Professional Documents
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Turbo Generator
Turbo Generator
Features of Turbogenerators
KAPIL NARULA
Sr. Engr./EME
HEEP, BHEL Hardwar
BHEL Hardwar
Index
1. History of Development
2. Power Output of Generator
3. Generator Modules & Types
4. Important Parameters of Generator Modules
5. Design Features
6. Main parts of TG/ Constructional features
7. Excitation System
8. Auxiliary Systems
9. Generator Testing
10. New Developments - Total Imp. of Stator Winding
BHEL Hardwar
History of Development - Globally
First generator with water cooling for stator and rotor wdg1959
BHEL Hardwar
History of Development in BHEL
IN 1960s:
At Hardwar with Russian Collaboration
100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled
IN 1960s:
At Hyderabad with CZECH Collaboration
60 MW Air Cooled & 110 MW Hydrogen Cooled
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Power Output of Turbogenerator
P D2 . L . B . A . n
P Power in MVA
D Bore Diameter of Core in meters
L Length of Active Rotor Body in meters
B Air Gap Flux Density in Tesla
A Stator Ampere-Turn Loading in Amp./meter
n Speed in rpm
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Power Output of Turbogenerator
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Generator Modules
Module Nomenclature -
THRI 108/44
THDF 115/59
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Module Nomenclature
T H R I 108/44
Stator winding
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Generator cooling System
BHEL Hardwar
Stator Slot - TARI / THRI
BHEL Hardwar
Stator Slot - THDF 500 MW
BHEL Hardwar
210/235 MW THW Generator
BHEL Hardwar
Library of Designs
TYPES OF GENERATORS
SUPPLIED BY BHEL:
# AIR COOLED
# HYDROGEN COOLED
# HYDROGEN/WATER
COOLED
FOR APPLICATIONS:
# THERMAL
# NUCLEAR
# GAS BASED
BHEL Hardwar
Library of Designs
1000 MW
350 MW
170 MW
AIR COOLED
DESIRED MW CAPACITIES
80 MW 1000 MW
BHEL Hardwar
Capability of Generator Modules
DESIGN VARIANT GENERATOR MODULE OUTPUT RANGE
ORDERS/MFD./COMMD.
TARI 93/38 75-92 MW
AIR COOLED TARI 108/36 100-120 MW
15/11/7 TARI 108/41 120-140 MW
TARI 108/46 140-170 MW
BHEL Hardwar
Improtant Parameters of Generator Modules
SL. TECHNICAL 210 MW 250 MW
NO.
PARAMETE
R
1. GENERATO THRI THRI
R TYPE 108/39 108/44(FI)
2. RATED 247 294.1
MVA 210 250.0
RATED MW
3. RATED 15.75 16.5
VOLT. KV
4. POWER 0.85 0.85
FACTOR
5. STATOR 9056 10291
CURRENT
6. SPEED 3000 3000
RPM
7. FREQ. HZ 50 50
8. HYDROGEN
PRESSURE 3.0 4.0
Kg/Cm2(g)
9. S.C.R 0.57 0.63
10. EXCITATIO
N 251 308
VOLTS 2260 2497
AMPS
11. NEG. SEQ.
CAP. I2,% 8 8
I2sq.xt 10 10
12. WEIGHTS, T
STATOR 215.3 232
HEAV. LIFT 192 212
ROTOR 39 43
13. BRG. - BRG.
DIST. IN MM 7420 7870
14. TYPE OF B’LESS/ B’LESS/S
EXCITATIO STATIC TATIC
N
BHEL Hardwar
Improtant Parameters of Generator Modules
SL. TECHNICAL TROMBA K’KULA K’KULA FARIDAB FARIDAB LIBYA
NO. Y STG M M STG AD GTG AD STG GTG
PARAMETE
GTG
R
1. GENERATO TARI TARI TARI TARI TARI TARI
R TYPE 93/38 108/36 108/36 108/41 108/46 108/46
2. BASE LOAD
MVA 100 137.5 154.3 170.1 188.2 18O.4
MW 80 116.8 131.1 144.6 160.0 153.3
3. RATED
VOLT. KV 10.5 10.5 10.5 10.5 15.75 15.75
4. POWER
FACTOR 0.80 0.85 0.85 0.85 0.85 0.85
5. STATOR
CURRENT 5499 7561 8484 9354 6900 6612
6. SPEED 3000 3000 3000 3000 3000 3000
RPM
7. FREQ. HZ 50 50 50 50 50 50
8. S.C.R 0.56 0.55 0.50 0.50 0.52 0.54
9. EXCITATIO
N 274 339 381 410 432 388
VOLTS 719 777 851 833 797 770
AMPS
10. NEG. SEQ.
CAP. I2,% 10 10 10 10 10 10
I2sq.xt 20 20 20 20 20 20
11. WEIGHTS, T
STATOR
HEAV. LIFT 128 170 170 181 200 200
ROTOR 28 37 37 40.1 44 44
12. BRG. – BRG.
DIST. IN MM 7050 7250 7250 7800 7900 7900
13. TYPE OF B’LESS B’LESS B’LESS STATIC B’LESS STATIC
EXCITATIO
N
BHEL Hardwar
TARI Generators - Design features
# DIRECT COOLING OF STATOR CORE AND ROTOR WINDING
# INDIRECT COOLING OF STATOR WINDING
BHEL Hardwar
THRI Generators - Design features
• DIRECT HYDROGEN COOLING OF STATOR CORE AND ROTOR
WINDING
• INDIRECT COOLING OF STATOR WINDING
• EXPLOSION PROOF SINGLE PIECE STATOR FRAME
• END SHIELD MOUNTED BEARINGS
• VPI INSULATION SYSTEM
• TOP RIPPLE SPRINGS IN STATOR SLOTS TO CONTAIN BAR
BOUNCING FORCES
• COLD GAS TEMPERATURE CONTROL VALVE TO MAINTAIN
COLD GAS TEMPERATURE CONSTANT
• SINGLE FLOW RING TYPE SHAFT SEALS
• STATIC/BRUSHLESS EXCITATION SYSTEM
BHEL Hardwar
THDF Generators - Design features
• DIRECT WATER COOLING OF STATOR WINDING
• DIRECT AXIAL HYDROGEN COOLING OF ROTOR WINDING
• OPTIMALLY DESIGNED LEAF SPRING SUPPORT FOR CORE
• END SHIELD MOUNTED BEARINGS
• VPI INSULATION SYSTEM
• MASSIVE SUPPORT RING FOR STATOR WINDING OVERHANG
TO ABSORB SHORT CIRCUIT FORCES
• SIDE AND TOP RIPPLE SPRINGS IN STATOR SLOTS TO
CONTAIN BAR BOUNCING FORCES
• 5 STAGE AXIAL COMPRESSOR AND VERTICAL HYDROGEN
COOLERS ON TURBINE END
• COLD GAS AND PRIMARY WATER TEMPERATURE CONTROL
VALVES TO MAINTAIN AVERAGE INLET COOLING MEDIUM
TEMPERATURES CONSTANT
• DOUBLE FLOW RING TYPE SHAFT SEALS
• BRUSHLESS EXCITATION SYSTEM
BHEL Hardwar
Gas Turbine Generators - Design features
• TERMINAL BUSHINGS ON TOP
BHEL Hardwar
Gas Turbine Generators - Design features
BHEL Hardwar
Gas Turbine Generators - Design features
BHEL Hardwar
Gas Turbine Generators - Design features
BHEL Hardwar
Forced Cooling Water System (MPR System)
BHEL Hardwar
Forced Cooling Water System (MPR System)
BHEL Hardwar
Gas Turbine Generators - Experience List
BHEL Hardwar
Main Parts of TG / Constructional features
1. Stator - Stator Frame (Fabrication & Machining)
2. Core Assembly - Stator Core, Core Suspension Arrangement
3. End Shield
4. Stator Winding Assembly - Stator Winding , Winding Assembly,
Connecting Bus bar
5. Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor,
Rotor Assembly
6. Completing Assembly - Bearing Assembly, Shaft Seal Assembly,
Oil Catchers, Insert Cover etc
7. Exciter
8. Auxiliary System
BHEL Hardwar
Main Parts of Turbogenerator
Stator Core Cooler
Insert
End Shield Cover
Oil Catcher
Rotor
Bearing
Shaft Seal
Stator
Terminal Bushing
BHEL Hardwar
Main Parts of Turbogenerator
Coolers
Foundation
Terminal bushing
BHEL Hardwar
Ventilation Circuit in THRI TG
BHEL Hardwar
Ventilation Circuit in THRI TG
BHEL Hardwar
Stator Frame
• Rigid fabricated cylindrical frame
• Withstands weight of core & wdg, forces & torques during operation
• Natural frequency away from exciting frequencies
•Provision for H2/CO2 filling
• Provision for temp measurements
• Foot plates for supporting on foundation
• provision for H2 coolers
BHEL Hardwar
Stator Frame (Fabrication & Machining)
BHEL Hardwar
Hydraulic/Pneumatic testing of Stator
TURBINE SIDE END STATOR
SHIELD EXCITER SIDE END
SHIELD
BHEL Hardwar
Stator Frame TARI 108/46
BHEL Hardwar
Stator Core
• Made up of punched segments of thin sheets of ETS
• Punchings coated by insulating varnish
• Vent segments at designed intervals for flow of cooling gas
• Compressed with tension bolts, pressure plate and clamping fingers
• Stepped arrangement at the end for reduction in eddy current losses
BHEL Hardwar
Core Suspension - TARI/THRI TG
BHEL Hardwar
Core Suspension - Air Cooled TG
Location for
Spring
Core Housing
Core
BHEL Hardwar
Core Suspension - 500 MW
BHEL Hardwar
End Shield
• Closes both ends of Stator Frame
•Fabricated rigid box type structure in two parts
• Supports and houses bearings
• Provision for mounting Shaft seal body, Oil catchers, etc
• Provision for supply of Bearing Oil, Seal oil, Thrust oil and its drain
BHEL Hardwar
End Shield (Exciter side 500 MW)
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End Shield (Turbine side 500 MW)
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Stator Winding
• Three phase windings in two layers of individual bars
• Top and bottom bar displaced by one winding pitch and connected to
coil groups
• Coil groups connected to Connecting Bus bar and finally to Term Bushing
• Involute shape at the end of bar helps withstands various forces
• Micalastic Insulation System (VPI process)
BHEL Hardwar
Stator Winding Assembly
1. CORE
2. CLAMPING FINGER
3. PRESSURE PLATE
4. TOP BAR
5. BOTTOM BAR
6. PHASE CONNECTOR
7. GAS OUTLET
8. GAS INLET
9. TERMINAL BUSHING
BHEL Hardwar
Stator END Winding Support
BHEL Hardwar
Stator End Winding Assembly
BHEL Hardwar
Stator End Winding 500 MW
BHEL Hardwar
Stator End Winding 500 MW
BHEL Hardwar
Rotor
1. A high strength alloy steel single forging prepared by vacuum cast steel
2. Slots for housing field windings
3. Strong coupling for withstanding short circuit forces
4. Bending critical speed away ±5% of operating speed
5. Supported on two journal Bearings
6. Provision of axial fan/compressor for forced ventilation
7. Provision of damper wedges for increasing negative sequence
capability of rotor
BHEL Hardwar
Rotor Body
BHEL Hardwar
Rotor Body with cross Pole Slot
Rotor
Wedge
Cross
Pole
Slot
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Rotor Slot
Rotor Wedge
Conductor
Slot Liner
Sub Slot
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Arrangement of Damper Wedges
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Rotor End Winding
1 2 3 4 5 6 7 8 9
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Rotor End Winding
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Rotor Fan Blades
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Rotor Slip Ring
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Bearing Assembly
• It is sleeve Bearing
• Supports Rotor weight
• Reduces shaft vibrations
• Minimises frictional losses
• Located in End Shields or outside stator depending upon type of machine
• Self aligning outer part
• Insulated from Stator or End Shield to prevent flow of shaft current
• Inner surface is made of babbit material (Tin alloy)
BHEL Hardwar
Bearing Assembly
BHEL Hardwar
Bearing Assembly
BHEL Hardwar
Bearing Assembly
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Shaft Seal Assembly
• Prevents escape of H2 through junction of rotor and stationary part
• Maintains continuous oil film between Seal Ring and rotor journal
• Clearance should be sufficient to maintain oil film without unnecessary
large oil flow and with minimum frictional losses
• Ring relief oil for balancing the gas pressure on seal ring
• Inner surface of Babbit material
BHEL Hardwar
Shaft Seal Assembly
Hydrogen
Side
Air Side
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Terminal Bushing
• Tubular construction for gas / water cooling
• High conductivity copper for taking out electrical power
• Connection flanges are silver plated to minimise contact resistances
• Insulated with a epoxy resin cylinder or porcelain cylinder
• Differential pressure of gases or forced water for cooling
• Bolted on to stator bottom/top directly or housed in a box type
construction which is bolted to stator bottom
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Terminal Bushing
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Cooling of Terminal Bushing
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Terminal Bushings Arrangement TARI
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Terminal Bushings Arrangement THRI
1. CORE
2. CLAMPING FINGER
3. PRESSURE PLATE
4. TOP BAR
5. BOTTOM BAR
6. PHASE CONNECTOR
7. GAS OUTLET
8. GAS INLET
9. TERMINAL BUSHING
BHEL Hardwar
Terminal Bushing Box 500 MW
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Excitation System
1. Static Excitation
• Rotor Field Winding is connected to Slipring mounted on rotor
• Excitation is provided by current transfer by contact through
Carbon Brushes, Slipring and field lead
Brush Gear
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Static Excitation System
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Brushless Excitation System
2. Brushless Exciter
•Eliminates Slip Rings, Brushgear and Field Breaker
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Brushless Exciter
•High response excitation with fast acting AVR
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Brushless Exciter
BHEL Hardwar
Rectifier Wheel
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PMG Rotor & Fan
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Auxiliary System
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Primary Water System
Losses in wdg, bushings, bus bar are dissipated
1. PRIMARY WATER TANK
2. PRESSURE REGULATOR
3. WASTE GAS TO ATM.
4. PUMP
5. COOLER
6. FILTER
7. BYPASS LINE
8. CW FOR STATOR WDG.
9. ION EXCHANGER
10. CW FOR BUSHINGS
11. TEFLON HOSE
12. C W MANIFOLD
BHEL Hardwar
Seal Oil System
Prevents H2 losses at the shaft entry into stator
BHEL Hardwar
Gas System
Facilitates H2 filling & maintains gas pressure in stator 1. H2 BOTTLE
2. H2 PRESS REDUCER
3. N2 BOTTLE.
4. N2 PRESS REDUCER
5. PW TANK
6. PRESS CONTROLLER
7. UPR. GEN GAS HEADER
8. LWR.GEN GAS HEADER
9. GAS DRIER HEATER
10. GAS DRIER FAN
11. GAS DRIER CHAMBER
12. CO2/H2 PURITY TRANS.
13. DEHYDR. FILTER
14. PRESS REDUCER
15. COMPRD. AIR HOSE
16. COMPRD. AIR FILTER
17. CO2 FLASH EVAPORTR
18. CO2 BOTTLE
BHEL Hardwar
Generating testing
1. Mechanical test
2. Open Circuit test
3. Short circuit test
4. Sudden short circuit test
5. Voltage wave form
6. Tan test
7. Vibration Measurement
BHEL Hardwar
500 MW Generator on test bed
BHEL Hardwar
Gas Turbine Generator-Faridabad
BHEL Hardwar
Gas Turbine Generator- Baiji, IRAQ
BHEL Hardwar
New dev - Total Impregnated generator
STATOR WINDING AND CORE BECOMES A MONOLITHIC STRUCTURE : NO
VOIDS, LESSER VIBRATIONS & BETTER HEAT TRANSFER
BHEL Hardwar
Advantages of Total Impregnated generator
BHEL Hardwar
WOUND STATOR CORE BEING LOADED FOR TOTAL
IMPREGNATION
BHEL Hardwar
CURING OF TOTALLY IMPREGNATED WOUND
CORE
BHEL Hardwar
INSERTION OF IMPREGNATED WOUND CORE
IN STATOR
BHEL Hardwar
THANK YOU
END
BHEL Hardwar