TURBOGENERATOR BASICS

Sharmendra Kumar
Sr Engineer (EMD)
 FUNDAMENTALS

• Inputs
– Mech. Power (Turbine) Power can’t be created
– Rate of Change of Flux (Excitation) FARADAY’ LAW OF EMI

Output
Electrical Power

• P=f (V ,I,)
• I=f (Load)
• V=f (Ø, N, n,reactive power balance of system) N=no of turns ,n =rpm

• V=f( -n dØ/dt
• Ø=f (Magnetic Field )
• Magnetic Field can be permanent magnet or electromagnet.
 FUNDAMENTALS

• Inputs
– Through a rotating member –ROTOR

• Output
– Through a stationary member –STATOR

– FOR THE EASE OF HANDLING ELECTRICAL POWER

TYPES OF GENERATOR BASED ON
EXCITATION

• STATIC EXCITATION

• SEMI STATIC EXCITATION

• BRUSHLESS EXCITATION
 STATIC EXCITATION
SLIP RINGS

GENERATOR TURBINE
+ -

3 PH AC
GT

EXC TX

CONTROLLED
RECTIFIERS

VARIABLE DC
 SEMI STATIC EXCITATION
BRUSH GEAR BRUSHGEAR

EXCITER GENERATOR TURBINE

VARIABLE DC
3 PH AC

STEP DOWN
EXCITER GENERATOR
TX
ROTOR CONTROLLED CONTROLLED
DC DC

CONTROLLED STATOR 3 H AC,50HZ 3 H AC,50HZ

RECTIFIERS

VARIABLE DC
 BRUSHLESS EXCITATION
PMG 3PH AC,150HZ
PILOT MAIN
GENERATOR TURBINE
EXCITER EXCITER
3 PH, 400HZ DIODE WHEEL
3 PH AC, 50 HZ
CONTROLLED
RECTIFIERS

PILOT MAIN EXCITER GENERATOR

EXCITER
ROTOR PERMANENT 3 PH AC,150HZ CONTROLLED
MAGNET AC DC

STATOR 3PH, 400HZ CONTROLLED 3 H AC,50HZ

AC DC
CAPACITY OF GENERATOR
MODULES
MODULE SIZE (THRI 108/44) GIVES THE SIZE OF THE MACHINE.

108 X10 = 1080 (1075) ROTOR OUTER DIA

44X100 = 4400 CORE LENGTH
 Library of Designs
1000 MW

WATER COOLED STATOR

350 MW

HYDROGEN COOLED 660 MW

170 MW

AIR COOLED

DESIRED MW CAPACITIES

80 MW 1000 MW
 210 MW 500 MW 660 MW 800 MW
DESCRIPTION THW THDF THRI THRI
Max. continuous MVA 247 588 776 1000
Rating
Max continuous MW 210 500 660 800
rating
Rated terminal voltage 15.75 21 21 27
(KV)
Rated Stator current 9050 16166 21334 21383
(Amps)
Power factor Lagging 0.85 0.85 0.85 0.8

Exciter current at MCR 2600 4040 5587 5864

(Amps)
Exciter Voltage at MCR 310 340 445 434
(V)
Rated hydrogen 3.5 3.5 6.0 6.0
pressure (atm)
Rated speed (rpm) 3000 3000 3000 3000
GENERAL ARRANGEMENT
 Main Parts of Turbogenerator
1. Stator - Stator Frame
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
 Main Parts of Turbogenerator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing
 Main Parts of Turbogenerator

Coolers

Foundation

Terminal bushing
STATOR
Stator Frame (Air Cooled TG)
Stator Frame (500 MW)
Stator Frame (Fabrication & Machining)
 Core Suspension - Air Cooled TG

Location for
Spring

Core Housing

Core End Plate

Core
Stator Slot - THDF 500 MW
End Shield - THRI TG
End Shield (Exciter side 500 MW)
End Shield (Turbine side 500 MW)
COOLING ARRANGEMENTS
GENERAL ARRANGEMENT OF 500 MW TURBOGENERATOR
 3-D MODELLING OF ROTOR
ASSEMBLY AND COMPONENTS

PLATFORM USED – PRO ENGINEER

WILDFIRE 2.0
TYPICAL ROTOR ASSEMBLY

ROTOR SHAFT

FAN BLADES

RETAINING RINGS

WEDGES

FIELD LEAD
 ROTOR SHAFT

BARREL

COUPLING
(TURBINE END)

BLOWER HUB

COUPLING
MATERIAL (EXCITER END)

26NiCrMoV145
Y p = 730-830N/mm2
 ROTOR SHAFT TURBINE END

TE COUPLING

JOURNAL
COUPLING TURBINE END

SPIGOT

12 HOLES
 COUPLING EXCITER END
STEPS FOR HYDROGEN SEALING
SPIGOT

14 HOLES
ROTOR COILS (210/250 MW ROTOR)

COIL A TO G (7 COILS) PER POLE

RADIAL COOLING
ROTOR WEDGES
MACHINING OF END SLOT WEDGES
ROTOR WEDGES (Without Rotor Shaft)

DAMPER WEDGE

DAMPER WEDGE

SLOT WEDGE

PRESSURE PLATE
 WEDGE

NOMEX PIECES
 WOUND ROTOR

OVERHANG ASSEMBLY
RETAINING RING ASSY.
 RETAINING RING CENTERING RING

MATERIAL X8CrMnN1818k MATERIAL 33NiCr Mo145

SECTIONED VIEW
RETAINING RING AND
CENTERING RING ASSY
COOLING SCHEME
COOLING IN END PORTION

BOTTOM CANAL
THROUGH VENTILATION SLOT TO AIR GAP
COLD ZONE

HOT ZONE

COOLING OF OVERHANG PORTION

BLOWER BLADE ASSY.
BLOWER BLADE FORGING
BLOWER BLADE
BLOWER BLADE

BLADE PROFILE

THREADED PORTION

FLAT FOR LOCKING

 ROTOR COIL

INCLINED
COOLING
DUCTS IN SLOT
PORTION

COOLING DUCT
IN OVERHANG
 TYPICAL OVERHANG COMPLETE

RECTANGULAR COILS
RECTANGULAR COIL ASSEMBLY
OVERHANG WEDGES (INTERIOR VIEW)

STOPPER FOR
WEDGES

STOPPER FOR
SPACERS
Bearing Assembly
Terminal Bushing Box 500 MW