By

Ashish Pahurkar
(Asst. Engineer K. T. P. S.)
 It is a rotating device which converts Mechanical energy
to Electrical energy.

 It is working on the principle of Faraday’s law of Electro

- magnetic induction.

 The rotor of the generator is rotated by means of prime

mover. And power generated is taken out from stator.

 A set of slip rings are provided on rotor for excitation

supply.
 Generation of
electricity is based
on principle of
electromagnetic
induction i.e. power
is produced by
rotation of
electromagnet
(rotor) within a
group of windings
(stator).
 The rotor of the generator acts
as a magnet. This magnet is
created by passing D.C. supply
through coils wrapped around
the pole.
 This creates an
electromagnetic field in the air
gap which, circulates through
the stator core.
 When the rotor rotates, the
magnetic field also rotates.
The field appears in the stator
as an alternating field, so that
an alternating voltage is
induced in the stator windings.
 Turbo generators
are designed to
produce 3 phase
A.C. voltage.
 In these generators,

there are 3 distinct

sets of coils in the
stator, two for each
phase.
 Prime mover

 Excitation system

 Protection system

 Circuit breaker
 Generating Voltage : 15.75 KV
 Current :9050 Amps
 Power Factor : 0.85
 Synchronous speed : 3000
 Excitation Voltage :210-310Vdc
 Full load Excitation Current :2600 Amps
 Cooling : Hydrogen and water
 Rotation (from SR) : ACW
 Stator

 Rotor

 Bearings

 Shaft sealing arrangement

 Main Parts of Turbogenerator
Stator Core Cooler

Insert
End Shield Cover

Wdg Overhang Rotor fan

Oil Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing
 Stator Frame
 Stator core - Laminated
 Stator winding- Double layer -

Y connected- grounded via N.G.T.

 Terminal Bushings – 3 Phase and 6 neutral
 Hydrogen Coolers
 Water header arrangement
 End shields
 STATOR FRAME

 The stator frame

embodies the stator
core & stator
winding.
 It also provides a

closed ventilation
circuit for the gas .
 Each lamination is punched in the
form of segments with the help
of compound die.

Slots punched on each lamination form

the space to keep stator winding bar in
position without difficulty.

The laminations are insulated from

one another by two layers of varnish
which has high mechanical &
electrical properties.
 Stator Frame
 Stator core - Laminated
 Stator winding- Double layer -

Y connected- grounded via N.G.T.

 Terminal Bushings – 3 Phase and 6 neutral
 Hydrogen Coolers
 Water header arrangement
 End shields
During manufacture, the laminations are pressed
in stages by means of hydraulic press.

The assembly of the core

is carried out in the vertical
direction.
 2 3
4
The complete core is kept
pressed between two non 1
magnetic press rings from
non magnetic alloy steel.

A copper screen is used

between the press ring & 1 6 5
the core at 1. Core key bar
either side, in order to 2. Insulation
3. Copper rope for
reduce the losses in the grounding
end region of 4. Radial cooling duct
the core 5. Pressure plate
6. Clamping finger
STATOR CORE

The stator core is made up of

laminations
(0.35 mm to 0.5 mm) punched
from high quality
electrical silicon steel.
 The stator frame consist of a cylindrical casing with an
inner partition wall & thick side wall.

It is designed to withstand shock forces which may be

caused by the explosion of hydrogen gas.
STATOR
The complete core is supported on core bars made from
resistant steel. This arrangement is used to dampen the
core vibration ,which may be transmitted to the foundation
through stator frame.
Finally assembled core is tested for any hot spots developed
due to presence of shorts. This is done by ELCID test.
(Electrical core imperfection detection test.)
The stator winding is 3 phase star connected, mostly double
layered short pitched winding.
Stator bars are manufactured as half coils & these coils are
displaced from each other by one winding pitch,& it’s ends
are connected to form the coil group.
Each coil is made of a bundle of sub
conductor
insulated from each other.

For water cooled machine a few hollow conductor,

which carry cooling water are also placed in between
these solid conductors.
STATOR SLOT – TARI / THRI
INSERTION OF IMPREGNATED WOUND CORE IN
STATOR
CORE INSERTION IN STATOR

30
The bar ends are connected to form turns & winding branches ,
which are then joined by connecting leads to form phase winding.
Output leads are brought out of the stator casing with the help
of terminal bushing. Normally there are 6 terminal bushing,
3 each for phase & neutral side.These are brought out at the
non driving end of the machine.
Stator frame has following component
Hydrogen gas coolers are provided to cool the hydrogen gas
after it gained heat in circulating through the generator stator
& rotor. They are situated in gas tight compartments & are
located in the outer casing of the generator.
Hydrogen gas coolers consists of cooling tubes made out of
brass. The tubes are arranged in a staggered form so as to
expose maximum surface area to hot hydrogen.
Copper wire is wound on the tubes to increase the surface
area of the cooling water tubes.
Cooling water flows through the tubes, & the hydrogen flows across the cooling tubes.

Hydrogen thus comes in contact with the external surface of the cooling water tubes
& gets cooled.
 END SHIELD
The ends of the stator
frame are closed by End
shield. These End shield are
made in two halves
to make it a simple
assembly.

Since the end shield have to withstand

rated gas pressure & the explosive pressure
of the H2 gas, it is rigid in nature with high stiffness
 Rotor shaft – Solid alloy
 Rotor Winding
 Rotor retaining rings
 Slip rings and brush gear
 Cooling fans
THW 210/235: ROTOR SHAFT
Rotor Fan Blades
 Rotor Body with cross Pole Slot

Rotor
Wedge

Cross
Pole
Slot
Two propeller types of fans are shaft mounted
on either end of the rotor body, for circulating
the cooling gas inside the generator casing.
 SLIP RING
For feeding the excitation current to the rotor winding slip ring
is provided on the rotor shaft. This is electrically connected to
the rotor winding by central feed lead.

The slip ring assembly is made of

alloy steel & insulating material &
is shrunk fit on rotor shaft.
 BRUSH GEAR
To make the electrical connection with the slip ring carbon
brushes are provided circumferentially on the slip ring.
BRUSH & BRUSH HOLDER
 Pedestal Mounted – 2 Nos (DE & NDE)

Lubrication is provided to journal bearings

(like turbine bearings ) to avoid friction with shaft.

The pedestal of bearing or housing is insulated .

The rotor shaft is supported on bearing at either end, & have
cooling fans mounted at both the ends for cooling the winding.
 Provided Between end shield and bearing - for
avoiding escaping of Hydrogen gas along the
rotor shaft

Oil pressure should be greater than the

Hydrogen pressure.
To prevent the escape of hydrogen gas along the rotor shaft,
shaft seal are provided at either end of the generator.

These are mounted between the end shield & the bearing.
1. There should be minimum H2 gas loss through the seals

1. It should have small friction losses which do not affect the

efficiency of machine.

2. It should provide a high degree of operational reliability

which means under all operation conditions. Sealing system
should not fail to prevent the escape of H2 gas from the
generator casing.
 GENERATOR ROUTINE CHECKS
Hourly checks of temperatures
Parametrer Safe value
Stator winding copper temperature 75˚C
Stator core iron temperature 95˚C
Rotor winding cooper temperature 110˚C
Cold / hot gas temperature 45˚C/75˚C
DM water temperature at inlet and at outlet of stator winding 46˚C / 85˚C

Babbit temperature of bearing 75˚C

Inlet and outlet temperature of cooling water to gas cooler. 38˚C
Inlet and outlet temperature of cooling (GS)water to stator 37˚C
water cooler and seal oil cooler
Inlet and outlet oil temperature of generator bearing and shaft 60˚C
seal
 GENERATOR ROUTINE CHECKS
Hourly checks of pressure
Parameter Safe value
Pressure and purity of hydrogen inside the generator 3.5 kg/cm²
97%
Differential pressure of seal oil and hydrogen
Seal oil and ring relief pressure at seal 1.9
Pressure of inlet and outlet of DM water to stator winding 3.3-3.5
Pressure of cold water at inlet and outlet of hydrogen gas cooler
, at stator water cooler and seal oil cooler

Pressure of DM water before and after mechanical filter 0.4kg/cm²

Pressure of inlet and outlet for seal oil filter
 GENERATOR ROUTINE CHECKS
Hourly checks of Flows
Parameter Safe value
Cooling water to gas cooler 87.5 M³/hr
Cooling DM water for stator winding 27 M³/hr
Cooling Water to stator water cooler and seal oil cooler 72 M³/hr
 GENERATOR ROUTINE CHECKS
•Daily check points:
Parameter
Record the hydrogen gas consumption and check the gas trap sample in stator water
system to determine leakage of Hydrogen.
Examine brush gear for unusual sparking, dust and oil accumulation
Examine condition of hydrogen dryer and reactivate if found necessary
Check Hydrogen purity
Check relative humidity of hydrogen it should not exceed 30%.
|Check liquid level detector for accumulation of water, oil particles. Drain if found
necessary
Maintain cleanliness around the generator, the area must be free from water, oil dust etc
 GENERATOR ROUTINE CHECKS
•Weekly check points:
Parameter
Examine the condition of brush gear.
Checking of DC seal oil pump by running trial .
Check of stator winding cooling water auto pump changeover between working and
stand by. Also check the pressure and flow of stand by pump by running for few minutes.
Check operation of hydrogen purity meter.
Check differential pressure across the filter in stator water system and seal oil system
Conductivity of DM water by laboratory method. Also check pH value of Dm water.
 Stator winding IR (polarisation Index)
 Stator winding resistance
 ELCID (for core perfection)
 Recurring surge oscilloscope

( For inter turn fault)

 Hydraulic Test for hollow conductor.
 Rotor IR value
 Rotor resistance measurement
 Impedance Measurement
 Purge Test to identify blockages in

ventilating canal
 Pneumatic test at Slip- ring portion.
 Slip – ring diameter ( < 20mm)
 Brush Length wearing (>50%)
 Open Circuit test ( To calculate no load core
loss and windage and friction losses)

 Short Circuit Test ( To calculate copper loss)