CONTENTS

1. GLANCE AT BHEL 2. GENERAL ON ELECTRICAL MACHINES 3. 4. ELECTRICAL DESIGN 5. MECHANICAL DESIGN 6. EXCITATION SYSTEMS 7. INTRODUCTION TO MiCOM RELAY 8.GENERATOR PROTECTION 9.RELAY SETTING CALCULATIONS 10.CONCLUSION

BHEL

AT

GLANCE

Established in the 1950s BHARAT HEAVY ELECTRICALS LIMITED (BHEL) is today a name to reckon with in the industrial world. It is the largest engineering and manufacturing enterprise of its kind in India and one of the leading international companies in the power field. BHEL offers over 180 products catering to a wide spectrum of fields like power generation and transmission, oil exploration and production, transportation, steel and metals, fertilizers and petrochemicals, refineries, cement plants, engineering industries, non conventional energy sources, defence equipment etc. BHEL Hyderabad has earned a name for itself by its successful diversification over the years into a wide range of products and systems for utility/industry sectors BHEL is the largest gas turbine manufacturer in India with state-of-art facilities in all areas of gas turbine manufacture. BHEL started as manufacturer of heavy-duty gas turbine in technical collaboration with GE, USA in 1986. BHEL is an ISO 9000 certified company with an export presence in more than 50 countries BHEL is truly Indias industrial ambassador to the world. Today BHEL has 14 manufacturing divisions, service centers, in addition to over 150 projects spread all over India and abroad to provide prompt and effective services to customers.

ABSTRACT
BHEL is the largest gas turbine manufacturer in India with stateof-art facilities in all areas of gas turbine manufacture. BHEL started as manufacturer of heavy-duty gas turbine in technical collaboration with GE, USA in 1986. BHEL is an ISO 9000 certified company with an export presence in more than 50 countries BHEL is truly Indias industrial ambassador to the world. Today BHEL has 14 manufacturing divisions, service centers, in addition to over 150 projects spread all over India and abroad to provide prompt and effective services to customers. A Generator is a rotating electromagnetic device producing electrical power taking mechanical input from prime mover (gas turbine/steam turbine) and magnetic energy from excitation. A modern generating unit is a complex system comprising the generator, stator winding, associated transformer & unit transformer, the rotor with its field winding and excitation system and the prime mover with its associated auxiliaries. There may be subjected to different types of failures. Thus for ensuring a secure, reliable and continuous supply of power, a proper protection system is a must. The protective gear, which is a collective term for all the equipments used for detecting, locating and initiating the removal of fault from the power system, thus forms a necessity for any power system. This Project entitled as DESIGN OF PROTECTION SYSTEM FOR TURBOGENERATOR gives a detailed description of various faults that occur on sync. Generator, which forms the core of any power system. The various protections schemes for different faults and their adverse effects discussed are: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Differential Protection Over Current Protection Under Voltage Protection Over Voltage Protection Under Frequency protection Over Frequency Protection Field Failure Protection (loss of Excitation) Negative Phase Sequence Reverse Power Protection Stator Earth Fault Protection (95%) 100% Stator Earth Fault Protection Rotor Earth Fault Protection Over Fluxing Protection Protection against Over Speed Protection against wrong Synchronization Dead Machine Protection

. In addition to this a brief explanation to synchronous generators and excitation systems are presented. Finally a tripping logic philosophy and various relay setting calculations for a generator are also presented

INTRODUCTION

I. GENERAL MACHINES:

DESCRIPTION

ON

ELECTRICAL

Principle of Generator: An electric generator is a machine, which converts mechanical energy into electrical energy. The energy conversion is based on the principle of the production of dynamically induced emf. Whenever the conductor cuts the magnetic flux dynamically induced emf is produced in it according to faradays laws of electro magnetic induction. This emf causes a current to flow if the conductor circuit is closed. The induced emf is directly proportional to the rate of change of flux and number of turns. It is given by the expression E= N.(d0/dt) Hence two basic essential parts of electrical generator are: 1) Magnetic field, 2) Conductor, which can so move as to cut the flux. Synchronous generator is the core of any generating power plant.A synchronous generator is a rotating electromagnetic device, which converts mechanical energy to the electrical energy by taking the mechanical input from a prime mover and magnetic energy from excitation.

General Aspects Of Turbo Generator Design: Turbo generators are classified according to their function and the conditions under which they are supposed to work and deliver the O/P. 1. Classification based on drive: a. Steam turbine generators: Small rating steam turbines are designed for high speeds and hence generators are driven by steam turbines through speed reduction gearboxes. But at higher capacities the losses in the gearbox offset any advantage obtained by high-speed design for steam turbines. Hence, large capacity steam turbines are designed for 3000 RPM & connected to generators directly. Steam turbines are erected on an elaborate civil foundation in a powerhouse at an elevation of 6 to 8 meters. The space below the turbines utilized for locating the condenser and other auxillaries. Hence as the generator also is located at this height, the space below the generator is utilized for locating the air coolers. The terminals are taken out from the bottom of the machine on the exciter side for onward connection to bus-ducts. b. Gas turbine generators: Gas turbine can be installed outdoors & without elaborate civil structure as required in steam turbine. They have to operate under extreme temp conditions. Hence, generators driven by gas turbines are usually installed with a minimum civil foundation on a base frame. An enclosure is provided to protect the machines from the effects of environment. They can be open circuit air cooled or closed circuit air-water cooled. The terminals are usually at the top of the generator on the exciter side for onward to bus-ducts or through a GAC.

2.

Classification based on speed:

The construction of the generator as well as the material used are dependent on the speed at which the machine is designed to operate high speed at which the machine is designed to operate. High speed machines are of 2-pole design. They employ solid cylindrical roots made of high quality steel forging. Slots are milled into the rotor to accommodate the rotor winding. Two retaining rings or end-bells made of high strength austenitic steel forging hold the rotor winding in place. Two axial fans, one on each side for circulating cooling air in the machine are provided. Generators with four poles run at 1500/1800 rpm and can have rotors built up of circular laminations stacked and bolted over a steel forging as we base or can be of salient pole construction. In the case of laminated rotors, slots punched into the lamination accommodate the rotor winding. Laminated rotors have ventilating ducts for circulation of cooling air & employ radius cooling fans for cooling the machine, which are fixed on each side of rotor barrer, Salient pole generators are of two types: a) b) Laminated pole rotor & Solid pole rotors

In the case of laminated pole rotors, the laminations are cut from stampings and assembling on the rotor main body along with the pole winding in the case of solid poles, the pole body is integral with the rotor. After assembling the pole body by screws. Salient pole generators are fitted with axial fans for circulating air in the machine or cooling purpose.4-pole generators are driven by gas turbine or steam turbines through speed reduction gearboxes.

3.

Classification based on Cooling:

All electrical machines produce heat, which is the result of losses generated inside the machine. These losses have two components, fixed and variable costs. Friction and windage losses are dependent on speed. Synchronous machines run at a constant speed and hence mechanical losses i.e. frictional and

windage losses and constant losses. As the magnetic flux passes through the stator laminations, hysterisis and eddy current losses result in and are dependent on the magnitude of flux. As long as the machine is delivering power at a constant voltage, which is the normal case, the losses in the laminations known as iron losses are fixed. Stator copper losses vary in square proportion to the stator current and the rotor losses also vary in square proportion to the rotor current. As a synchronous machine has to deliver the output on a continuous basis the heat generated inside the machine due to losses has to be taken away at the same rate, so that it can operate continuously at a stable temperature, which has to be within permissible limits to ensure a long life for the insulation system. Hence air cooled generators are the simplest in design. We can employ a) open air-cooling b) air to water closed air-cooling. Open circuit air-cooling is mainly for gas turbine generators are mounted on base-frames and hence the coolers are mounted on the side. Generators up to 125MW capacity are air-cooled. For a large rating machines, hydrogen cooling is employed. Even larger machines employ direct cooling of the stator and rotor windings by circulating of the stator and rotor windings by circulating water in the follow conductors. Rest of the machine is cooled by hydrogen. Hydrogen cooled machine require complicated arrangement for isolating Hydrogen gas from the surrounding atmosphere as hydrogen with air contamination forms an explosive mixture oil seals separate the hydrogen gas from outside air. Enclosures are provided for gas turbine generator (a) for protection of the machine from the effects of environment (b) to reduce noise to tolerable levels (c) to provide an aesthetic appearance. Enclosures can be on base or off base and are usually assembled at the site from pre-fabricated elements.

ELECTRICAL DESIGN

II. Electrical Design

The electromagnetic components are often referred to as the active parts of the generator. These parts consist of several entities within the generator involved in generation and interaction of electromagnetic flux with the current carrying conductors, the generation and maintenance of induced emf and finally delivery of load current to the external circuit. The different electro magnetic active parts of generator are: 1. 2. 3. 4. 5. 6. 7. 8. 1. Stator core. Stator coils/bars Stator winding O/P leads/bushings & Phase connectors. Rotor excitation leads Rotor coils Rotor winding Supervisory and monitoring components Stator core:

The stator core serves the twin function of providing the mechanical support for the stator coils and carrying effectively the electro magnetic flux generated by the rotor winding to ensure the perfect linkage between the two. In the process of carrying the flux a constant magnetic loss is produced in the stator core. In order to minimize hysterises and eddy current losses due to magnetic flux which interacts with the core the entire core is built of thin laminations. The stator core is made up of cold rolled non-grained oriented thin silicon steel laminations with a low loss index. Each layer is formed from a number of individual

segments, which are punched from 0.5 mm thickness carefully debugged and coated with insulation varnish on both sides. The entire core is divided into a number of packets separated by ventilating ducts to provide radial passage for the cooling gas. To obtain optimum compression and eliminate looseness during the operation the laminations are hydraulically compressed and heated during the stacking procedure when certain heights of stacks are reached. The complete stack is kept under pressure and located in the frame by means of clamping bolts and pressure plates. The clamping bolts are made of non-magnetic steel and are insulated from the core. The clamping plates to prevent the clamping bolts from short-circuiting the laminations and allowing the flow of eddy current. The pressure is transmitted from the clamping plates to the core by clamping fingers. The clamping fingers extend up to the ends of the teeth thus ensuring a firm compression in the area of the teeth. The stepped arrangement of the laminations at the core ends provides for an efficient support of the tooth portion and contributes to reduction of eddy current losses and local heating in this area.The clamping fingers are made of non-magnetic steel to avoid eddy current losses. To remove the heat, spacer segments are placed at intervals along the core length, which divide the core into sections to provide wide radial passages for cooling airflow. In the core end portion, the cooling air ducts are spaced more closely to account for the higher losses and to ensure more intensive cooling for the narrow core sections. The guide bars are insulated from the core to reduce end heating due to leakage flux and its associated electrical losses. Support of tooth portion and in addition contributes to reduction of eddy circuit losses and local heating in this area. The core key bars are inserted into the slots provide in the back of the core and welded to the pressure plates.

2.

Stator coils/bars: The stator bars/coils are the individual entities which are placed in the slots of the stator core and finally connected to each other as per a pre designed scheme to form three phase winding. The prime purpose of the stator bars is to carry the load current at minimal winding losses. These coils are provided with high voltage insulation to isolate the coils from the stator core by withstanding voltage of the machine different types of stator bars are designed. Conductors Construction Each bar consists of a large number of separately insulated strands to reduce the skin effect losses. In the straight slot portion, the strands are transported by 360 degrees. The transposition provides for a mutual neutralization of the voltages induces in the individual strands due to the slot cross field and ensures that no or only small circulating currents exists in the bar interior.The current flowing through the bar is thus uniformly distributed over the entire cross-section of a bar so that the current dependent losses will be reduced. The high voltage insulation provided for the stator bars is a thermo setting resign poor vacuum pressure impregnated (VPI) system for insulation.

3.

Stator winding:

Construction: The stator winding is a short pitch two layer type made of individual bars. The bars are located in slots of rectangular cross-section which are uniformly distributed on the circumference of the stator core. In order to minimize the losses, the bars are composed of separately insulated strands, which are transported by 360 deg. To minimize the stray losses in the end winding, the strands of the top and bottom bars are separately brazed and insulated from each other

4.

O/P Leads bushings and Phase connectors:

Phase connectors: The phase connectors consist of flat copper sections, the cross-section of which results in a low specific current loading. The connections to the stator winding are of riveted and brazed type. The phase connectors are wrapped with mica a tape applied half overlap. The phase connectors are located on the ring holders, which are fixed to the winding support brackets. The phase connectors are connections between the stator winding phase bars/coils to the output lead bushings. The output leads are taken out from the phase connectors through connecting legs and connectors. Connecting legs, connectors and output leads all consist of flat copper sections applied with mica tape applied half overlap as insulation. output leads are taken out from the exciter end of stator from the top and supported on an insulated glass fabric plate. Six terminals are brought out-three for phase and three for neutral connections. Machines of higher capacities are provided with output leads which are housed in insulated glass fabric bushings/tubes. Provision is made to supply cooling air from the main cooling chamber to individual output led bushings. 5. Excitation Leads:

The excitation lead provides electrical connection between rotor winding and output from brush less exciter. A flexible copper connector electrically joins the rotor winding to the excitation lead through radial current studs. The radial stud is screwed to the field lead in the shaft bore through a hole drilled radially in the shaft. The field leads are run in axial direction from the radial stud to the end of rotor. They consist of two semicircular conductors insulated from each other by an intermediate plate and from the shaft by a tube. The ends are suitably drilled to accommodate multi contact pins to receive output from the exciter.

6.

Rotor Coils Construction: The field winding consists of several series connected coils inserted into the longitudinal slots of the rotor body. The coils are wound so that two poles are obtained. The solid conductors have a rectangular cross-section and are provided with axial slots for radial discharge of the cooling air. All conductors have identical copper and cooling duct cross section. The individual conductors are bent to obtain half turns. After insertion into rotor slots, these turns are brazed to form full turns. The series connected turns of one slot constitute one coil. The individual coils of rotor winding are electrically series connected in such a way that one north and one south magnetic pole are obtained. Conductor material: The conductors are made of copper with a silver content of approximately 0.1%. As compared to electrolytic copper silver alloyed copper features high strength properties at higher temperatures so that coil deformations due to thermal stresses are eliminated.

7.

Rotor winding: The construction of the rotor winding consists of placement of preformed rotor coils as per the winding scheme in the slotted rotor body, providing necessary insulation both in the straight portion and over hang, end winding bracing, making connections of excitation leads, wedging of the straight part and mounting of retaining rings.

Insulation: The insulation between the individual turns is made of layer of glass fibre laminate. The coils are insulated from the rotor body with L-Shaped strips of glass fibre laminate with nomex inter liner. To obtain the required leakage paths between the coil and the rotor body thick tops strips of glass fibre laminate are inserted below the slot wedges. The top strips are provided with axial wedges. The top strips are provided with axial slots of the same cross section and spacing as used on rotor windings. Rotor slot wedges: To protect the winding against effects of centrifugal force, the winding is secured in the slots with wedges. The slot wedges are made from an alloy featuring high strength and good electrical conductivity and are used as damper winding bars. The slot wedges extend below the shrink seats of the retaining rings. The wedges and the retaining rings act as damper windings in the event of abnormal operations. The rings act as short circuit rings in the damper winding.

MECHANICAL DESIGN

III. MECHANICAL DESIGN The main assemblies in the mechanical design of generator are STATOR: 1. Stator Frame 2. Stator core suspension 3. Stator end covers Rotor: 1. 2. 3. 4. Rotor slotting Rotor wedges Retaining rings and fans Finish machined rotor

Bearings: AIR FILTER: 1. Stator Frame: The stator frame is a fabricated steel structure and consists of a bottom part and a top part. Fusion welding quality steel plates are used for the fabrication of stator frame. The stator frame mainly consists two feet on which radial ribs are assembled dividing the stator frame into a number of compartments like Hot air, cool air, end winding and suction compartments. Axial stiffeners are used radial ribs to provide sufficient rigidity to the frame to withstand operating and sudden short circuit forces. 2. Stator core suspension The impregnated core, which consists of stacked sheet steel lamination and windings impregnated under VPI process to form a monolithic mass, is supported in the stator frames resiliently. The resilient mounting reduces the transmission of double frequency core vibrations to the stator frame

3.

Stator end covers: The end covers used in the stator are 1. Air guide ring 2. Labyrinth Ring The air guide ring and labyringth rings are heat-treated aluminum alloy castings. The air guide ring is fixed to the stator frame to guide the cooling airflow into the generator. The labyrinth ring is fixed to the end plate of the stator frame. The labyrinth ring is provided with scrappers to prevent ingress of dust and oil into the generator.

4.

Rotor slotting: The rotor shaft is a single piece solid alloy steel forging stringent quality control checks are carried out during forging stage like. Chemical composition Mechanical properties FATT Ultrasonic Magnetic particle examination Residual stress measurement Axial slots for insertion of rotor coils are milled on the rotor barrel. The slots are distributed on the circumference such that two solid poles are obtained. The rotor slots consists of three portions viz dovetail part, wound slot and ventilation slot.

5.

Rotor wedges: After the rotor coils are placed in rotor slot, the coils are secured in position with the help of rotor wedges all along the slot length. The rotor wedges prevent the rotor coils from coming out of slots due to centrifugal forces arising out of rotating at full speed. The wedges are cupronickel drawn profiles of dovetail shaped cross section. They have good mechanical properties. Non-magnetic properties and good electrical conductivity.

6.

Retaining ring: Just like the rotor wedges secure the rotor coils in the slots along the lift, the overhang winding is secured by the retaining rings. The retaining ring is non-magnetic alloy steel forging with very high mechanical properties. This material is stress corrosion resistant. One end of the retaining ring is shrink fitted on the rotor body and the other end overhangs the end winding without making contact with the rotor. This arrangement ensures that the shaft deflection during operation is not obstructed by the retaining ring. The free end of the retaining ring is reinforced by shrinking a hub an inner diameter of the retaining ring. The amount of shrink fit is so chosen that the releasing speeds of retaining ring on rotor body and on hub are beyond the over speed of rotor (i.e. 120% of rated speed) Fans: The cooling air to the generator is circulated by two axial flow fans located on the shaft at both ends. Each of fans comprises of a number of individual blades, which are directly screwed onto the rotor. The number and profile of the blades are so chosen that threaded root fastening facilitates the change of blade angle depending on operating requirement. Every fan blade is secured at its root with a threaded pin. The fans circulate required quantity of cooling air at required head to over come the pressure drop inside the generator. Fan blades are all minimum alloy die forgings. Threading is mad on the fan blade root such that they can be fixed into the threaded holes provided on the rotor.

7.

8.

Finish machined rotor:

The finish-machined rotor will be dynamically balanced at rated speed in a vacuum-balancing tunnel to an accuracy . The rotor is also subjected to over speed at 120% rated speed for 2 minutes. Balance condition is also checked over the entire speed range from 0 rpm to 3000 rpm. 9. Generator bearings:

The generator rotor is supported on two journal bearings. The bearing consists of a bearing pedestal and a bearing shell. Both bearing pedestal and bearing shell are in two parts viz bottom part and top part. The inner diameter of bearing pedestal and outer diameter of shell has spherical surfaces. This will provide self-aligning property to the bearing. The inner surface of bearing shell is provided with Babbitt lining. This will provide a smooth surface for the rotating journal. The bearings are provided with forced oil lubrication. Both the generator bearings are provided with hydraulic shaft lift oil sim to reduce the friction during start up and barring gear operation. High-pressure oil is forced between bearing inner surface and rotor there by lifting the rotor and allowing the formation of lubricating oil film. The exciter side generator bearing is insulated from base and piping to prevent flow of shaft currents. Each bearing is provided with two numbers duplex thermo couples to measure the temp of the bearings. 10. Air Filter:

This generator is provided with an open circuit air-cooling system. In this system the atmospheric air is sucked by the fans mounted on the generator and after cooling the active parts of generator the same will be discharged into atmosphere again on the other side. To prevent the entry of dust and moisture into the generator, an air filter is provided on the suction side. The air filter is a self-cleaning type and sequentially cleans the filter cartridges when the pressure drop across the filter unit increases 3 W.C.

EXCITATION SYSTEMS

EXCITATION SYSTEMS

INTRODUCTION CONVENTIONAL EXCITATION SYSTEM HIGH FREQUENCY EXCITATION SYSTEM BRUSHLESS EXCITATION SYSTEM STATIC EXCITATION SYSTEM

EXCITATION SYSTEMS

INTRODUCTION
The electric power demand is ever increasing which demands for the design, development and construction of increasingly large capacity turbo generators. These should be highly reliable in operation. The exciter is a four pole DC generator which meets all the excitation requirements of the turbo generator. It is directly coupled to TB shaft. Earlier conventional excitation systems with DC exciter are adopted universally for all turbo generators. DC exciters however could not be adopted for large ratings because of the problems in the design of commutator and brush gear. To overcome the problems DC exciters are replaced by AC exciters and two systems the high-frequency excitation system and brush less excitation system were developed. The brush less excitatory system is highly reliable with good transient performance and least maintenance. The static excitation system was developed contemporarily as an alternative to brush less excitation system. This system was successfully adopted to medium and Large capacity turbo generators up to 1600MVA. The problems associated with this system are the slip rings and its brush gear. However, the selection of the system is influenced by the transient response required, nature of pollution and pollution level in the power plant and cost of the equipment.

CONVENTIONAL EXCITATION SYSTEM WITH DC EXCITER In this excitation system, DC Exciter is connected to the filed winding of turbo generator through a filed breaker. Current through exciter filed winding is controlled by an AVR depending upon generator voltage and load parameters. Different configurations in the conventional excitation system are adopted to suit the requirements of different excitations. In the system shown in fig (a) the DC exciter is separately excited through an AVR The PMG provides AC Power supply required by the AVR. Availability of excitation power is independent of external AC Power supplies and hence the system is very reliable. In the system shown in fig (b) the exciter has three windings, the shunt winding, magnetizing winding and demagnetizing winding. The shunt winding is connected to the armature terminals of the DC exciter through a filed rheostat. The magnetizing and demagnetizing windings are connected to AVR for boosting or bucking. Supply to AVR is provided by PMG. The advantage of this system is to provide the excitation power if the AVR or PMG fails. The disadvantage of this system is that the DC exciter shall be specially designed with 3 field windings. In the system shown in fig (c) the DC exciter has two windings, one winding is connected to compounding unit which takes input power from current Transformers provided in the phase side bus ducts of generator, rectifiers, filters and feeds the field winding of exciter. The other winding is connected to AVR, which provided the 30% (balance) excitation power. The winding connected to compounding unit provides 70% of excitation power. The advantage of the system is 1. 2. The availability of 70% of excitation power even in the failure of AVR or power supply. Elimination of PMG reduces the cost of the system.

In fig (d) the DC exciter is self-excited. The filed current of DC exciter is controlled by rolling sector type AVR. It works independent of all external DC or AC power supplies. The disadvantage of the system is the poor nominal exciter response. The fig (e) is an improvement of the system shown in fig (d). In this system DC exciter is separately excited and required power is provided by a DC Pilot exciter.

Generator Field Breaker

AVR

PMG

Generator

Fig (a)

Magnetizing Winding

Shunt Winding

Generato r Field Breaker

+
AVR

PMG

Discharge Resistor Generator

DeMagnetizing Winding

Field Rheostat

Fig-(b)

Generator Field Breaker

+
415V 3 Ph 50 HZ AVR Current Transformer

Discharge Resistor DC Exciter Compounding Unit Generator

Fig (c)

Generator Field Breaker

Shunt Winding

Discharge Resistor Generator Field Rheosta t

DC Exciter Potential Transformer

Fig (d)

Shunt Winding

Generator Field Breaker

Field Rheost at

Discharge Resistor

Pilot Excite r

DC Exciter AVR

Generator

Potential Transfor mer

Fig (e)

In conventional excitation system, the DC exciter is the main rotating and amplifying equipment. Usually up to 500KW capacity, exciters are

directly driven by the generator rotor at 3000 rpm. With the increase in unit size of generators, large capacity DC exciters are to be designed. Due to problems in Commutation, the design of large capacity DC exciter at low speed are required. This leads to the increase in dimensions of DC exciters and introduction of reduction gear boxes in the system. This adds to the problems in design. In an effort to liquidate these problems the DC exciters are replaced by AC exciters. HIGH FREQUENCY EXCITATION SYSTEM The excitation system mainly consists of a. b. c. d. e. An ac exciter driven by generator shaft A static rectifier bridge assembly A permanent magnet generator A generator field circuit breaker and An automatic voltage regulator

Here the AC exciter is a specially designed inductor type alternator with no winding on its rotor. The armature and filed windings are accommodated in the stator. The AC exciter is usually designed to operate at high frequency to reduce the size of the machine. The armature terminals of AC exciter are connected to the static rectifier assembly and the rectified output is connected to the filed winding of AC exciter through a field breaker. The rectifier bridge assembly consists of a number of 30, six pulse rectifier bridges arranged in parallel with necessary protection for each rectifier. The magnetizing and demagnetizing field windings of AC exciter are controlled by AVR. The power required by AVR is provided by PMG. Advantages 1. Since there is no field winding on the rotor of AC exciter, the AC exciter proved to be very reliable in operation. 2. By providing the adequate margins in the ratings of the rectifiers the chances of failures can be minimized and the overall reliability can be improved Disadvantages The problems are associated with slip rings and its brush gear.

Magnetizing Winding

Generator Field Breaker

Induc
AVR

PMG

t or Alt ern ato r

Rectifier Bridge

Discharg e Resistor
Generator

Series Winding

DeMagnetizing Winding

Fig: High Frequency Excitation System

BRUSHLESS EXCITATION SYSTEM This system comprises: a. b. c. d. A direct driven AC exciter Rotating rectifier rings A permanent magnet generator and An automatic voltage regulator

The AC exciter comprises a revolving armature and a stationary yoke with filed windings. The alternating voltage generated by AC exciter is rectified by two rotating rectifier rings and the rectified voltage is fed to the filed winding of generator. Electrical connections between AC exciter and rotating rectifier rings are made by leads running on the surface of the rotor. The DC output of rotating rectifier rings is connected to the filed winding of generator by insulated leads taken through the central bore of the rotor. The filed excitation for AC exciter is controlled by an automatic voltage regulator as per the requirements of generator voltage and load. For increased reliability of excitation system, the power supply to AVR is taken from a PMG interpored between the AC exciter and the bearing at the out board end. Advantages 1. Highly reliable. 2. Less maintenance 3. Absence of power cables and complete independence from external a.c. power supplier makes the system more reliable. 4. Problems associated with brushes like sparking, part wear out of brushes etc are eliminated. Disadvantages: 1. 2. 3. Lack of facility for fast de-excitation in case of an internal fault in the generator. For internal faults in the generator, the fault power in the AVR generator will be high and consequently the core damage will be more. Rotor is not accessible for measurement of field current, field voltage and field temperature and hence direct measurement of field parameters is not possible. Generator
AC Exciter Rotating Rectifier

PMG

Fig: Brush less Excitation System

STATIC EXCITATION SYSTEM

This system mainly consists of a. A rectifier transformer b. A thyristor bridge cubicle c. A field breaker d. A field flashing circuit and e. An automatic voltage regulator In the fig static(a), the primary winding of rectifier transformer is connected to stator terminals of generator through a tap off bus duct and the secondary winding is connected to input terminals of thyristor bridges through cables. The output from Thyristor Bridge is connected to the generator filed through a field breaker. The AVR controls the output from Thyristor Bridge by adjusting the firing angle depending on the generators voltage and load parameters. The field flashing circuit facilitates initial build up of generator voltage from AC or DC power supply available in the power station. This basic scheme is supplemented with a compoundation unit in industrial applications shown in fig - static(b) where the fault current is required to be maintained for a considerable period of time for selective isolation of faulty feeders. Advantages 1. Very good transient response 2. Recovery of generator voltage subsequent to sudden switching ON or OFF of inductive loads is faster than any other form of excitation system. 3. We can change the filed excitation by injecting signals proportional to velocity and acceleration of rotor into AVR for critical damping of post fault clearance oscillations. 4. Since all the equipments are static, the total losses are very less, which improves the efficiency 5. Facility for high-speed de-excitation and accessibility for measurement of field parameters are available. 6. Periodic maintenance of electric machines is eliminated. 7. Provides flexibility in the layout of equipment.

Generator Field Breaker

Thyristor Converter

Discharge Resistor
Generator

A V R

415 V
Field Flashing Contactor Field Flashing Equipment 3 Ph 50HZ

Rectifier Transformer

Static Excitation Systems Fig-(a)

Generator Field Breaker

Thyristor Converter

Generato r

A V R

Series Compounding Equipment

Rectifier Transformer

Static Excitation Systems Fig-(b)

CONCLUSION The choice of the excitation system mainly depends upon the complexity of grid, the pattern of loading the nature of pollution level in the power plant and cost of equipment. I. The static excitation is ideal if a) The power to be transmitted through long transmission lines or b) Induction motors of large capacity are to be started direct on line and the generator voltage is to be restored in the smallest possible time or c) Loading pattern is peaking and cyclic II. The brush less excitation system is ideal if a) The environment is heavily polluted with sulfur vapors and acidic fumes etc. b) The system demands least possible maintenance c) The unit size of generator is so high that the size of slip rings and brush gear assumes monstrous dimensions.

INTRODUCTION TO MiCOM RELAY

INTRODUCTION
The MICOM generator protection relays provide flexible and reliable integration of protection, control, monitoring and measurement functions. Extensive functionality is available to provide complete protection and control with two models for a wide range of applications covering most installations from small generators up to sophisticated systems. The settings and functions of the MICOM protection relay can be accessed both from the front panel keypad and LCD and via the front and rear communication ports.

FRONT PANEL
The front panel of the relay shown in fig with the hinged covers at the top and bottom of the relay is shown open. An optional transparent front cover can provide extra physical protection for the front panel. Read only access to the user interface is possible. Removal of the cover does not compromise the environmental withstand capability of the product but allows access to the relay settings. The front panel of the relay includes 1. A 16-character by 2 line alpha numeric liquid crystal display (LCD) 2. A 7-key keypad comprising 4 arrow keys ( key ( ), clear key (C) and a read key ( ), an enter )

3. 12 LEDS, 4 fixed function LEDs on the left hand side of the front panel and 8 programmable function LEDs on the right hand side. Under the top hinge cover The relay serial number and the relays currents voltage rating information.

Under the bottom hinge cover 1. Battery compartment, which is, used for memory back up for the real time clock, event, fault and disturbance records.

2. a 9 pin female D type front port for communication with pc locally at the relay via an RS 232 serial data connection. 3. A 25 pin female D type port providing internal signal monitoring and high speed local downloading of software and language text via a parallel data connection. The fixed function LEDs on the left hand side of the front panel are used to indicate the following conditions. Trip (Red) indicates that relay has issued a trip signal. It is reset when the associated fault record is cleared from the front display. Alarm (yellow) flashes to indicate that relay has registered an alarm. A fault, event or maintenance record may trigger this. The LED will flash until the alarms have been accepted and will extinguish when the alarms have been cleared Out of service (yellow) indicates that the relays protection is unavailable. Healthy (Green) indicates that the relay is in correct working order and should be on at all times. REAR PANEL All current and voltage signals, digital logic input signals and output contacts are connected at the rear of the relay. Also connected at the rear is the twisted pair wiring for the rear RS 485 communication port, the IRIG-B time synchronizing input and the optical fibre rear communication port which are both Optional. Also connected at the rear is the twisted pair wiring for the rear RS 485/k bus communication port, in addition to the optional IRGB time synchronizing I/P and optical fibre communication port.

MENU STRUCTURE OF THE RELAY

The relays menu is arranged in a tabular structure. Each setting in the menu is referred to as a cell, and each cell in the menu may be accessed by reference to a row and column address. The settings are arranged so that each column contains related settings, for example all

of the disturbance recorder settings are arranged within the same column. All of the settings in the menu fall into one of the three categories. Protection settings, disturbance recorder settings or control & support (C&S) settings. One of two different methods is used to change a setting depending on which category the settings fall into. Control and support settings are stored and used by the relay immediately after they are entered for either protection settings or disturbance recorder settings, the relay stores the new setting values in a temporary scratchpad. It activates all the new settings together, but only after it support settings are stored and used by the relay immediately after they are entered for either protection settings or disturbance recorder settings, the relay stores the new setting values in a temporary scratchpad. It activates all the new settings together, but only after it has been confirmed that the new settings are to be adopted. This technique is employed to provide extra security, so that several setting changes that are made within a group of protection settings will all take effect at the same time. The protection settings include the following items. a. Protection element settings b. Scheme logic settings c. Auto reclose and check synchronization settings d. Fault locator settings There are four groups of protection settings, with each group containing the same setting cells. One group of protection settings is selected as the active group and is used by the protection elements. Disturbance recorder settings The disturbance recorder settings include the record duration and trigger position, selection of analogue and digital signals to record and the signal sources that trigger the recording. Control and support settings The control and support settings include: a. Relay configuration settings b. Open/close circuit breaker c. CT & VT ratio settings

d. e. f. g. h. i. j. k. l.

Reset LEDs Active protection setting group Password and language setting Circuit breaker control and monitoring settings Communication settings Measurement setting Event and fault record setting User interface settings Commissioning settings

INTRODUCTION TO THE USER INTERFACES AND SETTING OPTIONS The relay has three user interfaces a. The front panel user interface via the LCD and keypad b. The front port which supports courier communication c. The rear port which supports one protocol of either courier, Modbus or IEC 60870-5-103. The protocol for the rear port must be specified when the relay is ordered. Front panel user interface (keypad and LCD) When the keypad is exposed it provides full access to the menu options of the relay, with the information displayed on the LCD. The ______________ and ______ keys which are used for menu navigation and setting value changes include an auto repeat function that comes into operation if any of these keys are held continuously pressed. a. Default display and menu time out: The front panel menu has a selectable default display. The relay will time out and return to the default display and turn the LCD backlight off after 15 minutes of key pad inactivity. The contents of the default display can be selected from the following options: 3 phase and neutral current, 3 phase voltage, power system frequency, date and time, relay description or a user-defined plant reference. Also from the default display the different default display options can be scrolled through using the _______ and __________ keys. Whenever there is an un

cleared alarm present in the relay (eg. Fault record, protection alarm, control alarm etc the default display will be replaced by ALARM / Faults Present b. Menu navigation and setting browsing The menu can be browsed using the four arrow keys, following the structure shown in fig. Thus starting at the default display the _________ key will display the first column heading. To select the required columb heading use the _______ and _______ keys. The setting data contained in the column can then be viewed by using the ___ and ____ keys. c. Password entry When entry of a password is required the following prompt will appear:

Press the ____ and _________ keys to vary each character between A to Z. To move between the character fields of the password, use _____ and ______ keys. The password is confirmed by pressing the enter key. The menu structure contains three levels of access. The level of access that is enabled determines which of the relays settings can be changed and is controlled by entry of two different password. Access Level Level 0 Level 1 Password 1 or required Level 2 Password 2 required Options Enabled Read Access to all settings, Alarms, Event records and fault records As level 0 plus, circuit breaker, control 2 commands, e.g. Open/close reset of fault and Alarm conditions As Level 1 Plus all other settings

Each of the two passwords is 4 characters of upper case text. Whether a correct password has been entered and if so what level of access has been un locked if this level is sufficient to edit the selected setting then the display will return to the setting page to allow the edit to continue. If the correct level of password has not been entered then the

password prompt page will be returned to escape from this prompt press the clear key C. d. Reading and clearing of alarm messages and fault records.

The presence of one or more alarm messages will be indicated by the default display and by the yellow alarm LED flashing. To view the alarm messages press the read key. When all the alarms have been viewed, but not cleared, the alarm LED will change from flashing to constant illumination and the latest fault record will be displayed. When all pages of the fault record have been viewed, the following prompt will appear. Press clear to reset alarms To clear all alarm messages press C to return to the alarms / faults present display and leave the alarms unlearned, press read key. When the alarms have been cleared the yellow alarm LED will extinguish. c. Setting changes

To change the value of a setting, first navigate the menu to display the relevant cell. To change the cell value press the enter key, which will bring up a flashing cursor on the LCD to indicate that the value can be changed. This will only happen if the appropriate password has been entered. The setting value can be changed by pressing the and keys. The desired new value is confirmed by pressing . For protection group settings and disturbance recorder settings, the changes must be confirmed before they are used by the relay. Front communication port user interface The front communication port is provided by a 9 pin female D-Type connector located under the bottom hinged cover. It provides RS 232 Serial data communication and is intended for use with a pc locally to the relay as shown in fig. The pin connections of the front port are Pin no.2 T x transmit data

Pin no 3 Pin no. 5

R X receive data OX zero volts common

The PC serial port pin connections are as follows: 25 way Pin no. 3 Pin no. 2 Pin No.7 9 way 2 RX receive data 3 TX Transmit data 5 OX zero, volts common

For successful data communication, the TX Pin on the relay must be connected to the RX pin on the PC, and the RX Pin on the relay must be connected to the TX pin on the PC as shown in Fig.

Advantages of MiCOM relay: 1.Trending can be done. 2.Event logging is possible. 3.Communication is possible. 4.Operation analysis can be done sequentially because of events Occurred during the fault. 5.Less wear and tear. 6.Accuracy is much better than conventional relays. 7.Much reliable than conventional relays. 8.More flexibility in setting and adapting. 9.Logics can be stored inside the relay for operation where as in Electro mechanical relay hard wiring has to be done. 10.password protection can be done.

Disadvantages of MiCOM Relay: 1.File corruption results in the replacement of the relay. 2.Once the relay goes faulting the protection scheme is lost

Classification of tripping Various tripping schemes shall be classified as given below: Class A Tripping scheme In class A tripping mode, generator and turbine will be tripped simultaneously and instantaneously. Generally electrical faults of generator, generator transformer and unit auxiliary transformer(s) will lead to class A tripping. This will lead to tripping of generator transformer HV side circuit-breakers, de-xecitation of generators. Unit auxiliary transformer(s) low voltage side incomer circuit-breaker(s) tripping auto changeover from unit to station supply for unit auxiliaries and tripping of turbine. A simultaneous trip is adopted for those electrical faults of generator, generator transformer and unit auxiliary transformer(s) for which tripping cannot be delayed. This provides the highest degree of protection for the unit although it does involve a small overspeed. Class B Tripping scheme ClassB tripping will take place for all turbines faults( mechanical in nature) and for some lectrical faults of generator and associated transformer for which it is safe to first trip the turbine and subsequently trip the generator through low forward/ reverse power interlock. This ensures that unit does not overspeed due to trapped steam in the turbine during the shutdown. Class C Tripping Scheme ClassC tripping will take place for all faults beyond the generator system which can be cleared by tripping of generator transformer HV side circuit breaker only. In this case, the TG set runs with HP-LP bypass system in operation and the generator continues to feed the unit-auxilary load through unit auxiliary transformer(s). Class D Tripping scheme ClassD tripping involves basiclly a generator trip alone i.e. generator line breaker is tripped and excitation is removed simultaneously, but the turbine is left running near rated speed. Where such trip is possible, it provides as high a degree of protection as classA and enables to take advantage of not tripping the turbine. Class E tripping scheme In this Class of trip signals are given to trip all circuit breakers connected to the busbar to which generator transformer circuit breaker is connected when thia breaker fails to trip on a trip command. The unit is also tripped in Class A mode to avoid feeding the fault further.

Generator and System Data

S.N o
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Rated Voltage Rated Current

Paramete rs
Rated active output Rated Apparent output

V alues
70.001MW 90.590MVA 11KV+/- 5% 4755A 0.85 lag 50Hz 0.23326 p.u 0.1774 p.u 0.1260 p.u 6000/1 A (11000/1.732)V/ (110/1.732)V I2s = 10% Cont. I2 Sq.t =20 3000 rpm

Rated Power Factor Rated frequency D-Axis Synchronous reactance (Xd) D-Axis Transient Reactance (Xd) D-Axis Sub Transient Reactance (Xd) CT Ratio PT Ratio Negative Sequence Capability Speed

1.Over voltage protection: Stage-I (59.1) This relay is provided to change regulation of AVR from Auto to Manual in case Auto channel of AVR fails. Rated voltage of generator : 11KV +/- 5% First stage of over voltage protection for change over from auto to manual Regulation is chosen at 5% higher than rated cont. voltage. Hence setting shall be 105+5=110% of rated voltage. Voltage measure mode selected : Phase-Phase. PT secondary rated voltage =110 Relay setting = 1.10 X 110 =121V

Time delay recommended = 0.3 sec

Action: Alarm and change regulation from Auto to Manual. 2. Over Voltage Protection :Stage II (59.2) This relay is provided to protect generator against over voltages This protection shall be chosen at 10% higher than Stage-I Over voltage setting = 110+10 = 120% of rated voltage PT Secondary voltage = 110V( Phase-Phase) Relay setting = 1.20 X 110 =132V Recommended time delay = 2 sec This time delay shall not be too long to avoid strain on the machine .

Action: To trip 86A

3. a) Over current relay, Definite time (51.1G) Rated current of generator: 4755A Current at 5% generator voltage = 4755/0.95 = 5003.16A CT primary current = 6000A Relay setting = 5003.16/6000 = 0.83 p.u Time delay recommended = 6 sec

Action: Alarm

3. b)Over current relay with voltage restraint (51V) This relay is provided to protect generator against heavy over loads and short circuits. The current setting is chosen such that neither false tripping nor false signals can occur during normal operation and yet minimum fault current is detected. Function recommended : Voltage Restrained Settings : Vs1 = 80V , Vs2 = 35V Characteristic recommended : Standard inverse t= [(0.14)/{(I/Is ^ 0.02 1)}]* TMS where I =Measured current, Is =Current threshold setting, TMS=Time multiplier setting If the relay has to operate in 3 sec when fault current is 2 times the rated current , Generator rated current in CT secondary =4755/6000= 0.7925A=0.7925 In The settings recommended are I>= 0.8 In (where In= 1A) Time multiplier(TMS)=0.3 K=0.4 This setting are required to be coordinated with upstream breaker by customer. Action: To trip 86A1 and 86A2.

4. Reverse power protection Stage-I (32R) This protection is provided to protect generator against motoring . _ Rated power in terms of signals o the relay = (\/3 * 110)*(4755/6000)*1))=150.99W Relay shall be able to sense 0.5% of rated power. Relay setting = (0.5*150.99)/100 =.7549 Minimum setting available= 4W Setting recommended Delay drop off : 0sec Compensating angle : 0deg Action : To trip 86A1 and 86A2. = 4W Time delay recommended = 1.0sec

5. Low forward power : (37G) _ Rated power in terms of signals to the relay = (\/3*110)*(4755/6000)*1) = 150.99W Relay shall be able to sense 0.5% of the rated power. Relay setting = (0.5*150.99)/100 = 0.7549 Minimum setting available = 4W Setting recommended = 4W Recommended time delay = 1 sec Action : To trip 86A1 and 86A2.

6. Under voltage relay : (27G) This protection is provided to protect the generator against operation at very low voltage. Rated voltage of generator = 11KV+/- 5% Under voltage setting recommended = 5% lower than minimum operating voltage = 90% Relay setting recommended = (90*110)/100 =99V Time delay recommended = 3 sec Action : To trip 86C1 and 86C2.

7. a) Under frequency protection : (81.1 & 81.2) This protection is provided to protect the generator against operation at low frequencies. From the capability and safety of Turbine-Generator set , trip setting is recommended at 47.5Hz.

Alarm setting are to be made at 1Hz interval to alert the operator for corrective action and load management . Hence, following settings are recommended. Stage-I : Freq. = 48.5Hz ; Time delay = 2 sec; Action : Alarm. Stage-II: Freq. = 47.5Hz ; Time delay = 2 sec; Action : To trip 86B1 and 86B2.

7. b) Over frequency protection (81.3) This protection is provided to protect the generator against operation at high frequencies. From the capability and safety of Turbine-Generator set , trip setting is recommended at 51.5Hz. Hence the following settings are recommended. Setting frequency =51.5Hz ; Time delay = 1 sec. Action : To trip 86B

Negative sequence current protection : (46G) This protection is provided to protect the generator against unbalanced loads and as a back up for uncleared unsymmetrical faults. Stage-I : Alarm stage Rated current of generator / CT primary current = 4755/6000 = 0.7925A I2s capability of generator = 10% of rated current Alarm threshold (I2>)= 0.1X 0.7925 = 0.07925 p.u Recommended alarm threshold = 0.07925 p.u Recommended time setting for alarm = 10 sec Trip threshold setting I2>>= 0.08 p.u (little higher than alarm threshold) Thermal capability constant (heating) K= 20X 0.80 X 0.80 = 12.8 sec

Hence setting K = 12.8 sec Thermal capacity constant (cooling) : Kreset = same as K Maximum operating time = 500 sec Minimum operating time = 3.0 sec Action : To trip 86A1 and 86A2.

9.0

Generator Differential Protection:

This protection is provided to protect the generator against phase to phase faults in generator. The basic differential current setting IS1 defines the pickup setting of differential protection for internal faults.The lowest possible value should be chosen to enable it to detect the worst case faults. Hence,recommended setting for IS1=0.05In. As per relay manufacturers recommendation recommended settings for I) Threshold for increase bias IS2=1.2In II) Bias K1=0% III) Bias K2=150%

10.0

Stator E/F relay(0 to 95%):

Voltage setting=7 volts. Time Delay=1sec This setting is typical.Voltage shall be measured during normal operation.Voltage setting may be adopted 1 volt higher than measured value. 11.0 Stator E/F protection(100%): Third harmonics U/V threshold setting(VN3H<) must be set below the 3rd harmonics voltage present during normal operation and Third harmonics O/V threshold setting(VN3H>) must be set above the 3rd harmonics voltage present during normal operation.

Third Harmonic U/V(VN3H<)=0.5V(Typical) Time Delay=1 sec. Third Harmonic O/V(VN3H>)=1.0V(Typical) Time Delay=1 sec. These settings are typical.Voltage shall be measured during normal operation.Voltage setting may be adopted accordingly.

12.0

Dead M/C Protection: Rated current of Gen./CT Primary current=4755/6000=0.7925A Setting chosen=0.1In Min setting available=0.07925A Min. Voltage setting available=30V Setting chosen=80V tpu=4 sec tpo=0.5 sec.

13.0

PT fuse failure relays:

Relays 60.1,60.2,60.3,60.4 are provided to monitor metering protections,AVR & protection PTs. Recommended setting=80%.

14.0

Rotor earth fault relay: Stage I:80 Kilo ohms(fixed),Time Delay=10 sec.

Action:Alarm
Stage II:5 Kilo ohms(fixed),Time Delay=5 sec

Action:To trip

15.0

PROTECTION AGAINST LOSS OF EXCITATION:

This protection is provided to prevent generator running as an induction generator. Gen.Transient reactance in Sec.Ohms. =Xd x Kv2xCTR 100 x MVAxPTR =17.74 X 11X11 X 6000/1 100 90.59 (11000/110) = 0.1774 X 11 X 11X 6000 90.59X100

=14.22 Mho offset = Xa=Xd/2 = 14.22 = 7.11 . 2 Nearest setting available above the required value of 7.11 is 7.5 Hence setting Xa=7.5 Gen. Syn. Reactance in Sec.Ohms=XdxKV2xCTR 100xMVAxPTR = 233.26x 11 X 11 X 6000 100 90.59 100 = 127.969 . Mho diameter=Xd=187 Recommended Setting for Xd=187 Delayed pickup time=2 Secs. Delayed drop off time=1 Secs.

Settings:Protection against loss of excitation Xa = 7.5 Xd=Xb=178 Delayed pick-up time = 2 seconds. Delayed Drop off time = 1 second. Action:To trip.

16.0

Under voltage relay: This relay is connected between R & Y phases of PT. This relay works in conjunction with loss of excitation. Voltage setting recommended = 70% of rated voltage = 77 V Action:To trip.

17.0

Check Synchronizing relay: Settings phase angle difference = 10 Deg. Voltage difference = 2% Time = 0.5 sec.

18.0

Over Fluxing Protection PT secondary voltage:110V Rated Frequency = = 50 Hz. V/F = 110/50 = 2.2 5% tolerance in voltage at rated frequency is allowed. Relay Setting Recommended =1.05 X 2.2 = 2.31 V / Hz. Relay Setting = 2.31 V/Hz(stage-1 for Alarm) Time Delay = 1 Sec. Trip setting = 1.10X2.2 = 2.42 V/Hz.(Stage-2 for Trip) Time Delay =1 Sec