94871612 turbo generator ppt

BHEL HardwarBHEL Hardwar

Design & Constructional Features of Turbogenerators

KAPIL NARULASr. Engr./EMEHEEP, BHEL Hardwar


Index

1. History of Development

2. Power Output of Generator

3. Generator Modules & Types

4. Important Parameters of Generator Modules

5. Design Features

6. Main parts of TG/ Constructional features

7. Excitation System

8. Auxiliary Systems

9. Generator Testing

10. New Developments - Total Imp. of Stator Winding


History of Development - Globally

First single phase generator of 75 KW 1888

First 3 phase generator, salient pole 1900

First turbo type 3 phase 25 MW generator 1912

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


History of Development in BHEL

THREE PLANTS SET UP:

IN 1950s:At Bhopal with British collaboration30 MW & 120 MW Hydrogen Cooled

IN 1960s:At Hardwar with Russian Collaboration100 MW Hydrogen Cooled & 200 MW Hydrogen Cooled

IN 1960s:At Hyderabad with CZECH Collaboration60 MW Air Cooled & 110 MW Hydrogen Cooled


Power Output of Turbogenerator

P D2 . L . B . A . n

P Power in MVAD Bore Diameter of Core in metersL Length of Active Rotor Body in metersB Air Gap Flux Density in TeslaA Stator Ampere-Turn Loading in Amp./metern Speed in rpm


Power Output of Turbogenerator

No increase of utilization Increased utilizationSame or higher mfg. Costs Lower mfg. costs possible


Generator Modules

Air Cooled Turbogenerator - TARI

Hydrogen Cooled Turbogenerator - THRI

Hydrogen/Water Cooled TG - THDF

Module Nomenclature -

THRI 108/44

THDF 115/59


Stator winding

Indirect Hydrogen Cooled

Rotor winding

Radial Hydrogen Cooled

T H R I 108/44

Stator Cooling - Indirect

Rotor Cooling- Radial

Cooling Gas in the Casing

H = Hydrogen

Product

Turbogenerator

4350 mm(44 dm) Core length

1075 mm(108 cm) Rotor dia.

Module Nomenclature


Generator cooling System


Stator Slot - TARI / THRI


Stator Slot - THDF 500 MW


210/235 MW THW Generator


TYPES OF GENERATORS

SUPPLIED BY BHEL: # AIR COOLED# HYDROGEN COOLED# HYDROGEN/WATER COOLED

FOR APPLICATIONS:# THERMAL # NUCLEAR # GAS BASED

Library of Designs


Library of Designs

80 MW 1000 MW

AIR COOLED

170 MW

HYDROGEN COOLED

350 MW

WATER COOLED STATOR

1000 MW

660 MW

DESIRED MW CAPACITIES


Capability of Generator ModulesDESIGN VARIANT GENERATOR MODULE OUTPUT RANGEORDERS/MFD./COMMD. TARI 93/38 75-92 MW AIR COOLED TARI 108/36 100-120 MW 15/11/7 TARI 108/41 120-140 MW TARI 108/46 140-170 MW

THRI 93/38 120-150 MW THRI 108/39 170-220 MW HYDROGEN COOLED THRI 108/44 200-260 MW 25/22/17 THRI 108/44 B 260-275 MW

THRI 108/55 350 MW

THW-200-2 UPTO 200 MW HYDROGEN/WATER THW-210-2 200-219 MW COOLED THW-235-2 220-237 MW 149/142/137 THDF 115/59 500-585 MW

THDF 115/55 500 MW(new)


Improtant Parameters of Generator ModulesSL.NO.

TECHNICALPARAMETE

R

130 MW 200 MW 210 MW 235 MW 210 MW 250 MW 500 MW 560 MW

1. GENERATOR TYPE

THRI93/38

THW-200-2

THW-210-2

THW-235-2

THRI108/44

THRI108/44

THDF115/59

THDF115/59

2. RATEDMVA

RATED MW

162.5130.0

235.3200.0

247.1210.0

264.1237.7

247.1210.0

294.1250.0

588.2500.0

659.0560.0

3. RATEDVOLT. KV

10.5 15.75 15.75 16.5 15.75 16.5 21.0 21.0

4. POWERFACTOR

0.80 0.85 0.85 0.90 0.85 0.85 0.85 0.85

5. STATORCURRENT

8935 8625 9054 9240 9054 10291 16166 18118

6. SPEEDRPM

3000 3000 3000 3000 3000 3000 3000 3000

7. FREQ. HZ 50 50 50 50 50 50 50 508. HYDROGEN

PRESSUREKg/Cm2(g)

3.0 3.0 3.5 3.5 2.0 3.0 3.5 4.0

9. S.C.R 0.57 0.50 0.49 0.58 0.55 0.52 0.48 0.4610. EXCITATIO

NVOLTSAMPS

2402039

3002515

3102600

3262755

2652080

3192386

3404040

4104463

11. NEG. SEQ.CAP. I2,%

I2sq.xt8

1078

78

78

810

810

810

810

12. WEIGHTS, TSTATOR

HEAV. LIFTROTOR

13228

17542.2

17542.2

17542.5

18243.3

18243.3

25568

25568

13. BRG. - BRG.DIST. IN MM 6700 7700 7700 7882 7870 7870 10410 10410

14. TYPE OFEXCITATIO

N

STATIC STATIC/

HFG

STATIC/

HFG

STATIC/

HFG

B’LESS/STATIC

B’LESS B’LESS B’LESS



TECHNICALPARAMETE

R

210 MW 250 MW

1. GENERATOR TYPE

THRI108/39

THRI108/44(FI)

2. RATEDMVA

RATED MW

247210

294.1250.0

3. RATEDVOLT. KV

15.75 16.5

4. POWERFACTOR

0.85 0.85

5. STATORCURRENT

9056 10291

6. SPEEDRPM

3000 3000

7. FREQ. HZ 50 508. HYDROGEN

PRESSUREKg/Cm2(g)

3.0 4.0

9. S.C.R 0.57 0.6310. EXCITATIO

NVOLTSAMPS

2512260

3082497


I2sq.xt8

108

1012. WEIGHTS, T

STATORHEAV. LIFT

ROTOR

215.319239

23221243

13. BRG. - BRG.DIST. IN MM 7420 7870


N

B’LESS/STATIC

B’LESS/STATIC



TECHNICALPARAMETE

R

TROMBAY STG

K’KULAM

GTG

K’KULAM STG

FARIDABAD GTG

FARIDABAD STG

LIBYAGTG

1. GENERATOR TYPE

TARI93/38

TARI108/36

TARI108/36

TARI108/41

TARI108/46

TARI108/46

2. BASE LOADMVAMW

10080

137.5116.8

154.3131.1

170.1144.6

188.2160.0

18O.4153.3

3. RATEDVOLT. KV 10.5 10.5 10.5 10.5 15.75 15.75

4. POWERFACTOR 0.80 0.85 0.85 0.85 0.85 0.85

5. STATORCURRENT 5499 7561 8484 9354 6900 6612

6. SPEEDRPM

3000 3000 3000 3000 3000 3000

7. FREQ. HZ 50 50 50 50 50 508. S.C.R 0.56 0.55 0.50 0.50 0.52 0.549. EXCITATIO

NVOLTSAMPS

274719

339777

381851

410833

432797

388770


I2sq.xt1020

1020

1020

1020

1020

1020

11. WEIGHTS, TSTATOR

HEAV. LIFTROTOR

12828

17037

17037

18140.1

20044

20044

12. BRG. – BRG.DIST. IN MM 7050 7250 7250 7800 7900 7900


N

B’LESS B’LESS B’LESS STATIC B’LESS STATIC


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

# TOP RIPPLE SPRINGS IN STATOR SLOTS TO CONTAIN BAR BOUNCING FORCES

# SEPARATELY ASSEMBLED STATOR CORE AND WINDING FOR REDUCING THE MANUFACTURING CYCLE

# STATIC/BRUSHLESS EXCITATION SYSTEM


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• SINGLE FLOW RING TYPE SHAFT SEALS• STATIC/BRUSHLESS EXCITATION SYSTEM


THDF Generators - Design features

• DIRECT WATER COOLING OF STATOR WINDING • 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


Gas Turbine Generators - Design features

• TERMINAL BUSHINGS ON TOP

• STATIC EXCITATION SYSTEM

• SFC (SYNCHRONOUS FREQUENCY CONVERTOR) STARTING SYSTEM

• FORCED COOLING WATER SYSTEM (MPR SYSTEM)



TARI Generator Outline



TARI Generator Cross section



TARI Generator End View


A SYSTEM TO TAKE CARE OF DM COOLING WATER REQUIREMENT OF GAS TURBINE GENERATORS

1. TO DELIVER DM COOLING WATER TO GENERATOR AIR COOLERS

2. TO ENSURE HEAT TRANSFER FROM GENERATOR AIR COOLERS TO THE FIN-FAN COOLERS.

3. TO MAINTAIN COOLING WATER TEMPERATURE AND PRESSURE AT ALLOWABLE VALUES.

Forced Cooling Water System (MPR System)


Forced Cooling Water System (MPR System)


GENERATOR MODULE TARI 108/46

SUPPLIED / UNDER SUPPLY :

BAIJI GPP, IRAQ 4 SETS

W. MOUNTAIN, LIBYA 4 SETS

GENERATOR MODULE TARI 108/41 (SUPPLIED)

FARIDABAD CCPP, INDIA 1 SET

GENERATOR MODULE TARI 108/36

SUPPLIED / UNDER SUPPLY:

KAYAMKULAM, INDIA 2 SETS - GE Turbines

Gas Turbine Generators - Experience List


Main Parts of TG / Constructional features

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


Main Parts of Turbogenerator

Stator

Stator Core

End Shield

Rotor

Wdg Overhang

Bearing

Shaft Seal

Terminal Bushing

Oil Catcher

Cooler

Rotor fan

InsertCover


Main Parts of Turbogenerator

Coolers

Terminal bushing

Foundation


Ventilation Circuit in THRI TG


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 Frame (Fabrication & Machining)


TURBINE SIDE END SHIELD EXCITER SIDE END

SHIELD

STATOR

Hydraulic/Pneumatic testing of Stator


Stator Frame TARI 108/46


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


Core Suspension - TARI/THRI TG


Core Suspension - Air Cooled TG

Core End Plate

Core Housing

Location forSpring

Core


Core Suspension - 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, Oil catchers, etc

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


End Shield (Exciter side 500 MW)


End Shield (Turbine side 500 MW)


Stator Winding

• Three phase windings in two layers of individual bars

• Top and bottom bar displaced by one winding pitch and connected to

coil groups

• Coil groups connected to Connecting Bus bar and finally to Term Bushing

• Involute shape at the end of bar helps withstands various forces

• Micalastic Insulation System (VPI process)

- Micalastic good conductor of heat- Low flamability- High resistance to moisture and chemical action- Accommodates thermo-mechanical stresses- Retains properties even after years of operation

VPI- Vacuum Pressure Impregnation


Stator Winding Assembly

1. CORE2. CLAMPING FINGER3. PRESSURE PLATE4. TOP BAR5. BOTTOM BAR6. PHASE CONNECTOR7. GAS OUTLET8. GAS INLET9. TERMINAL BUSHING


Stator END Winding Support


Stator End Winding Assembly


Stator End Winding 500 MW


Rotor

1. A high strength alloy steel single forging prepared by vacuum cast steel

2. Slots for housing field windings

3. Strong coupling for withstanding short circuit forces

4. Bending critical speed away ±5% of operating speed

5. Supported on two journal Bearings

6. Provision of axial fan/compressor for forced ventilation

7. Provision of damper wedges for increasing negative sequence

capability of rotor


Rotor Body


Rotor Body with cross Pole Slot

Rotor Wedge

CrossPoleSlot


Rotor Slot

Sub Slot

Top Slot Liner

Rotor Wedge

Conductor

Inter turn Insulation

Slot Liner


1. ROTOR BODY 5. RETAINING RING2. DAMPER BAR 6. SILVER PLATED SHRINK SEAT3. SILVER PLATED ROTOR END WEDGE 7. TRANSVERSE SLOTS4. ROTOR WINDING 8. ROTOR WEDGE

Arrangement of Damper Wedges


1 2 3 4 5 6 7 8 9

1. ROTOR BODY 6. GAS BAFFLE2. SNAP RING 7. RETAINING RING3. TERMINAL LUG 8. END RING4. ROTOR WINDING 9. BALANCING BORE5. FILLER

Rotor End Winding


Rotor End Winding


Rotor Fan Blades


Rotor Slip Ring


Bearing Assembly

• It is sleeve Bearing

• Supports Rotor weight

• Reduces shaft vibrations

• Minimises frictional losses

• Located in End Shields or outside stator depending upon type of machine

• Self aligning outer part

• Insulated from Stator or End Shield to prevent flow of shaft current

• Inner surface is made of babbit material (Tin alloy)


Bearing Assembly


Shaft Seal Assembly

• Prevents escape of H2 through junction of rotor and stationary part

• Maintains continuous oil film between Seal Ring and rotor journal

• Clearance should be sufficient to maintain oil film without unnecessary

large oil flow and with minimum frictional losses

• Ring relief oil for balancing the gas pressure on seal ring

• Inner surface of Babbit material


1. OIL WIPER RING AIR SIDE 7. SEAL RING 13. INSULATION2. SEAL RING CHAMBER 8. SEAL RING CARRIER 14. PACKING3. PRESSURE OIL GROOVE 9. OIL WIPER RING H2 SIDE 15. SEAL OIL GROOVE4. BABBIT 10. SEAL STRIP 16. END SHIELD5. SEAL OIL INLET BORE 11. ROTOR SHAFT 6. SEAL OIL GROOVE 12. INNER LABYRINTH RING

Shaft Seal Assembly

HydrogenSide

Air Side


Terminal Bushing

• Tubular construction for gas / water cooling

• High conductivity copper for taking out electrical power

• Connection flanges are silver plated to minimise contact resistances

• Insulated with a epoxy resin cylinder or porcelain cylinder

• Differential pressure of gases or forced water for cooling

• Bolted on to stator bottom/top directly or housed in a box type

construction which is bolted to stator bottom


Terminal Bushing


Cooling of Terminal Bushing

1. HYDROGEN SIDE FLANGE2. TUBULAR COPPER COND.3. INSULATING CYLINDER4. MOUNTING FLANGE5. RUBBER GASKET6. AIR SIDE TERMINAL BOLT


Terminal Bushings Arrangement TARI


1. CORE2. CLAMPING FINGER3. PRESSURE PLATE4. TOP BAR5. BOTTOM BAR6. PHASE CONNECTOR7. GAS OUTLET8. GAS INLET9. TERMINAL BUSHING

Terminal Bushings Arrangement THRI


Terminal Bushing Box 500 MW


Excitation System

1. Static Excitation

• Rotor Field Winding is connected to Slipring mounted on rotor• Excitation is provided by current transfer by contact through Carbon Brushes, Slipring and field lead

Brush Gear


Static Excitation System

Brush Gear Assly Brush Holder


Brushless Excitation System

2. Brushless Exciter

•Eliminates Slip Rings, Brushgear and Field Breaker

•Eliminates all problems associated with transfer of current via sliding contacts

•Simple, Reliable and ideally suited for large sets

•Minimum operating and maintenance cost

•Self generating excitation unaffected by system fault/disturbances because of shaft mounted pilot exciter

•Increasingly popular system the world over


•High response excitation with fast acting AVR

•Multi contact electrical connections between exciter and generator field

•Stroboscope for fuse failure detection

•Rotor Earth fault monitoring system

•RC circuit to avoid over voltages

•Dehumidifier for use during shut down

Brushless Exciter


Brushless Exciter


Rectifier Wheel


PMG Rotor & Fan


Auxiliary System

1. Primary Water System

2. Seal Oil System

3. Gas Flow System


1. PRIMARY WATER TANK2. PRESSURE REGULATOR3. WASTE GAS TO ATM.4. PUMP5. COOLER6. FILTER7. BYPASS LINE8. CW FOR STATOR WDG.9. ION EXCHANGER10. CW FOR BUSHINGS11. TEFLON HOSE12. C W MANIFOLD

Primary Water System

Losses in wdg, bushings, bus bar are dissipated


Seal Oil System

Prevents H2 losses at the shaft entry into stator


1. H2 BOTTLE2. H2 PRESS REDUCER3. N2 BOTTLE.4. N2 PRESS REDUCER5. PW TANK6. PRESS CONTROLLER7. UPR. GEN GAS HEADER8. LWR.GEN GAS HEADER9. GAS DRIER HEATER10. GAS DRIER FAN11. GAS DRIER CHAMBER12. CO2/H2 PURITY TRANS.13. DEHYDR. FILTER14. PRESS REDUCER15. COMPRD. AIR HOSE16. COMPRD. AIR FILTER17. CO2 FLASH EVAPORTR18. CO2 BOTTLE

Gas System

Facilitates H2 filling & maintains gas pressure in stator


Generating testing

1. Mechanical test

2. Open Circuit test

3. Short circuit test

4. Sudden short circuit test

5. Voltage wave form

6. Tan test

7. Vibration Measurement


500 MW Generator on test bed


Gas Turbine Generator-Faridabad


Gas Turbine Generator- Baiji, IRAQ


STATOR WINDING AND CORE BECOMES A MONOLITHIC STRUCTURE : NO VOIDS, LESSER VIBRATIONS & BETTER HEAT TRANSFER

THERMAL CONDUCTIVITY OF VPI INSU. 2.2 - 2.5 mW/Cm°C

THERMAL CONDUCTIVITY OF H2 1.4 - 1.5 mW/Cm°C

THERMAL CONDUCTIVITY OF AIR 0.257 mW / Cm °C

New dev - Total Impregnated generator


+ PARTIAL DISCHARGES ARE REDUCED, RESULTING IN BETTER LIFE OF MACHINE

+ NO POSSIBILITY OF CORE OR BAR LOOSENESS: Thus a major cause of failure, resulting in stator earth faults is eliminated.

+ NO POSSIBILTY OF LOOSENESS IN STATOR WINDING OVERHANG: Lesser overhang vibrations. Glue injection in overhang is not required.

+ NO POSSIBILTY OF WEDGE LOOSENESS - Wedge tightness checking not required. Rotor withdrawl during initial inspection not required.

+ LESSER MAINTENANCE

+ LESSER OVERHAUL TIME

+ REDUCTION IN SPARES INVENTORY - STATOR BARS AND STATOR SLOT WEDGES ARE NO MORE REQUIRED AS SPARES

Advantages of Total Impregnated generator


WOUND STATOR CORE BEING LOADED FOR TOTAL IMPREGNATION


CURING OF TOTALLY IMPREGNATED WOUND CORE


INSERTION OF IMPREGNATED WOUND CORE IN STATOR


THANK YOU

END

94871612 turbo generator ppt

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