Alternator

1 11/26/20
Stamford Range

 BC 16 - 10 – 15 KVA
 BC 18 - 15 – 40 KVA
 UC22 - 30 - 82.5 KVA
 UC27 - 100 - 200 KVA
 HC4- 225 - 380 KVA
 HC5 - 400 - 625 KVA
 HC6- 750 - 1250 KVA
 P7 - 1260 – 2200 KVA
Stamford Range New Frame

5 core lengths up to 17.5 kVA

BC164A 8.1 - PI044D 7.5

BC164B 11 - PI044E 10
BC164C 13.5 - PI044F 12.5
BC164D 16 - PI044G 15
New PI044H 17.5

2 Pole will also be replaced

Stamford Range New Frame

6 core lengths 20kVA to 42.5kVA

BC184E 22.5 - PI144E 25

BC184F 27.5 - PI144F 27.5
BC184G 31.3 - PI144G 30
BC184H 37.5 - PI144H 35
BC184J 42.5 - PI144J 40

UC224C 42.5 -
Alternator Overview

AVR
Main Stator
Exciter Field (Stator)

Exciter Rotor
(Armature)

Rotating Diodes

Main Field Rotor

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Alternator Types

Two type of alternator (based on excitation) :--

1) Self excited alternator. A design of a.c generator where the source of

power for the electrically produced magnetic
field is derived from the residual magnetism in
the exciter stator.

2) Separately excited alternator. A design of a.c generator where the source

of power for electrically produced magnetic
field is derived externally.

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Self-Excited operation principle

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Separately-Excited operation principle

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Advantages of PMG

 In these type of machines voltage build up process is not

dependent on residual voltage.

 Better motor starting characteristics with comparatively less

transient voltage dip.

 Since AVR is supplied from separate power source i.e. PMG,

the harmonic current distortion in main stator is not passed on
to AVR. Hence voltage distortion is reduced.

 Ability to sustain short circuit current in event of fault. This

provides circuit breaker enough time to effect trip to eliminate
the fault and provide better fault discrimination.

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Alternator Overview

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Main Complete Generator
Terminals
Assembly
A.V.R.
on A.V.M,s Main Rotor
Main Stator Drive end
Non drive
end Bracket Frame Bracket

P.M.G
Rotor
P.M.G
Stator
Rotating Rectifier Assembly

Positive

Diodes

Varistor

Negative

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Diode Checking with Multi-Meter

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Surge Suppressor

 The surge suppressor is metal oxide varistor connected across two

rectifier plates to prevent high transient reverse voltages in the field
winding from damaging the diodes.

 The device is not polarized and will show a virtually infinite reading
in both directions with an ordinary resistance meter.

 If defective this will be visible by inspection, since it will fail to short

circuit and show signs of disintegration.

 Replace if faulty.

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Maintenance of alternator

Maintenance requirements for A.C Brushless Generators are :-

 1. Bearing inspection ( Single or 2 Bearing).

 2. Winding Insulation/ Contamination checks.

 3. Visual Inspection for Corrosion and Contamination

 4. Operational Checks
 Maintenance requirements - Bearings

Generators are supplied with three types of bearing assembly :-

1. Manufacturers Sealed for Life Ball bearings :-
Standard on Frames BC16,BC18, and UC22,UC27, ranges.
Introduced as standard on Frames HC4,
HC5, HC6, from July 1999.
Introduced on P7 (Single bearing Generators only), from April 2005.

2. Sealed Cartridge Assemblies, (Non- re-greaseable).

Standard on Frames HC4, HC5, HC6, up to July 1999.
Standard on Frame HC7, up to March 1999.

3.Re-greaseable Cartridge Assemblies.

Standard on Frame HC7 from March 1999.

Optional on Frame HC 5 & 6 from April 2000.
Standard on Frame P7(2 bearing), Frame 8, & P80.
All HC range, P7, & P80, bearings are packed with Kluber Asonic GHY72 grease,
which is a Synthetic Polyurea / Ester oil based grease, and should not be mixed with
dissimilar greases.
 Maintenance requirements - Bearings
What are the symptoms of a Bearing problem?

Non drive INCREASED INCREASED INCREASE Drive end

end Bearing TEMPERATURE VIBRATION NOISE. Bearing
 Maintenance requirements - Bearings
What are the symptoms of a Bearing problem?

 Temperature rise in the bearing housing

Monitoring temperature is achieved with R.T.D’s or Laser (remote) thermometer.
( Note: Localised Ambient temperature variations should be taken into account).

 Vibration
Increased vibration in the Generator, suddenly, or slowly over a period of time.
Vibration equipment is expensive, a check by hand near the bearing will give an
indication. ( Note: this could also be an engine related problem).

 Noise
Bearing making abnormal noises, audible, with or without Stethoscope. (
A Stethoscope is required for elimination of other possible causes of noise )
Experience gained from touch and sound, will establish ‘normal’ conditions.
Periodic Health monitoring is recommended throughout the life of the Generator to
establish normal conditions.
 Maintenance requirements - Bearings

Re-lubricated Bearings Frames HC7, P7, F8,

 Re-lubrication with Kluber Asonic grease type GHY72, is recommended,

 Full details of grease quantities for both initial fill and re-lubrication are
available in the manual supplied with the Generator, or from the factory.

Frames HC6 and HC7 Re-lubrication Bearing Kits

 Conversion kits with full instructions to upgrade HC6 and HC7 Generators to
re-greasable specification are available

 Special tool kits, and greasing equipment are available on request.

 2 BEARING KITS
HC6, 45 - 0880, HC7 45 - 0872.

 1 BEARING KITS
HC6, 45 - 0879, HC7 45 - 0877
 Maintenance requirements - Insulation checks

Winding Insulation levels should be checked if :-

1. The Generator has been STATIONARY for a long period with Anti-
Condensation heaters SWITCHED OFF.

 2. The Generator has been subjected to intake of high volumes of water

 3. The Generator windings are contaminated with Airborne DUST and

DIRT, and have become DAMP ( through high humidity).

 The Generator windings have become contaminated with airborne

corrosive elements ( Salt or corrosive chemicals in the atmosphere).
 Maintenance requirements - Insulation checks

Insulation Resistance (IR) tests in order of importance :-

1. The Main Stator Winding

Minimum value of Insulation should be 1 M to EARTH.
(For Low voltage machines up to 690V).
 2. The Exciter Stator Winding
This winding is subject to all contamination from the air intakes. Severe
contamination may cause temporary or permanent low IR, which could
effect the AVR performance.

 3. The Exciter Rotor, & Main Rotor

These are rotating low voltage windings, and are unlikely to be affected
by low IR. Minimum value of insulation should be 1 M to EARTH.

 4. Permanent Magnet Stator

This windings is totally enclosed and unlikely to be affected by low IR.
Cleaning of alternator

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 Maintenance requirements - Testing the Main Stator Insulation
Connections shown in Series Star
EARTH

AVR Sensing W6
& Power supply N 
UV6 Neutral
6
00
0  10
M
0 10 1 0
.1 
.01
from Main  1

Stator W
6 5
W
2 W W1

V Test
7
V
5
2 V V1
 3 Phase M 1KV

U  Output M 500V

8 5
U
2 U U
1

 EARTH MEGGE
FRAME R

 1. Disconnect the AVR completely before carrying out this test.

 2. Disconnect any connections from Neutral to Earth.
 3. The Stator insulation should be checked with an Insulation tester. The test
instrument should be 500volts for low voltage Generators (up to 690V).
 4. For low voltage machines (up to 690V), the MINIMUM insulation value is 1.0 Meg-
Ohm to Earth (Ground).
WINDINGS MUST BE DRIED OUT IF BELOW 1.0 MEG-OHM.
 Maintenance requirements - Cleaning the Windings

When is it necessary to clean the windings?

 1. When (after drying), the windings are still reading less than 1 M to
earth.

 2. When the windings are heavily contaminated with dust,dirt, and/or

diesel exhaust deposits.

 3. When the windings are contaminated with corrosive chemicals ( salt

deposits or other deposits), which immediately give a temporary low IR
reading when damp.
 Maintenance requirements - Health checks

Final Inspection before running Gen-set :-

1. AVR 2. MAIN
CONNECTION TERMINAL
S CONNECTIONS

3. MAIN
RECTIFIER
COMPONENTS
 Maintenance requirements – Health checks

Final Inspection before running Gen-set :-

A.C Generators may be subjected to environmental conditions which are

detrimental to the Generator :-

High humidity, or exposure to the elements, rainwater, and/or offshore sea mists.
Dust, dirt, and/or corrosive chemicals in the atmosphere.
Excessive vibration from the Engine, or worn coupling rubbers/ vibration mounts.

Periodic checks should be made to :-

1. AVR and accessory terminal connections, for corrosion or loose joints.

2. Main Rectifier diodes, should be cleaned or changed if badly corroded.
3. Main output terminal, look for loose or high resistance joints,
(Joints can be scanned with a laser thermometer for ‘hot-spots’ while running on load).
 Maintenance requirements – Health checks

Running checks on the the Generator

Run the Generator up to nominal speed, and check :-

 1. The NO LOAD D.C voltage across the AVR terminals X+ (F1) and X-.
Keep this reading in the Gen-set maintenance record book for future reference.
Example :-

DATE FRAME SIZE SERIAL NUMBER R.P.M VOLTS LOAD D.C EXT
######## HCI734E C098976/2 1560 415 0 11.5

 If the D.C reading becomes HIGHER, it is an indication of :-

1. Possible SHORTS in the EXCITATION WINDINGS, OR,
2. Possible faults with the MAIN RECTIFIER DIODES.
THE NO-LOAD D.C VOLTAGE GIVES AN INDICATION OF GENERATOR HEALTH
FAULTS WITHIN THE GENERATOR WILL CAUSE AN INCREASE IN THE D.C. VOLTS.
Non-PMG AVR Examples

K2 K1 P2 P3 P4 XX X 3 2 2 1
VOLTS XX X 6 7 8
A1
4 TRIM A2
S1
DROOP S2

1
2
UFRO SX460 SX440 VOLTS
3
3 4
5
6
50 7
8
C UFRO STABILITY
STABILITY
260
50 C 60 C B A

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PMG AVR Examples

K2 K1 P2 P3 P4 XX X 3 2 2 1 VOLTS
A1 P4 XX X 6
K2 K1 P2 P3 7 8 1 2
TRIM A2
S1
I/LIMIT
MX341 DROOP S2
MX321
UFRO
3 2 1
1
2 DIP RMS
VOLTS 3
4 DWELL
DIP 5
EXC TRIP STABILITY
6 EXC
7 OVER/V DROOP
8
TRIP S2 S2 S2 A2 TRIM
UFRO STABILITY
E0 E1 B0 B1 C B A S1 S1 S1 A1

3 2 1 C B A

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AVR General Fault Findings
Check Speed.
No voltage build
Check residual voltage.
up when starting
Follow separate excitation test. Procedure to check
set.
generator & AVR.
Unstable voltage
Check speed stability.
either on no load
Check stability setting of AVR.
or with load.
High voltage Check speed.
either on no load Check that generator load is not capacitive (leading
or with load. power factor).
Check speed.
Low voltage on
Check link 1 – 2 or external hand trimmer leads for
no load.
continuity.
Check speed.
Low voltage on Check UFRO setting.
load. Follow separate excitation test procedure to check
generator & AVR.

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Parallel Operation

Parallel Operation - When is it Required?

 1. To increase the capacity of available power without loss of supply

to the customers distribution system.

 2. To allow the Generator to be connected to a live system ( e.g ; the

Mains, (Grid, Utility,), Multiple Generator systems, C.H.P, etc.

 3. To allow shutdown of individual Generators for Maintenance or

repair purposes.

 4. To economise operating costs by running multiple generators

according to load demand.

 5. To provide an emergency back-up to critical supplies without

loosing power, ( e.g ; Hospitals, Ships, Computer data systems, etc).
 Parallel Operation - Essential Requirements

 1. All Generators must have the same voltage.

 2. All Generators must have the same phase rotation.

 3. All Generators must have the same frequency.

 4. All Generators and Prime Movers (Engines), must have similar no

load, to full load, voltage and frequency characteristics.

 5. Generator installation must be provided with Synchronising

equipment.
 6. Essential protection should include Reverse power, Over-current ,

Over-temperature, Generator Over/Under excitation.

 7. Generator of dissimilar design or manufacturer, should have similar

waveform characteristics (harmonics), if Neutrals are joined.

 Parallel Operation - Synchronising AC Generators

 Synchronisation is carried out in order to parallel a Generator onto a

live Bus-bar, either in Island mode ( with multiple Generator sets as the

only supply), or to the Utility..

 Synchronisation can be achieved Manually, Semi-Automatic with

Check-sync, or by fully automatic P.L.C systems.

 Parallel Operation - Synchronising AC Generators

 GEN 1
AVR DROOP CT

CB1 BUS-BAR

LOAD
 GEN 2 MCB
AVR DROOP CT

CB2

 Consider a simple installation with two Identical Gen-sets, (breakers open circuit).
 Normally, one (or more), generators will already be connected to the load, and
supplying power. (GEN 2 is now closed onto the Bus-bar).
 It is also normal that the Generator on line (GEN2) will be running at nominal
frequency (50HZ), while the incoming generator (GEN1), can be running at a higher
(NO LOAD), frequency of about 52 HZ.
 Parallel Operation - Synchronising AC Generators

 GEN 1 Synchronising
AVR DROOP CT
Equipment

CB1 BUS-BAR

LOAD
 GEN 2 MCB
AVR DROOP CT

CB2

 When the relative Engine speeds are different, the Generator waveforms will be
rapidly going in and out of phase with each other.
 To correctly Synchronise A.C. Generators, the frequencies must be ALMOST identical.
 Frequency (HZ), is the Electrical equivalent of Speed (RPM), which means that the
engine SPEEDS must be ALMOST identical.
 Synchronising equipment is required to monitor the Bus Frequency and the
Incoming Generator frequency, to ensure that the Generators are in Synchronism.
 Parallel Operation - Synchronising AC Generators
SYNCHRONISED
Incoming Generator Set On-line Generator Set

 EXAMPLE : In this analogy two trucks represent two Generator sets, to be paralleled .

 If both trucks are travelling at EXACTLY THE SAME SPEED, they will ALWAYS
remain the SAME DISTANCE APART, ( IRRESPECTIVE OF SPEED).
 However, if the REAR truck is A FEW RPM FASTER than the FRONT truck, it will
VERY SLOWLY catch up with the truck in front.

 SYNCHRONISING is exactly the same process, the RATE OF CHANGE in speed must be
SLOW ENOUGH to allow the BREAKER to close when the Generators are IN PHASE .
 Parallel Operation - Synchronising AC Generators

 GEN 1
IN PHASE
50 HZ
(1500 RPM)

 GEN 2 50.1 HZ
(1503 RPM)

 Example :- GEN 2 is supplying load and is running at 50HZ (1500 RPM).

 GEN 1 is INCOMING, and the engine speed has been adjusted down slightly to
almost 1500 RPM (for example 50.1 HZ).
 As there is a SMALL RELATIVE DIFFERENCE between speeds, the Synchronising
equipment should be indicating that the Generators are moving IN and OUT of phase
SLOWLY enough to ALLOW TIME to close the breaker.
 Parallel Operation - Synchronising AC Generators

 GEN 1 180o OUT OF PHASE

IN PHASE
50 HZ

 GEN 2 50.1 HZ

 Consider above condition:-

 The Generator is IN PHASE, , but is now about to go OUT OF PHASE.

 What will happen if the circuit breaker is closed in the final condition above ?
 Parallel Operation - Synchronising AC Generators

 GEN 1
CRASHED
180º
 INTO PHASE

 GEN 2

 The Generator waveforms are 180º OUT OF PHASE with each other.
 As the breaker closes, GEN 1 will instantly try to reverse the rotation of GEN 2.
 This is IMPOSSIBLE, because of the inertia in the Engine/Generator moving parts.
 The Generators will be INSTANTLY ‘CRASHED’ into synchronism. .
 The transient forces created are both Electrically and Mechanically DESTRUCTIVE
 Electrical damage can occur to Diodes, Varistors, and Main Stator windings.
 Mechanical damage may also occur to Couplings, Bearings, and Shaft.
 Parallel Operation - Synchronising AC Generators

 GEN 1
IN PHASE
50 HZ
1500 RPM

 GEN 2 50.1 HZ
1503 RPM

 Example 2 :- GEN 2 is supplying load and is running at 50HZ (1500 RPM).

 GEN 1 engine speed has been adjusted to almost 1500 RPM (50.1 HZ).

 The Generator waveforms are SLOWLY moving IN and OUT of phase.

 The Synchronising equipment indicates that the Generator are IN PHASE.
 The circuit breaker can be SAFELY closed in the above condition.
 Parallel Operation - Synchronising AC Generators

Synchronising
 GEN 1 AVR DROOP CT
Equipment
OK !
CB1 BUS-BAR

LOAD
 GEN 2 AVR MCB
DROOP CT

CB2

 When the Synchronising equipment indicates that the incoming Generator (GEN 1) is IN
PHASE with the Bus-bar frequency, the circuit breaker can be safely closed.

 The INCOMING Generator should ALWAYS be slightly FASTER than the loaded
generator. This ensure that the incoming Generator ALWAYS takes a small proportion of
load when the breaker is closed. This will prevent REVERSE POWER protection tripping.
 The Generators are now IN PARALLEL
 Parallel Operation - Circulating Current
WHY IS DROOP IS REQUIRED FOR GENERATORS IN PARALLEL ?

 GEN 1 AVR 1 SYNCHRONISING

403V EQUIPMENT
400V

CB1
BUS
0 LOAD
403V
 GEN 2 AVR 2 MCB
403V
406V

CB2

 EXAMPLE: Two similar 400V Generators are required to operate in parallel

 Generator 2 is incorrectly adjusted to 406V (at no load).
 GEN 2 is connected to the Bus by closing circuit breaker CB2
 GEN 1 is synchronised with GEN 2, and breaker CB1 is closed
 The resultant Bus-Bar Voltage will be approximately average of the two Generators.
 Parallel Operation - Circulating Current
WHY IS DROOP IS REQUIRED FOR GENERATORS IN PARALLEL ?

 GEN 1 AVR

BUS-BAR
400V CB1
403 V
403V LOAD
 GEN 2 AVR MCB
406V

CB2 CIRCULATING CURRENT

 GEN 1 EXCITATION SYSTEM is trying to PULL the voltage DOWN to 400 V.

 GEN 2 EXCITATION SYSTEM is trying to PUSH the voltage UP to 406 V.
 The RESULTANT VOLTAGE will be approximately. AVERAGE of the two Generators
 This ‘PRESSURE DIFFERENCE’ (VOLTS), forces CIRCULATING CURRENT into GEN 1.
 CIRCULATING CURRENT is WATTLESS, (POWER FACTOR 0).
 Parallel Operation - kW Load Sharing
kW
kW
LEA
D
kWATT
METER
 GEN 1 AVR 1 DROOP CT

BUS-BAR

LOAD
 GEN 2 AVR 2 DROOP CT MCB

 ACTIVE CURRENT or
kW kW
LEA
D
kWATT
METER

 ACTIVE CURRENT (power factor 1) is the kWATT component of the load, and is
CONTROLLED and SHARED by the PRIME MOVERS (ENGINES).

 The PRIME MOVERS (ENGINES), must have similar NO LOAD to FULL LOAD
GOVERNOR CHARACTERISTICS, in order to share the ACTIVE CURRENT, (PF1).
 KW Load Sharing is unequal

Check for Engine

governer droop
setting
KVAR Load Sharing is unequal
Reverse Power failure symptoms.

48 11/26/20
Reverse Power failure symptoms.

49 11/26/20
 3 PHASE UNBALANCED LOADS
Example 2 66 kVA 3 phase 380 Volts 100 Amps Generator with unbalanced
load current
U
100
O
U
Line - Line Voltage Line - Neutral Voltage T
= 380 V = 220 V P
U
T
N 35 T
O

L
O
w 85
v A
D

60
 Unbalanced single phase loads kVA = (220 X 100 ) + (220 X 85) + (220 X 60) / 1000
kVA = 22000 + 18700 + 13200 / 1000 =
53.9 kVA
Note1. U phase has FULL LOAD AMPERES, therefore preventing further addition of 3 phase load.
Note 2. The Neutral current is equal to the VECTORIAL sum of the three line currents i.e, = 35 Amps

NEUTRAL CURRENTS
Unbalance Loading failure symptoms.

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