Presentation on

Generator
Fundamentals
BY
Kumar Vikram
Dy. Supdt.(E/M)
03/28/25 Kumar Vikram 1
Ac generator
 Faraday’s laws state:
1. when the number of magnetic lines of force associated with a
conductor changes ,an induced voltage is set up in the
conductor.
2. The voltage induced is proportional to the rate of change of
the magnetic lines associated with the conductor.
If ,therefore ,a stator winding consists of Z- conductors
connected in series so that the voltages induced in them are
added together ,and ф is the field flux sweeping across the
conductors in time t seconds, by Faradays laws:
Total induced voltage=(Number of Conductors) x (rate of change
of flux)
or E= Z фx 10 volts
t
Thus ,in any generator operating at constant speed the voltage
can be altered by changing the field flux , i.e, by changing the
value of the excitation current applied to the rotor winding.
03/28/25 Kumar Vikram 2
 FARAKK
A
Generator Excitation Principle

Rotor
mounted on
ROTOR
common
shaft,
rotated by
AIRGAP Turbine.

STATOR

Contd…

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 FARAKK
A
Generator Excitation Principle

ROTOR

S
‘+’ ve ‘-’ ve

Variable DC

Rectified DC supply to rotor

2-pole magnetic field
Field control by Automatic Voltage Regulator

Contd…

03/28/25 Kumar Vikram 4

 FARAKK
A
Generator Excitation Principle

S
N
Rotating N

S
N S

ROTOR
magnetic field

R
R
ROTOR
O T R
O
T R
produces 3- ROTOR

T R

S
O

N
N

TR
O
ROTOR

OO
O
phase a.c. in

O
NR

R
stator. S

S N
N
S

STATOR

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 Static Excitation System is used in most of the 200 MW Generator
sets. The AC power is tapped off from the generator terminal,
stepped down and rectified by fully controlled thyristor bridges and
then fed to generator field as excitation power, to control the
generator-output voltage. A high control speed is achieved by using
an inertia free control and power electronic system. Any deviation in
generator terminal voltage is sensed by an error detector and
causes the voltage regulator to advance or retard the firing angle of
thyristor thereby controlling the field excitation.

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 The generator is capable of delivering 247 MVA continuously
at 15.75 KV terminal voltage and stator current 9050 A, at a
Hydrogen pressure (g) of 3.5 Kg/cm2. The cold gas
temperature not to exceed 44 0C and distillate temperature
at inlet of stator winding not to exceed 45 0C. Output of the
generator at various lagging and leading power factors are as
per the generator capability curve.

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The static excitation system consists of:
i. Rectifier Transformer
ii. Thyristor Converter
iii. Automatic Voltage Regulator
iv. Field flashing Circuit
v. Field breaker and field discharge
equipment

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 Excitation
system

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 In 200 MW units, the field current to the Generator rotor winding is
provided through the Generator Brush gear. The current carrying brush
gear assembly is rigidly fixed on the extended part of bearing pedestal
on the exciter side. There are two brush gear stands, each made up of
two symmetrical silicon brass casting half-rings, which are bolted at the
top to make one stand assembly, kept vertically. These ring stands are
designed as helical; from one end to the other to achieve uniform wear
of slip rings as well as carbon brushes and smooth removal of carbon
dust all along the width of slip rings . Provision is made on these ring
stands for connecting cables which can be taken through the foundation
underneath.

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 Slip rings

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 CC bolt removal

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 CC bolt

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 Removing flexible link

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• Stator
• Rotor
Components of Stator
Stator Frame
Stator Core
Stator Winding
Distillate Header
Terminal Bushing
End Shield

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 Cut view of Turbo
generator

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Stator Frame
Stator body with core and stator winding form
the heaviest component of the entire TG.
Made up of high quality mild steel and
austenitic steel.
Designed to withstand high internal pressure
which may arise due to unlikely event of
explosion of Hydrogen air mixture without any
residual deformation.
Consists of two distinct parts , the inner
frame and the outer frame.
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 Inner part of Stator
Frame

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 Stator
Frame

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Stator core
Stator core provides path for machines magnetic
flux and slots in which the winding is assembled.
Made of cold rolled high quality silicon steel.
Built up of thin laminations in order to reduce
Eddy current loss.
The winding slots are punched in the inner
periphery of the core the diameter of which must
be such that the teeth between slots are of
sufficient section area to carry the required flux.
Further, the teeth must not be weakened to the
stage where there can be any failure in operation.
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 Core Packets

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 End Core Packet

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 Core view from
Bottom

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Core Suspension
 The Revolving magnetic field exerts a pull on
the core , resulting in a revolving and nearly
elliptical deformation of the core which sets
up a stator vibration at twice the system
frequency known as double frequency
vibrations. All generator cores featuring high
dynamic vibration amplitudes are spring
mounted in the stator frame to damper the
transmission of double frequency vibrations
to the foundation.

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Stator Windings
 The stator has a three phase, double layer,
short pitched and bar type of windings having
two parallel paths.
Each slot accommodates two bars.
Each bar consists of solid as well as hollow
conductors
In the straight slot portion the strands are
transposed by 3600 to reduce the eddy losses.

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 STATOR BAR

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 Bar cross-section
view

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 Bar solid and
hollow strands

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 Conductors of small rectangular cross section
are provided with glass lapped strand
insulation.

 A layer of glass tape is wrapped over the

complete stack in order to give dimensional
stability in slot portion.

Bar insulation is done with epoxy mica

thermosetting insulation.
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 Hollow Conductor

1. Slot Wedge
2. Hollow Copper
Conductor
3. Solid Copper
Conductor
4. Main
insulation(Compound
ed Mica)
5. Glass Cloth ins.
6. Insulating Packing

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 Slot configuration

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Corona prevention

To prevent corona discharges between

insulation and the wall of the slot, the
insulation in the slot portion is coated with
Semiconducting varnish.

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 Semiconducting
varnish on
stator bar

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 Side spring
insertion
Ensures good
contact
between
semiconducting
coating and slot
wall

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 Ripple springs and
insulating packers
These are put
under slot wedges
in order to prevent
vibrations which
may be set up by
the bar currents.

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 Wedge fixing

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Electrical and water connection
Electrical connection between top and
bottom bar is made by putting copper ferrule
over the two limbs of coil lugs.
Copper wedges are inserted in between and
soldering is done.
Water connection on Exciter side is done by
connecting copper tube in two lugs
On turbine side each lug is connected
through a Teflon hose to inlet/outlet header.

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 Copper ferrule

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 Ferrule and taper
wedges

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 Soldering
preparedness

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 Soldering

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 TE
30 29 28 27 26 25 24 23 22 21
1C3

55 54 53 52 51 50 49 48 47 46

EE
C6

51 52 53 54 55 56 57 58 59 60

2C3

PH TE 16 17 18 19 20 21 22 23 24 25 NE

TOP BAR
R - PHASE
ELECTRICAL CONNECTIONS OF STATOR WINDING
BOTTOM BAR

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 TE
50 49 48 47 46 45 44 43 42 41
1C2

15 14 13 12 11 10 9 8 7 6

EE
C5

11 12 13 14 15 16 17 18 19 20

2C2

PH TE 36 37 38 39 40 41 42 43 44 45 NE

TOP BAR
Y - PHASE
ELECTRICAL CONNECTIONS OF STATOR WINDING
BOTTOM BAR

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 TE
10 9 8 7 6 5 4 3 2 1
1C1

35 34 33 32 31 30 29 28 27 26

EE
C4

31 32 33 34 35 36 37 38 39 40

2C1

PH TE 56 57 58 59 60 1 2 3 4 5 NE

TOP BAR B - PHASE

ELECTRICAL CONNECTIONS OF STATOR WINDING

BOTTOM BAR

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 Copper connecting
tubes

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 Copper connecting
tubes connected
outside

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 Bars connection at
Turbine End

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 Insulation box filled with putty

The bar
heads are
insulated by
fibre molded
covers filled
with putty.

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 Insulation box
fitted over top and
bottom bar

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Distillate Header
Ring type water header, made of copper are
provided separately for distillate inlet and
outlet in the stator on turbine side.
The headers are supported on insulators and
isolated from stator body.
Vent pipe connections are provided at the top
of both inlet and outlet header to expel air
during filling these headers with distillate.
These vent pipes are connected to the gas trap
to measure the extent of hydrogen leaking into
water circuit.
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 Inlet and Outlet
distillate header

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 Stator water
bushing

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 Water Cooling of Stator Winding
1. Upper Winding
Bar
2. Lower winding Bar
3. Stator Core
4. Feed Header
5. Drain Header
6. P.T.F.E Hoses
7. Insulating Bush
8. Water Connecting
tubes
9. Ferrul
10. Coil Lugs
11. Insulator
12. Cover

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Terminal Bushing
Three phases and six neutral terminals are
brought out from the stator frame through
bushings.

The conductor of the bushing is made of high

conductivity copper tube on which silver plated
terminal plates are brazed at both ends.

The bushing is connected to terminal bus bar by

means of flexible copper leads for making the
electrical connections conveniently.
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 Neutral
Bushing

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 Bushing Water
connection

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 Bushing coming out of frame

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 Flexible link and bus duct

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End Shield
The end shields are fabricated from mild steel
plates.
The construction of the end shield is such that
there is a square channel in the vertical plane
through which cold hydrogen flows into cool
the overhang portion of rotor.
Through rest of portion of the end shield the
hot hydrogen is pushed to gas cooler by axial
propeller type fans.
Also End Shields houses shaft seal, Aluminum
alloy casting of fan shield and LLDs.
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 End Shield

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 Top half End
shield

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 Fan Guard

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Components of Rotor
Rotor Shaft
Rotor Winding
Rotor Wedges
Retaining Ring
Fans
Field lead connections

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Rotor Shaft
Rotor shaft is single forging measuring more
than 9770 mm in length and 1075mm in
diameter.

Made of alloy steel having constituents

chromium, Molybdenum, Nickel and
Vanadium.

Longitudinal slots are made on about 2/3rd of

total circumference to accommodate Field
windings.
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 Rotor Shaft

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Rotor Winding
Rotor or Field winding is housed in the
longitudinal slots of the rotor.
Conductors are made of silver bearing copper.
Conductor has low electrical resistance.
This grade of copper exhibits high creep
resistance so that coil deformation due to
thermal cycling due to start and stop operation
are minimum.
The rectangular cross section copper conductor
have ventilating ducts on the two sides thus
providing a channel for hydrogen flow.
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 Rotor Winding

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Rotor Wedges
Wedges are used to retain the field winding
into the slot against the effect of centrifugal
force.
Wedges are made of Duralumin ,an alloy of
copper, magnesium and Aluminum having
high electrical conductivity and high
mechanical strength.
Wedges at the end of slot are made of an
alloy of chromium and copper.

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 Rotor Wedges

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Retaining Ring
The overhang portion of field winding is held
in its position against the effect of centrifugal
force by a non-magnetic steel ring called
'Retaining Ring’.

Made of alloy 60MnNi85Cr35W75.

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 Retaining
Ring

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Rotor Fan
The generator cooling gas is circulated by
two single stage axial flow propeller type
fans.

The fan hubs are shrunk fitted on either side

of the rotor body.

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 Fan Blades

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 Fan Hub

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