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    GENERATOR Mech Construction Original

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    Sam
    The document provides an overview of turbogenerators (TGs), including their main components and functions. It discusses the historical development of TGs globally and in India. The key types of TGs are described, including air cooled, hydrogen cooled, and hydrogen/water cooled models. The main parts of a TG like the stator, rotor, end shields, and bearings are explained. New developments in TGs are mentioned, such as total impregnated generators and increased power capacities.

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    Attribution Non-Commercial (BY-NC)
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    GENERATOR Mech Construction Original

    Uploaded by

    Sam
    797 views50 pages
    The document provides an overview of turbogenerators (TGs), including their main components and functions. It discusses the historical development of TGs globally and in India. The key types of TGs are described, including air cooled, hydrogen cooled, and hydrogen/water cooled models. The main parts of a TG like the stator, rotor, end shields, and bearings are explained. New developments in TGs are mentioned, such as total impregnated generators and increased power capacities.

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    The document provides an overview of turbogenerators (TGs), including their main components and functions. It discusses the historical development of TGs globally and in India. The key types of TGs are described, including air cooled, hydrogen cooled, and hydrogen/water cooled models. The main parts of a TG like the stator, rotor, end shields, and bearings are explained. New developments in TGs are mentioned, such as total impregnated generators and increased power capacities.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    797 views50 pages

    GENERATOR Mech Construction Original

    Uploaded by

    Sam
    The document provides an overview of turbogenerators (TGs), including their main components and functions. It discusses the historical development of TGs globally and in India. The key types of TGs are described, including air cooled, hydrogen cooled, and hydrogen/water cooled models. The main parts of a TG like the stator, rotor, end shields, and bearings are explained. New developments in TGs are mentioned, such as total impregnated generators and increased power capacities.

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    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
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    Turbogenerator -An Introduction

    BHEL Hardwar

    Index
    1. Historical developments 2. Types of Generator

    3. Main parts of Turbogenerator & its functions


    4. New developments in Turbogeneartors

    BHEL Hardwar

    Development of TG
    Global development First single phase generator of 75 KW 1888 First 3 phase generator, salient pole 1900 First turbo type 3 phase 25 MW generator 1912 CEA, UK made 50 HZ as standard frequency for Europe 1925 First Hydrogen cooled 3 phase 30 MW generator 1937 First Hydrogen cooled TG with direct cooling of rotor 1949 First generator with water cooled stator winding 1956 First generator with water cooling for stator and rotor wdg1959

    BHEL Hardwar

    Development of TG
    In India
    THREE PLANTS SET UP: IN 1950s:
    At Bhopal with British collaboration 30 MW & 120 MW Hydrogen Cooled

    IN 1960s: At Hardwar with Russian Collaboration 100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled IN 1960s: At Hyderabad with CZECH Collaboration 60 MW Air Cooled & 110 MW Hydrogen Cooled

    BHEL Hardwar

    Types of Turbogenerator
    Generator Modules :Air Cooled Turbogenerator - TARI Hydrogen Cooled Turbogenerator - THRI Hydrogen/Water Cooled TG - THDF and THW

    Module Nomenclature THRI 108/44 THDF 115/59

    BHEL Hardwar

    Generator cooling System

    BHEL Hardwar

    Stator Slot - TARI / THRI

    BHEL Hardwar

    Stator Slot - THDF 500 MW

    BHEL Hardwar

    210/235 MW THW Generator

    BHEL Hardwar

    Capability of Generator Modules


    DESIGN VARIANT GENERATOR MODULE TARI 93/38 TARI 108/36 TARI 108/41 TARI 108/46 THRI 93/38 THRI 108/39 THRI 108/44 THRI 108/44 B THRI 108/55 THW-200-2 THW-210-2 THW-235-2 THDF 115/59 THDF 115/55 OUTPUT RANGE 75-92 MW 100-120 MW 120-140 MW 140-170 MW 120-150 MW 210 MW 200-260 MW 260-275 MW 350 MW UPTO 200 MW 200-219 MW 220-237 MW 500-585 MW 500 MW(new)

    AIR COOLED

    HYDROGEN COOLED

    HYDROGEN/WATER COOLED

    BHEL Hardwar

    Capability of Generator Modules


    125/67

    800

    BHEL Hardwar

    Library of Designs
    1000 MW
    WATER COOLED STATOR

    350 MW
    HYDROGEN COOLED

    660 MW

    170 MW
    AIR COOLED
    DESIRED MW CAPACITIES

    80 MW

    1000 MW

    BHEL Hardwar

    THRI Generators - Design features


    DIRECT HYDROGEN COOLING OF STATOR CORE AND ROTOR
    WINDING INDIRECT COOLING OF STATOR WINDING EXPLOSION PROOF SINGLE PIECE STATOR FRAME END SHIELD MOUNTED BEARINGS VPI INSULATION SYSTEM TOP RIPPLE SPRINGS IN STATOR SLOTS TO CONTAIN BAR BOUNCING FORCES COLD GAS TEMPERATURE CONTROL VALVE TO MAINTAIN COLD GAS TEMPERATURE CONSTANT RING TYPE SHAFT SEALS STATIC/BRUSHLESS EXCITATION SYSTEM

    BHEL Hardwar

    THDF Generators - Design features


    DIRECT WATER COOLING OF STATOR WINDING 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 5 STAGE AXIAL COMPRESSOR AND VERTICAL HYDROGEN COOLERS ON TURBINE END COLD GAS AND PRIMARY WATER TEMPERATURE CONTROL VALVES TO MAINTAIN AVERAGE INLET COOLING MEDIUM TEMPERATURES CONSTANT DOUBLE FLOW RING TYPE SHAFT SEALS BRUSHLESS EXCITATION SYSTEM BHEL Hardwar

    TARI Generators - Design features


    # DIRECT COOLING OF STATOR CORE AND ROTOR WINDING # INDIRECT COOLING OF STATOR WINDING # HORIZONTALLY SPLIT CASING DESIGN FOR STATOR # VERTICALLY SIDE MOUNTED COOLERS IN A SEPARATE HOUSING # VPI INSULATION SYSTEM # SEPARATELY ASSEMBLED STATOR CORE AND WINDING FOR REDUCING THE MANUFACTURING CYCLE # STATIC/BRUSHLESS EXCITATION SYSTEM

    BHEL Hardwar

    500 MW Generator on test bed

    BHEL Hardwar

    Gas Turbine Generator-Faridabad

    BHEL Hardwar

    THRI 108/39 Stator with End Shield & Terminal box


    BHEL Hardwar

    Main Parts of Turbogenerator


    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 BHEL Hardwar

    Main Parts of Turbogenerator


    Stator Core Cooler Insert Cover Rotor fan

    End Shield

    Wdg Overhang
    Oil Catcher Rotor

    Bearing Shaft Seal

    Stator

    Terminal Bushing

    BHEL Hardwar

    Main Parts of Turbogenerator


    Coolers

    Foundation

    Terminal bushing

    BHEL Hardwar

    Ventilation Circuit in THRI TG

    BHEL Hardwar

    Ventilation Circuit in THRI TG

    BHEL Hardwar

    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

    BHEL Hardwar

    Stator Frame (500 MW)

    BHEL Hardwar

    Stator Frame (Fabrication & Machining)

    BHEL Hardwar

    Hydraulic/Pneumatic testing of Stator


    TURBINE SIDE END SHIELD STATOR EXCITER SIDE END SHIELD

    TEST PRESSURE= 10 BAR FOR

    30 MIN

    BHEL Hardwar

    Stator Frame (Air Cooled TG)

    BHEL Hardwar

    Stator Core
    Made up of punched segments of thin sheets of ETS 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

    BHEL Hardwar

    Core Suspension - THRI/THW TG

    BHEL Hardwar

    Core Suspension - 500 MW

    BHEL Hardwar

    Core Suspension - Air Cooled TG


    Location for Spring Core Housing

    Core End Plate

    Core

    BHEL Hardwar

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

    BHEL Hardwar

    End Shield - THRI TG

    BHEL Hardwar

    End Shield (Exciter side 500 MW)

    BHEL Hardwar

    End Shield (Turbine side 500 MW)

    BHEL Hardwar

    Bearing Assembly

    BHEL Hardwar

    Terminal Bushing Box 500 MW

    BHEL Hardwar

    New dev - Total Impregnated generator


    A VOID FREE HIGH VOLTAGE INSULATION ALON G THE ENTIRE LENGTH OF THE BAR A MECHANICALY FIRM BOUND BETWEEN ALL WINDING COMPONENTS AND THE INNER FRAME AND CORE BETTER SUITABILITY AGAINST THERMAL STRESSES DURING OPERATION BETTER HEAT TRANSFER LESS INSULATION THICKNESS - SPACE OPTIMIZED MACHINE LIFE IMPROVES INCREASE IN GENERATOR EFFICIENCY INCREASE IN SHORT CIRCUIT RATIO

    INCREASE IN LINE CHARGING CAPABILITY


    REDUCTION IN SPARES INVENTORY - STATOR BARS AND STATOR NO MORE REQUIRED AS SPARES REDUCTION IN OVERHAULING REQUIREMENTS : STATOR WEDGE TIGHTNESS CHECKING NOT REQUIRED SLOT WEDGES ARE

    LOOSENING OF CORE AND FASTNERS REDUCED


    GLUE INJECTION NOT REQUIRED ROTOR WITHDRAWL DURING INITIAL INSPECTION NOT REQUIRED

    BHEL Hardwar

    WOUND STATOR CORE BEING LOADED FOR TOTAL IMPREGNATION

    BHEL Hardwar

    CURING OF TOTALLY IMPREGNATED WOUND CORE

    BHEL Hardwar

    INSERTION OF IMPREGNATED WOUND CORE IN STATOR

    BHEL Hardwar

    Core Insertion into Stator


    Activities :Measurement of dimensions for alignment of Stator & Core

    Welding of Springs into Stator Placement of Impreg. Wound Core on C-Beam for deflection Placement of Wound Core on C-Beam with packing Insertion of Stator Frame over Core with the help of Crane Alignment of Stator with reference to Core Welding of Bush with Spring and Core Housing Rechecking of alignment dimensions

    BHEL Hardwar

    Meas. Of Controlling dimensions

    Stator

    BHEL Hardwar

    Welding of Springs

    Supports in the middle of Spring

    L-Supports at the end of Spring

    BHEL Hardwar

    Welding of Springs

    Supports for bottom Spring

    BHEL Hardwar

    Placement of Wound Core on C-Beam

    Wound Core being placed on C-Beam

    Wound Core on C-Beam

    BHEL Hardwar

    Insertion of Stator over Core

    BHEL Hardwar

    Welding of Bush with Spring & Core Housing

    Alignment Bolt

    Bush in position

    Sealing during Welding

    BHEL Hardwar

    THANK YOU

    END

    BHEL Hardwar

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