The document provides information about AC generator construction and operation. It discusses how rotating conductors can generate AC power using a rotating magnetic field. It explains that AC is preferable to DC for distribution due to simpler machine design without brushes or commutators. The document also covers topics like the sine wave output, effects of frequency and rotor pole number on generator speed, and three-phase power generation using star and delta connections.
The document provides information about AC generator construction and operation. It discusses how rotating conductors can generate AC power using a rotating magnetic field. It explains that AC is preferable to DC for distribution due to simpler machine design without brushes or commutators. The document also covers topics like the sine wave output, effects of frequency and rotor pole number on generator speed, and three-phase power generation using star and delta connections.
The document provides information about AC generator construction and operation. It discusses how rotating conductors can generate AC power using a rotating magnetic field. It explains that AC is preferable to DC for distribution due to simpler machine design without brushes or commutators. The document also covers topics like the sine wave output, effects of frequency and rotor pole number on generator speed, and three-phase power generation using star and delta connections.
The document provides information about AC generator construction and operation. It discusses how rotating conductors can generate AC power using a rotating magnetic field. It explains that AC is preferable to DC for distribution due to simpler machine design without brushes or commutators. The document also covers topics like the sine wave output, effects of frequency and rotor pole number on generator speed, and three-phase power generation using star and delta connections.
AC GENERATOR CONSTRUCTION CONTENT 01 | Rotating conductors
02 | Why use AC & the Sine Wave
03 | Frequency & Speed
04 | 3-Phase Generation
05 | Generator Stator
06 | Generator Rotors
• Low Speed Salient Pole
• High Speed Salient Pole • Cylindrical Rotor
07 | Generator Cooling
08 | Maintenance 2 AC Generator Construction
3 of 43 Rotating Two Conductors
N S DC Commutator • Termination of the individual windings
• Individual segments on the
commutator
• Spring loaded brush gear
• Old open design became a
modern closed design
• Closed design gave
protection but distanced the crew Re: visual inspection… So Why Use AC? • Simpler machines – No brushes • DC generator may have 8 brush arms with 12 brush boxes on each brush arm, two brushes to a box = 192 brushes to maintain per generator – No commutator • No maintenance as DC commutators can foul with carbon dust or deform at the edges and short – Greater reliability • Simple to control using modern power electronics • Cheap & effective distribution using transformers… Rather than rotate conductors what would happen if we could Rotating The Magnet Let’s build a generator S
If we now wrap wire
round iron cores, and rotate the magnets, what will happen? N The rotating field will induce a voltage in the wires as flux passes through the wires i.e. flux cutting in occurring… LOAD Rotating The Magnet
What happens if we rotate the magnets faster? S
The frequency increases as the rate which we pass the flux N through the wires is increased
Basic governor control
= speed control of the generator = frequency control… LOAD The Sine Wave The generated sine wave has a peak value, however the value normally quoted is the RMS value The RMS value of a perfect sine wave is the peak value/ √2 = peak/1.414, or peak × 0.7071 1.5
The frequency of the wave is the number of complete waveform cycles per second – unit Hz… Multiple Magnets If we double the poles, for the same speed, what happens? N S S The frequency will double N The other benefit is that we can now reduce the speed of the prime mover…
LOAD 10 of 64 The Generated Voltage • Generated voltage depends on Magnetic field strength The rate at which flux is cut
• Generated frequency depends on speed
Fixed – usually 60Hz
• Voltage therefore depends on
Flux density Which is controlled by the Excitation… FREQUENCY & SPEED
• Relationship of Speed & frequency
• Rotor Poles • Standard Speeds • 50Hz • 60Hz Frequency and Speed Frequency depends on two things 1. The speed of the rotor 2. The number of rotor poles ƒ = nP Hz Where ƒ is frequency (Hz) n is speed (rev/second) P is number of PAIRS of poles A complete cycle is generated each time two poles pass each winding, therefore the critical matter is the number of PAIRS of poles, so P= number of PAIRS of poles… Frequency/Speed Equation • If N is in RPM we use the following to state the speed in Rev / Sec
ƒ=NP 60 Synchronous Speed The speed that relates the frequency and number of pairs of poles
Speed (rev/min) Pairs of Poles 50Hz 60Hz 1 3000 3600 2 1500 1800 3 1000 1200 4 750 900 5 600 720 6 500 600 8 375 450 15 of 64 3 - P H A S E G E N E R AT I O N
• Theory • Star Connection • Generator Connection • Star Vs Delta Generating Three Phase
• Marine generation normally three phase
• Generator fitted with three windings – Red Yellow Blue phases • Windings stationary i.e. the “Stator” • Poles rotate i.e. the “Rotor” • Each phase displaced from the others by 120°… Three Phase Generator Three windings, red, yellow & blue placed 120° apart A simple two pole (one pair!) rotor If we spin the rotor as each pole passes a phase winding it generates either a positive or S negative half cycle in that winding We can show this graphically as a three phase waveform… N Star Connection
• Sum of instantaneous voltages is zero at any given point
• Connect one end of each winding – No potential difference – No current flow… Generator Connection
• Three phase generators are almost always star
connected
STAR or NEUTRAL point
20 of 64 Star & Delta Connections
Phase Volts 254 V 440 Volts
Line Phase Voltage Volts 440 Volts 440 V
440 Volts
STAR DELTA G E N E R ATO R S TATO R
• Construction • Conductor Types • Interconnections AC Alternator – Has 3 distinct parts
Stator – The stationary part where the voltage is generated Rotor – The rotating part where magnetic flux is produced – Where ‘Excitation’ occurs Frame – Holds the stator, rotor and ancillaries… • Tubular – Has slots for conductors Stator • Constructed from silicon iron – Strengthens magnetic fields – Low hysteresis
• Laminated – Reduces eddy currents
• Cooling gaps… Generator Stator
25 of 64 Generator Stator Small Stator Wedge
Round copper conductors fitted in an
insulated slot, that improves the magnetic field
Slot Insulation:
• Protects the enamelled conductors from
potential electrical contact with the stator laminations. The laminations may not be flush, giving potentially rough Conductors edges resulting in increased likelihood of damage to conductor insulating enamel/varnish… Large Stators – Flat Bar Conductors
Slot Conductor Insulation Insulation
Bar Bar Closing Wedge
Stator Formed Stator Conductors 30 of 64 Generator Stator Post clean and varnish Interconnections
• Stator coils are interconnected in the end winding area
• Formed to produce three windings with six ‘ends’ – A1-A2 B1-B2 C1-C2 • Ends lead to a terminal box • 3 ends – to breaker in switchboard – A1, B1 & C1 • 3 ends – star point – A2, B2 & C2 • Small machines – may have only 3 ends – Internal star point… R O TO R S
• Types • Salient • Cylindrical • Speeds • Poles • Construction
PRESENTATION TITLE – GO TO INSERT > HEADER & FOOTER TO EDIT THIS TEXT Rotor • Provides field excitation via magnetic poles • Residual magnetism should start the voltage production • A lot of modern excitation systems “flash” the fields as part of their design • There are two distinct rotor forms – Salient pole S – Cylindrical… N S A L I E N T P O L E R O TO R
35 of 64 Salient Pole Rotor Salient Pole Rotor • Projecting poles – Bolted or keyed to shaft hub • Field winding fitted round each pole which carries the excitation current – Remember that we are talking about pairs of poles • For medium and slow shaft speeds – Speed at or below 1000 (50Hz) or 1200 (60Hz) • Very common for marine generators – 450 – 1200 rpm normal speed…
37 of 64 Salient Pole Rotor 39 Salient Pole Rotor Features
• Advantages • Disadvantages 1. Relatively cheap to 1. Heavy manufacture 2. Damaged pole pieces and 2. Limited maximum speed spools “easily” replaced 3. Produces a good waveform 3. Large surface area 4. Flywheel effect an – Difficult to clean… advantage – Diesel engine drive High Speed Salient Pole Rotor • For higher speeds (typically 1500 / 1800 rev/min) a special design of salient pole rotor is required
• Typically used for gas or steam turbine driven generators
• To cope with the higher centrifugal forces the poles are keyed to the shaft assembly in machined slots (“dovetailed”), spreading the load - Changing of the poles or spools is now more difficult
• Rotors tend to be longer and smaller in diameter…
Constructional Details
42 of 63 C Y L I N D R I C A L R O TO R
43 of 64 Cylindrical Rotor Detail Cylindrical Rotor
• For very high speeds
– 3000 – 3600 rpm • Rotor laminations stamped with slots – Keyed directly to shaft • 2 poles at 3600 rpm will deliver 60Hz • Conductors are laid in slots • Metal areas between conductors form poles… Magnetic field produced by a current carrying conductor • When an excitation current flows through a conductor, a magnetic field is produced in the space around the conductor
• Lets look at how the cylindrical rotor is formed…
Note the direction of the current through the upper windings compared to the lower windings
Now consider the fields generated by the
conductors
Now lets look at how these conductors act
similar to those in a solenoid coil… The magnetic fields that pass through each conductor impact on each other. Like a solenoid coil the resultant magnetic field establishes a North and South relationship
The flux surrounding the rotor now cuts through the windings of the stator and therefore develops an alternating current…
North North South South Cylindrical Rotor Frame
• Encloses entire machine
• May include rotor support bearings – Bearings may be external – plain or ball/roller • Forms a cooling space • Mounting: – Connection box – Control system components… G E N E R ATO R C O O L I N G
51 of 64 Enclosed Or Open?
Enclosed Open (Drip-proof)
• Higher cost • Simpler construction • Higher weight • Cheaper & lighter • Physically larger • Susceptible to atmospheric • More instrumentation pollutants • Less cleaning – Salt, oil, moisture…
• Increased reliability • Suitable for hostile environments Enclosed Or Open?
Open Closed Closed • Power losses of around 10% of the generator output appear as heat, which must be dissipated to prevent excessive temperature rise
• The closed circuit prevents ingress
of contaminants from the surrounding atmosphere
• Air is circulated by the fan through
the cooler (may be SW or FW) which is fitted with a leakage alarm and manual test facility… Closed • Alarm and indication for air and winding temperatures will be fitted
• Alarm transducers embedded in the
windings (Pt100/thermistors) are normally duplicated (or even triplicated) so that in the event of one failing a spare can be connected without having to rewind the machine…
55 of 63 Air Cooler – Double tube construction
Inner tubeplate
Outer protecting tube Inner cooling medium tube
Cooling Water in
Leakage detection cofferdam Air circulation
Outer tubeplate
To alarm Cooler Failure Emergency cooling doors
• In the case of cooler failure forced
circulation cooled generators may be operated at reduced output by opening emergency cooling doors
• If no filters are fitted consideration
should be given to fitting temporary cloth type filters (aircon type?) to protect the machine from excessive oil/salt contamination as the cooling air is now from the machinery space… MAINTENANCE
• Air temperatures • Bearing temperatures • Cooler leakage • Noise • Vibration • Diode monitor • V, I, kW, Cosθ, kVAr – specifically for machines running in parallel… Maintenance – Periodic (examples) • May be time based or running hour based – Internal condition – moisture, oil, dust – Internal condition – terminal & diode security – Cooler condition – water side and air side – Earth bonding – Routine cleaning – Vibration analysis / thermal imaging – Insulation resistance – stator & rotor…
61 of 64 Testing Insulation Resistance • Semi-conductor devices – May be connected to stator and/or rotor – Protect from IR test voltages • Short circuit during test – by-passes test voltage & current
– Remove link afterwards!
• Disconnect during test – May result in long term damage to fastenings due to repeated operations – Danger of under/over tightening Maintenance Precautions • Check time/place suitability (Master) • Risk assessment? • Permit to Work? • Isolate and secure generator and prime mover • Switch off space heaters • Affix notices • Protect semiconductor devices • Brief personnel involved… AC GENERATOR CONSTRUCTION
