CONSTRUCTIONAL
CONSTRU CTIONAL FEATURES
FEATURES OF
GENERATOR

Sharmendra Kumar 
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
DC CONTROLLED
DC

STA
STATOR 3 H AC,50HZ 3 H AC,50HZ
AC,50H Z
CONTROLLED
RECTIFIERS

VARIABLE DC
 

SEMI STATIC 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 H AC,150HZ CONTROLLED
MAGNET AC DC

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

CAPACITY OF GENERATOR
MODULES
 

MODULE SIZE (THRI 108/44) GIVES THE SIZE OF THE MACH

MACHINE.
INE.

108 X10 = 1080 (1075) ROTOR OUTER DIA

44X100 = 4400 CORE LENGTH
 

Capability of Generator Modules

125/67

800
 

Library of Designs
1000 MW 
MW 

WATER COOLED STATOR 

STATOR 

350 MW 
MW 

HYDROGEN COOLED  660 MW 

MW 

170 MW 
MW 

COOLED 
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 (Fabrication & Machining)

2. Core Assembly - Stator Core, Core Suspension Arr

Arrangement
angement
3. End Shield
4. Stator Winding Assembly - Stator Winding , Winding Assembly,
Assembly,

Connecting Bus bar

5. Rotor - Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor
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
 

THDF Generators - Design features

• DIRECT WATER COOLING
C OOLING OF STATOR
STATOR WINDING
WIND ING AND

• 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
 

THDF Generators - Design features

•5 STAGE AXIAL COMPRESSOR AND VERTICAL HYDROGEN

COOLERS ON TURBINE END

• COLD GAS
G AS AND PRIMARY
PRIM ARY WA
WATER TEMPERA
TEMPER ATURE CONTROL
VAL
ALVES
VES TO MAINTAIN AAVERAGE
VERAGE INLET COOLING MED
MEDIUM
IUM
TEMPERATURES CONSTANT

• DOUBLE FLOW RING TYPE SHAFT SEALS

• BRUSHLE
BRUSHLESS
SS EXCITA
EXCITATION
TION SYSTEM
 

Stator Frame (Air Cooled TG)

 

Stator Frame (500 MW)

 

Stator Frame (Fabrication & Machining)

 

Stator Core

• Made up of punched segments of thin sheets

• 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

 

Core Suspension - Air Cooled TG

Location for
Spring

Core Housing

Core End Plate

Core
 

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
 

Stator Slot - THDF 500 MW

 

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,

body, Oil catchers, etc

• Provision for supply of Bearing Oil, Seal oil, Thrust oil and its drain
 

End Shield - THRI TG

 

End Shield (Exciter side 500 MW)

 

End Shield (Turbine side 500 MW)

 

COOLING ARRANGEMENTS
 

GENERAL ARRANGEMENT OF 500 MW TURBOGENE

TURBOGENERA
RATOR
TOR
 

3-D MODELLING
ASSEMBL
ASSEMBLY OF ROTOR
Y AND COMPONENTS

PLATFORM USED – PRO ENGINEER

WILDFIRE 2.0
 

TYPICAL
TYPI CAL ROTOR ASSE
ASSEMBL
MBLY
Y

ROTOR SHAFT

FAN BLADES

AINING RINGS 
RETAINING
RET

WEDGES

FIELD LEAD 
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
 

BARREL

POLE 1

BALANCING HOLES
 

BARREL
CROSS POLE SLOTS(MOON SLOTS)

VENTILATION HOLES
 

BARREL

SLOTS ( PARTITION)

MAIN SLOTS 28 NO.

BALANCING HOLES
 

BARREL (Contd.)

SLOTS 
(VENTILATION)

HOLE ( C.C. BOLT)

SLOTS ( DAMPER WEDGES)

 

BARREL (Contd.)

HOLES (COOLING OF END ZONE)

HOLE FOR LOCKING

PRESSURE PLATE OF
 

BARREL (Contd.)

HOLES (VENTILATION)

HOLES (BALANCING)

RETAINING RING SEAT

 

BARREL (Contd.)

SECTION OF INCLINED HOLES

(COOLING END ZONE)
 

BLOWER HUB
GROOVE FOR

BALANCING WTS

HOLES FOR LOCKING OF BLAD

BLADES
ES
 

COUPLING EXCITER END

STEPS FOR HYDROGEN SEALING
SPIGOT

14 HOLES
 

FIELD LEAD CORE BAR

THREADED HOLE FOR C.C. BOLT

 

FIELD LEAD CORE BAR

INSULATING CYLINDER

INSULATING
INSULATING PARTITIO
ARTITIONN

CURRENT CARRYING BOLT

BOLT
 

FIELD LEAD WITH H2 SEALING ARRANGEMENT

O RINGS

CONTACT PIN

INSULATING
COVER

FIELD LEAD INSULATING

CORE BAR COVER
 

FIELD LEAD WITH H2 SEALING

S EALING ARRANGEMENT
ARRANGEMENT (Contd.)

HOLE FOR HE LEAK TEST

THREADED

RING

THREADED RING

PACKING
 

FIELD LEAD CONNECTION TO ROTOR COILS (Contd.)

ROTOR COIL A FLEXIBLE

CONNECTION

INSULATING
TUBE
FIELD
LEAD

CURRENT
 CARRYING BOLT

ROTOR COIL

MATERIAL
SILVER BEARING COPPER

SIZE 36.8X9.6mm
Y p = 245 N/mm2

RADIAL SLITS

EDGEWISE BENDING
 

ROTOR COILS

BRAZED JOINT
 

ROTOR COIL CROSSSECTION 500 MW ROTOR

 

ROTOR COILS (210/250 MW ROTOR)

COLL A TO G (7 COILS) PER POLE

 

RADIAL COOLING
 

ROTOR SLOT FILLING 

SLOT
LINER

SLOT
ANGLE
ROTOR COILS
 

SLOT ANGLE

MATERIAL

GLASS CLOTH AND

 NOMEX PAPER
 

SLOT ANGLE

TAPERED AT ENDS
 

TOP SLOT LINER 

HOLES FOR VENTILATION 

 

ROTOR WEDGES
 

MACHINING OF END SLOT WEDGES

 

ROTOR WEDGES (Without Rotor Shaft)

DAMPER WEDGE

DAMPER WEDGE

SLOT WEDGE

PRESSURE PLATE
 

ROTOR WEDGES (CONTD.)

DAMPER WEDGE (short)  DAMPER WEDGE 

SLOT WEDGE 
SLOT WEDGE (END)
 

SLOT WEDGE

HOLES FOR VENTILATION 

 

END WEDGES

MACHINING FOR RETAINING

RING SEA
SEATING
TING
 

DAMPER WEDGE

MACHINING FOR KEY RING

SEATING
 

ROTOR SHAFT WITH WEDGES

 

ROTOR END WINDING

 

1. ROTOR BODY 5. END WDG INSULULA

INSULULATION
TION
2. SNAP RING 6. FILLER

3.
4. RET
RETAINING
AINING
ROTOR RING
WINDING 7.
8. END RING
BALANCING
BALA NCING WEIGHTS
 

OVERHANG SPACERS
END
SPACERS

SPACERS

PARTITION

POLE
SPACERS
 

POLE SPACER

MATERIAL

GLASS TEXOLITE
 

SP
SPACER
ACER ASSE
ASSEMBL
MBLY
Y

NOMEX PIECES
 

SPACER

MATERIAL

GLASS TEXOLITE
 

OVERHANG WEDGES 
 

WEDGE

NOMEX PIECES

MATERIAL

GLASS TEXOLITE
 

WEDGE

NOMEX PIECES
 

WOUND ROTOR

OVERHANG ASSEMBL
ASSEMBLY
Y
 

RETAINING RING ASSY.

 

RETAINING RING CENTERING RING

MATERIAL X8CrMnN1818k MATERIAL

MATERIAL 33NiCr Mo145

SECTIONED VIEW
RETAINING
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.
ASSY.

BLOWER BLADE FORGING

 

BLOWER BLADE
 

BLOWER BLADE

BLADE PROFILE

THREADED PORTION

FLAT FOR LOCKING

 

ROTOR COIL 

INCLINED
COOLING
DUCTS IN SLOT
PORTION  
PORTION
 COOLING DUCT
IN OVERHANG

TYPICAL OVERHANG COMPLETE

 RECTANGULAR COILS
 

COIL
RECTANGULAR C OIL ASSEMBLY
ASSEMBLY
 

OVERHANG WEDGES (INTERIOR VIEW) 

STOPPER FOR
WEDGES
 STOPPER FOR
SPACERS

Bearing Assembly
 

Terminal Bushing Box 500 MW