Design & Constructional

Features of Turbogenerators
Gyanendra Sharma
NPTI Delhi
 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

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 History of Development - Globally

· First single phase generator of 75 KW 1888

· First 3 phase generator, salient pole 1900

· First turbo type 3 phase 25 MW generator 1912

· UK made 50 Hz as standard frequency for Europe 1925

· First Hydrogen cooled 3 phase 30 MW generator 1937

· First Hydrogen cooled TG with direct cooling of rotor 1949

· First generator with water cooled stator winding 1956

· First generator with water cooling for stator and rotor wdg1959

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 History of Development in BHEL

THREE PLANTS SET UP:

IN 1950s:
At Bhopal with British collaboration
30 MW & 120 MW Hydrogen Cooled

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

No increase of utilization Increased utilization

Same or higher mfg. Costs Lower mfg. costs possible

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 Generator Modules

Air Cooled Turbogenerator - TARI

Hydrogen Cooled Turbogenerator - THRI
Hydrogen/Water Cooled TG - THDF

Module Nomenclature -
THRI 108/44
THDF 115/59

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 Module Nomenclature
T H R I 108/44
Stator winding

4350 mm(44 dm) Core length Indirect Hydrogen

Cooled
1075 mm(108 cm) Rotor dia.

Stator Cooling - Indirect

Rotor Cooling- Radial

Cooling Gas in the Rotor winding

Casing
Radial Hydrogen
H = Hydrogen Cooled

Product
Turbogenerator

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 Generator cooling System

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 Stator Slot - TARI / THRI

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 Stator Slot - THDF 500 MW

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 210/235 MW THW Generator

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 Library of Designs

TYPES OF GENERATORS
SUPPLIED BY BHEL:
# AIR COOLED
# HYDROGEN COOLED
# HYDROGEN/WATER
COOLED

FOR APPLICATIONS:
# THERMAL
# NUCLEAR
# GAS BASED

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 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

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 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

THRI 93/38 120-150 MW

THRI 108/39 170-220 MW
HYDROGEN COOLED THRI 108/44 200-260 MW
25/22/17 THRI 108/44 B 260-275 MW
THRI 108/55 350 MW

THW-200-2 UPTO 200 MW

HYDROGEN/WATER THW-210-2 200-219 MW
COOLED THW-235-2 220-237 MW
149/142/137 THDF 115/59 500-585 MW
THDF 115/55 500 MW(new)

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 Improtant Parameters of Generator Modules
SL. TECHNICAL 130 MW 200 MW 210 MW 235 MW 210 MW 250 MW 500 MW 560 MW
NO.
PARAMETE
R
1. GENERATO THRI THW- THW- THW- THRI THRI THDF THDF
R TYPE 93/38 200-2 210-2 235-2 108/44 108/44 115/59 115/59
2. RATED 162.5 235.3 247.1 264.1 247.1 294.1 588.2 659.0
MVA 130.0 200.0 210.0 237.7 210.0 250.0 500.0 560.0
RATED MW
3. RATED 10.5 15.75 15.75 16.5 15.75 16.5 21.0 21.0
VOLT. KV
4. POWER 0.80 0.85 0.85 0.90 0.85 0.85 0.85 0.85
FACTOR
5. STATOR 8935 8625 9054 9240 9054 10291 16166 18118
CURRENT
6. SPEED 3000 3000 3000 3000 3000 3000 3000 3000
RPM
7. FREQ. HZ 50 50 50 50 50 50 50 50
8. HYDROGEN
PRESSURE 3.0 3.0 3.5 3.5 2.0 3.0 3.5 4.0
Kg/Cm2(g)
9. S.C.R 0.57 0.50 0.49 0.58 0.55 0.52 0.48 0.46
10. EXCITATIO
N 240 300 310 326 265 319 340 410
VOLTS 2039 2515 2600 2755 2080 2386 4040 4463
AMPS
11. NEG. SEQ.
CAP. I2,% 8 7 7 7 8 8 8 8
I2sq.xt 10 8 8 8 10 10 10 10
12. WEIGHTS, T
STATOR
HEAV. LIFT 132 175 175 175 182 182 255 255
ROTOR 28 42.2 42.2 42.5 43.3 43.3 68 68
13. BRG. - BRG.
DIST. IN MM 6700 7700 7700 7882 7870 7870 10410 10410
14. TYPE OF STATIC STATIC STATIC STATIC B’LESS/ B’LESS B’LESS B’LESS
EXCITATIO / / / STATIC
N HFG HFG HFG

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 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

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 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

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 TARI Generators - Design features
# DIRECT COOLING OF STATOR CORE AND ROTOR WINDING
# INDIRECT COOLING OF STATOR WINDING

# HORIZONTALLY SPLIT CASING DESIGN FOR STATOR

# VERTICALLY SIDE MOUNTED COOLERS IN A SEPARATE

HOUSING

# VPI INSULATION SYSTEM

# TOP RIPPLE SPRINGS IN STATOR SLOTS TO CONTAIN BAR

BOUNCING FORCES

# SEPARATELY ASSEMBLED STATOR CORE AND WINDING

FOR REDUCING THE MANUFACTURING CYCLE

# STATIC/BRUSHLESS EXCITATION SYSTEM

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 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

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 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

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 Gas Turbine Generators - Design features
• TERMINAL BUSHINGS ON TOP
• STATIC EXCITATION SYSTEM

• SFC (SYNCHRONOUS FREQUENCY CONVERTOR) STARTING SYSTEM

• FORCED COOLING WATER SYSTEM (MPR SYSTEM)

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 Gas Turbine Generators - Design features

TARI Generator Outline

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 Gas Turbine Generators - Design features

TARI Generator Cross section

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 Gas Turbine Generators - Design features

TARI Generator End View

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 Forced Cooling Water System (MPR System)

A SYSTEM TO TAKE CARE OF DM COOLING WATER

REQUIREMENT OF GAS TURBINE GENERATORS

1. TO DELIVER DM COOLING WATER TO GENERATOR AIR

COOLERS

2. TO ENSURE HEAT TRANSFER FROM GENERATOR AIR

COOLERS TO THE FIN-FAN COOLERS.

3. TO MAINTAIN COOLING WATER TEMPERATURE

AND PRESSURE AT ALLOWABLE VALUES.

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Forced Cooling Water System (MPR System)
 Gas Turbine Generators - Experience List

GENERATOR MODULE TARI 108/46

SUPPLIED / UNDER SUPPLY :
BAIJI GPP, IRAQ 4 SETS
W. MOUNTAIN, LIBYA 4 SETS

GENERATOR MODULE TARI 108/41 (SUPPLIED)

FARIDABAD CCPP, INDIA 1 SET

GENERATOR MODULE TARI 108/36

SUPPLIED / UNDER SUPPLY:
KAYAMKULAM, INDIA 2 SETS - GE Turbines

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 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

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 Main Parts of Turbogenerator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing

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 Main Parts of Turbogenerator

Coolers

Foundation

Terminal bushing

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 Ventilation Circuit in THRI TG

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 Ventilation Circuit in THRI TG

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 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

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 Stator Frame (Fabrication & Machining)

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 Hydraulic/Pneumatic testing of Stator
TURBINE SIDE END SHIELD STATOR
EXCITER SIDE END SHIELD

TEST PRESSURE= 10 BAR FOR 30 MIN

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 Stator Frame TARI 108/46

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 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

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 Core Suspension - TARI/THRI TG

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 Core Suspension - Air Cooled TG

Location for
Spring

Core Housing

Core End Plate

Core

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 Core Suspension - 500 MW

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 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

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 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)

- Micalastic good conductor of heat

- Low flamability
- High resistance to moisture and chemical action
- Accommodates thermo-mechanical stresses
- Retains properties even after years of operation

VPI- Vacuum Pressure Impregnation

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 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

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 Stator END Winding Support

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 Stator End Winding Assembly

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 Stator End Winding 500 MW

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 Stator End Winding 500 MW

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 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

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 Rotor Body

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 Rotor Body with cross Pole Slot

Rotor
Wedge

Cross
Pole
Slot

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 Rotor Slot

Rotor Wedge

Top Slot Liner

Conductor

Inter turn Insulation

Slot Liner

Sub Slot

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 Arrangement of Damper Wedges

1. ROTOR BODY 5. RETAINING RING

2. DAMPER BAR 6. SILVER PLATED SHRINK SEAT
3. SILVER PLATED ROTOR END WEDGE 7. TRANSVERSE SLOTS
4. ROTOR WINDING 8. ROTOR WEDGE

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 Rotor End Winding
1 2 3 4 5 6 7 8 9

1. ROTOR BODY 6. GAS BAFFLE

2. SNAP RING 7. RETAINING RING
3. TERMINAL LUG 8. END RING
4. ROTOR WINDING 9. BALANCING BORE
5. FILLER

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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)

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 Bearing Assembly

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 Bearing Assembly

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 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

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 Shaft Seal Assembly
Hydrogen
Side
Air Side

1. OIL WIPER RING AIR SIDE 7. SEAL RING 13. INSULATION

2. SEAL RING CHAMBER 8. SEAL RING CARRIER 14. PACKING
3. PRESSURE OIL GROOVE 9. OIL WIPER RING H2 SIDE 15. SEAL OIL GROOVE
4. BABBIT 10. SEAL STRIP 16. END SHIELD
5. SEAL OIL INLET BORE 11. ROTOR SHAFT
6. SEAL OIL GROOVE 12. INNER LABYRINTH RING

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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

1. HYDROGEN SIDE FLANGE

2. TUBULAR COPPER COND.
3. INSULATING CYLINDER
4. MOUNTING FLANGE
5. RUBBER GASKET
6. AIR SIDE TERMINAL BOLT

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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

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 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

Brush Gear Assly Brush Holder

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 Brushless Excitation System
2. Brushless Exciter
•Eliminates Slip Rings, Brushgear and Field Breaker

•Eliminates all problems associated with transfer of current via

sliding contacts

•Simple, Reliable and ideally suited for large sets

•Minimum operating and maintenance cost

•Self generating excitation unaffected by system fault/disturbances

because of shaft mounted pilot exciter

•Increasingly popular system the world over

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 Brushless Exciter
•High response excitation with fast acting AVR

•Multi contact electrical connections between exciter and

generator field

•Stroboscope for fuse failure detection

•Rotor Earth fault monitoring system

•RC circuit to avoid over voltages

•Dehumidifier for use during shut down

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 Brushless Exciter

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 Rectifier Wheel

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 PMG Rotor & Fan

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 Auxiliary System

1. Primary Water System

2. Seal Oil System
3. Gas Flow 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

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 Seal Oil System
Prevents H2 losses at the shaft entry into stator

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 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

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 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

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 500 MW Generator on test bed

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 Gas Turbine Generator-Faridabad

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 Gas Turbine Generator- Baiji, IRAQ

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 New dev - Total Impregnated generator
STATOR WINDING AND CORE BECOMES A MONOLITHIC STRUCTURE : NO VOIDS, LESSER
VIBRATIONS & BETTER HEAT TRANSFER
THERMAL CONDUCTIVITY OF VPI INSU. 2.2 - 2.5 mW/Cm°C
THERMAL CONDUCTIVITY OF H2 1.4 - 1.5 mW/Cm°C
THERMAL CONDUCTIVITY OF AIR 0.257 mW / Cm °C

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 Advantages of Total Impregnated generator

+ PARTIAL DISCHARGES ARE REDUCED, RESULTING IN BETTER LIFE OF MACHINE

+ NO POSSIBILITY OF CORE OR BAR LOOSENESS: Thus a major cause of failure, resulting
in stator earth faults is eliminated.
+ NO POSSIBILTY OF LOOSENESS IN STATOR WINDING OVERHANG: Lesser overhang
vibrations. Glue injection in overhang is not required.
+ NO POSSIBILTY OF WEDGE LOOSENESS -
Wedge tightness checking not required. Rotor withdrawl during initial inspection not
required.
+ LESSER MAINTENANCE
+ LESSER OVERHAUL TIME
+ REDUCTION IN SPARES INVENTORY - STATOR BARS AND STATOR SLOT WEDGES ARE NO
MORE REQUIRED AS SPARES

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 WOUND STATOR CORE BEING LOADED FOR TOTAL
IMPREGNATION

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 CURING OF TOTALLY IMPREGNATED
WOUND CORE

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 INSERTION OF IMPREGNATED WOUND
CORE IN STATOR

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 THANK YOU

END

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