROTOR CURR.16 / 90 A C ARON 16NOV02 .

2 120 11KV 100% STATOR VOLTS % 60 60 SLOTS VARIANT OCC % In ARMATURE CURRENT LOAD MAGNETIZATION SCC 1 PF 0.company name organization ELECT.110MW .8 PF 100%=7216A 80 60 40 20 20 0 600 1000 1400 1800 1600 AMPS ROTOR CURR. CHARACTERISTICS .17 / 90 A C ARON 16NOV02 . 595 940 1150 40 ACA .

5 2.0 -7.5 -5.0 7.FREQUENCY LIMITS RATED: 295 MVA 10. C.5 -10. 0 -2.company name organization VOLTAGE .0 A. ARON .5 % VOLT 0.5 0.0 2.5 5.0 -2.0 ACA .110MW -18 / 90 137 MVA AREA -5.0 % FREQUENCY 5.

goes to cold gas compartments between housing & core. Rotor has direct radial gas cooling. ACA . The stator core is radial gas cooled. whereas other stream enters sub slots and then flows radially to cool rotor slot parts.110MW . Another stream cools stator overhangs. One stream cools end winding.company name organization GENERATOR COOLING Stator is indirectly cooled.19 / 95 . then flows through ducts. Rotor is cooled by 2 streams.

Flow resistance CW side: 4000 mm W.company name organization GENERATOR COOLING .2 3rd flow goes to air gap via retaining rings. H2 gas temperature rise:  17°C ACA -110MW .C.20 / 90 HO . then flows radially outwards through core ventilation ducts.C. All the 3 flows combine in air-gap. Flow resistance H2 side: 12mm of W. travel radially outwards cooling stator core and then enter the gas coolers.

H2 coolers: HC-W II-Bs/Cu 6 (10x5-2-260) Number of cooler elements: 2 x 3 = 6 ACA .21 / 95 .110MW .3 Cold gas minimum temperature value is specified to prevent condensation.company name organization GENERATOR COOLING . CW flows into gas-coolers at both TE and Ex E ends of generator.

22 / 95 . Casting has ribs to permit flow of H2 gas. It is hydraulically tested at 7 atg for 2 min. Core is directly fixed to the body through a set of steel dove tails welded to square steel beams. Nonmagnetic cast steel core end pressure plates and fingers provided.company name organization STATOR CONSTRUCTION Stator body can withstand explosion in it. Copper ring screens at core ends arrest the axial flux and minimize end packets’ heating. ACA .110MW .

Core vibrations calculated: 30 Micr p/p.company name organization STATOR CONSTRUCTION .2 Low loss 0. Core laminations insulated by Class ‘B’ varnish suitable for 105ºC temperature.110MW . Closely spaced 5 mm ducts.5 mm ‘CRNO’ core steel used. 8 mm vent-ducts provided in main core portion. End shields are made of Mn steel casting.23 / 90 . for intensive cooling given in end packets. ACA . Stator core weight:  45 Tons.

ACA .24 / 90 .company name organization STATOR CONSTRUCTION .3 Double flow ring type Hydrogen shaft seals prevent H2 leakage. Stator is transported on special wagon.110MW .

25 / 95 20° STATOR END WINDING A C ARON 30 SEP 02 .company name organization 110MW .

company name organization ASSEMBLY OF OUTPUT LEADS 900 120 CT ‘A’ 900 A 65 210 100 15 160 HGL LAMINATE 120 170 ACA .110MW .26 / 95 A C ARON 12 NOV 2002 .

in slots.company name organization WINDING INSULATION Resin rich Samicatherm class F insulation is used for main winding insulation. Nose joints made by silver alloy brazing of conductors together in two groups each. braidings. Bar copper strips are transposed.27 / 95 HO .added later . Reliable & robust winding overhang with large number of brackets. ACA . Top ripple springs . so as to reduce eddy current losses.110MW .

2 ACA .company name organization STATOR SLOT 11 62 70 166 4 22 30.28 / 95 SLOT WEDGE TOP PACKER TOP RIPPLE SPRING SEMI CONDUCTING WRAPPER TOP BAR SEMI CONDUCT.110MW .FILLER PACKER WDG. RTD BOTTOM BAR CORE RTD A C ARON 99 07 17 .

29 / 90 SEMI-CONDUCTING COATS GLASS TAPE + DOBECKON (POLYEURATHANE) A C ARON SEPT 2002 .company name organization SEMI CONDUCTING COAT ISOLA 642 ACA .110MW .

6 Amp/mm² 26 SOLID BRAZING 2 R10 Each phase has ‘mid phase’ transposition ARON on TS to reduce eddy losses in winding A26CSEPT 02 ACA .company name organization STATOR WINDING NOSE JOINT 32 STRIPS 10x1.6 BARE 3.30 / 95 .110MW .

company name organization ROTATION 1 66 STATOR WINDING DIAGRAM 66 SLOTS ACA .31 / 95 A C ARON 11 NOV 2002 .110MW .

END 60 SLOTS A-A 4 A A 1 60 16 46 70 20 ACA .company name organization EX.32 / 95 31 A C ARON 21 NOV 02 .110MW .

For 1 x 0.3 for 75%. Movement: <0. After rewedging to be: >0. 1x 0.company name organization STATOR SLOT WEDGES TIGHTNESS Tightness check in o/haul is done on 20% slot wedges.8mm:10xBxL.9: 30xBxL Kg.55mm for 60% and <0. Test pressure varies with thickness.but on not less than 5 per slot Test points to be helically located in bore. For the rest to be <0.1 <0. width length. number of top ripple springs used.45.9mm:18xBxL 2 x 0.75 for 40%. 110MW-33/95 . B and L being in cm.

it is like 3 WEDGE 50 rubber. After curing. Its curing time is 1.110MW .34 / 95 TOP BAR A C ARON 15NOV 02 .company name organization LOCKING OF STATOR SLOT WEDGES End wedges of stator slots are locked against movement using Metallon E-2082 consisting of adhesive paste & hardener Mixture in equal amounts has 1 hour life.2 days at room temp. COMPRESSION STRIP ACA . Ripple spring to be shorter by 50mm.

ACA . Non magnetic flange is shrink fitted over the insulation and cemented in position for gas tightness. longer ones are neutral.company name organization TERMINAL BUSHINGS 3 ph+3 neutral terminals provided.Gas tightness between copper and insulation is ensured by a gasket and clamping ring on air side. Conductor is of leak proof hollow copper tube with its both ends silver plated.35 / 95 . Shorter ones are phase.110MW . with capacitor grading to control elect field. Insulation is of epoxy-glass.

They have radial holes for outlet of hot gas. Axial fans with Aluminium alloy die forged blades fitted to hubs by fit bolts provided.company name organization ROTOR Half coupling is shrink fitted on the shaft. Blades are with Clark Y profile for pressur of 8. & 30 CuM /sec discharge Sub slot at slot bottom carries cold H2 for cooling rotor copper.110MW . Retaining rings shrunk fit on shaft barrel and end wedges.36 / 95 . ACA .C.5 mm W.

L-shape slot insulation liners have Nomex lining.37 / 95 . 110MW . These get electrically shorted by retaining rings and act as damper winding. Wedges in slots adjacent to poles are of steel forging to improve flux wave forms. Cross pole slots for inertia equalization. Slot wedges are made of Alumin-Bronze forging.2 Conductors have slits for radial flow of H 2 gas. Inter-turn insulation is made of glassepoxy laminates.company name organization ROTOR .

& balance checked again at rated speed. ACA .38 / 95 . Rotor is over-speeded at 120% for 2 min. Then winding is heated to working temperature and balance rechecked at rated RPM.company name organization ROTOR .. Finished rotor is balanced in cold.3 Field lead consists of 2 semicircular steel conductors duly insulated.110MW .

ARON SEP 02 .21 SUB SLOT A.4 A/mm² ACA .C.39 / 90 SLOT WEDGE TOP PACKER CONDUCTOR (16 PER SLOT) SLOT CELL INTER-TURN 2 x 0.110MW .company name organization ROTOR SLOT 6 148 32 36 Slots: 32 Pitch: 1/42 Coils: CD: 7.

C. ARON 99 07 21 .company name organization ROTOR OVERHANG RR NUT D985 ACA .110MW .40 / 95 ~112 HOLES D14 RETAINING RING CENTERING RING INSULATION ROTOR COPPER A.

110MW .41 / 95 D911 A C ARON 12 NOV 02 .company name organization RETAINING RING .OLD DESIGN 610 D14 D985 D1015 B D1040 D1140 D825 1640 UPTO CENTRE D445 B D916 D942.4 ACA .

company name organization RETAINING RING . ACA .42 / 95 A C ARON 15 NOV 02 .NEW DESIGN 2 SCREWS M9 D985 30 10 595 D1140 D1040 1640 465 UPTO CENTRE D825 85 75 D445 2450 UPTO CENTRE RR NUT IS HEATED TO 200°C BEFORE SCREWING ON TO RETAINING RING.110MW .

Minimum permitted slip ring dia is 420mm.company name organization SLIP RINGS & BRUSHGEAR Steel radial bolts connect flexible Cu lead from winding to steel field lead. No.110MW . ACA . The recommended brush grade is HM 6R. Another set of steel bolts connect slip rings rigidly to the steel field leads.43 / 95 . of carbon brushes 25 x 32 mm is 42. Steel forged slip ring has helical groove and skewed holes in it for ring ventilation.

44/ 95 . gives the film its lubricating properties & allows brushes to operate with minimum friction and wear rates. shows poor performance. 125 µ in 1000 Hrs.company name organization SLIP RINGS & BRUSHGEAR .110MW . This layer of water molecules. ACA . Brushes ride on a film. few microns thick and composed of brush material with a top layer of water molecules absorbed from air.2 Slip ring wear rate normally is 25 Microns per 1000 Hrs.

110MW . Only if after slip rings grinding. Change of brushes in operation is ‘not allowed’. it is seen that one ring has lesser diameter.company name organization SLIP RINGS & BRUSHGEAR . it may be done. Brush pressure to be180 gm/cm².3 Change of polarity is not encouraged lest it may upset the established films. ACA .45 / 90 .

company name organization

46/9
5

BEARINGS
Bearings are babbited steel castings with
elliptical bore for greater hydro dynamic
stability.They rest in generator end shields
Six steel pads are bolted to a bearing and
outer spherical surface of the pads makes
the bearing ‘self aligning type’. Pads are
electrically insulated by thick glass textolit.
Lub oil at 1 - 1.5 atg comes from turbine.
Hydraulic lift is provided at 40 - 80atg oil
and is so adjusted, that lift is about 50%
of top gap which is  0.12% of bearing dia.

company name organization

UPRATING TO 120 MW

Hydrogen

gas pressure to be increased.
Rotor cooling to be converted to 4-flute.
Stator winding bars overhang tying to be
improved - braidings to be increased.
Cast stator end shields to be replaced by
fabricated ones due to higher H2 pressure.
Gas coolers to be checked - water flow
may have to be increased.
Overall-any shortcomings to be corrected.
ACA - 110MW- 47 / 91

company name organization

RADIAL SEAL RING
AIR SIDE OIL

H2 SIDE OIL
SEAL CHAMBER

AIR SIDE
SEAL RING

H2 SIDE RING

ACA - 110MW - 48 / 90

A C ARON
12 NOV 2002

OIL SYSTEM Main seal oil pump draws oil from vacuum tank and feeds to H2 side seal via cooler and filter. 110MW . standby emergency DC seal oil pump takes over. H2 side drain flows to defoaming tank and then to vacuum tank through a float valve.48 / 90 HO . Turbine governing oil is used to feed air side seal oil via another set of cooler+filter.company name organization DOUBLE FLOW SEAL. If main oil pump fails. Oil is drained in about equal quantities towards H2 side and air side.

ACA . This flow. maintaining its level.49/ 90 . From here. is independent of main seal oil system. Part oil flows to equalizing tank also. drained towards air side mixes with air side seal oil flow and also with bearing oil and together goes to stilling tank.company name organization DOUBLE FLOW SEAL SYSTEM .110MW . it returns to main turbine oil tank. from turbine oil. giving reliability.2  H2 side main seal oil.  Air side seal oil pressure is controlled by DPR ‘R-3’ at 0.2 less than H2 side press.

3 DOUBLE FLOW SEAL SYSTEM .company name organization DOUBLE FLOW SEAL SYSTEM . 50 / 95 .7 by R-2 when emergency pump runs  Oil from de-foaming comes to equalizing via a float valve that ensures a level in defoaming tank. oil flows to vacuum tank through another float valve.3 H 2 side seal oil pressure is maintained at 0.  From equalizing tank. Always there is a column of oil in stilling tank to make up the level in equalizing tank.9 bar above H2 press.thus preventing Hydrogen ingress into equalizing tank. by PRV ‘R-1’ and at 0.

when pressure in main seal oil line fails. They remove all gases & air from oil. safety valves and flexible couplings given. Over press. ACA .51 / 95 .4  An oil jet ejector and an oil pump maintain vacuum in vacuum tank. It stops automatically.company name organization DOUBLE FLOW SEAL SYSTEM .  Oil-gear pump pumps oil at 5 .  Seal oil is pumped by rotary gear pumps to deliver 190 LPM at 10 bar.110MW . maintaining H 2 purity.6 bar to oil jet ejector for creating vacuum.

52 / 90 A. OIL DPR ‘R3’ H2 DEFOAMING STILLING TANK F EQUALIZING VACUUM F DPR ‘R1/R2’ ACA . ARON 03DEC 02 .company name organization DOUBLE FLOW SEAL SYSTEM .110MW . C.5 AIR TO TURBINE OIL TANK FROM DEFOAMING GOVERN.

53 / 95 R3 EMERG.company name organization DOUBLE FLOW SEAL SYSTEM . PUMP V A C ARON 15 NOV 02 .110MW .6 ROOF H2 DEFOAMER EQUALIZING VACUUM TANK R1 C F STILL TANK Z Z F C R2 MAIN ZZ REGULATING TURBINE OIL ROOF Z ACA .

alarm set at 2. Pressure switches initiate alarms if: Main oil supply.7.7. H2 side oil is at 0.7. ACA .05 atg.5 kg/cm².5. Air side oil at 2.54 / 95 . At 0.company name organization ALARMS AND ANNUNCIATIONS Equalising tank low level: If oil flow from defoamer or from stilling tank is improper. Alarms for both are set at 0.9.110MW . alarm set at 2. Low pressure of seal oil: At 2 atg. High level in vacuum tank: If level is high due to float valve problem etc. H2 side oil is at 2.9 & air side oil at 0.Emergency oil supply fails.

2 Differential pressure alarm for both H2 and air side oils is set at 0.5 kg/cm².55 / 90 . Temp. of oil in vacuum & equalising tanks and of seal oils after filters are monitored. and turbine regulating oil pressures are also monitored. Pressure & vacuum gauges are installed for local indications.company name organization ALARMS AND ANNUNCIATIONS . ACA .Oil jet pump discharge press.110MW .

56 / 90 A C ARON 30 NOV 02 .110MW .company name organization OIL REFUSE & SUCKED GASES OIL JET AIR EJECTOR UNDER PRESSURE AREA NOZZLE DIFFUSER GASES STILLING CHAMBER OF BALANCING TANK PRESSURE OIL ACA .

57 / 90 A C ARON 30 NOV 02 .110MW .company name organization FLOAT VALVE ID-70 FOR OIL LEVEL IN DEFOAMER ACA .

company name organization REGULATING VALVE ID-40 FOR SEAL OIL REGULATION SPRING TIGHTENER OIL FROM DEFOAMER OIL FROM SEAL RINGS ACA .58 / 90 A C ARON 30 NOV 02 .110MW .

110MW . Interruption in air side oil supply: Air side oil to be at H2 press.company name organization SEAL OIL SYSTEM .5 minim. Purity in machine may get affected. ACA .OPERATION Both main and emergency systems faulty: Ensure air side supply at correct pressure. If so.+ 0.increase gas pressure to rated value.59 / 90 . If either main oil  or emergency oil  are not fit. stop the set with Hydrogen in. Low seal oil pressures alarm can come if H2 gas pressure is much less than 2 atg.

bye pass vacuum tank and repair the float Vacuum tank level is low: Check valves. ACA . Strong foaming in vacuum tank: Reduce vacuum from 0. Check float valve and repair it. Stop the pump. restart.OPERATION .110MW . If float valve is defective.60 / 90 . When foam is normal. Check valve to balancing tank. Fill the tank by opening valve to balancing tank.company name organization SEAL OIL SYSTEM .2 Vacuum tank level maximum: If tank is full of foam.9 to 0.5 or to zero.decrease vacuum.

it permits inflow of fresh humid lubricating oil with foaming in vacuum tank Finally.110MW . direct by opening a valve. If this does not help. ACA . in vacuum tank by feeding cool oil after oil cooler. In opened condition.2 atg below normal and oil pressure to oil jet ejector reduced by throttling related valve.OPERATION .3 Foaming is also reduced by lowering oil temp. vacuum can be lowered by 0. check if the valve to stilling tank is properly closed.company name organization SEAL OIL SYSTEM .61 / 90 .

It enters into the machine. Stop the set.  Opening direct valves. expel H2 and fill with CO2. Oil is forced to flow to balancing tank. 62 / 90 . Valve not opening: Oil floods H2 defoamer & does not go to balancing tank.company name organization FAULTY FLOAT VALVE IN DEFOAMING TANK Valve not closing:Signal ‘Low H2 pressure’ appears. LLI gives alarm. If in LLI. allow oil to flow to balancing tank. remove H 2. stop the set. H2 enters balancing tank & escapes.15 litre oil collects in 5 minutes. ‘Low oil level in balancing tank’ alarm appears.

63 / 90 . This is best tested when machine is at rest.90 Cu M of pure H2. Oscillation in SOP values >0. Rinsing can be done on load. remove the valve for repair / replacement.ensuring availability of other systems. Check air & H2 side seal oil pressures and correct if required.company name organization Faulty regulating valves are first corrected by adjusting the regulating spring.2 is adjusted by throttling the valve in impulse line. H2 purity below 92%: Rinse generator with 60 . If this fails.

The tubes can be cleaned with H2 inside at reduced load.company name organization GAS COOLERS Horizontally mounted 3 cooler units. Each unit is in two halves along length.110MW .64 / 90 HO . Tube material is brass CuZn28Sn / Cupro nickel as required. Tube fins are made of copper. ACA . 0.38 mwc.Later they get tin-plated with tubes Tube plate material is brass CuZn40. The Water boxes: Steel. Cooler pressure drop: Approx. plastocor protected.

company name organization HYDROGEN GAS SYSTEM H2 DISTRIBUTOR + CO2 GAS ANALYZER H2 DRIER OUT HYDROGEN ACA .65 / 90 AIR CO2 WASTE DETECTOR  65 bar A.110MW . ARON 27 NOV 02 . C.

2 gas press. Some globe type shut off valves also used  Silica jel gas dryers are given. Wet silica is of pink color. Silica jel is activated by 240V. is reduced from 150 to 3.  H2 ACA .  Gas system valves are of diaphragm type.5 bar pressure for feeding into machine.66 / 90 .company name organization HYDROGEN GAS SYSTEM .  Diaphragm type gas valve ID20 with servo motor+remote control is sometimes added to urgently expel H2 from control room. 600 W heater to 120°C by a thermostat.110MW .

H2 losses to be within 24 Cu Meter at NTP during any 24 hours period. minimum of 90% CO2 is filled. ACA . H2 in CO2 0-100%. During operation. during scavenging operations.company name organization HYDROGEN GAS SYSTEM .67 / 90 . To expel H 2 or air. H2 in air 76-100%.only 1H2 cylinder is kept connected at a time.110MW . The 3-range analyzer measures: CO 2 in air 0-100%.3 H2 purity:98-99% in operation is indicated by single range H2 in air purity meter.

110MW .company name organization LOOKING GLASS GAS DRYER SILICA JEL THERMAL ISOLATOR BUSH HOT PLATE H2 WATER DRAIN TERMINAL ACA .68 / 90 GLASS WOOL COMPRESSED SPRING FILLING TERMINAL COVER A C ARON 30 NOV 02 .

company name organization NEOPRENE TEFLON DIAPHRAGM VALVE ID-20 PRESSURE:10 BAR MEMBRANE TYPE TEMP.110MW .: 120ºC ACA .69 / 90 A C ARON 30 NOV 02 .

company name organization

BEARING INSULATION CHECK

Turbine

end of shaft to be
well grounded. Measure V1,
then measure V2 using AC
range. If two are not
identical,grounding of shaft to
be corrected.
Bridge oil film on Exc.End
and measure V3. If different
R
from V2 bearing insulation is
bad. Shaft current is
measured.
In non excited regime, use

V1

Roil

A
V

V2, V3
ACA - 110MW - 70 / 90

company name organization

OPERATIONAL EXPERIENCE

Stator core looseness observed especially

in end packets. Cases of broken vent duct
spacers also reported, causing hot spots.
Stator core teeth found loose and vibrated
They thus damaged the top winding bars
causing stator earth faults.
Stator winding overhang braidings found
loose. Gaps between the lower bars and
winding holders noticed, causing winding
overhang vibrations and damages.
ACA - 110MW - 71 / 90

company name organization

OPERATIONAL EXPERIENCE - 2
Heavy ingress of oil reported. Oil covered

stator winding and even stator core. Oil
& carbon dust seen on rotor also, causing
decrease in its IR and repairs.
Loosening of stator slot wedges was seen
in overhaul. Earlier top ripple springs were
not used in this design, and were added
later as a modification.
Occasionally, high winding vibrations in
overhang also caused damages.
ACA - 110MW - 72 / 90

it was changed to 18-5 alloy. Core tightening pressures have been increased ACA .110MW . Stator end copper ring screens have been removed. The constructional design of this machine was changed to improve core tightness and better fastening of stator winding. Still later.company name organization MODIFICATIONS Earlier 8-8-4 alloy was used for retaining rings.73 / 90 .18-18 alloy was introduced. Axial through bolts introduced to improve core tightness in operation. Later.

2 sets made and commissioned at Talcher & Kothaguddam and running smoothly. Rotor coils made in halves with inter-turn insulation glued to copper.74 / 90 . ACA . Steel winding support brackets welded to press rings Rotor overhang ventilation is redesigned eliminating radial holes in retaining rings.2 Stator core end plates are now made of carbon steel with welded press fingers.110MW .company name organization MODIFICATIONS .

71° C Cold H2 gas : 41° . AS ON MAY 2004 Load 113 MW 11.72° C Stator winding in slots: 64° .76 / 92 .46° C Hot H2 gas: 55° .110MW . 6100.59° C CW hot from coolers: 39° .42° C ACA .3 kV.6230. AFTER MODIFICATION • • • • • • AECO UNIT ‘D’.company name organization TEMPS.6243 A Stator core laminations: 57° .

They were tightened using ripple springs in slots in 1987. Rotor was rectified in BHEL Hyderabad by machining its rotor journals. Oil starvation in 1983 caused vibrations in the bearings.75 / 90 . Rotor was balanced and used with special bearings. Journal diameters got reduced.110MW . ACA .company name organization PARICHA GENERATORS UNIT 1: Stator winding had loose stator wedges in slots.

asynchronous motoring occurred.company name organization PARICHA GENERATORS . ACA . Rotor was replaced with spare rotor and unit re-commissioned in 1994. Rotor got overheated at ends developing cracks on retaining ring seating surfaces.76 / 90 .2 UNIT 2: in 1994.110MW .

77 / 90 . Machine was opened to find: Core end packet near slot 56 was found burnt because of HV failure. Overhauled in July 1983 with following observations: Several stator overhang braiding broken. In Nov1983. terminal bushing of R & B phase cracked in outside portions.110MW . end wedges loose.2 Commissioned: Feb 1980.CASE ‘A’ PANIPAT . set tripped while being rolled on stator E/F at 7 kV while building up the voltage.company name organization CASE STUDIES . ACA .

Bar insulation was seen to be monolithic without any delayering etc. Cracks in bars were upto copper.2 PANIPAT . Another 8 bars of R and B failed in subsequent HV tests. ACA .company name organization CASE ‘A’ . Y ph bars were OK. It was concluded that such a failure could either be due to ph to ph fault or improper closing / opening of GCB.78 / 90 .110MW .2 8 bars were seen cracked just outside the core before first bend.

Thereafter the set operated at full load. Water+oil @ 300 ml used to be collected. O/hauled in Oct 1981 Stator wedges and braiding found loose and were attended to.increased from 1. relay and rotor E/F relay operated.110MW .  In March 1984.company name organization CASE ‘B’ . H2 purity dropped from 99 to 97% Differential relays.negative seq. it tripped Cl A with a loud bang.79/ 90 .D  1st syn: Oct 1978.H2 press. ACA .9 to 2.08 atg.1 SABARMATI .

company name organization CASE ‘B’ .80 / 90 . They came out after braiding got broken during likely abnormal operation and got entangled between bars  Rubbing of top bars in vibration caused loss of insulation. top and bottom bars. Oil spray on Ex.D  Many top bars had cut marks upto copper because of rubbing of HGL packers betw. Side precipitated failure: Ph B & Ph C to earth.2 SABARMATI . 110MW .  Copper of 54T and 60T had melted on Ex Side with extensive damage in 9’O clock to 12’O clock to 3’O clock zone.

Molten copper had entered rotor as well. Finally heavy arc caused oil to burn causing H2 pressure to increase etc. Machine was replaced and later repaired and rewound at works.company name organization CASE ‘B’ .D No damage or oil was seen on TS at all. It is suspected that machine ran for some time with arcing short of tripping. ACA . It also appears that stator E/F relay was in-operational.81 / 90 .3 SABARMATI .110MW .

Set tripped in July 1985 with R & B phase to earth fault. Rubbing with the winding brackets seen with insulation damages.company name organization CASE ‘C’ BHATINDA-4 1st syn:Dec1978. Seen core looseness. stator wedges’ looseness.110MW . Damages were similar to ‘B’ Lot of oil found on TS overhang and core. Bottom bars in slot 40 -53 zone damaged with melting. rubbing of top packers with top bars and looseness and breakage of braiding.82 / 90 .1st O/H:Jan 1985. ACA .

Core was found loose in many packets. gaps between bottom bars and winding holders. was OK. Core repaired earlier. Set tripped in Sept 1985 on R & Y to earth fault. breaking the wedges and hit rotor. ACA .O/H: Apr’81and Sept’84 Seen: Core looseness. loose stator wedges.company name organization CASE ‘D’ BHATINDA-3 1st syn:Mar 1978. oil leakage.83 / 90 . Overhangs of 11 top had come out.4 top bars’ damage due to loose core. loose braidings.110MW . broken at eyes.

ACA .company name organization BHATINDA-3 CASE ‘D’ .2 Bottom bars resting on bracket near slot 24 got wear cuts. Possibly bottom bars’ braiding with above winding holder got broken. Holder near 24 was delaminated/damaged.41 zone. and subsequent damage to them over time.110MW . causing high vibrations in these bars. Flash overs. Eyes of 8-12 Top bars were charred on Ex Side.84 / 90 . damages seen in 38 .

000 Both stator and rotor were repaired in BHEL works. partially closing ventilation holes in barrel end portion. Total running hours when tripped 41.85 / 90 .3 BHATINDA-3 Rotor inter-turn insulation found shifted. It is suspected that unit was mal-operated with either wrong synchronizing or some other phase to phase fault near terminals. ACA .company name organization CASE ‘D’ .110 MW .

Inspected: May 1987 Severe core burns. Final ring flux test for 2. 31T. some by grinding to 1mm depth and by elctro-chemical machining etc. charred wedges seen in 23 packets. ACA .32T & 63B.5 Hrs and ELCID tests done in stages and core cleared. Hit marks and dents seen on rotor as well as on core surfaces.86 / 90 . 600 spots were repaired.110MW .64B and related top bars were removed.company name organization CASE ‘E’: CORE DAMAGE PANIPAT-3 1st syn: Nov 1985.

Gap between winding holders and bottom bars was  4 .110MW . Core looseness seen in 30 packets.8 mm.9 O’clock zone on both ends.000 hours of operation. overhang covered with lot of coal dust.company name organization FARIDABAD-2 CASE ‘F’:DAMAGES IN A 60MW TG AN AIR-COOLED GENERATOR 1st syn:Mar 1976.87 / 90 . 1st O/H:May’82. Core. Braiding between holders and bottom bars seen broken in 3 . ACA . 2nd in July 1986 after 51.

88 / 90 . Two bars: 46T of A phase and 32T of B ph failed at slot exits. FARIDABAD-2 ACA . It appears that bars got damaged at exit points due to high overhang vibration. this air-cooled set was overhauled only twice.2 Stator was HV tested. Set was rewound. In 10 years operation. Leakage currents were high in all 3 phases indicating minor damages.company name organization CASE ‘F’: DAMAGES IN A 60MW TG .110MW .that in turn was because of loose and broken braiding etc.

company name organization CASE ‘G’: HARDUAGANJ MARCH 1986 1st syn: May 1978. Oil deposit seen in bore of the core. Operating hours: 35. Rotor shaft journals were gray due to flow of shaft currents.000. Reddish rust deposits seen on teeth. 6 end packets on TS and 5 on ExS loose: all in upper half core portion. Starts: 380. Few braiding loose / broken in upper half.110MW . Inspection:1986. 5 months idle in 1980 due to bearing damages.89 / 90 END . ACA .

company name organization .