Vindhyachal

Generator
Components
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 CURING OF TOTALLY IMPREGNATED WOUND
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CORE

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 INSERTION OF IMPREGNATED WOUND CORE IN
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STATOR

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THW 210/235: ROTOR SHAFT

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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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TURBO GENERATOR CONSTRUCTION

 CONSTRUCTION OF GENERATOR IS ESSENTIALLY MANUFACTURE

 OF COMPONENT PARTS WHICH ARE ASSEMBLED PARTLY AT

 MANUFACTURER’S WORKS AND PARTLY AT SITE.

 IT IS USUAL TO CONSIDER THE MACHINE IN TWO MAJOR

COMPONENTS:

FRAME

1. STATOR MAGNET CORE

WINDINGS

2. ROTOR

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• Stator
Stator frame
End shields
Stator core
Stator winding

• Rotor
Rotor shaft
Rotor winding
Rotor retaining rings
Field connections
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Main Parts of Turbo generator
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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STATOR BODY

FABRICATED GAS TIGHT STEEL STRUCTURE SUITABLY

RIBBED INTERNALLY.

CAN WITH STAND EXPLOSION PRESSURE OF HYDROGEN

AIR MIXTURE WITHOUT ANY RESIDUAL DEFORMATION.

HYDROGEN GAS COOLERS HOUSED LONGITUDINALLY

INSIDE STATOR BODY.

END SHIELDS FOR CLOSING CASING AND SUPPORTING

FAN SHIELDS AND SHAFT SEALS.

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STATORE CORE
 IT PROVIDES PATH FOR MACHINE’S MAGNETIC FLUX AND HAS
SLOTS IN WHICH WINDINGS ARE ASSEMBLED.

 MADE UP OF SEGEMENTAL, VARNISH INSULATED PUNCHINGS

OF COLD ROLLED GRAIN ORIENTED SILICON STEEL

 IT CONSISITS OF SEVERAL PACKETS SEPARATED BY STEEL

SPACERS FOR RADICAL COOLING OF THE CORE BY HYDROGEN.

 THICKNESS OF LAMINATIONS USED

0.013” – 0.014”
1-1/2 – 2-1/2” THICK PACKETS SEPARATED BY RADIAL COOLING
DUCTS TO PROVIDE PASSAGE FOR HYDROGEN.

* CORE BARS DESIGEND TO PROVIDE ELASTIC SUSPENSION OF

CORE IN THE STATOR

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STATOR CORE
Core is made of segmental laminations
0.5mm thick, insulated by Class B or
F varnish permitting maximum or hot
spot temp. of 135°C or 155°C
continuous.
Lamination thickness is uniform
within a specified tolerance range.
Core is pressed at a press.of 12 -18
Kg/cm² in assembly. Tightness checked
in stages.
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Generator

Stator Winding
Lap type bar type of winding , and employs
the direct water cooling.
The use of water cooling in the winding
permits high value of current densities in
the machine and thus reducing the size
as well as output per kg. of the materials.

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Generator Stator

The use of combination of solid and

hollow conductors effectively reduces the
depth of the slot which affect the losses
in the winding, and better utilization of
slots.

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Generator Stator

The three-phase stator winding is a

fractional-pitch two-layer type consisting
of individual bars. Each stator slot
accommodates two bars.
The slot bottom bars and top bars are
displaced from each other by one winding
pitch and connected at their ends to form
coil groups.

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•The generator frame is pressure-resistant

and gastight and equipped with one stator
end shield on each side. The hydrogen
coolers are arranged vertically inside the
turbine end stator end shield.

•The generator consists of the following

components:
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•The two-pole generator uses direct water

cooling for the stator winding phase
connectors and bushings and direct
hydrogen cooling for the rotor winding.

• The losses in the remaining generator

components, such as iron losses, windage
losses and stray losses, are also
dissipated through hydrogen.
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Stator Frame

•The stator frame with flexible core

suspension components, core, and stator
winding is the heaviest component of the
entire generator.
•The use of hydrogen for the generator
cooling requires the frame to be pressure-
resistant up to an internal pressure of
approximately 10 bar.
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Stator Frame

•The stator frame consists of a

cylindrical centre section and two end
shields which are gas tight and
pressure-resistant.

•The stator end shields are joined and

sealed to the stator frame, with , 0-Ring
and bolted flange connections.
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•The stator frame accommodates the

electrically active parts of the stator, i.e.
the stator core and the stator windings.

•Both the gas ducts and a large number

of welded circular ribs provide for the
rigidity of the stator frame Ring-shaped
supports for resilient core suspension
are arranged between the circular ribs.
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•The generator coolers subdivided into

cooler sections arranged vertically in
the turbine side stator end shield.

•In addition, the stator end shields

contain the shaft Seal and bearing
components.
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Stator End Shields

•The ends of the stator frame are closed
by pressure containing end shields.

•The end shields feature a high stiffness

and accommodate the generator bearings,
shaft seals and hydrogen coolers.

•The end shields are horizontally split to

allow for assembly.
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Stator End Shields

•The end shields contain the generator

bearings.

•One manhole in both the upper and lower

half end shield provides access to the end
winding compartments of the completely
Assembled machine.
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ABOUT HYDROGEN

H2 is lightest gas with 0.09 gm /

litre while air’s 1.3 i.e. 14.4 times.
Thermal capacity of H2 as gas is high.
Thermal conductivity of H2 is 5 times
that of air. Its specific heat is 3.42 at
0°C, as compared to 0.237 of air.
2 H2 + O2 mixture ignites on adiabatic
compression at 526°C, 3H2 + O2 at
544°C.

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ABOUT HYDROGEN
H2 and O2 combine slowly at 180°C
or in bright sunlight. Explosion occurs
with moist gases at 550 - 700°C.
Ignition temp. of H2 in air is 538°C.
Calorific value of H2 is 136 k Cal / gm.
For filling in TGs, 99.9% v/v purity
gas is used. Traces of SO2 and NH3
shall not be detectable by analysis.

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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
ROTOR SHAFT AND BODY FORGED IN ONE PIECE FROM

CHROMIUM NICKET MOLYBDENIUM AND VANADIUM STEEL.

IT IS SUBJECTED TO A SERIES OF ULTRASONIC EXAMINATIONS

AND OTHER TESTS TO ENSURE ABSENCE OF INTERNAL DEFECTS.

DYNAMICALLY BALANCED TO A HIGH DEGREE OF ACCURACY

AND SUBJECTED TO 20% OVERSPEEDING FOR TWO MINUTES

TO ENSURE MECHANICAL STRENGTH.

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Generator Rotor

The winding is manufactured in the form

of half coils which are insulated by means
of glass textolite formed along with each
turn of coils.

Complete coil is brazed together.

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Generator Rotor

The coil is held against centrifugal forces

by means of wedges and by means of
non-magnetic retaining ring on the
overhang part of the winding.

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Generator Rotor
Two axial fans are mounted on both sides of the
rotor for the purpose of providing gas circulation
inside the machine.
Special ducts (fins) are provided in the rotor body,
through which the cooling gas flows to the rotor
end windings

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Generator Rotor
Two axial fans are mounted on both sides of the
rotor for the purpose of providing gas circulation
inside the machine.
Special ducts (fins) are provided in the rotor body,
through which the cooling gas flows to the rotor
end windings

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G. BEARINGS

- PEDESTAL TYPE WITH SPHERICAL SEATING TO ALLOW SELF

ALIGNMENT.

- PEDESTAL MASSIVE STEEL CASTING. BEARING BUSH ALSO OF

CAST STEEL AND LINED WITH HIGM QUALITY WHITE METAL.

- TO PREVENT SHAFT CURRENTS, SLIP RING SIDE BEARING AND

CONNECTED PIPING INSULATED FROM EARTH.

H. SHAFT SEALS:

- USED TO PREVENT ESCAPE OF HYDROGEN FROM GENERATOR

CASING TO ATHMOSPHERE A LONG THE ROTOR SHAFT.

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5. TERMINAL BUSHINGS

• WATER COOLED TERMINAL BUSHINGS HOUSED IN LOWER PART

OF STATOR ON SLIP RING SIDE.

• TERMINAL BUSHINGS ARE HOUSED IN A CHAMBER OF NON-

MAGNETIC STEEL PLATES AND EFFECTING SEALING PROVIDED
BETWEEN BUSHINGS AND STATOR BODY.

• THREE PHASE AND SIX NEUTRAL TERMINALS BROUGHT OUT.

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Rotor Shaft

• The rotor shaft is a single piece mild

forging manufactured from a vacuum
casting.
• Slots for insertion of the field winding are
milled into the rotor body.
• The longitudinal slots are distributed over
the circumference so that two solid poles
are obtained.
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Rotor Shaft

• Only high-quality forgings are used,

Strength tests, material analyses, and
ultrasonic tests are performed during
manufacture of the rotor.
• After completion, the rotor is balanced in
various planes at different speeds and then
subjected to an overspeed test at 120 % of
rated speed for two minutes
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Rotor Winding
• The rotor winding consists of several coils
which are inserted into the slots and series
connected such that two coil groups form one
pole.
•Each coil consists of several series connected
turns, each of which consists of two half turns
which are connected by brazing in the end
Section.
•The rotor winding consists of silver-bearing de-
oxidized copper hollow conductors with two
lateral cooling ducts.
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Retaining Rings
• The centrifugal forces of the rotor end
windings are contained by single-piece rotor
retaining rings.
• The retaining rings are made of non-
magnetic high-strength steal in order to
reduce stray losses.
• Each retaining ring with its shrink-fitted
insert ring is shrunk onto the rotor body in
an overhung position.
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Field Connections
• The field current is Supplied to the rotor
winding through radial terminal bolts and
two semicircular conductors located in the h
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The field connections provide the electrical

connection between the rotor winding and
the exciter and consist of:

• Field current lead at end winding

• Radial bolts
• Field current lead in shaft bore
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Static type
In this ac supply from station bus is provided during starting.
This supply is automatically cutoff after generator builds up its
own voltage.
In this no rotating machine is involved.

OUTPUT

AC SUPPLY

TYRISTOR
GENERATOR BRIDGE RECTIFIER
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VSTPP EXCITATION SYSTEM DIAGRAM
1,4 –ISOLATOR 5,6-BREAKERS 2,3-SWITCHES 7-FIELD
FLASHING BREAKER
UM1,UM2-BOTH MAIN BRIDGES IN SERVICE
UN1,UN2-ONE BRIDGE IN SERVICE

AVR

1 2
UM1,UM2

6 2 UN1/UN2

7
4 3
220 VOLT DC FROM
UNIT DC BOARD
5 3
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SEMISTATIC TYPE
During starting dc supply is provided.
Here one extra rotating machine is involved apart from bridge
rectifier.
So it is called semi static.
THY.

DC DURING STARTUP

MAIN GEN. AUX. GEN.